Hyundai R130VS PRO Manual
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Hyundai R130VS PRO Manual

Hyundai R130VS PRO Manual

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Foreword ----------------------------------------------------------- 0-1
Before servicing this machine --------------------------- 0-2
EC regulation approved ------------------------------------ 0-3
Table to enter S/No and distribution --------------------- 0-4
Safety labels ------------------------------------------------------ 0-5
Guide (direction, S/No, symbol) ------------------------ 0-19
Machine data plate -------------------------------------------- 0-20
1. Before operating the machine -------------------- 1-1
2. During operating the machine -------------------- 1-15
3. During maintenance ----------------------------------- 1-22
4. Parking -------------------------------------------------------- 1-25
1. Major components ------------------------------------- 2-1
2. Specifications -------------------------------------------- 2-2
3. Working range ------------------------------------------- 2-3
4. Weight ------------------------------------------------------- 2-4
5. Lifting capacities ---------------------------------------- 2-5
6. Bucket selection guide ------------------------------- 2-6
7. Undercarriage ------------------------------------------- 2-7
9. Recommended oils ------------------------------------ 2-12
1. Cab devices ----------------------------------------------- 3-1
2. Cluster ------------------------------------------------------- 3-2
3. Switches ---------------------------------------------------- 3-19
4. Levers and pedals ------------------------------------- 3-23
5. Air conditioner and heater ------------------------- 3-25
6. Others -------------------------------------------------------- 3-28
1. Suggestion for new machine ---------------------- 4-1
3. Starting and stop the engine ---------------------- 4-3
4. Mode selection system ------------------------------ 4-7
5. Operation of the working device ----------------- 4-12
6. Traveling of the machine ------------------------- 4-13
7. Efficient working method ---------------------------
9. Normal operation of excavator ------------------- 4-22
10. Attachment lowering ---------------------------------- 4-23
11. Storage -----------------------------------------------------
12. RCV lever operating pattern ----------------------- 4-26
1. Preparation for transportation -------------------- 5-1
2. Dimension and weight ------------------------------- 5-2
3. Loading the machine --------------------------------- 5-4
4. Fixing the machine ------------------------------------ 5-6
1. Instruction ------------------------------------------------- 6-1
2. Tightening torque --------------------------------------- 6-6
3. Fuel, coolant and lubricants ----------------------- 6-9
4. Maintenance check list ------------------------------ 6-11
5. Maintenance chart ------------------------------------ 6-16
6. Service instruction ------------------------------------- 6-18
7. Electrical system --------------------------------------- 6-42
8. Air conditioner and heater -------------------------- 6-45
1. Engine ------------------------------------------------------ 7-1
2. Electrical system --------------------------------------- 7-2
3. Others ------------------------------------------------------- 7-3
1. Selecting hydraulic breaker ------------------------ 8-1
2. Circuit configuration ----------------------------------- 8-2
3. Maintenance --------------------------------------------- 8-3
5. Quick clamp ---------------------------------------------- 8-6
CONTENTS
CONTENTS
4-16
4-24

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  • Page 1: Table Of Contents

    CONTENTS CONTENTS Foreword ----------------------------------------------------------- 0-1 6. Traveling of the machine ------------------------- 4-13 Before servicing this machine --------------------------- 0-2 7. Efficient working method --------------------------- 4-16 EC regulation approved ------------------------------------ 0-3 8. Operation in the special work sites ------------- 4-20 Table to enter S/No and distribution --------------------- 0-4 9.

  • Page 2: Foreword

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

  • Page 3: Before Servicing This Machine

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

  • Page 4: Ec Regulation Approved

    EC REGULATION APPROVED EC REGULATION APPROVED · Noise level (EN474-1 : 2006 and 2000/14/EC) are as followings. : 102 dB (EU only) 78 dB · The value of vibrations transmitted by the operator's seat are lower than standard value of (EN474-1 : 2006 and 2002/44/EC)
  • Page 5 EC Declaration of Conformity 1. HYUNDAI CONSTRUCTION EQUIPMENT EUROPE N.V VOSSENDAAL 11, 2440 GEEL (Belgium), as authorized repre- sentative in the European Community of HYUNDAI CONSTRUCTION EQUIPMENT Co. Ltd.(Korea) certifies that the construction equipment machinery. Machine Type : ******* Brand : HYUNDAI...
  • Page 6 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR Machine Serial No. Engine Serial No. Manufacturing year Manufacturer Hyundai Construction Equipment co., Ltd. 12th, Fl., Hyundai Bldg. 75, Yulgok-ro, Jongno-Gu, Address Seoul, 03058, Korea Hyundai Construction Equipment U.S.A, Inc Distributor for U.S.A 6100 Atlantic Boulevard Norcross...

  • Page 7: Safety Labels

    SAFETY LABELS SAFETY LABELS 1. LOCATION 1. LOCATION Always keep these labels clean. If they are lost or damage, attach them again or replace them with a new label.

  • Page 8: Lifting Chart

    FOPS FOG PLATE LIFTING CHART 2-17 REFLECTOR/RH 2-16 REFLECTOR/LH 2-15 STAY FIX 2-14 NO STEP 2-13 FALLING 2-12 CONSOLE TILTING 2-11 FUELING-CHINA 2-10 SERVICE INSTRUCTION KEEP CLEAR/SIDE KEEP CLEAR/REAR KEEP CLEAR/ATTACH REFLECTING-RH REFLECTING-LH HYUNDAI LOGO HYUNDAI LOGO LOGO-ROBEX MODEL NAME...

  • Page 9: Safety Seat

    1-32 FUSE CAUTION 1-31 SWING BEARING 1-30 RCV/LEVER PATTERN 1-29 CABIN RH PILLAR(LC) 1-28 SHEARING 1-27 WATER SEPARATOR 1-26 LIFTING EYE 1-25 R/GEAR GREASE 1-24 TRANSPORTING 1-23 HYD. OIL LEVEL 1-22 ECU CONNECTOR 1-21 TURBOCHARGER 1-20 SAFETY SEAT 1-19 DIRECTION 1-18 CAUTION KEY OFF 1-17...

  • Page 10: Radiator Cap

    2. DESCRIPTION 2. DESCRIPTION There are several specific warning labels on this machine please become familiarized with all warning labels. Replace any safety label that is damaged, or missing. If a safety label is attached to a part that is replaced, install a safety label on the replacement part.

  • Page 11: High Pressure Hose

    HYDRAULIC OIL LUBRICATION HYDRAULIC OIL LUBRICATION (item 3) 3) 1-3) This warning label is positioned on the top ※ of the hydraulic tank. Do not mix with different brand oils. Do not mix with different brand oils. Never open the filler cap while high tem- Never open the filler cap while high tem- perature.

  • Page 12: Air Conditioner Filter

    6) 6) SAFETY LEVER SAFETY LEVER (item 1-7) This warning label is positioned on the cover of the safety lever. Before you get off the machine be sure Before you get off the machine be sure to place the safety lever LOCKED posi- to place the safety lever LOCKED posi- tion.

  • Page 13: Air Cleaner Filter

    A special air bleed valve is accumulator. A special air bleed valve is necessary for this operation, so please necessary for this operation, so please contact your Hyundai distributor. contact your Hyundai distributor. AIR CLEANER FILTER AIR CLEANER FILTER (item 1-11) This warning label is positioned on the air cleaner cover.
  • Page 14 SAFETY FRONT WINDOW SAFETY FRONT WINDOW (item 1-14) This warning label is positioned on the both side window of the cab. Be careful that the front window may be Be careful that the front window may be promptly closed. promptly closed. 13 13) SAFETY REAR WINDOW SAFETY REAR WINDOW (item 1-15)
  • Page 15 CAUTION KEY OFF CAUTION KEY OFF (item 1-18) This warning label is positioned on the right side window of the cab. Park on a flat place and stop the engine Park on a flat place and stop the engine ※ for inspecting and repairing.

