Hyundai HL740-9A Manual
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Hyundai HL740-9A Manual

Hyundai HL740-9A Manual

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EC declaration of conformity ----------------------------- 0-1
Foreword ----------------------------------------------------------- 0-2
(USA and CANADA only) --------------------------------- 0-2-1
Before servicing this machine --------------------------- 0-3
Table to enter S/No and distribution --------------------- 0-4
EC regulation approved ------------------------------------ 0-5
Safety labels ------------------------------------------------------ 0-6
Machine data plate -------------------------------------------- 0-15
Guide (direction, S/No, symbol) ------------------------ 0-16
1. Before operating the machine -------------------- 1-1
2. During operating the machine -------------------- 1-15
3. During maintenance ----------------------------------- 1-24
4. Parking -------------------------------------------------------- 1-28
1. Major components -------------------------------------- 2-1
2. Specifications ---------------------------------------------- 2-2
3. Weight --------------------------------------------------------- 2-6
1. Cab devices ------------------------------------------------ 3-1
2. Cluster -------------------------------------------------------- 3-2
3. Monitors ------------------------------------------------------ 3-12
4. Switches ----------------------------------------------------- 3-33
5. Control device --------------------------------------------- 3-40
6. Air conditioner and heater -------------------------- 3-43
7. Others --------------------------------------------------------- 3-47
1. Suggestion for new machine ---------------------- 4-1
3. Starting and stop the engine ---------------------- 4-3
4. Warming-up operation -------------------------------- 4-8
6. Traveling of the machine ----------------------------- 4-10
7. Efficient working method ---------------------------- 4-15
10. Storage -------------------------------------------------------- 4-25
5.
1. Road traveling -------------------------------------------- 5-1
2. Preparation for transportation -------------------- 5-2
3. Loading the machine --------------------------------- 5-3
4. Fixing the machine ------------------------------------- 5-4
6. Towing the machine ------------------------------------- 5-7
1. Instructions ------------------------------------------------- 6-1
2. Tightening torque --------------------------------------- 6-5
3. Spec of fuel, coolant and lubricants ----------- 6-8
4. Maintenance check list ------------------------------- 6-10
5. Maintenance chart ------------------------------------- 6-13
6. Service instruction ------------------------------------- 6-15
7. Electrical system ---------------------------------------- 6-45
8. Air conditioner and heater -------------------------- 6-48
1. Engine -------------------------------------------------- ------ 7-1
2. Electrical system ---------------------------------------- 7-2
3. Power train system --------------------------------------- 7-3
4. Hydraulic system --------------------------------------- 7-4
2. Quick coupler -------------------------------------------
------------------------------------------------------------ 9-1
CONTENTS
8-1
8-6

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Summary of Contents for Hyundai HL740-9A

  • Page 1: Table Of Contents

    CONTENTS EC declaration of conformity ----------------------------- 0-1 7. Efficient working method ---------------------------- 4-15 Foreword ----------------------------------------------------------- 0-2 8. Adjustment of the work equipment ------------- 4-22 Emission-related components warranty 9. Operation in the special work sites ------------- 4-23 (USA and CANADA only) --------------------------------- 0-2-1 10.

  • Page 4: Emission-Related Components Warranty (Usa And Canada Only)

    EMISSION-RELATED COMPONENTS WARRANTY (USA AND CANADA ONLY) Hyundai shall have obligation under the EPA (Environmental Protection Agency) regulation of warranty about Emission-related components. This warranty shall exist for 3,000 hours or five years, whichever occurs first. Naturally, this warranty does not cover to damage arising from accident, misuse or negligence, use of non-Hyundai parts, or from alterations not authorized by Hyundai.

  • Page 19: Safety Hints

    1. SAFETY HINTS 1. 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 are caused by disregar- ding the simple and fundamental safety hints.
  • Page 20 Check daily according to the operator's manual. Repair the damaged parts and tighten the loos- ened bolts. 73031SH05 Check for leakage of engine oil, hydraulic oil, fuel and coolant. 73031SH06 Do not operate the machine if it requires repairs. Operate after complete repair. 73031SH07 Make sure safety lock pin is removed before operating the machine.

  • Page 21: Safety Rules

    Any injuries, accidents, product failures resulting from the use of unauthorized attachments will not be the responsibility of Hyundai. SAFETY RULES SAFETY RULES Only trained and authorized personnel can operate and maintain the machine.
  • Page 22 UNAUTHORIZED MODIFICATION Any modification made without authorization from Hyundai can create hazards. Before making a modification, consult your Hyundai distributor. Hyundai will not be respon- sible for any injury or damage caused by any unauthorized modification. SEAT BELT SEAT BELT...
  • Page 23 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 24 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. 3001SH02 Use caution when you are fueling a machine. Do not smoke while you are fueling a machine.
  • Page 25 Fire on a machine can result in personal injury or death. Exposed battery cables that come into contact with a grounded connection can result in fires. Replace cables and related parts that show signs of wear or damage. Contact your Hyundai dealer. Wiring Check electrical wires daily.
  • Page 26 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. Ether Ether (if equipped) is commonly used in cold weather applications.
  • Page 27 Fire 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 28 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. 1-10...
  • Page 29 THE EUROPEAN UNION PHYSICAL AGENTS (VIBRATION) DIRECTIVE 2002/44/EC THE EUROPEAN UNION PHYSICAL AGENTS (VIBRATION) DIRECTIVE 2002/44/EC Vibration Data for Earth-moving Machines ibration Data for Earth-moving Machines Information 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 Information Concerning Whole Body Vibration Level nformation Concerning Whole Body Vibration Level...
  • Page 30 ※ 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 31 Guidelines 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 32 Modifications may be considered to be officially approved, if at least one of the following conditions has been met : 1. The attachment, the accessory, or the spare part has been made or distributed by Hyundai and has been installed according to approved methods described in a publication available from Hyundai; or 2.

  • Page 33: 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. 73031SH12 Sound the horn to warn nearby personnel before operating the machine. KEEP RIDERS OFF MACHINE KEEP RIDERS OFF MACHINE Riders on a machine are subject to injury...
  • Page 34 Provide proper ventilation when operating engine in a closed area to avoid the danger of exhaust gases. 73031SH16 Check the locations of underground gas pipes or water line and secure the safety before oper- ation. 73031SH17 The operating near the electrical lines is very dangerous.
  • Page 35 While traveling on public roads, lift the bucket 40~50 cm above the ground. Do not drive with the bucket loaded. 73031SH20 When the bucket is loaded, avoid sudden swinging or starting. Overloading is dangerous. Make sure the load does not exceed the per- missible level.
  • Page 36 Avoid parking and stopping on a slope. Lower the bucket to the ground and block the tire when parking. 73031SH24 Avoid traveling in a cross direction on a slope as it can cause the danger of rolling over and slid- ing.
  • Page 37 The engine angularity limits are 30˚. Do not operate by more than the engine limits in any case. 30 ? 30˚ 73031SH28 Watch out for obstacles. Be particularly careful to check the machine clearance during steering. 73031SH29 Always operate machine with proper ROPS/ FOPS installed.
  • Page 38 This machine is intended to be used only for excavation and loading. Do not use this for pull- ing up materials. Unlike a crane, this machine is not equipped with devices needed to pull up things. 73031SH32 Slow down when traveling through obstacles or uneven ground.
  • Page 39 Use lights at night or in dark areas. 73031SH36 Be careful in the condition of bad clearance of sight caused by cloud, snow or rain. 73031SH37 Put the chains on the tires when moving or working on the snowed and frozen road, and avoid doing sudden start, stop and swing.
  • Page 40 Be careful when traveling on icy surface. Keep bucket low to ground. 73031SH40 Be careful when driving under a height limit- ed place, for instance, a tunnel, an overpass, and an overhead cable. 73031SH41 1-22...

  • Page 41: Mounting And Dismounting

    MOUNTING AND DISMOUNTING MOUNTING AND DISMOUNTING Never jump on or off the machine. Never get on or off a moving machine. When getting on or off the machine, face the machine and use the handhold and steps. Never hold any control levers when getting on or off the machine.

