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 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 5: Table Of Contents
Contents Safety...........................1-1 Advice for Operation of Loader.......................1-1 Safety Decals..........................1-3 Unauthorized Modifications......................1-6 General Hazard Information......................1-6 Before Starting Engine........................1-15 Operation of Loader........................1-19 Maintenance..........................1-29 Battery............................1-44 Towing............................1-46 Shipping and Transportation......................1-47 Operation Controls ......................2-1 Component Locations....................2-2 O p e r a t o r ’ s A r e a ..................2-4 M a ni pu la tin g Fa c il ity ...
Page 6 Working Hydraulic System..................4-10 Working device..........................4-16 Electrical system..........................4-18 Others..........................4-16 Transportation........................5-1 Transporting machine....................5-1 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 Technical specification....................7-1 Basic Parameters........................7-1 Engine............................7-2 Transmission system........................7-2 Braking system..........................7-3 Steering system..........................7-3 Hydraulic system for working device....................7-3 Electrical system..........................7-4 Oil filling capacity...........................7-4 A/C System........................7-4...
Page 8: 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 9: 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 10: 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 11 1.Never stand under the bucket. Figure 2 2.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 3 3. Severe injury and death from crushing could occur in articulation position when machine turns.
Page 12 4. S t a n d i n g h e r e i s s t r i c t ly p ro h i b i t e d w h i l e t h e machine is moving. Otherwise, it will cause serious injury or death accidents.
Page 13: Unauthorized Modifications
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 14 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 15: Mounting And Dismounting
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. Mounting and Dismounting Before getting on or off machine, if there is any oil, grease, or mud on handrails or steps, wipe it off immediately.
Page 16 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 17 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 18 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 19 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 20 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 21 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 22: Before Starting Engine
BEFORE STARTING ENGINE Matters needing attention on site Com p le te ly c h e c k th e wo r k in g a r e a fo r th e abnormal conditions which may cause dangers before starting. Check the terrain and ground surface on site, and identify the best and the safest operation method.
Page 23 Clear thoroughly off the mud and fine sand on your shoes before you get on this machine, because these sand and mud will accumulate on the pivots of the accelerating pedal and brake pedal, interfering the reset of these pedals. Clear immediately and thoroughly the sand and mud accumulated at these places if any.
Page 24 Start the engine Before you get on this machine, perform again the patrol inspection for your machine. And check places on the machine, below the machine and around the machine for the presence of persons or objects. Watch whether there are persons in the working area.
Page 25 Starting The el e ct ri ca l sy s te m se c ti on in O pe ra ti o n Instructions shall be carefully read before you drive the vehicle. Perform the inspection prior to driving and start the engine after confirming that each component is normal.
Page 26: Operation Of Loader
OPERATION OF LOADER Inspection after starting engine 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 obsta- cles, and do not let anybody to approach the ma- chine while you are checking.
Page 27 Matters needing attention on travelling Never put the key in the starter switch to SWITCH OFF position when the vehicle is traveling. It is dangerous for the engine to be switched off when it is traveling, because the steering becomes very serious.
Page 28 If you are prepared to perform the continuous traveling, please consult the distributor specified by HYUNDAI. Inspection when the direction changes In order to prevent the injury or death, it is necessary to comply with following regulations...
Page 29 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 30 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 31 Matters needing attention on operating Be careful not to be too close to the edge of the cliff. When constructing the dike or filling in earth, or dumping earth to the cliff, it is possible to unload the soil into one pile, and then use another pile of earth to push the first pile .
Page 32 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 33 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 34 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 35 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 36: 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 31 Operation and maintenance of this machine may only be carried out by personnel equipped with corresponding resources.
Page 37 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 38 Maintenance and inspection of vehicles body Working under the machine Park the machine on the flat ground,and then lower all working devices down to the ground before performing maintenance or repairing under the machine. Use wedges to fix the tires. It is dangerous to work under the machine if the tires are above the ground and the machine is supported only by working devices.
Page 39 Do not hang the foreign objects inside the machine. When performing maintenance with manhole or oil filler opened, be careful for not letting any foreign object (e.g., nut, bolt, cotton yarn or tools) fall down into the machine. The falling of such objects into machine will cause the machine to be damaged, the operation failed, or other faults.