  • Page 16: Hydraulic Oil Level

    HYDRAULIC OIL LEVEL HYDRAULIC OIL LEVEL (item 1-23) This warning label is positioned on the screen plate. Place the bucket on the ground whenev- Place the bucket on the ground whenev- er servicing the hydraulic system. er servicing the hydraulic system. Check oil level on the level gauge.

  • Page 17: Water Separator

    WATER SEPARATOR WATER SEPARATOR (item 1-27) In order to protect high pressure fuel sys- tem. Please drain water in water separator beforestarting the engine. In order to protect high pressure fuel system, In order to protect high pressure fuel system, please drain water in water separator before please drain water in water separator before starting the engine.
  • Page 18 FUSE CAUTION FUSE CAUTION (item 1-32) When the CAN communication between the ECM and the MCU is abnormal due to malfunciton of the MCU and the CAN BUS,follow next step. Disconnect CN-16 with CN-16A Disconnect CN-16 with CN-16A When the CAN communication Connect CN-16 with CN-16B Connect CN-16 with CN-16B between the ECM and the MCU is...
  • Page 19 KEEP CLEAR / REAR KEEP CLEAR / REAR (item 2-8) This warning label is positioned on the rear of counterweight. To prevent serious personal injury or To prevent serious personal injury or death keep clear or machine swing radi- death keep clear or machine swing radi- Do not deface of remove this label from Do not deface of remove this label from the machine.
  • Page 20 FALLING FALLING (item 2-13) This warning label is positioned on the top of the hydraulic tank. Falling is one of the major cause of Falling is one of the major cause of per-sonal injury. per-sonal injury. Be careful of slippery conditions on the Be careful of slippery conditions on the platforms, steps and handrails when platforms, steps and handrails when...

  • Page 21: Guide (Direction, S/No, Symbol)

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

  • Page 22: Machine Data Plate

    The machine serial number assigned to this particular machine and should be used when requesting ※ information or ordering service parts for this machine from your authorized HYUNDAI dealer. The machine serial number is also stamped on the frame. 0-20...

  • Page 23: Safety Hints

    SAFETY HINTS SAFETY HINTS 1. BEFORE OPERATING THE MACHINE 1. BEFORE OPERATING THE MACHINE Think-safety first. In special situation, wear protective clothing including a safety helmet, safety shoes, gloves, safety glasses and ear protection as required by the job condition. Almost every accident is caused by disregarding the simple and fundamental safety hints.
  • Page 24 Check daily according to the operation manual. Repair the damaged parts and tighten the loosened bolts. Check for leakage of engine oil, hydraulic oil, fuel and coolant. Keep machine clean, clean machine regularly. Do not operate the machine if it requires repairs. Operate after complete repair.

  • Page 25: Unauthorized Modification

    UNAUTHORIZED MODIFICATION Any modification made without authorization from Hyundai can create hazards. Before making a modification, consult your Hyundai distributor. Hyundai will not be responsi- ble for any injury or damage caused by any unau- thorized modification. PREPARE FOR EMERGENCY...

  • Page 26: Safety Rules

    When you operate a machine on a road or beside a road, a rotating beacon is required to avoid any traffic accident. Please contact your Hyundai distributor to install it. PRECAUTIONS FOR ATTACHMENTS PRECAUTIONS FOR ATTACHMENTS When installing and using an optional attachment,...

  • Page 27: Safety Features

    SAFETY FEATURES SAFETY FEATURES Be sure all guards and covers are in their proper position. Have guards and covers repaired if damaged. Use safety features such as safety lock and seat belts properly. Never Never remove any safety features. Always Always keep them in good operating condition.

  • Page 28: Fire Prevention And Explosion Prevention

    FIRE PREVENTION AND EXPLOSION PREVENTION FIRE PREVENTION AND EXPLOSION PREVENTION Regeneration Regeneration The exhaust gas temperatures during regeneration will be elevated. Follow proper fire prevention instructions and use the disable regeneration function when appropriate. General General All fuels, most lubricants, and some coolant mixtures are flammable.
  • Page 29 Store fuels and lubricants in properly marked containers away from unauthorized personnel. Store oily rags and flammable materials in protective containers. Do not smoke in areas that are used for storing flammable materials. Use caution when you are fueling a machine. Do not smoke while you are fueling a machine.
  • Page 30 Attaching electrical wiring to hoses and tubes that contain flammable fluids or combustible fluids should be avoided. Consult your Hyundai dealer for repair or for replacement parts. Keep wiring and electrical connections free of debris.
  • Page 31 Do not operate a machine when a fire hazard exists. Repair any lines that are corroded, loose, or damaged. Leaks may provide fuel for fires. Consult your Hyundai dealer for repair or for replacement parts. E E ther ther Ether (if equipped) is commonly used in cold weather applications.
  • Page 32 F F ire Extinguisher ire Extinguisher As an additional safety measure, keep a fire extinguisher on the machine. Be familiar with the operation of the fire extinguisher. Inspect the fire extinguisher and service the fire extinguisher regularly. Follow the recommendations on the instruction plate. Consider installation of an aftermarket Fire Suppression System, if the application and working conditions warrant the installation.
  • Page 33 Do not weld the ROPS structure in order to install the fire extinguisher. Also, do not drill holes in the ROPS structure in order to mount the fire extinguisher on the ROPS. Consult your Hyundai dealer for the proper procedure for mounting the fire extinguisher. 1-11...
  • Page 34 THE EUROPEAN UNION PHYSICAL AGENTS (VIBRATION) DIRECTIVE 2002/44/EC THE EUROPEAN UNION PHYSICAL AGENTS (VIBRATION) DIRECTIVE 2002/44/EC V V ibration Data for Earth-moving Machines ibration Data for Earth-moving Machines I I nformation Concerning Hand/Arm Vibration Level nformation Concerning Hand/Arm Vibration Level When the machine is operated according to the intended use, the hand/arm vibration of this machine is below 2.5 m/s I I nformation Concerning Whole Body Vibration Level...
  • Page 35 All vibration levels are in meter per second squared. All vibration levels are in meter per second squared. ※ ISO Reference Table A – Equivalent vibration levels of whole body vibration emission for earthmoving equipment. Vibration Levels Scenario Factors Machine Typical operating Machine kind family...
  • Page 36 G G uidelines for Reducing Vibration Levels on Earthmoving Equipment uidelines for Reducing Vibration Levels on Earthmoving Equipment Properly adjust machines. Properly maintain machines. Operate machines smoothly. Maintain the conditions of the terrain. The following guidelines can help reduce the whole body vibration level : Use the right type and size of machine, equipment, and attachments.