  • Page 42: During Maintenance

    3. DURING MAINTENANCE 3. DURING MAINTENANCE During maintenance do not allow any unauthor- ized person to stand near the machine. Also, be careful of people in the vicinity. ON THE INSPECTION 73031SH43 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 clus- ter then repair.
  • Page 43 Do not work below the machine. When working under of around the bucket or linkage, with the bucket raised, proper support must be provided for the bucket and / or the link- age. 73031SH47 There is the danger of fire in fuel and oil. Store in cool dry area, away from any open flames.
  • Page 44 Be prepared if a fire starts. Keep a fire extinguisher handy and emergency numbers for a fire department near your tele- phone. 73031SH51 When servicing and checking engine compart- ment at the side door opened, be careful head against door. Do not open the side door while engine is run- ning.
  • Page 45 The anti-slip protection should be replaced if they have become worn or have been printed over. 73031SH55 KEEP THE MACHINE CLEAN KEEP THE MACHINE CLEAN Spilled oil or grease, or scattered tools or bro- ken pieces are dangerous because they may cause you to slip or trip.

  • Page 46: Parking

    4. PARKING 4. PARKING When leaving the machine lower the bucket to the ground completely and put the safety lever at parking position then remove the key. Lock the cab door. 73031SH58 Park the machine in the flat and safe place. 73031SH59 Hope you can work easily and safely observing safety rules.

  • Page 47: Specifications

    2. SPECIFICATIONS 2. SPECIFICATIONS 1. MAJOR COMPONENTS 1. MAJOR COMPONENTS Hydraulic tank Bucket Tire Head light Radiator Main control valve Battery Boom Boom cylinder Counterweight Bell crank Bucket cylinder Main pump Muffler Air cleaner Bucket link Front axle Steering cylinder Transmission Rear axle Engine Fuel tank...

  • Page 48: Specifications

    2. SPECIFICATIONS 2. SPECIFICATIONS 1) 1) WITH BOLT-ON CUTTING EDGE TYPE BUCKET WITH BOLT-ON CUTTING EDGE TYPE BUCKET (HL740-9A) 7409A2SP01 Description Unit Specification Operating weight kg (lb) 12700 (28000) Struck 2.0 (2.6) Bucket capacity Heaped 2.3 (3.0) Overall length 7345 (24' 1") Overall width 2600 (8' 6")
  • Page 49 WITH BOLT-ON CUTTING EDGE TYPE BUCKET WITH BOLT-ON CUTTING EDGE TYPE BUCKET (HL740XTD-9A) 7409A2SP02 Description Unit Specification Operating weight kg (lb) 13000 (28660) Struck 2.0 (2.6) Bucket capacity Heaped 2.3 (3.0) Overall length 7785 (25' 6") Overall width 2600 (8' 6") Overall height 3260 (10' 8") Ground clearance...
  • Page 50 2) 2) WITH TOOTH TYPE BUCKET WITH TOOTH TYPE BUCKET (HL740-9A) 7409A2SP03 Description Unit Specification Operating weight kg (lb) 12700 (28000) Struck 1.9 (2.5) Bucket capacity Heaped 2.2 (2.9) Overall length 7465 (24' 6") Overall width 2650 (8' 8") Overall height 3260 (10' 8")
  • Page 51 WITH TOOTH TYPE BUCKET WITH TOOTH TYPE BUCKET (HL740XTD-9A) 7409A2SP04 Description Unit Specification Operating weight kg (lb) 13000 (28660) Struck 1.9 (2.5) Bucket capacity Heaped 2.2 (2.9) Overall length 7905 (25' 11") Overall width 2650 (8' 8") Overall height 3260 (10' 8") Ground clearance 417 (1' 4") Wheelbase...

  • Page 52: Weight

    3. WEIGHT 3. WEIGHT Item Front frame assembly 1990 Rear frame assembly 1313 2890 Front fender (LH & RH) HL740-9A Counterweight HL740XTD-9A 1320 Cab assembly 1540 Engine assembly 1280 Transmission assembly Drive shaft (front) Drive shaft (center) Drive shaft (rear)

  • Page 53: Specification For Major Components

    4. SPECIFICATION FOR MAJOR COMPONENTS 4. SPECIFICATION FOR MAJOR COMPONENTS 1) 1) ENGINE ENGINE Item Specification Model Cummins QSB6.7 Type 4-cycle turbocharged and charge air-cooled diesel engine. Cooling method Water cooling Number of cylinders and arrangement 6 cylinders, in-line Firing order 1-5-3-6-2-4 Combustion chamber type Direct injection type...

  • Page 54: Main Control Valve

    2) 2) MAIN PUMP MAIN PUMP Item Specification Type Variable piston pump Capacity 74 cc/rev Maximum operating pressure 280 kgf/cm (3980 psi) Maximum operating speed 2100 rpm Rated output flow 155ℓ/min (40.9 U.S.gpm) 3) 3) FAN AND BRAKE PUMP FAN AND BRAKE PUMP Specification Item Brake...
  • Page 55 7) 7) DYNAMIC POWER TRANSMISSION DEVICES DYNAMIC POWER TRANSMISSION DEVICES Item Specification Model ZF 4WG160 Torque converter Type Single-stage, single-phase Ratio 2.30 : 1 Type Full-automatic power shift Gear shift Forward fourth gear, reverse third gear Transmission Control Electrical single lever type, kick-down system Pump rated fl...

  • Page 56: Control Devices

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

  • Page 57: Cluster

    2. CLUSTER STRUCTURE The cluster consists of gauges, lamps and LCD as shown below, to warn the operator in case of abnormal machine operation or conditions for the appropriate operation and inspection. Gauges : Indicate operating status of the machine. Warning lamps : Indicate abnormality of the machine.
  • Page 58 Fuel gauge This gauge indicates the amount of fuel in the fuel tank. Fill the fuel when the indicator moves red range or lamp blinks in red, refuel as soon as possible to avoid running out of fuel. If the gauge indicates below red range even though the machine is on the normal condition, check the electric device as that can be caused by the poor connection of electricity or 7609A3CD04...

  • Page 59: Warning Lamps

    WARNING LAMPS Stop engine warning lamp Emergency warning lamp T/M oil temperature warning lamp Check engine warning lamp Engine overheat warning lamp Hydraulic oil temperature warning lamp Fuel level warning lamp T/M error warning lamp Air cleaner warning lamp Battery charging warning lamp Engine oil pressure warning lamp Steering warning lamp(Emergency) Steering warning lamp(Primary)
  • Page 60 Immediately pull the machine to a convenient stop. Stop the engine. Investigate the cause. Consult a HYUNDAI dealer to investigate the cause. 77073CD19 Do not operate until the cause has been corrected. Air cleaner warning lamp This lamp lights ON when the filter of air cleaner is clogged.
  • Page 61 Steering warning lamp Primary This lamp indicates that the primary steering has failed. When the indicator comes on and the action alarm sounds, steer the machine immediately to a convenient location and stop the machine. Stop the engine and investigate the cause. Do not operate the machine until the cause has been cor- 77073CD66 rected.
  • Page 62 (13) Stop engine warning lamp If the lamp lights ON and the buzzer sounds, stop the engine immediately and check the engine. Check the fault codes on the monitor. Please contact your Hyundai service center or local dealer. 7609A3CD51...

  • Page 63: Pilot Lamps

    PILOT LAMPS Warming up pilot lamp Seat belt pilot lamp Fuel warmer pilot lamp Mirror defrost pilot lamp High beam pilot lamp Preheater pilot lamp Parking brake pilot lamp Fan reverse pilot lamp Maintenance pilot lamp FNR select pilot lamp Clutch cut off pilot lamp Ride control pilot lamp(Auto) Ride control pilot lamp(On)
  • Page 64 High beam pilot lamp This lamp works when the illuminating direction is upward. This lamp comes ON when the dimmer switch is operated, e.g., when passing another vehicle. 77073CD12 Preheat pilot lamp This lamp lights ON when start switch is turned clockwise to the ON position.
  • Page 65 FNR select pilot lamp (option) The lamp comes ON when FNR select button on the optional FNR remote control lever is pressed. Refer to page 3-41. 7807A3CD24 (10) Ride control pilot lamp (option) Auto ride control This lamp lights ON when push in the bottom of the ride control switch (auto position).
  • Page 66 (12) Fuel warmer pilot lamp This lamp is turned ON when the coolant temperature is below 10˚C (50˚F ) or the hydraulic oil temperature 20˚C ( 68˚F ). The automatic fuel warming is cancelled when the engine coolant temperature is above 60˚C and the hydraulic oil tem- perature is above 45˚C since the start switch was ON position.