Page 40 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 33 The explosion-proof lighting devices should be...
Page 41 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 42 Welding maintenance Welding maintenance The welding work shall be performed in the place with appropriate devices and by the qualified welders. The electric welding can produce gases and cause electric shock and fire damage, therefore never allow the unqualified persons to operate.
Page 43 Comply with correct welding operation procedure to prevent the electrical parts and bearing from being damaged. Comply with following procedures when you perform welding on a loader equipped with electrical parts or on the engine: Park the machine on a flat surface. ●...
Page 44 Matters needing attention for welding: Prohibit using the grounding points for the electrical components on the machine as the Grounding Point for the welding machine! If you want to perform welding near the electrical grounding points, you should disconnect the electrical Grounding point, and ensure the welding circuit of the welding machine does not pass this electrical component, then you can perform the...
Page 45 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 46 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 47 Regulations you should comply when filling fuel or lubrication oil Fuel, lubrication oil, hydraulic oil, anti-freeze fluid, braking fluid, windshield detergent can be on fire by flame. Please obey the following regulations: S w i t c h o f f t h e e n g i n e w h e n y o u f i l l f u e l o r lubrication oil.
Page 48 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 49: 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 50 Check after maintenance I f y o u h a v e n o t p e r f o r m e d t h e c o m p l e t e maintenance or the check of the functions of each maintenance part, the unexpected problems will possibly occur, even causing serious personal injury or machine damage.
Page 51: 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 ●...
Page 52 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 ● connecting to battery, including the electric switch for battery charger and auxiliary starting device. When using other machine to perform the ●...
Page 53 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 54 SHIPPING AND TRANSPOTA- TION Matters needing attention for loading/ unloading machine There is always danger in loading/unloading machine, so you should be very careful. When you perform loading/unloading of machine,the engine shall run at low speed, and the machine shall travel at low speed.
Page 55 When transportation, the machine may be divided into several parts if necessary. Therefore when you transport this machine, please consult the distributor specified by Hyundai for performing such operation. 1-48 Safety...
Page 56: Towing
If the engine on a fault machine could not start or ● the braking system is in fault, please consult the distributor specified by Hyundai for repairing. It is dangerous to tow a machine on the slope. ● You should select a place with flat slope. If not applicable, select a place with a slope as less as possible for towing.
Page 57: Operation Controls
Operation Controls Description of each component position and each control switch, instrument and valve through drawings or photos. The meters on the dashboard are attached with indicators through which the operator monitors the operation of the machine and with which the faults are displayed WARNING Warning lamp: If any warning lamp or several lamps on the...
Page 58: Component Locations
COMPONENT LOCATIONS Figure 1 2-2 Operation Controls...
Page 59 Reference Number Description Reference Number Description Lever Pilot Pump Bucket Cylinder Main Pump Boom Cylinder Transmission Frame Break Piping Electric Part-Fuse Box Sequence Valve Electric Part-cab Shaft Joystick Main Pump Cabin Axle Seat Engine Cover Tire Engine Lift Arm Cooler Piping Link Lighting Lamp-Rear frame Bucket...
Page 60: O P E R A T O R ' S A R E A
OPERATOR`S AREA(STAND) Figure 2a 2-4 Operation Controls...
Page 61 Reference Number Description Reference Number Description Fire Extinguisher Bracket Accelerator Pedal Console Pilot Control Handle Combo switch handle Pilot Control Box Steering wheel Engine Flameout Lever Gearshift Handle High-Low Speed Control Lever Operation Box Washing Pot Hand Brake Lever A\C assembly Control switch such as OFF Seat Brake Piping...
Page 62 OPERATOR`S AREA(OPTION) Figure 2b 2-6 Operation Controls...
Page 63 Reference Number Description Reference Number Description Fire Extinguisher Bracket Accelerator Pedal Console Bucket control lever Combo switch handle Boom control lever Steering wheel Engine Flameout Lever Gearshift Handle High-Low Speed Control Lever Operation Box Washing Pot Hand Brake Lever Heater system assembly Control switch such as OFF Seat Brake Piping...