  • Page 37: During Operating The Machine

    2. DURING OPERATING THE MACHINE 2. DURING OPERATING THE MACHINE Use the handle and footstep when getting on or off the machine. Do not jump on or off the machine. Sound the horn to warn nearby personnel before operating the machine. Remove all the obstacles like frost on the window before operating the machine for the good visibility.
  • Page 38 Provide proper ventilation when operating engine in a closed area to avoid the danger of exhaust gases. Check the locations of underground gas pipes or water line and secure the safety before operation. The operating near the electrical lines is very dangerous.
  • Page 39 Watch out for obstacles. Be particularly careful to check the machine clearance during the swing. When using the machine as breaker or working in a place where stones may fall down, cab roof guard and head guard should be provided for proper protection.
  • Page 40 The operation on a slope is dangerous. Avoid operating the machine on a slope of over 10 degree. Operate the machine after making ground flat when operation is required on a slope. The swing on the slope can be danger of rolling over.
  • Page 41 Avoid traveling in a cross direction on a slope as it can cause the danger of rolling over and sliding. Traveling on a slope is dangerous. Be sure to operate slowly when traveling down a slope and maintain the bucket at a height of 20~30 cm (1 ft) above the ground so that it can be used as brake in an emergency.
  • Page 42 Before traveling the machine, sound the horn to warn nearby personnel. Operate forward and backward correctly with confirming the location of the travel motor. Slow down when traveling through obstacles or uneven ground. When working on soft ground, place mats or wood boards on the ground to prevent the machine sinking.

  • Page 43: Mounting And Dismounting

    Additional track frame step can be fitted for wider optional shoe. In this case please contact your Hyundai distributor. Do not hold any control levers when getting on or off the machine.

  • Page 44: During Maintenance

    3. DURING MAINTENANCE 3. DURING MAINTENANCE Stop the engine immediately when the trouble of the machine is found. Inspect immediately the cause of trouble such as vibration, overheating and trouble in the cluster then repair. Park on a flat place and stop the engine for inspecting and repairing.
  • Page 45 There is the danger of fire in fuel and oil. Store in cool and dry area, away from any open flames. Do not touch exhaust pipe, or may cause severe burn. Do not open the engine hood and covers while the engine is running.
  • Page 46 Be careful that the front window may be promptly closed. Be sure to support stay, when the side door needs to be opened. Be careful that the open side door may closed by the external or natural force like strong wind. The antislip protection should be replaced if they have become worn or have been printed over.

  • Page 47: Parking

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

  • Page 48: Specifications

    SPECIFICATIONS SPECIFICATIONS 1. MAJOR COMPONENT 1. MAJOR COMPONENT Boom cylinder Boom Arm cylinder Counterweight Bucket Swing bearing Bucket cylinder Travel motor Idler Connecting link Side cutter Sproker Connecting rod Track rollor Carrier rollor Track Tool box Fuel tank Hydraulic tank Main pump Engine Tooth...

  • Page 49: Specifications

    2. SPECIFICATIONS 2. SPECIFICATIONS Description Unit Specification Operating weight kg (lb) 13400 (29541) Bucket capacity (SAE heaped), standard 0.52(0.68) Overall length 7820 (25' 8") Overall width, with 500 mm shoe 2500 (8' 2") Overall height 2850 (9' 4") Superstructure width 2476 ( 8' 1") Overall height of cab 2860 ( 9' 5")

  • Page 50: Working Range

    3. WORKING RANGE 3. WORKING RANGE · · 4.60 4.60 m m (15' 1") (15' 1") BOOM BOOM Description 2.5 m (8' 2") Arm Max digging reach 8330mm (27' 4") Max digging reach on ground 8180mm (26' 10") Max digging depth 5550 mm (18' 3") Max digging depth (8ft level) 5340 mm (17' 6")

  • Page 51: Weight

    4. WEIGHT 4. WEIGHT R130VSPRO Item Upperstructure assembly 5630 12420 Main frame weld assembly 1160 2560 Engine assembly Main pump assembly Main control valve assembly Swing motor assembly Hydraulic oil tank assembly Fuel tank assembly Counterweight 2000 4410 Cab assembly 1100 Lower chassis assembly 5340...

  • Page 52: Lifting Capacities

    Lifting capacities will vary with different work tools, ground conditions and attachments. The difference between the weight of a work tool attachment must be subtracted. Consult your Hyundai dealer regarding the lifting capacities for specific work tools and attachments. Failure to comply to the rated load can cause possible personal injury or property damage.

  • Page 53: Bucket Selection Guide

    6. BUCKET SELECTION GUIDE 6. BUCKET SELECTION GUIDE 1) 1) GENERAL BUCKET GENERAL BUCKET 0.52 m heaped bucket Recommendation Capacity Width boom 4 . 60 m (15' 1") Weight CECE Without With 2 . 5 m arm heaped heaped side cutter side cutter (8' 2") 0.45m...

  • Page 54: Undercarriage

    Triple grouser Model Shapes Shoe width mm (in) 500 (20) Operating weight kg (lb) 13400 (29541) R130VS PRO Ground pressure kgf/cm (psi) 0.43(6.11) Overall width mm (ft-in) 2500 (8' 2") 3) 3) NUMBER OF ROLLERS AND SHOES ON EACH SIDE...
  • Page 55 4) 4) SELECTION OF TRACK SHOE SELECTION OF TRACK SHOE Suitable track shoes should be selected according to operating conditions. Method of selecting shoes Method of selecting shoes Confirm the category from the list of applications in table 2 table 2, then use table 1 table 1 to select the shoe.

  • Page 56: Specification For Major Components

    8. SPECIFICATIONS FOR MAJOR COMPONENTS 8. SPECIFICATIONS FOR MAJOR COMPONENTS ENGINE ENGINE 1) 1) Item Specification Model Cummins F3.8 Type 4-cycle turbocharged charger air cooled diesel engine Cooling method Water cooling Number of cylinders and arrangement 4 cylinders, in-line Firing order 1-3-4-2 Combustion chamber type Direct injection type...

  • Page 57: Main Control Valve

    3) 3) GEAR PUMP GEAR PUMP Item Specification Type Fixed displacement gear pump single stage Capacity 15cc/rev Maximum pressure 40 kgf/cm Rated oil flow 25.5ℓ/min 4) 4) MAIN CONTROL VALVE MAIN CONTROL VALVE Item Specification Type 11 spools Operating method Hydraulic pilot system Main relief valve pressure 350 kgf/cm...
  • Page 58 7) 7) CYLINDER CYLINDER Item Specification Bore dia×Rod dia×Stroke Ø105×Ø75×1075 mm Boom cylinder Cushion Extend only Bore dia×Rod dia×Stroke Ø115×Ø80×1138 mm Arm cylinder Cushion Extend and retract Bore dia×Rod dia×Stroke Ø100×Ø70×850 mm Bucket cylinder Cushion Extend and retract ※ Discoloration of cylinder rod can occur when the friction reduction additive of lubrication oil spreads on the rod Discoloration of cylinder rod can occur when the friction reduction additive of lubrication oil spreads on the rod surface.

  • Page 59: Recommended Oils

    Use only oils listed below. Do not mix different brand oil. Use only oils listed below. Do not mix different brand oil. Please use HYUNDAI genuine oil and grease. Please use HYUNDAI genuine oil and grease. Ambient temperature C#( F)

  • Page 60: Control Devices

    CONTROL DEVICES CONTROL DEVICES 1. CAB DEVICES 1. CAB DEVICES The ergonomically designed console box and suspension type seat provide the operator with comfort. 2) 2) ELECTRONIC MONITOR SYSTEM ELECTRONIC MONITOR SYSTEM The centralized electronic monitor system allows the status and conditions of the machine to be monitored at a glance.