  • Page 67: Monitors

    3. MONITOR (5.7 inch touch screen) The monitor is adjustable. - Vertical : 14˚ - Horizontal : 30˚ Vertical (touch screen) Menu button Enter button Right move / Left move button buzzer stop button Camera / ESC button 7609A3CD23 BUTTONS Menu button Main display to main menu, main menu to main display.
  • Page 68 MAIN MENU You can select or set the menu by the select switch or touch screen. Please refer to button, page 3-12 for selection and change of menu and input value. Display type can be changed by operator. See page 3-30. Main display screen Main menu screen Sub menu screen...
  • Page 69 Warning Warning sign will be shown when the temperature of hydraulic oil, cooling water and transmission oil is not normal state (red icon will be shown at center of display and then move to assigned area). Case of warning sign Above 105˚C of hydraulic oil temperature Above 104˚C of cooling water temperature Above 107˚C of T/M oil temperature...
  • Page 70 MAIN & SUB MENU STRUCTURE Main menu Sub menu Description Engine warming up Engine warming up Engine speed Engine speed Kick down Mode 1 (down/up), Mode 2 (down only) Wiper speed 4 steps Fan-auto mode Interval and time setting AEB setting Speed meter setting Pulse setting Boom / bucket angle...
  • Page 71 Function of sub menu icons 1 Previous step button (same as ESC function) Move to previous screen. Close pop up screen. 2 Scroll Display present page / total page. Move to page by using up / down arrow button. 3 Move to main menu Main menu icon is shown at the below of screen.
  • Page 72 Kick down 7609A3M17 7609A3M17A Mode 1 (down/up) : Press kick down switch once, shift down and press switch again, shift up. Mode 2 (down only) : Press kick down switch every time, shift to lower gear respectively. Refer to page 3-39. Wiper speed 7609A3M18 7609A3M18A...
  • Page 73 7609A3M19 7609A3M19A AEB mode controls the disk clearance of the transmission, automatically. To start AEB setting, press AEB bar (or ) for 3 seconds. To cancel AEB setting, press If "OK" in actual gear window, press to complete AEB setting. Display during AEB mode Symbol Meaning...
  • Page 74 Boom / bucket angle 7609A3M21 7609A3M21A Press NEXT button after following the instruction at each step. If correction is right, NEXT button will be activated, then go to next stage. After following each step correctly, the message "Calibration is done" will be shown. Press OK button, then process be ended.
  • Page 75 Boom-pressure 7609A3M21C 7609A3M21D Display A Press START button after following the instruction. After a few minutes, "Calibration fail" or "Calibration success" message will be shown. Press OK button then process be ended. Using button : Using instead of NEXT, confirm button. Boom pressure calibration Bucket max tilting and Boom up position...
  • Page 76 Monitoring Fault code 7609A3M23 7609A3M23H 7409A3M23A-1 7609A3M23K 7609A3M23L 7409A3M23M 7609A3M23N 7609A3M23G 7609A3M23J Monitor the fault code of the Machine / ECU /TCU . Not define will be indicated in case of that there's no fault. 3-21...
  • Page 77 Machine monitoring 7609A3M24 7609A3M24A 7609A3M24B Monitor the status of the machine. To display the item in main display, select the item by touch bar (or The right icon shows selected status (ON/OFF). Priority in the main display The priority of the weighing system is the highest. If the weighing system is selected, the other items are not available.
  • Page 78 Weighing system Principle The weight indication in bucket is calculated by measuring boom position and boom pressure. The weight is '0.0 ton' when the boom 7409A3CD126 is placed at below -15˚. The weight is indicated when the boom is placed at the range (-5˚ 15˚). The weight is calculated when the boom is placed at above -5˚...
  • Page 79 Management ESL system setting 7609A3M26 7609A3M26A 7609A3M26B Machine security ESL : Engine Starting Limit ESL mode is designed to be a theft deterrent or will pre- vent the unauthorized operation of the machine. If the ESL mode was selected Enable, the password will be required when the start switch is turned ON.
  • Page 80 Manage to smart key usage (opt) Set the using or not of smart key. If you using smart key, ESL function always be activated. 7609A3M26G 7609A3M26H Using smart key Smar t key icon (yellow) is on the 7609A3M50B 7609A3M50A screen. Verifi...
  • Page 81 Axle oil (front and rear) 1500 Aircon & heater outer fi lter 1000 Air cleaner element (safety) 4000 Air cleaner element (primary) 4000 Crankcase ventilation fi lter 2000 : Conventional hydraulic oil : Hyundai genuine long life hydraulic oil 3-26...
  • Page 82 Machine information HL740-9A 7609A3M28 7609A3M28A 7409A3M28B 7609A3M28C 7609A3M28D Version information - Software versions of MCU, cluster and monitor can be checked. Machine information - Display information of each sensors. 7609A3M28E Service contact 7609A3M29 7609A3M29A 7609A3M29B The phone number of the service man can be checked and changed.
  • Page 83 Service menu 7609A3M30 7609A3M30A 7609A3M30B 7609A3M30F 7609A3M30D 7609A3M30E Software update - Update file in USB memory. Manage the smart key tag. - Resister or delete user tag. - When delete user tag, all user tag will be deleted. - Display the number of registered user tag. 3-28...
  • Page 84 Display set up Clock Select number of digit, then input value using +/- button. Using button Change digit by , input next digit by 7609A3M32 7609A3M32A Brightness setting 7609A3M33 7609A3M33A 7609A3M33B 7609A3M33D 7609A3M33C 7609A3M33E 7609A3M33F Manual - Manual setting for LCD brightness. Automatic - Automatic control of LCD brightness as set level of day/night.
  • Page 85 Display type 7609A3M33Y 7609A3M33X Unit 7609A3M34 7609A3M34A Temperature : ˚C ˚F Speed : km/h Weight : ton Pressure : bar kgf/m Using button - Move to other item by 3-30...
  • Page 86 Rear camera 7609A3M35 7609A3M35A 7609A3M35B 7609A3M35C 7609A3M35D 7609A3M35F 7609A3M35E Reverse mode - If transmission engages the reverse gear (R1~R3), the camera mode is displayed automatically in main display. Active camera - Three cameras can be installed on the machine. Display order - Set the channel sequence of each camera.
  • Page 87 Multimedia 7609A3M36C 3 4 5 7609A3CD36D 3 4 5 7609A3CD36E File name of playing Repeat Play Open file (USB memory) Stop Volume Previous song (movie) Close player Next song (movie) 3-32...

  • Page 88: Switches

    4. SWITCHES Cab LH side Mirror defrost switch(option) Heated seat switch(option) Rear wiper/washer switch Boom kickout & bucket leveler Beacon switch(option) set switch USB socket(-#0086) Fan control switch Attachment lock switch(opt) Attachment unlock switch(opt) Emergency test switch(opt) Main light switch Work lamp switch Hazard switch Workload switch...
  • Page 89 HAZARD SWITCH Use for parking, or roading the machine. Both turn signal lights will flash simultaneously. If the switch is left ON for a long time, the battery may be dis- charged. 75793CD42 PILOT CUT OFF SWITCH When the switch is pressed to OFF position, the hydraulic pilot line Safety button will be cut off, so the work equipment will not operate.
  • Page 90 REAR WIPER AND WASHER SWITCH The switch use to operates the rear wiper and washer by two step. First step : The rear wiper operates. Second step : The washer liquid is sprayed and the rear wiper is operated only while pressing. If release the switch, return to the first step position.
  • Page 91 RIDE CONTROL SWITCH (option) AUTO Press in the bottom of the ride control switch in order to turn on the MANUAL AUTO automatic ride control. The automatic ride control automatically turns on when the travel speed exceeds a preset speed of approxi- mately 7 km/h.
  • Page 92 ATTACHMENT UNLOCK SWITCH ATTACHMENT UNLOCK SWITCH (option) Press this switch in order to disengage the quick coupler pins. Safety button If this switch is pressed for 5 seconds, the quick coupler pins move Lock in the disengaged position. Unlock If the switch is released, the quick coupler pins will remain in the dis- engaged position.