Page 64: Manipulating Facility
MANIPULATING FACILITY Steering Wheel 1. The steering wheel rotation angle is not equal to the machine’s rotation angle. Continuously ro- tate 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 65 3. ON – the ﬁrst gear position you meet when you insert the starter key and rotate it clockwise. At this position, the electrical system of the whole vehicle can be powered to operate normally. 4. START – the second gear position you meet when you insert the starter key and rotate it clockwise.
Page 66 Operation of Pre-heating 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) Figure 7 When When the resistivity of the engine coolant...
Page 67 3. When the pre-heat time is up, the pre-heat indi- cator (DL) goes out (If the start switch is turned off during the pre-heat time, the controller will stop) and the pre-heat system then wait to start the engine for 30s •...
Page 68 Schematic Figure 10 2-12 Operation Controls...
Page 69: Parking Brake Lever
Parking brake Lever The parking brake lever is on the left side of the seat (Fig.11.) Put upward the lever to lock the parking brake. Press down the lever to release the parking brake. When you press down the lever, you need to press and hold the button at the top of the lever.
Page 70: Engine Cutoff Switch
Engine cutoff switch The engine cutoff of this machine is located on the right side of the control box(Fig.14). The engine cutoff of this machine is realized by pull-up the cut- off handle for a few seconds. Release your hand after the engine flame-out, then the handle will re- turn automatically Figure 14...
Page 71 Pilot manipulating handle (stand) 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 bucket manipulating handle with leftward and rightward manipulation is used to control the bucket’s movement and the arm ma- nipulating handle with forward and backward manipulation is used to control the arm’s movement.
Page 72 Mechanical manipulating lever (option) 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 73: Rocker Switch
ROCKER SWITCH Figure 19 Rocker switch located below the steering wheel, integration on the console （ Fig.19 ） 1. Warning alarm switch (the ﬁrst on the left) -- When the vehicle is in a state of need warn- ing, Closing the switch can control the four turn- ing lamps on or off at the same time.
Page 74 MORNITORING INSTRUMENT Figure 20 All monitoring instruments,alarm indicator lights , hour meter and so on are integrated instrument un- der the steering wheel assembly. Instrument contains a list of the torque converter oil temperature, cooling water thermometer, brake air pressure meter, hour meter, voltmeter, a total of five kinds of indicator;...
Page 75 2. Indicator light When open the turning lamp, the corresponding turning indicator should be in light condition; When open the high beam , high beam indicator should be in light condition; When the loader is in a state of parking brake and parking brake indicator light should be in light condition;...
Page 76 Lamp and Switch The lamps for the vehicle are divided into front/ rear combo lamp (one each for left and right), rear combo lamp (one each for left and right), indoor lamp, work lamp(one each for left and right),and rear lamp (one each for left and right) Where, the front/rear combo lamp includes head lamp, front signal lamp, front steering lamp;...
Page 77 A/C system 1. Refrigeration A. Close the heater water valve; B. After the engine working normal, turn the blowing rate switch to the proper position; C. Rotate the temperature control switch to the proper position (Green indicator lit up), and the refrigeration system starts working and the cooled air begins to be sent out from the Figure 24...
Page 78 Heater system (option) Heater is mounted under the seat. operation notes: • In Warranty, it is strictly prohibited to disassem- ble the air conditioning system; • In the winter, if you want to keep warm, you need to open the water valve; In the summer, don’t need to keep warm, you must close the Figure 26a water valve(Fig.26a);...
Page 79 Fan (option) The fan is mounted on the top of the cabin(Fig.27). switch is on the side of the base,contain neutral position, low gear and high gear. Figure 27 Operation Controls 2-23...
Page 80: Wiper And Wisher
Wiper and washer This machine is equipped with a front window wiper, and the control switch is under the steering wheel. 1. Front wiper switch The front wiper switch has three gears with Stop, low speed and high speed. (Fig.28, left) Figure 28 2.
Page 81 Adjustment of steering gear The inclination of steering gear of this machine may be adjusted within a certain range to adapt to driver’s operation customs. There is a spanner at the middle of steering gear (Fig.69). The method of adjusting the inclination angle of the steering gear is as follows.
Page 82 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 83 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 84 Audio system---multimedia Audio system is located in the cab, including multimedia, speaker, and antenna. Host panel(Fig.64) Figure 33 Speaker(Fig.65) Figure 34 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 85: Key Introduction
Key introduction Figure 35 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 86 Operating instructions 1. Radio mode button function declaration 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 87 2. USB/SD/MMC Mode button function declaration 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 88 Front and right side switch panel Figure 36 2-32 Operation Controls...