  • Page 61: Cluster

    2. CLUSTER(CMCU) 2. CLUSTER(CMCU) STRUCTURE STRUCTURE The monitor panel consists of LCD and lamps as shown below, to warn the operator in case of abnormal machine operation or conditions for the appropriate operation and inspection. ·LCD : Indicate operating status of the machine. ·Warning lamp : Indicate abnormality of the machine(Red).
  • Page 62 2) 2) GAUGE GAUGE (1) (1) Operation screen Operation screen Time display Fuel level guage Engine coolant temperature guage Hydraulic oil temperature guage Engine speed(rpm) RPM / Tripmeter display Operation screen type can be set by the screen type menu of the display. Operation screen type can be set by the screen type menu of the display.

  • Page 63: Warning Lamps

    (5) (5) RPM / Tripmeter display RPM / Tripmeter display This displays the engine rpm or the tripmeter. ① WARNING LAMPS WARNING LAMPS 3) 3) Warning lamp ※ The warming lamp lights ON and the buzzer sounds when the machine has a problem. In this case, The warming lamp lights ON and the buzzer sounds when the machine has a problem.
  • Page 64 (3) (3) Fuel level Fuel level This warning lamp pops up and the buzzer sounds when the ① level of fuel is below 31 (8.2 U.S. gal). Fill the fuel immediately when the lamp blinks. ② (4) (4) Check engine warning lamp Check engine warning lamp This lamp blinks and the buzzer sounds when the ①...
  • Page 65 (8) (8) Air cleaner warning lamp Air cleaner warning lamp This lamp blinks when the filter of air cleaner is clogged. ① Check the filter and clean or replace it. ② (9) (9) Overload warning lamp Overload warning lamp (opt) ①...

  • Page 66: Pilot Lamps

    4) 4) PILOT LAMPS PILOT LAMPS Pilot lamps (1) (1) Mode pilot lamps Mode pilot lamps Mode Pilot lamp Selected mode Max power mode Power mode High power mode Standard power mode User mode User preferable power mode General operation mode Work mode Heavy duty work mode Low speed traveling...
  • Page 67 Preheat pilot lamp Preheat pilot lamp (3) (3) Turning the start key switch ON position starts preheating in cold ① weather. Start the engine after this lamp is OFF. ② (4) (4) Warming up pilot lamp Warming up pilot lamp This lamp is turned ON when the coolant temperature is below ①...

  • Page 68: Switches

    5) 5) SWITCHES SWITCHES Auto decel switch Buzzer stop switch ESC switch Menu switch Power mode switch Travel speed switch Work mode switch User mode switch When the switches are selected, the pilot lamps are displayed on the LCD. When the switches are selected, the pilot lamps are displayed on the LCD. ※...
  • Page 69 (3) (3) User mode switch User mode switch This Switch select User Mode ① Menu switch Menu switch (4) (4) ① This switch used to select the main menu and subordinate menu on the LCD (5) (5) Auto idle/ buzzer stop switch Auto idle/ buzzer stop switch This switch is used to activate or cancel the auto idle function.
  • Page 70 MAIN MENU MAIN MENU 6) 6) (1) (1) Structure Structure Main menu Sub menu Description Equipment Device information and status Switch Switch state Output output state Current Error CMCU, engine ECM fault record confirmation Recorded Error and delete Change the exchange cycle of oil and filter Equipment element maintenance...
  • Page 71 (2) (2) Monitoring Monitoring Equipment Equipment ① Equipment status information. · Switch Switch ② Switch status information. · Output Output ③ · Output status information 3-12...
  • Page 72 (3) (3) Diagnosis Current Error Current Error ① Equipment status information. · Recorded Error Recorded Error ② · You can check past CMCU or engine ECM failures 3-13...
  • Page 73 (4) (4) Management Management Maintenance information Maintenance information ① · The exchange cycle and remaining time of consumables can be confirmed. Remaining time initialization: The remaining time can be initialized. · Change the switching period: You can set the switching period. ·...
  • Page 74 Machine security Machine security ② ESL mode ESL mode · ESL : Engine Starting Limit ESL mode is desingned to be a theft deterrent or will prevent the unauthorized operation of the machine. If the ESL mode was selected Enable, the password will be required when the start switch is turned Disable : Not used ESL function Enable (always) : The password is required whenever the operator start engine.
  • Page 75 Dual mode Dual mode ③ You can change the mode of the device. · Camera Camera ④ 3-16...
  • Page 76 (5) (5) Display Display Operation skin Operation skin ① You can set the screen type. (Analog/digital) · Brightness Brightness ② · You can set and store the values of engine high-speed idling RPM, autotorque reduction RPM and EPPR valve input current respectively in user mode (U). The menu is only accessible when user mode (U) is selected.
  • Page 77 Language Language ③ User can select preferable language and all displays are changed the selected language. · (6) (6) User mode User mode User mode switch User mode switch ① You can set and store the values of engine high-speed idling RPM, autotorque reduction RPM and ·...

  • Page 78: Starting Switch

    3. SWITCHES 3. SWITCHES Accel dial Breaker selection switch(opt) Start switch Cab light switch Switch Radio control panel Travel alarm switch panel Preheat switch Washer switch Wiper switch Main light switch Horn switch Breaker operation switch Master switch One touch decel switch Power max switch 1) 1) STARTING SWITCH...

  • Page 79: Master Switch

    2) 2) MASTER SWITCH MASTER SWITCH This switch is used to shut off the entire electrical system. I : The battery remains connected to the electrical system. O : The battery is disconnected to the electrical system. Never turn the master switch to Never turn the master switch to O O (OFF) (OFF) with the engine running.

  • Page 80: Preheat Switch

    6) 6) WIPER SWITCH WIPER SWITCH This switch used to operate wiper. Pilot lamp(2nd) - Press the switch once to intermittently operate wiper. - Press the switch once to intermittently operate wiper. - Press the switch once more to operate wiper low speed. - Press the switch once more to operate wiper low speed.
  • Page 81 BREAKER OPERATION SWITCH BREAKER OPERATION SWITCH On pressing this switch, the breaker operates only when the breaker Breaker Breaker operation operation mode is selected. operation switch switch RH RCV-lever RH RCV-lever BREAKER OPERATION SWITCH BREAKER OPERATION SWITCH This switch activate power max function. When this switch is kept pressed, hydraulic power of work equipment Power max switch...

  • Page 82: Levers And Pedals

    4. LEVERS AND PEDALS 4. LEVERS AND PEDALS RH control lever Dozer control lever(opt) Travel lever Safety lever LH control lever(opt) Travel pedal Seat and console box adjust lever 1) 1) LH CONTROL LEVER LH CONTROL LEVER This joystick is used to control the swing and the arm. Refer to operation of working device in chapter 4 for details.
  • Page 83 3) 3) SAFETY LEVER SAFETY LEVER All control levers and pedals are disabled from operation by locating the lever to lock position as shown. ※ Be sure to lower the lever to LOCK position when leaving from Be sure to lower the lever to LOCK position when leaving from operator's seat.

  • Page 84: Air Conditioner And Heater

    5. AIR CONDITIONER AND HEATER 5. AIR CONDITIONER AND HEATER THE AIR CONDITIONER AND HEATER ARE PROVIDED TO ENSURE THE COMFORT DURING THE AIR CONDITIONER AND HEATER ARE PROVIDED TO ENSURE THE COMFORT DURING ■ ■ OPERATION. OPERATION. Location of air flow ducts Location of air flow ducts ·...