  • Page 93: Horn Button

    TRANSMISSION SHIFT MODE SWITCH Four modes are available for operator's preference and job condition. MAN (Manual) : Machine is operated by selected gear on lever. AL (Auto Light) : Automatic shifting point is fast for long-dis- tance transportation and fuel efficiency. 75793CD59 AN (Auto Normal) : Automatic shifting point is normal without automatic kick-down to 1st gear for general...

  • Page 94: Kick Down Switch

    KICK DOWN SWITCH Manual mode Kick down switch It is effective 2nd speed to 1st speed only and recover to 2nd speed quickly when push the switch one more time. Automatic mode Mode 1 (down/up) It shifts down quickly from current gear to one step lower speed by pushing the switch and recover to current speed quickly when push the switch one more time.

  • Page 95: Control Device

    5. CONTROL DEVICE Steering wheel lever Remote control lever(STD) Steering wheel FNR remote control lever(OPT) Gear selector lever Fingertip remote control lever(OPT) Brake pedal Accelerator pedal 74093CD28 REMOTE CONTROL LEVER These joystick are used to control the boom and the bucket. RCV(STD) Refer to operation of working device in chapter 4 at page 4-9.

  • Page 96: Gear Selector Lever

    FNR REMOTE CONTROL LEVER (option) This switch is used for froward and backward drive. Kick down Gear range can be selected by gear selector lever. FNR switch button Select button If the select button is pressed, the indication lamp on the cluster will be ON and this FNR switch will start to operate.

  • Page 97: Brake Pedal

    BRAKE PEDAL Left brake pedal (service brake + clutch cut off function) If the pedal is pushed down, this will generate braking force and bring the machine to a stop. If the power train operation is to be cut off, set the clutch cut off mode switch to ON (L , M, H) and press the pedal.

  • Page 98: Air Conditioner And Heater

    6. AIR CONDITIONER AND HEATER FULL AUTO AIR CONDITIONER AND HEATER Full auto air conditioner and heater system automatically keeps the optimum condition in accordance with operator's temperature configuration sensing ambient and cabin inside temperature. Fresh air switch Mode switch Auto switch Power OFF switch Fan speed switch...

  • Page 99: Auto Switch

    POWER OFF SWITCH This switch makes the system and the LCD OFF. Just before the power OFF, set values are stored. Default setting values Function Air conditioner In/outlet Temperature Mode Value Inlet OFF Previous sw OFF Previous sw OFF 370073CD54 AUTO SWITCH Turn the starting switch to ON position, LCD lights ON.

  • Page 100: Temperature Control Switch

    TEMPERATURE CONTROL SWITCH Setting temperature indication Type A : 17~32˚C, scale : 1˚C Type B : Lo, 18~31˚C, Hi, scale : 1˚C Max cool and max warm beeps 5 times. The max cool or the max warm position operates as following table. 370074CD57 Temperature Compressor...

  • Page 101: Self Diagnosis Function

    SELF DIAGNOSIS FUNCTION Procedure Starting switch ON Press the air recirculation button over 5 times within 2 secondsduring pressing the AUTO switch All symbol of LCD blink 5 times Switch OFF Error check System OFF Press AUTO switch Cancelled diagnosis function(normal function) 3607A3CD69 Error check The corresponding error code flickers on the setup temperature display panel, the other symbol...

  • Page 102: Others

    7. OTHERS Master switch Radio & USB player Cab roof Engine control module LH battery box Machine control unit(MCU) Transmission control unit(TCU) Rear camera(opt) 12V socket(opt) Cigar lighter Fuse & relay box 7409A3CD38 CIGAR LIGHTER This can be used when the engine starting switch is ON. The lighter can be used when it springs out in a short while after being pressed down.
  • Page 103 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. Always check the condition of the seat belt and mounting hardware before operating the machine.
  • Page 104 Height adjustment (AIR SUSPENSION, OPT) The seat height can be set pneumatically and is continuously adjustable. The seat height can be altered by pulling or press- ing the actuator lever fully out or in (arrow). If the adjustment reaches the top or bottom endstop, the height is adjusted automatically in order to guaran- tee a minimum spring travel.
  • Page 105 Armrest (LH) The armrests can be folded up if required and the height can be individually adjusted. To adjust the armrest for height, separate the round cap (see arrow) from the cover and loosen the hexagon nut (size 13 mm) behind it adjust the armrests to the desired position (5 steps) and tighten the nut again (25 Nm).
  • Page 106 Document box The document box is placed on the rear side of the backrest. To open the document box, first twist the turn lock closures 90° to the left or the right and then fold the cover of the document box upwards. 290F3CD265 Seat heater switch The seat heater can be turned on/off by pressing...

  • Page 107: Master Switch

    (12) Lumbar support By turning the adjustment knob to the left (2) or right (1), both the height and curvature of the back- rest cushion can be individually adjusted. This increases both the seating comfort and the performance of the operator. 290F3CD267 (13) Backrest adjustment...
  • Page 108 FUSE BOX AIRCON TURN LAMP SPARE (24V) CR-5 CR-25 CR-35 CR-26 CR-2 CR-7 CR-55 CR-3 CR-46 CLUSTER AUDIO(24V) FUEL WARMER SAFETY ECM POWER WIPER LOW HORN AIRCON WORK LAMP IGNITION WORK LAMP SPARE (24V) POWER REAR FRONT ECM (IG) START SW SPARE CR-39 CR-60...

  • Page 109: Engine Control Unit (Ecu)

    TRANSMISSION CONTROL UNIT (TCU) The control unit is shifting the required speeds fully-automatically under consideration of the following criteria. Gear selector lever position Driving speed Load level 77073CDS91 ENGINE CONTROL UNIT (ECU) The engine control unit (ECU) is the control center of the engine system.

  • Page 110: Front Panel Presentation

    RADIO AND USB PLAYER (+BLUETOOTH) Type A 15 16 1 13 LCD display 11 12 75793CD62-1 FRONT PANEL PRESENTATION -------- Sound function selection button -------- Preset memory button 6 (audio selection) D+ --------------- Directory up -------- Aux function -------- Power and volume button -------- Preset scan (PS) -------- Mode button MODE...
  • Page 111 Type B LCD display 75793CD62-2 FRONT PANEL PRESENTATION -------- Audio selection button -------- Preset memory button 6 D+ --------------- Directory up -------- Audio selection knob -------- Aux function -------- Preset scan (PS) -------- Power and volume button Best station memory (BSM) MODE -------- Mode button MUTE...
  • Page 112 GENERAL Power and volume button Power ON/OFF button Press power button to turn the unit ON or OFF shortly. When the power is ON, the previous mode (last memory) will appear. Volume up / down control 75793CD66 Turn volume up / down button right to increase the volume level. The level will be shown in VOLUME xx on the LCD display.
  • Page 113 Balance control To adjust the left-right speaker balance, first select the balance mode by pressing the SEL button until the BAL indication appears on the LCD display. Within 5 seconds of choosing the balance mode, turn power button (type A) or selection knob (type B) right / left to adjust the balance as desired.
  • Page 114 Mode button Press mode button to select RADIO / USB / AUX / BT audio. MODE 75793CD67 Audio mute button Press mute button momentarily to mute volume and MUTE mark will blink on the LCD display. Press the button again to return to the mode in use before the MUTE mute mode was activated.

  • Page 115: Usb Player

    Pre-set scan (PS) / Best station memory (BSM) button Pre-set scan (PS) Press BSM button shortly to scan the 6 pre-set station stored the memories on each band (AM/FM/LW). The unit will stop at each pre-set station (the pre-set number on the LCD display will flash during pre-set scan operation) and remain on 75793CD76 the selected frequency.
  • Page 116 Type B 75793CD81-1 USB function Connect a USB device if you want to listen to MP3 file in a USB device. It will automatically play MP3 file in the USB device and the LCD display will show “READING USB”. If there are no files on USB device, playback will revert back to the previous mode after display- ing “NO FILE”.
  • Page 117 MP3 directory / file searching The D-, D+ button is used to select a particular directory and file. Press and hold for more than 3 seconds while playing MP3 file. Turn right / left the power button (type A) or selection knob (type B) to search the directory. Press the button when you find the wanted directory.
  • Page 118 File scan (SCN) During USB play, press SCN button to play the first 10 seconds of each file on the whole file on the USB (SCN mark will appear on the LCD display). When a desired file is reached, press the SCN button again to can- cel the function.