Page 89 Reference Number Description Reference Number Description Starter switch Fuel pumping switch Combine switch Pilot cutoff switch Accelerate switch(Option) Engine mode switch(Option) Shift lever Diagnostic switch Hazard Warning lamp switch Wiper and washer switch Rotating lamp switch Wiper switch Front working lamp switch spare Rear working lamp switch Power socket...
Page 90 1. Starting switch A three-position starter switch is used to start or stop engine for equipment operation. Turning switch to this position turns the engine “OFF” with its electrical system. In this position the engine is “OFF” but the interior cabin light is functional. Turning switch to this position turns engine electrical system “ON”.
Page 91 2. combination switch A. Left Side Directional Switch - Pushing lever forward, activates left outside directional lights and directional indicator light on instrument panel. B. Right Side Directional Switch - Pulling lever back, activates right outside directional lights and directional indicator light on instrument Figure 38 panel.
Page 92 5. Hazard Warning Light Switch This warning light is used when the equipment is stopped because of a malfunction or when an emergency occurs. When this switch is pressed the directional indicator lights in front and back of the machine light up and flash, warning others in the area.
Page 93 8.Rear Work Light Switch O. In this position, this switch turns “OFF” work lights mounted on the sides of radiator. I. In this position, this switch turns “ON” work lights mounted on the sides of radiator. CAUTION: Do not turn “ON” the work light when traveling Figure 45 on public roads.
Page 94: Wiper Switch
12. Diagnostic switch(Option) This switch is self return type; It can clear the history of the fault error code of ECU when press one time; Figure 49 13. Wiper and washer switch O. In this position, this switch turns “OFF” windshield washer;...
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. C o m p l e t e l y c h e c k b o l t a n d n u t o f e a c h component for the tightening.
Page 99: Operating Machine
Operating 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 100 11. Check fuel quantity. 12. Slightly depress the throttle pedal, and rotate clockwise for another one increment to switch on diesel engine starter motor. The engine will be started to work within 10s. Now it is necessary to immediately release your hand to let the starting electric lock reset.
Page 101 18. If there is no obstacle around the machine, it is necessary to slowly rotate the steering wheel and observe whether the machine has the ac- tions for leftwards or rightwards rotation. Operation 3-7...
Page 102 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 103 6. Check the engagement states of each gear. Drive the machine to the flat ground. Check the gear shifting of the machine respectively with combination of each gear. 7. Steering operation of the machine: When the machine needs to turn due to the bend ahead in the driving direction, please perform the operation following the local traffic laws and regulation.
Page 104 When performing 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. WARNING Strictly prohibit conduct the steering operation on the slope. You should drive the machine down to the flat ground to perform these operations.
Page 105 Parking of machine 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 106 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 107 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 108: 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 109 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 110 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 111 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 112 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 113 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 114: 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 115 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 116 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 117: 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 118 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 119 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 120 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 121 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 122: On The Last Page Of Operation Under Special Conditions,Insert
On the last page of Operation Under Special Conditions,insert 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 123: 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 124 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 125: 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. Some special maintenance requires the Note: machinery has different parking mode. However, after completion of maintenance, the machine must be reset to the following positions.
Page 126: 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 127 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 128: Fluid Capacity
FLUID CAPACITY Item Size Crankcase(Engine oil) Engine Cooler system Fuel tank 155L Hydraulic oil Tank Capacity 123L Gearbox system Axle housing assembly Front axle /Rear axle Hub wheel assembly 4.5L/ Edge 4-6 Inspection, Maintenance and Adjustment...
Page 129 LUBRICATION OIL & MAINTENANCE CHART Figure 5 Inspection, Maintenance and Adjustment 4-7...
Page 130: 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 131 Maintenance items 10 hours/routine maintenance Visually check around the machine for informalities or oil leakage. ● Check the engine and transmission oil level. ● Check hydraulic oil level. ● Lighting and instrument ● Check tyre for damage and wear patterns. ●...
Page 132 Maintenance items 500 hours / quarterly maintenance Tighten the connecting bolt between front/ rear axle and frame. ● Replace engine diesel oil filters. ● Clean the oil filling and oil sucking filtration screen of fuel tank replace fuel filter. ● Replace the outer and inner element of the air filer.