  • Page 85: Temperature Control Switch

    1) 1) POWER OFF SWITCH POWER OFF SWITCH This switch makes the system and the LED OFF. Just before the power OFF, set values are stored. (2) (2) Default setting values Default setting values Function Air conditioner Fan speed Outlet Temperature Inlet Max warn...
  • Page 86 5) 5) OUTLET CHANGE OVER SWITCH OUTLET CHANGE OVER SWITCH Operating this switch, it beeps and displays symbol of each mode in order. ·A type : Vent → Vent/Foot → Foot → Foot/Def → Vent Mode Switch position ● ● Outlet ●...

  • Page 87: Others

    6. OTHERS 6. OTHERS Radio & USB player Radio remote Seat controller CMCU Cluster Electric box Electric box Service meter EMERGENCY 3-28...
  • Page 88 1) 1) RADIO RADIO (1)Power (1)Power (2)Mut/Loudness (2)Mut/Loudness (3)APS/Band (3)APS/Band (4)Memory radio (4)Memory radio (5)LCD (5)LCD (6)VOL +/- (6)VOL +/- (7) Sound effect / clock setting (7) Sound effect / clock setting (8) Radio search (8) Radio search (1) (1) Power Power ▶...
  • Page 89 (6)VOL+/- VOL+/- Press the Vol + / - key to increase or decrease the volume. Press the Vol + / - key to increase or decrease the volume. (7)Sound effect / clock setting Sound effect / clock setting ▶ ▶ Short press the display clock and press this key within 5 seconds to enter the Short press the display clock and press this key within 5 seconds to enter the sound effect setting.
  • Page 90 2) 2) SEAT SEAT The seat is adjustable to fit the contours of the operator's body. It will reduce operator fatigue due to long work hours and enhance work efficiency. (1) (1) Technical characteristics Technical characteristics Maximum suspension stroke of vibration reduction is ①...
  • Page 91 (4) (4) Seat front and rear adjustment instructions Seat front and rear adjustment instructions Move the seat slideway to adjust the handle. ① Drag the seat forward or backward to slide back ② and forth. After adjusting to a proper position, release the ③...
  • Page 92 (8) (8) Matters needing attention Matters needing attention When adjusting the seat before and after adjusting ① the Angle of the backrest, the adjusting handle plate should be in place and the lock should be completely removed before adjustment. After adjustment, the return position of each handle ②...

  • Page 93: Fuse & Relay Box

    FUSE & RELAY BOX FUSE & RELAY BOX The fuses protect the electrical parts and wiring from burning out. The fuse box cover indicates the capacity of each fuse and circuit it protects. ※ Replace a fuse with another of the same capacity. Replace a fuse with another of the same capacity.
  • Page 94 6) 6) EMERGENCY ENGINE EMERGENCY ENGINE SPEED CONTROL SPEED CONTROL CONNECTOR CONNECTOR When the CAN communication between the ECM and the MCU is abnormal due to malfunction of the MCU, change CN-16 connection from CN-16A to CN-16B and then control the engine speed by rotating accel dial switch.
  • Page 95 9) 9) UPPER WINDSHIELD UPPER WINDSHIELD Perform the following procedure in order to open the upper windshield. Release both latches(1) in order to release the upper windshield. ① Hold both grips that are located at the bottom of the windshield frame ②...

  • Page 96: Operation

    OPERATION OPERATION 1. SUGGESTION FOR NEW MACHINE 1. SUGGESTION FOR NEW MACHINE It takes about 100 operation hours to enhance its designed performance. Operate according to below three steps and avoid excessive operation for the initial 100 hours. Avoid excessive Avoid excessive operation for initial operation for initial...

  • Page 97: Check Before Starting The Engine

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

  • Page 98: Starting And Stop The Engine

    3. STARTING AND STOP THE ENGINE 3. STARTING AND STOP THE ENGINE 1) 1) CHECK INDICATOR LIGHTS CHECK INDICATOR LIGHTS Check if all the operating levers are in the neutral position. Turn the starting switch to the ON position. and check following: ①...

  • Page 99: Starting Engine In Cold Weather

    3) 3) STARTING ENGINE IN COLD WEATHER STARTING ENGINE IN COLD WEATHER Sound horn to warn surroundings after check- Sound horn to warn surroundings after check- ※ ing if there are obstacles in the area. ing if there are obstacles in the area. Replace the engine oil and fuel referring to Replace the engine oil and fuel referring to ※...

  • Page 100: Warming-Up Operation

    4) 4) INSPECTION AFTER ENGINE START INSPECTION AFTER ENGINE START Inspect and confirm the following after engine starts. Is the level gauge of hydraulic oil tank in the nor- mal level? Are there leakages of oil or water? Are all the warning lamps turned OFF ? Are the indicator of water temperature gauge and hydraulic temperature gauge in the operat- ing range?

  • Page 101: To Stop The Engine

    6) 6) TO STOP THE ENGINE TO STOP THE ENGINE If the engine is abruptly stopped before it has If the engine is abruptly stopped before it has ※ cooled down, engine life may be greatly cooled down, engine life may be greatly Low idling for shortened.

  • Page 102: Mode Selection System

    STRUCTURE OF MECHATRONICS MECHATRONICS SYSTEM SYSTEM CAPO, Computer Aided Power Optimization system, is the name of mode selection system developed by Hyundai. Please refer to chapter 3, cluster for below Please refer to chapter 3, cluster for below ※ modes setting.
  • Page 103 High idle rpm, auto idle rpm and EPPR pressure can be adjusted and memorized in the U-mode. (4) (4) Travel mode Travel mode : Low speed traveling. : High speed traveling. (5) (5) Auto idle mode Auto idle mode Pilot lamp ON : Auto idle function is activated. Pilot lamp OFF : Auto idle function is canceled.
  • Page 104 ECU diagnoses and displays on the LCD as fault codes (3 digit or more). fault codes (3 digit or more). CMCU ※ Consult Hyundai or Huyndai dealer for details. Anti-restart system (8) (8) The system protects the starter from inadvertent restarting after the engine is already operational.
  • Page 105 After engine start After engine start When the engine is started, rpm display ① indicates low idle. If coolant temperature is below 30˚C, the ② START warm-ing up pilot lamp lights ON and after 4 seconds the engine speed increases automati- cally to warm up the machine.
  • Page 106 M mode M mode When the accel dial is at setting 10 and auto decel mode is cancelled . M mode pilot lamp Effect Engine rpm Power mode switch Approximately 120 % of 1800 ± 50 power and speed available than S mode.

  • Page 107: Operation Of The Working Device

    5. OPERATION OF 5. OPERATION OF THE THE W W ORKING DEVICE ORKING DEVICE Confirm the operation of control lever and Confirm the operation of control lever and ※ working device. working device. Left control lever controls arm and swing. Right control lever controls boom and bucket.

  • Page 108: Traveling Of The Machine

    6. TRAVELING OF THE MACHINE 6. TRAVELING OF THE MACHINE 1) 1) BASIC OPERATION BASIC OPERATION (1) (1) Traveling position Traveling position It is the position which the traveling motor is in Traveling position Traveling position the rear and the working device is forward. Be careful as the traveling direction will be Be careful as the traveling direction will be reversed when the whole machine is swinged...
  • Page 109 TRAVELING ON A SLOPE TRAVELING ON A SLOPE Make sure that the travel lever is properly maneuvered by confirming the travel motor is in the right location. Lower the bucket 20 to 30 cm (1 ft) to the ground so that it can be used as a brake in an emergency.