  • Page 119: Aux Player

    Directory up Press D+ button briefly while playing MP3 . The next directory is located each time you press this button. If the MP3 file does not have a directory, the unit play MP3 at 10-file intervals. If any MP3 file does not exist in USB, this button can not oper- 75793CD87 ate.
  • Page 120 Introduce The bluetooth radio supports bluetooth wireless technology. Bluetooth technology provides a wire- less link between a bluetooth mobile phone or bluetooth music player and the hyundai bluetooth radio. The bluetooth radio features a hands-free system so that you may talk on the telephone without tak- ing your eyes off the road or your hands off the wheel.
  • Page 121 Bluetooth function Pairing a bluetooth mobile phone or music player A bluetooth connection must first be established between your bluetooth mobile phone or bluetooth music player and the bluetooth radio. The first step to connecting the bluetooth radio and bluetooth device is to introduce or "Pair"...
  • Page 122 The bluetooth radio will give connection priority to the last connected mobile phone. It is recommended that all other bluetooth devices other than mobile phones are switched off during the registration or pairing process. Disconnecting a bluetooth device If you need to disconnect your bluetooth mobile phone or music player with the bluetooth radio, fol- low the steps below.
  • Page 123 Deleting a previously paired bluetooth device If you no longer need to use a paired bluetooth device with the bluetooth radio, it can be deleted. It is from the registration assignment for another mobile phone. Refer to the example of paired devices shown table 2-1. Press SEND button, to select BLUETOOTH mode.
  • Page 124 Last call number redials Select BLUETOOTH mode by pressing SEND button. To making a call to the last dialed number, press SEND button again. OUTGOING CALL appears on the radio display for 1 second. Some mobile phones may require an additional press of SEND button to start the last number redial call.
  • Page 125 Bluetooth setting Setting the automatic call answer feature If this function is selected, the bluetooth radio automatically answers all INCOMING calls. This feature enhances safety as the driver does not need to take their hands from the steering wheel to accept an INCOMING call. Note that this feature cannot be set at different settings for each of the paired mobile phones.

  • Page 126: Front Panel Presentation

    RADIO AND USB PLAYER (WITH BLUETOOTH) : MACHINE SERIAL NO.: #0359~ 9403CD100 FRONT PANEL PRESENTATION -------- Power ON/OFF, ------- Station preset 5 Volume UP/DOWN button DIR- ----------- Directory down button -------- Manual UP/DOWN Tuning, -------- Station preset 6 File search, SEL button DIR+ ---------- Directory up button -------- Mode button, -------- Scan play button (SCAN)
  • Page 127 RADIO AND USB PLAYER (WITHOUT BLUETOOTH) : MACHINE SERIAL NO.: #0359~ 9403CD101 FRONT PANEL PRESENTATION -------- Power ON/OFF, ------- Station preset 5 Volume UP/DOWN button DIR- ----------- Directory down button -------- Manual UP/DOWN Tuning, ------- Station preset 6 File search, SEL button DIR+ ----------- Directory up button -------- Mode button, -------- Scan play button (SCAN)
  • Page 128 GENERAL Power and volume button Power ON / OFF button Press power button (1) to turn the unit on or off. Volume UP/DOWN control knob Turn VOL knob (1) right to increase the volume level. Turn VOL knob (1) left to decrease the volume. 9403CD102 After 5 seconds the display will return to the previous display mode.
  • Page 129 Menu Selection This button can adjust the sound effect and other things. Each time you press this button (2), LCD displays as follows : TREB BAL L=R FAD F=R LOUD ON BEEP 2ND On each setting, the level can be controlled by turning TUNE knob (2). 9403CD103 When the last adjustment is made, after 5 seconds, the display will automatically return to the previous display mode.
  • Page 130 Loud control When listening to music at low volume levels, this feature will boost the bass and treble response. This action will compensate for the reduction in bass and treble performance experienced at low volume. To select the loudness feature, press button (2) until LOUD is displayed, then turn knob (2) right or left to activate or deactivate loudness.
  • Page 131 RADIO Mode button Repeat press MODE button to select FM1, FM2 or AM. 9403CD104 Manual tuning button To manually tune to a radio station, simply turn encoder TUNE (2) left or right to increase or decrease the radio frequency. 9403CD105 Auto tuning button To automatically select a radio station, simply press Seek up or Track down button.
  • Page 132 Preset scan (PS) / Best station memory (BSM) button Press BSM button (12) momentarily to scan the 6 preset stations stored in the selected band. When you hear your desired station, press it again to listen to it. Press BSM button (12) for longer than 2 seconds to activate the Best Station Memory feature which will automatically scan and 9403CD109 enter each station into memory.
  • Page 133 USB PLAYER USB playback The unit was equipped with a front USB jack and also a rear USB Jack. With a USB device plugged in the front USB jack, it will be detected as front USB mode. And with a USB device plugged in the rear USB jack, it will be detected as rear USB.
  • Page 134 Track Scan Play (SCAN) button SCAN playback : Simply press SCAN (12) button to play the first 10 seconds of each track. SCAN folder : Press and hold SCAN button for longer than 2 seconds to scan play the tracks in current folder. SCAN off : Simply press it again to cancel SCAN feature.

  • Page 135: Aux Operation

    AUX OPERATION It is possible to connect your portable media player to the audio system for playback of the audio tracks via the cab speakers. To get the best results when connecting the portable media to the audio system, follow these steps : Use a 3.5 mm stereo plug cable to connect the media player headphone socket at each end as follows.
  • Page 136 BLUETOOTH (if equipped) Using a bluetooth wireless connection Your audio unit supports bluetooth wireless technology. You can set up a wireless link with bluetooth cellular phone. Keep PAIRING the cellular phone with audio unit in a few minutes as the phone are being switched on well enough.
  • Page 137 Please retry to the pairing instruction if HYUNDAI does not appear on the cellular phone screen. Please select authorized, if there is authorized menu in the menu of bluetooth connection in your cellular phone.
  • Page 138 Bluetooth connection and disconnection When established bluetooth connection between this audio unit and the cellular phone, bluetooth icon on the display appears and then the display shows HF/AV CONN when handsfree & AV profile connected. To disconnect bluetooth link Press and hold CALL END button (4) for 2 seconds, it shows DIS CON and disappears bluetooth Icon on the display.
  • Page 139 Audio transfer between the audio unit and phone The audio transfer function is for switching the call from the audio unit to the cellular phone for private conversation. Press CALL button (4) briefly during conversation, it appears CALL TRANS on the display. To switch back to the audio unit, press button (4) briefly during private conversation, then it appears CALL TRANS on the display again.
  • Page 140 Using the audio unit as bluetooth music The audio unit supports A2DP (Audio Advanced Distribution Profile) and AVRCP (Audio Video Remote Control Profile), and both profiles are available to listen music at the audio unit via cellular phone which is supporting the two profiles above. To play music, search the menu on your cellular phone as below : i.e : Menu File manager...
  • Page 141 RESET AND PRECAUTIONS Reset function Interfere noise or abnormal compressed files in the MP3 disc or USB instrument may cause extraordinary operation (or unit frozen/locking up). It’s strongly recommended to use appropriate USB storage not cause any malfunction to the audio unit. In the unlikely event that the player fails to operate correctly, try out to reset unit by any of following two methods.

  • Page 142: Operation

    4. OPERATION 4. OPERATION 1. SUGGESTION FOR NEW MACHINE 1. SUGGESTION FOR NEW MACHINE It takes about 100 operation hours to enhance its designed performance. Operate according to below three steps and avoid excessive operation for the initial 100 hours. Service meter Load Avoid excessive...

  • Page 143: Check Before Starting The Engine

    2. CHECK BEFORE STARTING THE ENGINE 2. CHECK BEFORE STARTING THE ENGINE Make sure that the steering frame lock bar is stored in the unlocked position. The steering frame lock bar must be removed The steering frame lock bar must be removed in order to steer the machine.