Page 133: Working Hydraulic System
WORKING HYDRAULIC SYTEM (pilot control) : HL635V Working hydraulic system is used to control the actions of working devices such as arm and bucket in loader. The whole working hydraulic system is mainly composed of: hydraulic oil tank (with oil return fil- ter), gear pump, main control valve, boom cylinder, bucket cylinder, control lever and leveling system.
Page 134 Introduction to main elements of working hydraulic system: Main control valve: ● Model ............DVS20 ● Pressure setting of relief valve…..……...16.5MPa ● Overload valve pressure of bucket small cham- ● ber………...........… 18.5MPa Overload valve pressure of bucket big chamber… ● …………..........18.5MPa The main control valve is a pilot operated, integrated, serial-parallel, duplicated valve, and is mainly consisted of valve body, boom slide valve,...
Page 135 The interior of bucket valve and boom valve is in- stalled with check valve to prevent the “Nodding” phenomenon during operation. The bucket slide valve can automatically reset, but the boom slide valve needs manual reset due to the internal steel ball locating.
Page 136 WORKING HYDRAULIC SYTEM (Mechanical Control) : HL630V Working hydraulic system is used to control the actions of working devices such as arm and bucket in loader. The whole working hydraulic system is mainly composed of: hydraulic oil tank (with oil return fil- ter), gear pump, main control valve, boom cylinder, bucket cylinder, control lever and leveling system.
Page 137 Introduction to main elements of working hydraulic system: Main control valve: ● Model ..........GDF-25-00B ● Pressure setting of relief valve…..……...16.5MPa ● Overload valve pressure of bucket small cham- ● ber………...........… 18.5MPa Overload valve pressure of bucket big chamber… ● …………..........18.5MPa The main control valve is a mechanical operated, integrated, serial-parallel, duplicated valve, and is mainly consisted of valve body, boom slide valve,...
Page 138 The interior of bucket valve and boom valve is in- stalled with check valve to prevent the “Nodding” phenomenon during operation. The bucket slide valve can automatically reset, but the boom slide valve needs manual reset due to the internal steel ball locating.
Page 139 Observation and inspection A f t e r t h e f a u l t o c c u r s , t h e f i r s t s t e p f o r troubleshooting is to perform the observation of the steering system and its elements.
Page 140: Working Device
WORKING DEVICE The working device is consisted of four main parts: bucket, lift arm, lever and link, as shown in Fig. 7. The lift arm is a single plate structure, whose rear end is supported on the front frame, and the front end is connected to the bucket, and the middle portion is connected to lift arm oil cylinder.
Page 141 Measures to be Nominal Permissible adopted after the Pin position Check item dimension Fit clearance(mm) gap after being permissible value is (mm) worn(mm) exceeded(replace pin or bush) Link and lever 0.220~0.394 0.90 （as above） φ60 hinge pin Link and bucket 0.220~0.394 0.90 （as above）...
Page 142 Figure 7 Reference Number Description Reference Number Description Bucket Flat Pin Link Tooth Sleeve Lever O-Ring Seal Lift Arm Bush Wearable Plate Tooth Body 4-20 Inspection, Maintenance and Adjustment...
Page 143: Electrical System
ELECTRICAL SYSTEM Electrical system includes: battery, alternator, starter motor, gauge panel, switch, lamp system, control elements, A\C circuit and other electric equipment etc.. The machine’s voltage is DC 24V, with negative pole grounded, and single wire system (See “Electrical System” of Parts Catalogue for more information) Battery bank This machine uses two batteries in series.
Page 144 5. When handling battery, do not tow it on the ground. 6. If the specific weight of electrolytes level of the battery drops to be less than 1.18kg/L, you should immediately charge the battery to pre- vent the acidulation of the pole plate. After first charging of the newly used battery, it is better to discharge the battery at a rate of 10 hours discharge rate, then continue the charge to...
Page 145 Under normal conditions, the alternator can either supply power to electric equipment or to the battery. This can be obviously observed on Voltmeter installed on dashboard. After running of engine, if the voltage indicated on voltmeter is greater than that before operation, this indicates the alternator is charging the battery and supplying power to electric equipment.