  • Page 110: Towing The Machine

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

  • Page 111: Efficient Working Method

    7. EFFICIENT WORKING METHOD 7. EFFICIENT WORKING METHOD Do the digging work by arm. Use the pulling force of arm for digging and use together with the digging force of the bucket if necessary. When lowering and raising the boom operate Operate softy softly for the beginning and the end.
  • Page 112 Dig slowly with keeping the angle of boom and arm, 90-110 degree when maximum digging force is required. 90~110 Operate leaving a small safety margin of cylinder Margin Margin stroke to prevent damage of cylinder when working with the machine. Keep the bucket to the dumping position and the arm horizontal when dumping the soil from the bucket.
  • Page 113 Never carry out operations which may damage the machine such as overload or over-impact- load. Never travel while carrying a load. In case you need installing over load warning device for object handling procedure, please contact Hyundai distributor. 4-18...

  • Page 114: Bucket With Hook

    BUCKET WITH HOOK BUCKET WITH HOOK When carrying out lifting work, the special lifting hook is necessary. The following operations are prohibited. ·Lifting loads with a wire rope fitted around the Hook bucket teeth. ·Lifting loads with the wire rope wrapped directly around the boom or arm.

  • Page 115: Operation In The Special Work Sites

    8. OPERATION IN THE SPECIAL WORK SITES 8. OPERATION IN THE SPECIAL WORK SITES OPERATION THE MACHINE IN A COLD WEATHER OPERATION THE MACHINE IN A COLD WEATHER Use proper engine oil and fuel for the weather. Fill the required amount of antifreeze in the coolant.
  • Page 116 SEA SHORE OPERATION SEA SHORE OPERATION Prevent ingress of salt by securely tightening plugs, cocks and bolts of each part. Wash machine after operation to remove salt residue. Pay special attention to electrical parts, and hydraulic cylinders and track tension cylinder to prevent corrosion.

  • Page 117: Normal Operation Of Excavator

    9. NORMAL OPERATION OF EXCAVATOR 9. NORMAL OPERATION OF EXCAVATOR Followings may occur during operation due to the nature of a hydraulic excavator. When rolling in the arm, the roll-in movement stop momentary at point X in the picture shown, then recovers speed again after passing point X.

  • Page 118: Attachment Lowering

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

  • Page 119: Storage

    11. STORAGE 11. STORAGE Maintain the machine taking care of following to prevent the deterioration of machine when storing the machine for a long time, over 1 month. BEFORE STORAGE BEFORE STORAGE (1) (1) Cleaning the machine Cleaning the machine Clean the machine.

  • Page 120: During Storage

    Refer to the service instruction, section 6 for the drain plug location. ※ ※ If the machine is stored without carrying out the monthly lubricating operation, consult your If the machine is stored without carrying out the monthly lubricating operation, consult your Hyundai dealer for service. Hyundai dealer for service. 4-25...

  • Page 121: Rcv Lever Operating Pattern

    3 Swing right ③ ① 4 Swing left 5 Boom lower ④ 6 Boom raise ② Right 7 Bucket out ① Hyundai 8 Bucket in ③ 1 Boom lower ② A Type 2 Boom raise ④ Left 3 Swing right ③...

  • Page 122: Transportation

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

  • Page 123: Dimension And Weight

    2. DIMENSION AND WEIGHT 2. DIMENSION AND WEIGHT (1) (1) Base machine Base machine Mark Description Unit Specification Length mm (ft-in) 7820 (25' 8") Height mm (ft-in) 2775 (9' 1") Width mm (ft-in) 2500 (8' 2") Weight kg (lb) 11600(25580) ※...
  • Page 124 (5) (5) Boom cylinder Boom cylinder Mark Description Unit Specification Length mm (ft-in) 1760 ( 5' 9") Height mm (ft-in) 210 ( 0' 8") Width mm (ft-in) 310 ( 1' 0") Weight kg (lb) 260 (570) ※ Included piping. (6) (6) Cab assembly Cab assembly Mark...

  • Page 125: Loading The Machine

    3. LOADING THE MACHINE 3. LOADING THE MACHINE Load and unload the machine on a flat ground. Use the gangplank with sufficient length, width, thickness and gradient. Place the safety lever to the LOCK position (if equipped) before fixing the machine at the bed of trailer and confirm if the machine parallels the bed of trailer.
  • Page 126 Lower the working equipment gently after the location is determined. Place rectangular timber under the bucket Place rectangular timber under the bucket ※ cylinder to prevent the damage of it during cylinder to prevent the damage of it during transportation. transportation.

  • Page 127: Fixing The Machine

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

  • Page 128: Loading And Unloading By Crane

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

  • Page 129: Maintenance

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

  • Page 130: Proper Maintenance

    Confirm if the cluster is in the normal condition after completion of service. For more detail information of maintenance, please contact local Hyundai dealer. Be sure to start the maintenance after fully Be sure to start the maintenance after fully ※...
  • Page 131 RELIEVING THE PRESSURE IN THE HYDRAULIC SYSTEM RELIEVING THE PRESSURE IN THE HYDRAULIC SYSTEM ※ Spouting of oil can cause the accident when Spouting of oil can cause the accident when loosening the cap or hose right after the loosening the cap or hose right after the operating of machine as the machine or oil is operating of machine as the machine or oil is on the high pressure on the condition.
  • Page 132 PRECAUTION WHEN INSTALLING HYDRAULIC HOSES OR PIPES PRECAUTION WHEN INSTALLING HYDRAULIC HOSES OR PIPES Be particularly careful that the joint of hose, pipe and functioning item are not damaged. Avoid contamination. Assemble after cleaning the hose, pipe and joint of functioning item. Use genuine parts.
  • Page 133 PERIODICAL REPLACEMENT OF SAFETY PARTS PERIODICAL REPLACEMENT OF SAFETY PARTS It is desirable to do periodic maintenance the machine for using the machine safely for a long time. However, recommend to replace regularly the parts related safety not only safety but maintain satisfied performance.

  • Page 134: Tightening Torque

    2. TIGHTENING TORQUE 2. TIGHTENING TORQUE Use following table for unspecified torque. 1) 1) BOLT AND NUT BOLT AND NUT (1) (1) Coarse thread Coarse thread Bolt size kg·m lb·ft kg·m lb·ft M 6×1.0 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6 M 8×1.25...
  • Page 135 2) 2) PIPE AND HOSE PIPE AND HOSE (FLARE type) Thread size (PF) Width across flat (mm) kgf·m lbf·ft 1/4" 28.9 3/8" 36.2 1/2" 68.7 3/4" 1" 1-1/4" 3) 3) PIPE AND HOSE PIPE AND HOSE (ORFS type) Thread size (UNF) Width across flat (mm) kgf·m lbf·ft...
  • Page 136 TIGHTENING TORQUE OF MAJOR COMPONENT TIGHTENING TORQUE OF MAJOR COMPONENT Torque Descriptions Bolt size kgf·m lbf·ft Engine mounting bolt (engine-bracket, FR) M12 × 1.75 11.5 ± 1.0 81.2 ± 7.2 Engine mounting bolt (engine-bracket, RR) M12 × 1.75 11.5 ± 1.0 81.2 ±...