  • Page 144: Starting And Stopping The Engine

    Monitor Monitor ① The buzzer sounds for 3 seconds with Monitor HYUNDAI logo on monitor. ② If the ESL mode is set to the enable, enter the password to start engine. ③ If the password has failed 5 times, please wait 30 minutes before re-attempting to enter the password.
  • Page 145 2) 2) STARTING ENGINE IN NORMAL TEMPERATURE STARTING ENGINE IN NORMAL TEMPERATURE ※ Sound the horn to warn the surroundings Sound the horn to warn the surroundings after checking if personnel or obstacles are in after checking if personnel or obstacles are in the area.
  • Page 146 3) 3) STARTING ENGINE IN A COLD WEATHER STARTING ENGINE IN A COLD WEATHER ※ Sound horn to warn surroundings after check- Sound horn to warn surroundings after check- ing if there are obstacles in the area. ing if there are obstacles in the area. ※...
  • Page 147 INSPECTION AFTER ENGINE START INSPECTION AFTER ENGINE START 4) 4) Inspect and confirm the following after engine starts. Is the level gauge of hydraulic oil tank in the nor- mal level? Are there leakages of oil or water? Are all the warning lamps (1-7) OFF? Check the following after warming up operation.

  • Page 148: 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 shortened.

  • Page 149: Warming-Up Operation

    4. WARMING-UP OPERATION 4. WARMING-UP OPERATION ※ The most suitable temperature for the hydraulic The most suitable temperature for the hydraulic oil is about 50 oil is about 50˚C (11 C (112˚F). It can cause serious ˚F). It can cause serious Parking brake switch trouble in the hydraulic system by sudden oper- trouble in the hydraulic system by sudden oper-...

  • Page 150: Operation Of The Working Device

    5. OPERATION OF THE WORKING DEVICE 5. OPERATION OF THE WORKING DEVICE ※ Confirm the operation of control lever and Confirm the operation of control lever and working device. working device. Control lever operates the boom and the bucket. When you release the control lever, control lever returns to neutral position automatically.

  • Page 151: Traveling Of The Machine

    6. TRAVELING OF THE MACHINE 6. TRAVELING OF THE MACHINE 1) 1) BASIC OPERATION BASIC OPERATION (1) (1) Traveling posture Traveling posture Lift the boom so that the bucket is placed 40-50cm above the ground. 40~50cm 7409A4OP10 (2) (2) Traveling operation Traveling operation Release When warm-up operation is completed after the...
  • Page 152 ※ When traveling at high speed, do not When traveling at high speed, do not abruptly decelerate by using the transmiss- abruptly decelerate by using the transmiss- ion lever, to slow down instead press the ion lever, to slow down instead press the brake pedal.
  • Page 153 (6) (6) Stopping the machine Stopping the machine ① Press the brake pedal to stop the machine. Gear selector lever ② Put the gear selector lever in the neutral posi- Parking brake switch tion. ③ Push the parking brake switch to the ON posi- tion.
  • Page 154 (7) (7) Stopping engine Stopping engine ※ If the engine is abruptly stopped before it has If the engine is abruptly stopped before it has Parking brake switch cooled down, its service life may be short- cooled down, its service life may be short- Gear selector lever ened.
  • Page 155 TRAVELING ON A SLOPE TRAVELING ON A SLOPE 2) 2) Never travel down a slope in neutral. Lower the bucket 20-30 cm (1 ft) to the ground so that it can be used as a brake in an emergency. If the machine starts to slide or loses stability, lower the bucket immediately and brake the machine.

  • Page 156: Efficient Working Method

    7. EFFICIENT WORKING METHOD 7. EFFICIENT WORKING METHOD 1) 1) GENERAL GENERAL Lift the bucket about 40-50 cm (2 ft) above the ground to ensure safety and to gain a good range of view. Clear the jobsite and level the ground. Be careful that excessive force is not applied to the bucket.
  • Page 157 2) 2) EXCAVATION WORK EXCAVATION WORK (1) (1) Shovel work Shovel work As the machine loads on the bucket with travel- ing, tires may start to slip because of heavy load. Then lift the bucket slightly to reduce load. ① Keep the bucket shovel parallel to the ground (If the bucket is pushed in a non-horizontal position, power may be reduced, and the buck-...
  • Page 158 (2) (2) Excavation on level ground Excavation on level ground Advance the machine with the bucket lowered slightly and make sure that the bucket is evenly loaded on both sides. ① Lower the bucket edge slightly. 73034OP07 ② Advance the machine and lift the bucket using the bucket control lever to dig out the soil.
  • Page 159 3) 3) LEVELING LEVELING Load the bucket with soil and dump gradually the soil while driving backward. After dumping the soil, move backward with the bucket lowered to the ground to level the ground. Load the bucket with soil and place the bucket in the horizontal position.
  • Page 160 6) 6) LOADING LOADING Maximum efficiency can be attained by carrying out work in such a way that the swinging angle and the traveling distance are kept as small and short as possible in accordance with the terrain. I method I method ①...

  • Page 161: Precautions During Operation

    ※ After using the parking brake as an emer- gency brake, ask Hyundai dealer to check complete brake system. 74094OP19 Precautions when driving on a slope Precautions when driving on a slope ①...
  • Page 162 ③ As the optimum air pressure of tire and opti- mum driving speed is different according to the kinds of tires and road conditions, consult Hyundai dealer or tire distributor. ④ Check the air pressure of tire before driving. ⑤...

  • Page 163: Adjustment Of The Work Equipment

    8. ADJUSTMENT OF THE WORK EQUIPMENT 8. ADJUSTMENT OF THE WORK EQUIPMENT The bucket can be adjusted to a height desired by using the boom kick-out device. Park the machine on level ground and block the Park the machine on level ground and block the tires to prevent sudden movement of the tires to prevent sudden movement of the machine.

  • Page 164: Operation In The Special Work Sites

    9. OPERATION IN THE SPECIAL WORK SITES 9. OPERATION IN THE SPECIAL WORK SITES 1) 1) OPERATION THE MACHINE A COLD WEATHER OPERATION THE MACHINE A COLD WEATHER Use proper engine oil and fuel for the weather. Fill the required amount of antifreeze in the cool- ant.
  • Page 165 3) 3) SEA SHORE OPERATION SEA SHORE OPERATION Prevent ingress of salt by securely tightening plugs, cocks and bolts of each part. Wash machine after operation to remove salt residue. Pay special attention to electrical parts and hydraulic cylinders to prevent corrosion. Inspection and lubrication must be carried out more frequently.

  • Page 166: Storage

    10. STORAGE 10. STORAGE Maintain the machine taking care of following to pre- vent the deterioration of machine when storing the machine for a long time, over 1 month. 1) 1) CLEANING THE MACHINE CLEANING THE MACHINE Clean the machine. Grease each lubrication part.

  • Page 167: During Storage

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

  • Page 168: Transportation

    5. TRANSPORTATION 5. TRANSPORTATION 1. ROAD TRAVELING 1. ROAD TRAVELING If it is necessary to travel on a road, observe the followings. Comply with regulations regarding this machine for the sake of safety. Perform daily inspection before starting the machine. Check the air pressure of tires and traveling speed limitations.

  • Page 169: Preparation For Transportation

    2. PREPARATION FOR TRANSPORTATION 2. PREPARATION FOR TRANSPORTATION When transporting the machine, observe the vari- ous road rules, road transportation vehicle laws and vehicle limit ordinances, etc. Overall width Make sure the cooling system has proper anti- freeze if moving machine to a cold climate. Select proper trailer after confirming the weight and dimension from the page 2-2.

  • Page 170: Loading The Machine

    3. LOADING THE MACHINE 3. LOADING THE MACHINE Load and unload the machine on a flat ground. Use the gangplank with sufficient length, width, thickness and gradient. Move slowly and carefully when the machine is on the gangplank. Do not change the direction of the machine while it is on the gangplank.

  • Page 171: Fixing The Machine

    4. FIXING THE MACHINE 4. FIXING THE MACHINE Fix front and rear frame by linking safety lock bar. Push the parking brake switch. Safety lock bar 7409A5TA04 Push the pilot cut off switch to the OFF position to prevent the hydraulic system from operating. Pilot cut off switch Stop the engine, turn the starting switch off and remove the key.
  • Page 172 Block the tires and fix firmly with wire rope or chain to prevent the machine from moving during transportation. 7409A5TA07...