Page 146 Check the welding heads on coils, rotor, and silicon diode for disordering. Use multimeter high-resistance position to check silicon diode one-by-one. If the great difference between Positive direction and Negative direction resistances, this indicates the silicon diode is damaged, and must be replaced.
Page 147: Starter Motor
Starter motor The Starter motor used in this machine is a corol- lary product for diesel engine. The starter circuit is shown in Fig.10 When the electric lock is rotated clockwise to start, its contact is ON, and +24V voltage reaches the electric lock through Line 15 Line 16A starter mo- tor electromagnetic coil energized and closed bat- Figure 10...
Page 148 Lamp system The electrical system is equipped with head lamp, rear lamp, signal lamp, steering lamp, instrument lamp, brake lamp etc.. Where, the head lamp has low/high beam, thus ensuring to meet the require- ments for operation and traveling. Except brake lamp, in-cab lamp, head lamp low/ high beam switching, steering lamp, the aforemen- tioned lamps are controlled trough lower-left com- Figure 11...
Page 149 Instrument The pressure gauge for this machine adopts mechanical-type instrument, including engine oil pressure gauge, barometer, and gearbox oil pres- sure gauge. The pressure gauge is a mechanical structure consisting of elastic element, spring pipe, and connecting joint. When the gauge is working, the working pressure of measured system enters the gauge through connecting pipe;...
Page 150 A\C system circuit See Fig.14 for the principle of the circuit of A\C system. Main technical parameters of A\C system: Voltage 24VDC Heat-release capacity Refrigerating capacity Figure 14 Introduction to A\C circuit operation The air-conditioner system for this machine has three function of: refrigerating, he ating and dehu- midifying.
Page 151: Others
OTHERS There are also other elements in this system, mainly including: Fuse It is installed beneath the seat. When the power supply system is short circuited, it may be burnt, thus protecting the main circuit. Wiper switch The switch of the wiper is on the combo rocker switch as shown Fig.15, and it has 3 gears with stop, low, high speed Washer switch...
Page 152: Transportation
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 153 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 154 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 155 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 156 Transportation dimension Figure 3 Basic dimension Sign Description Dimensions Transportation length 6990mm Transportation width 2510mm Cab height 3250mm Ground clearance 330mm Space between front and rear Tires 2670mm Transportation 5-5...
Page 157: 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 158 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 159: Braking System
Braking system Characteristics of faults Cause Remedy Air in braking hydraulic pipeline Bleed the pipeline 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- line Foot braking force not adequate Seals for bake pump worn...
Page 160: 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 to worn. Fit clearance between valve make the clearance meet require- stem and valve body exceeds the ments on specified value , or re- specified value place distribution valve...
Page 161: Steering Hydraulic System
Steering hydraulic system Characteristics of faults Cause Remedy Increase the oil temperature , then Oil temperature too low 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 162: 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 163: Engine
Characteristics of faults Cause: Remedy Instrument damaged Replace instrument Sensor damaged Replace sensor No indication on electric sensing Check whether the terminal volt- instrument instrument Generator or battery is in fault age of generator or battery is nor- Sensor drops off Re-tighten it Battery damaged or its capacity R e p l a c e w i t h n e w b a t t e r y o r...
Page 164: Specification
Specification Stnadard specification Item Size Bucket capacity 1.7m Rated load 3000kg Boom lifting time(full load) ≤5.4s Cycle time 9.3s Highest speed at each gear Gear Forward I 8km/h Gear Forward II 13km/h Gear ForwardⅢ 　 24km/h Gear Forward IV 36km/h Gear Reverse I 9km/h Gear Reverse II...
Page 165 Model WEICHAI WP6G125E22 Displacement 6750cc...
Page 166: Braking System
Braking system Item Size Service braking (foot braking)： Single pipeline, air-poppet oil 4-wheel caliper disc brake Brake disc diameter φ460mm Parking braking Flexible shaft control System air pressure 0.71~0.784 MPa Steering system Item Specification Type Articulation frame, full hydraulic system Steering cylinders —...
Page 167: Electrical System
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 155L Hydraulic oil Tank Capacity 127L Crankcase Gearbox system Axle (Housing and hub wheel ) Front axle Rear axle A/C System (optional)
Page 168: 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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