  • Page 137: Fuel, Coolant And Lubricants

    3. FUEL, COOLANT AND LUBRICANTS 3. FUEL, COOLANT AND LUBRICANTS 1) 1) NEW MACHINE NEW MACHINE New machine used and filled with following lubricants. Description Specification Engine oil SAE 15W-40 (API CI-4), ★ SAE 5W-40 (API CH-4) Hydraulic oil Conventional hydraulic oil (ISO VG 32, VG 46, VG 68) ★...
  • Page 138 Use only oils listed below. Do not mix different brand oil. Use only oils listed below. Do not mix different brand oil. Please use HYUNDAI genuine oil and grease. Please use HYUNDAI genuine oil and grease. Ambient temperature C#( F)

  • Page 139: Maintenance Check List

    4. MAINTENANCE CHECK LIST 4. MAINTENANCE CHECK LIST 1) 1) DAILY SERVICE BEFORE STARTING DAILY SERVICE BEFORE STARTING Check items Service Page Visual check Engine oil level Check, Add 6-18 Coolant level Check, Add 6-20 Fan belt tension Check, Adjust 6-26 Air cleaner Check, Clean, Add...

  • Page 140: Initial 50 Hours Service

    3) 3) INITIAL 50 HOURS SERVICE INITIAL 50 HOURS SERVICE Check items Service Page Lubricate 6-41 Attachment pin and bushing ·Boom cylinder tube end ·Boom foot ·Boom cylinder rod end ·Arm cylinder tube end ·Arm cylinder rod end ·Boom + Arm connecting ·Bucket cylinder tube end EVERY 200 HOURS SERVICE EVERY 200 HOURS SERVICE...

  • Page 141: Every 250 Hours Service

    6) 6) EVERY 250 HOURS SERVICE EVERY 250 HOURS SERVICE Check items Service Page Bolts & Nuts Check, Tight ·Sprocket mounting bolts ·Travel motor mounting bolts ·Swing motor mounting bolts ·Swing bearing mounting bolts ·Engine mounting bolts ·Counterweight mounting bolts ·Turning joint locating bolts ·Track shoe mounting bolts and nuts ·Hydraulic pump mounting bolts...
  • Page 142 8) 8) EVERY 1000 HOURS SERVICE EVERY 1000 HOURS SERVICE Check items Service Page Hydraulic oil return filter Replace 6-33 Drain filter cartridge Replace 6-34 Pilot line filter Replace 6-34 Swing reduction gear oil Change 6-35 Travel motor reduction gear oil Change 6-36 Grease in swing gear and pinion...

  • Page 143: When Required

    WHEN REQUIRED WHEN REQUIRED Whenever you have trouble in the machine, you must perform the service of related items, system by system. Check items Service Page Engine lubrication system ·Engine oil Change 6-18, 19 ·Engine oil filter Replace 6-18, 19 Engine cooling system Add or Change 6-21, 22, 23, 24...

  • Page 144: Maintenance Chart

    5. MAINTENANCE CHART 5. MAINTENANCE CHART Caution Caution 1. Service intervals are based on the hour meter reading. 2. The number of each item shows the lubrication point on the machine. 3. Stop engine while filling oil, and use no open flames. Service Service Capacity...
  • Page 145 Service Service Capacity Service Description interval action symbol points No. ℓ(U.S.gal) 7 Attachment pins & bushing Check, Add 8 Fuel tank (water, sediment) Check, Clean 50 Hours 10 Swing reduction gear case Check, Add 3.5(0.8) or weekly 12 Track tension Check, Adjust 24 Bucket connecting rod pin Check, Adjust...

  • Page 146: Service Instruction

    6. SERVICE INSTRUCTION 6. SERVICE INSTRUCTION 1) 1) CHECK ENGINE OIL LEVEL CHECK ENGINE OIL LEVEL Check the oil level with the machine on a flat ground before starting engine. Pull out the dipstick and wipe with a clean cloth. Check the oil level by inserting the dipstick completely into the hole and pulling out again.
  • Page 147 Apply a light film of lubricating oil to the gasket sealing surface before installing the filters. Fill the filters with clean lubricating oil. Fill the filters with clean lubricating oil. ※ Install the filter to the filter head. Mechanical over-tightening may distort the Mechanical over-tightening may distort the ※...
  • Page 148 CHECK COOLANT CHECK COOLANT Check if the level of coolant in reservoir tank is between FULL and LOW. Add the mixture of antifreeze and water after removing the cap of the reservoir tank if coolant is not sufficient. Be sure to add the coolant by opening the cap of radiator when coolant level is below LOW.
  • Page 149 45 seconds after dipping strip, compare results ③ to color chart and record in the following order: All three readings must be completed no later ④ than 75 seconds after dipping strip. If uncertain about the color match, pick the low ⑤...
  • Page 150 3-2) 3-2) FLUSHING AND REFILLING OF RADIATOR FLUSHING AND REFILLING OF RADIATOR Change coolant Change coolant (1) (1) Avoid prolonged and repeated skin contact Avoid prolonged and repeated skin contact with used antifreeze. with used antifreeze. Such prolonged Such prolonged repeated contact can cause skin disorders or repeated contact can cause skin disorders or other bodily injury.
  • Page 151 Operate the engine for 5 minutes with the ② coolant temperature above 80˚C (176˚F) . Shut the engine off, and drain the cooling system. START Fill the cooling system with clean water. ③ Be sure to vent the engine and aftercooler Be sure to vent the engine and aftercooler ※...
  • Page 152 3-3) 3-3) Cooling system filling Cooling system filling Soft water Use a mixture of 50 percent soft water and 50 ① Antifreeze percent ethylene glycol antifreeze to fill the cooling system. Never use water alone for coolant. Never use water alone for coolant. ※...
  • Page 153 Visually inspect the radiator for core leaks. 7) 7) CHECK CHARGE AIR COOLER CHECK CHARGE AIR COOLER Inspect the charge air cooler for dirt and debris blocking the fins. Check for cracks, holes, or other damage. If damage is found, please con- tact Hyundai distributor. 6-25...

  • Page 154: Fan Belt Tension

    8) 8) FAN BELT TENSION FAN BELT TENSION Measure the belt deflection at the longest span of the belt. ·Maximum deflection : 7.0±1.0 mm (0.28±0.04 inch) Inspect the drive for damage. NOT OK Inspect the drive belt and fan hub. 9) 9) INSPECTION OF COOLING FAN INSPECTION OF COOLING FAN...
  • Page 155 BELT TENSIONER, AUTOMATIC BELT TENSIONER, AUTOMATIC ADJUSTMENT ADJUSTMENT Every 1000 hours, or 1 year, whichever occurs first, inspect the automatic belt tensioner. With the engine turned off, check that neither the top nor bottom tensioner arm stop is touching the cast boss on the tensioner body. If either of the stops is touching a boss, the alternator belt must be replaced.
  • Page 156 Check the location of the drive belt on the belt tensioner pulley. The belt should be centered or close to the middle of the pulley. Misaligned belts, either too far forward or backward, can cause belt wear, belt roll-offs, or increase uneven tensioner bushing wear.

  • Page 157: Cleaning Of Air Cleaner

    CLEANING OF AIR CLEANER CLEANING OF AIR CLEANER Primary element Primary element Open the cover and remove the element. ① Clamp Clamp Clean the inside of the body. ② Clean the element with pressurized air. ③ · Remove the dust inside of the element by the pressurized air (below 3 kgf/cm , 40 psi) forward and backward equally.

  • Page 158: Replacement Of Fuel Filter

    REPLACEMENT OF FUEL FILTER REPLACEMENT OF FUEL FILTER Clean around the filter head, remove the filter and clean the gasket surface. Replace the O-ring. Make sure O-ring does not stick to filter head. Make sure O-ring does not stick to filter head. ※...
  • Page 159 LEAKAGE OF FUEL LEAKAGE OF FUEL Be careful and clean the fuel hose, injection Be careful and clean the fuel hose, injection FIRE !! FIRE pump, fuel filter and other connections as the pump, fuel filter and other connections as the leakage from these part can cause fire.