  • Page 173: 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 chapter 2, Specification Wire rope when you are going to hoist the machine. Stay Use long wire rope and stay to keep the distance with the machine as it should avoid to touch with the machine.

  • Page 174: Towing The Machine

    6. TOWING THE MACHINE 6. TOWING THE MACHINE Personal injury or death could result when tow- Personal injury or death could result when tow- ing a disabled machine incorrectly. ing a disabled machine incorrectly. Block the machine to prevent movement before Block the machine to prevent movement before releasing the brakes.
  • Page 175 ※ Consult your HYUNDAI dealer for the equipment Consult your HYUNDAI dealer for the equipment that is necessary for towing a disabled machine. that is necessary for towing a disabled machine.
  • Page 176 3) 3) WHEN THE ENGINE DOES NOT WORK WHEN THE ENGINE DOES NOT WORK When towing the machine with the engine stopped, do it in the following order. The transmission oil does not lubricate the sys- tem, so remove the front and rear drive shafts. Loosen the steering cylinder as the steering operation is not workable.

  • Page 177: Maintenance

    Do not allow unauthorized personnel to reset them. Ask to your local dealer or Hyundai for mainte- nance advise 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 178: 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 understand the chapter 1, understand the chapter 1, Safety hints.
  • Page 179 4) 4) RELIEVING THE PRESSURE IN THE HYDRAULIC SYSTEM RELIEVING THE PRESSURE IN THE HYDRAULIC SYSTEM ※ Spouting of oil can cause the accident when Spouting of oil can cause the accident when loosening the cap or hose right after the oper- loosening the cap or hose right after the oper- ating of the machine as the machine or oil is on ating of the machine as the machine or oil is on...
  • Page 180 5) 5) PRECAUTION WHEN INSTALLING HYDRAULIC HOSES OR PIPES PRECAUTION WHEN INSTALLING HYDRAULIC HOSES OR PIPES Be particularly careful that the joint of hose, pipe and functioning item are not damaged. Avoid contamination. Assemble after cleaning the hose, pipe and joint of functioning item.

  • Page 181: 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 182 2) 2) PIPE AND HOSE PIPE AND HOSE (FLARE type) Thread size Width across flat (mm) kgf·m lbf·ft 1/4" 28.9 3/8" 36.2 1/2" 68.7 3/4" 1" 1-1/4" 3) 3) PIPE AND HOSE PIPE AND HOSE (ORFS type) Thread size Width across flat (mm) kgf·m lbf·ft 9/16-18...
  • Page 183 TIGHTENING TORQUE OF MAJOR COMPONENT TIGHTENING TORQUE OF MAJOR COMPONENT Torque Descriptions Bolt size kgf·m lbf·ft 57.9 ± 8.7 418.8 ± 63.0 Engine mounting bolt, nut (rubber, 2EA) M20×2.5 10.7 ± 1.6 77.4 ± 11.6 Engine mounting bolt (bracket, 6EA) M12×1.75 29.7 ±...

  • Page 184: New Machine

    New machine used and filled with following lubricants. Description Specification Engine oil SAE 15W-40 (API CJ-4) Hyundai genuine long life hydraulic oil (ISO VG46, VG68 only) Hydraulic oil ★2 Conventional hydraulic oil (ISO VG 15, cold region ) Transmission oil SAE 15W-40 ★...
  • Page 185 2) 2) RECOMMENDED OILS RECOMMENDED OILS Use only oils listed below or equivalent. Do not mix different brand oil. Ambient temperature˚C (˚F) Capacity Service point Kind of fluid ℓ (U.S. gal) (-58) (-22) (-4) (14) (32) (50) (68) (86) (104) ★2 SAE 5W-40 SAE 30...

  • Page 186: Maintenance Check List

    4. MAINTENANCE CHECK LIST 4. MAINTENANCE CHECK LIST Scheduled maintenance is the normal maintenance necessary to provide proper and efficient machine operation. To protect your investment and prolong the service life of your machine, follow the scheduled maintenance list below. 1) 1) EVERY 10 HOURS SERVICE EVERY 10 HOURS SERVICE...
  • Page 187 4) 4) EVERY 250 HOURS SERVICE EVERY 250 HOURS SERVICE Check items Service Page Wheel nuts Check, Tight 6-34, 35 Fuel tank (water, sediment) Drain 6-25 Battery (voltage) Check 6-45, 46 Hydraulic tank air breather element Replace 6-31 Air conditioner and heater outer filter Check, Clean 6-48 5) 5)

  • Page 188: When Required

    9) 9) EVERY 5000 HOURS SERVICE EVERY 5000 HOURS SERVICE Check items Service Page Hydraulic oil * Change 6-25 *2 Hyundai genuine long life hydraulic oil WHEN REQUIRED WHEN REQUIRED Check items Service Page Air cleaner element · Replace 6-24 Safety ·...

  • Page 189: Maintenance Chart

    5. MAINTENANCE CHART 5. MAINTENANCE CHART 9,10 1,15,17 27 19 9,10 23 22 11 7409A6MI10 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.
  • Page 190 Air cleaner element (primary) Clean, Replace Air cleaner element (safety) Replace *1 Conventional hydraulic oil *2 Hyundai genuine long life hydraulic oil ※ Oil symbol Oil symbol Refer the recommended lubricants for specification. ·EO : Engine oil ·PGL : Grease ·HO : Hydraulic oil...

  • Page 191: Service Instruction

    6. SERVICE INSTRUCTION 6. SERVICE INSTRUCTION 1) 1) CHECK ENGINE OIL LEVEL CHECK ENGINE OIL LEVEL Dipstick Check the oil level with the machine on a flat ground before starting engine. Pull out the dipstick and wipe with a clean cloth. Check the oil level by inserting the dipstick com- pletely into the hole and pulling out again.
  • Page 192 Apply a light film of lubricating oil to the gasket sealing surface before installing the filter. ※ Fill the filter with clean lubricating oil. Fill the filter with clean lubricating oil. 7807AMI07 Install the filler to the filter head. Tighten the filter until the gasket contacts the fil- ter head surface.

  • Page 193: Check Coolant Level

    (10) Operate the engine at low idle and inspect for leaks at the filter and the drain plug. Shut the engine off and check oil level with dip- stick. Allow 15 minutes for oil to drain down before checking. ※ Do not overfill the engine with oil.
  • Page 194 4) 4) FLUSHING AND REFILLING OF RADIATOR FLUSHING AND REFILLING OF RADIATOR Change coolant Change coolant Avoid prolonged and repeated skin contact Avoid prolonged and repeated skin contact with used antifreeze. Such prolonged repeat- with used antifreeze. Such prolonged repeat- ed contact can cause skin disorders or other ed contact can cause skin disorders or other bodily injury.
  • Page 195 ※ During filling, air must be vented from the During filling, air must be vented from the engine coolant passages. engine coolant passages. The system must be filled slowly to prevent The system must be filled slowly to prevent air locks. Wait 2 to 3 minutes to allow air to air locks.
  • Page 196 Cooling system filling SIGHT GAUGE Use a mixture of 50 percent soft water and 50 WATER WATER percent ethylene glycol antifreeze to fill the ANTIFREEZE ANTIFREEZE cooling system. Refer to the page 6-9. Never use water alone for coolant. This can result in damage from corrosion. Do not use hard water such as river water or well water.
  • Page 197 6) 6) 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. 7609A6MI02 6-21...
  • Page 198 7) 7) FAN BELT TENSION FAN BELT TENSION Use the belt tension gage to measure the belt tension. ·Fan belt tension : 11.3 kg (25 lb) 120096MA42 Inspect the drive belt for damage. ① Transverse (across the belt) cracks are accept- able.
  • Page 199 9) 9) FAN BELT TENSION FAN BELT TENSION With the engine stopped, check the tensioner arm, pulley, and stops for cracks. If any cracks are found, the tensioner must be replaced. 2609A6MA23 With the belt installed, verify that neither tension- er arm stop is in contact with the spring case stop.