  • Page 160: Hydraulic Oil Check

    HYDRAULIC OIL CHECK HYDRAULIC OIL CHECK Red line Stop the engine after retract the arm and bucket cylinders, then lower the boom and set the bucket Level gauge on the ground at a flat location as in the illustration. Check the oil level at the level gauge of hydraulic oil tank.
  • Page 161 CLEAN SUCTION STRAINER CLEAN SUCTION STRAINER Clean suction strainer as follows paying attention to Air breather the cause to be kept during oil filling. Cover Remove the cover on the top of the oil tank. O-ring ·Tightening torque : 6.9±1.4 kgf·m (50±10 lbf·ft) Suction strainer Pull out the strainer in the tank.
  • Page 162 REPLACEMENT OF ELEMENT IN HYDRAULIC TANK REPLACEMENT OF ELEMENT IN HYDRAULIC TANK BREATHER BREATHER Relieve the pressure in the tank by pushing the top Cover Element of the air breather. Remove the cover. Remove the snap ring and pull out the filter element.
  • Page 163 CHECK THE SWING REDUCTION GEAR OIL CHECK THE SWING REDUCTION GEAR OIL Pull out the dipstick and clean it. Insert it again. Pull out one more time to check the oil level and fill the oil if the level is not sufficient. CHANGE SWING REDUCTION GEAR OIL CHANGE SWING REDUCTION GEAR OIL Filling...
  • Page 164 SWING GEAR AND PINION SWING GEAR AND PINION (1) (1) Drain old grease Drain old grease Remove under cover of lower frame. ① Remove drain cover of lower frame. ② Filler cover Remove filler cover of upper frame. ③ Operate full turn (360。 ) of swing several times. ④...
  • Page 165 LUBRICATE RCV LEVER LUBRICATE RCV LEVER Remove the bellows and with a grease gun grease the joint part (A) and sliding parts (B). ADJUSTMENT OF TRACK TENSION ADJUSTMENT OF TRACK TENSION It is important to adjust the tension of track It is important to adjust the tension of track ※...

  • Page 166: Replacement Of Bucket

    REPLACEMENT OF BUCKET REPLACEMENT OF BUCKET When knocking the pin in with a hammer, When knocking the pin in with a hammer, metal particles may fly and cause serious metal particles may fly and cause serious injury, particularly if they get into your eyes. injury, particularly if they get into your eyes.
  • Page 167 REPLACEMENT OF BUCKET TOOTH REPLACEMENT OF BUCKET TOOTH Timing of replacement Timing of replacement Check wearing condition as shown in the illustra- ① Tooth adapter tion and replace tooth tip before adapter starts to Tooth tip wear. If excessive use, tooth adapter has worn out, ②...
  • Page 168 ADJUSTMENT OF BUCKET CLEARANCE ADJUSTMENT OF BUCKET CLEARANCE Lower the bucket on the ground as the picture shown in the right. Swing to the left and keep the arm boss to be contact to the bucket left. Lock the safety lever to the LOCK position and stop the engine.
  • Page 169 LUBRICATE PIN AND BUSHING LUBRICATE PIN AND BUSHING (1) (1) Lubricate to each pin of working device Lubricate to each pin of working device Lubricate the grease to the grease nipple according to the lubricating interval. Description Lubrication manifold at boom Boom cylinder pin Boom and arm connection pin Arm cylinder pin (rod side)

  • Page 170: Electrical System

    7. ELECTRICAL SYSTEM 7. ELECTRICAL SYSTEM WIRING, GAUGES WIRING, GAUGES Check regularly and repair loose or malfunctioning gauges when found. 2) 2) BATTERY BATTERY (1) (1) Clean Clean Wash the terminal with hot water if it is contami- ① nated, and apply grease to the terminals after washing.
  • Page 171 STARTING THE ENGINE WITH A BOOSTER CABLE STARTING THE ENGINE WITH A BOOSTER CABLE Keep following order when you are going to start engine using booster cable. (1) (1) Connection of booster cable Connection of booster cable Connection of booster cable ※...
  • Page 172 (4) (4) Welding repair Welding repair Before start to welding, follow the below procedure. Master ① Shut off the engine and remove the starting switch switch. ② Disconnect ground cable from battery by master switch. ③ Before carrying out any electric welding on the machine, the battery cables should be discon- nected and the connectors pulled out of the electronic control units (MCU, cluster etc).

  • Page 173: Air Conditioner And Heater

    8. AIR CONDITIONER AND HEATER 8. AIR CONDITIONER AND HEATER CLEAN AND REPLACE OF CLEAN AND REPLACE OF FRESH AIR FRESH AIR FILTER Always stop the engine before servicing. Always stop the engine before servicing. Open the LH side cover. LH side cover Remove the fresh air filter.
  • Page 174 Remove recirculation filter Clean the recirculation filter using a pressurized air (below 2 kgf/cm , 28 psi) or washing with water. When using pressurized air, be sure to wear safety glasses. Dry off after washing with water. ※ Inspect the filter after cleaning. If it is damaged Pressurized air 2 kgf/cm below...

  • Page 175: Troubleshooting Guide

    TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE 1. ENGINE 1. ENGINE ※ This guide is not intended to cover every conditions, however many of the more common possibilities This guide is not intended to cover every conditions, however many of the more common possibilities are listed.

  • Page 176: Electrical System

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

  • Page 177: Others

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

  • Page 178: Hydraulic Breaker And Quick Clamp

    Become familiar with the manual and select break- ers suitable to machine specifications. Make careful selection in consideration of oil quan- tity, pressure and striking force, to enable satisfied performance. When apply a breaker to the machine, consult your local dealer of Hyundai for further explana- tion.

  • Page 179: Circuit Configuration

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

  • Page 180: Maintenance

    3. MAINTENANCE 3. MAINTENANCE 1) 1) MAINTENANCE OF HYDRAULIC OIL AND FILTER MAINTENANCE OF HYDRAULIC OIL AND FILTER Service interval As machine with an hydraulic breaker provides unit : hours the hydraulic oil becomes severely Operating Hydraulic Filter Attachment rate element contaminated.

  • Page 181: Precaution While Operating The Breaker

    4. PRECAUTIONS WHILE OPERATING THE BREAKER 4. PRECAUTIONS WHILE OPERATING THE BREAKER DO NOT BREAK ROCK WHILE LOWERING DO NOT BREAK ROCK WHILE LOWERING Incorrect As the breaker is heavy in comparison with bucket, it must be operated slowly. If breaker is rapidly pushed down, working device may be damaged.
  • Page 182 DO NOT CONTINUE TO WORKING OVER ONE DO NOT CONTINUE TO WORKING OVER ONE Incorrect MINUTE AT SAME POSITION OF BOOM AND ARM MINUTE AT SAME POSITION OF BOOM AND ARM This will increase the temperature of the oil, and One minute cause problem in the accumulator and seals.

  • Page 183: Quick Clamp

    5. QUICK CLAMP(OPTION) 5. QUICK CLAMP(OPTION) 1) 1) FIXING BUCKET WITH QUICK CLAMP FIXING BUCKET WITH QUICK CLAMP Before fixing bucket, remove safety pin of Quick clamp switch the moving hook. Safety button Pulling safety button, press the quick clamp switch to unlock position.
  • Page 184 HYUNDAI will not be responsible for HYUNDAI will not be responsible for any injury or damage in case that any injury or damage in case that safety pin is not installed properly.

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