  • Page 200: Cleaning Of Air Cleaner

    CLEANING OF AIR CLEANER CLEANING OF AIR CLEANER (1) (1) Primary element Primary element ① Open the cover and remove the element. ② Wipe all contaminant and debris from inside the housing body. ③ Do not clean the filter element by striking or hitting the filter against any object to shake the debris from the filter element.
  • Page 201 FUEL TANK FUEL TANK Fill fuel fully when system the operation to mini- Strainer mize water condensation, and check it with fuel gauge before starting the machine. Drain the water and sediment in the fuel tank by opening the drain cock. ※...

  • Page 202: Replacement Of Fuel Filter

    (2) (2) Replace element Replace element ① Drain the unit of fuel. Follow "Drain water" instructions above. Fuel warmer Open ② Remove element, fuel warmer and bowl from Element filter head. Bowl ※ The bowl is reusable, do not damage or dis- The bowl is reusable, do not damage or dis- Open card.

  • Page 203: Bleeding The Fuel System

    BLEEDING THE FUEL SYSTEM BLEEDING THE FUEL SYSTEM Plug Lift pump Loosen fuel supply line plug at the outlet of pre- Open filter. Do hand-priming the lift pump repeatedly until air bubbles comes out from fuel supply line com- Close pletely.
  • Page 204 If the gasket is damaged, remove the gasket by grasping the tab on the gasket and pulling up. Clean the crankcase ventilation filter mounting surface and O-ring sealing surfaces on the rock- er lever cover. Clean the crankcase ventilation filter cover with warm soapy water.

  • Page 205: Hydraulic Oil Check

    (10) Install the crankcase ventilation filter cover. Install the filter cover capscrews. Capscrew Tighten the capscrews, starting with the inner- most capscrews and working outward in a circu- lar manner. Cover ·0.71 kgf·m (5.16 lbf·ft) Install the oil fill cap. 7609A6MI30 LEAKAGE OF FUEL LEAKAGE OF FUEL...

  • Page 206: Filling Hydraulic Oil

    FILLING HYDRAULIC OIL FILLING HYDRAULIC OIL Cap nut Stop the engine to the position of level check. Pushing Rotate the cap nut counter-clockwise by hand Air breather and push the rod to release the air pressure. Remove the breather on the top of oil tank and fill the oil to the specified level.
  • Page 207 CLEANING AND REPLACING RETURN FILTER CLEANING AND REPLACING RETURN FILTER Clean and replace the return filter in the following Cover manner. O-ring Spring Remove the cover. Cover O-ring Remove spring, by-pass valve and return filter Strainer Spring from the tank. By-pass valve Replace element with new one and assemble Return filter...
  • Page 208 REPLACE OF PILOT LINE FILTER REPLACE OF PILOT LINE FILTER Loosen the bowl positioned on the safety valve. Safety valve Pull out the filter element and clean the bowl. Install the new element and tighten the bowl using spanner. ·Spanner size : 27 mm Bowl 7409A6MI26 LUBRICATE RCV LEVER...

  • Page 209: Tire Pressure

    TIRE PRESSURE TIRE PRESSURE Inappropriate tire pressure is a primary cause for tire damage. Insufficient tire pressure will dam- age internal carcass of tire. Repeated excessive bending will damage or break the carcass. Excessive pressure will also cause premature damage of tire. Recommended tire pressure (When tire is cooled) Size Pressure...

  • Page 210: Replacement Of Tire

    REPLACEMENT OF TIRE REPLACEMENT OF TIRE Disassembly, reassembly, replacement and Disassembly, reassembly, replacement and repair of tire requires special skills and equip- repair of tire requires special skills and equip- ment. Contact a tire repair shop. ment. Contact a tire repair shop. (1) (1) Tires to be replaced Tires to be replaced...
  • Page 211 Direction of tire to be installed Direction of tire to be installed ① Be careful that the valve should be facing the outside. Valve 73036MI13 Mounting of tire Mounting of tire ① Lightly tighten nuts as shown in the illustration. ②...

  • Page 212: Check Transmission Oil Level

    CHECK TRANSMISSION OIL LEVEL CHECK TRANSMISSION OIL LEVEL The oil level check must be carried out as follows; oil level check (weekly). Before the oil level check, Transmission must have been running to warm up enough. When the oil level is checked, machine must be on flat ground and engine must be at idling speed, transmission must be in neutral position.
  • Page 213 Remove the transmission oil filter cartridge. Dispose of the used transmission oil filter car- tridge properly. Clean the filter cartridge mounting base. Remove any part of the filter cartridge gasket that remains on the filter cartridge mounting base. 7409A6MI66 Apply a light coat of oil to the gasket of a new transmission oil filter cartridge.

  • Page 214: Front Axle

    CLEANING TRANSMISSION AIR BREATHER CLEANING TRANSMISSION AIR BREATHER Air breather Remove dust or debris around the air breather. Remove the air breather and wash it with cleaning oil. 7409A6MI35 CHECK AND SUPPLYING AXLE OIL CHECK AND SUPPLYING AXLE OIL FRONT AXLE Move the machine to flat ground.
  • Page 215 CHANGE THE AXLE OIL CHANGE THE AXLE OIL FRONT AXLE Place a case under drain plug to catch oil. Fill & oil level plug Remove the air breather to relieve internal pres- sure. Air breather The basic condition for a correct oil change of the axle is horizontal plane of installation in every Drain plug direction.
  • Page 216 LUBRICATION LUBRICATION Supply grease through the grease nipple, using grease gun. After lubricating, clean off spilled grease. Press the parking brake switch and fix front Press the parking brake switch and fix front and rear frames using the safety lock bar. and rear frames using the safety lock bar.
  • Page 217 REPLACEMENT OF BOLT ON CUTTING REPLACEMENT OF BOLT ON CUTTING EDGE EDGE (1) (1) Replacement time Replacement time Replace the cutting edge before it has worn out to the end of bucket. (2) (2) Replacement method Replacement method Make sure the work equipment does not Make sure the work equipment does not move when replacing the cutting edge.
  • Page 218 Replacement method Replacement method Make sure the work equipment does not Make sure the work equipment does not move when replacing the bucket tooth. move when replacing the bucket tooth. Set the work equipment in a stable position, Set the work equipment in a stable position, put the pilot cut off switch in the OFF position put the pilot cut off switch in the OFF position and stop the engine.
  • Page 219 MAINTENANCE OF WORK EQUIPMENT MAINTENANCE OF WORK EQUIPMENT Lubricate to each pin of working device. Lubricate the grease to grease nipple in accor- dance with lubrication intervals. Description Bucket cylinder (front frame side) pin LH side RH side Boom cylinder (front frame side) right pin Boom-front frame right connection pin Boom-front frame left connection pin Boom cylinder (front frame side) left pin...
  • Page 220 WORK EQUIPMENT SUPPORT WORK EQUIPMENT SUPPORT When carrying out inspection and maintenance with the equipment raised, fit a stand under the lift arm securely to prevent the work equipment from coming down. In addition, set the work equipment control levers to the Hold position and put the pilot cut off switch to the OFF position.

  • Page 221: Electrical System

    7. ELECTRICAL SYSTEM 7. ELECTRICAL SYSTEM 1) 1) WIRING, GAUGES WIRING, GAUGES Check regularly and repair loose or malfunctioning gauges when found. 73036MI27 2) 2) BATTERY BATTERY (1) (1) Clean Clean ① Wash the terminal with hot water if it is contami- nated, and apply grease to the terminals after washing.
  • Page 222 (2) (2) Recycle Recycle Never discard a battery. Always return used batteries to one of the fol- lowing locations. ·A battery supplier ·An authorized battery collection facility ·Recycling facility (3) (3) Method of removing the battery cable Method of removing the battery cable Remove the cable from the ground connection first ( terminal side) and reconnect it last...
  • Page 223 (3) (3) Taking off the booster cable Taking off the booster cable Disconnection of booster cable ① Take off the booster cable (black). ② Take off the booster cable (red) connected to the (+) terminal. ③ Run engine with high idle until charging the exhausted battery by alternator, fully.

  • Page 224: Air Conditioner And Heater

    8. AIR CONDITIONER AND HEATER 8. AIR CONDITIONER AND HEATER 1) 1) CLEAN AND REPLACE OF OUTER FILTER CLEAN AND REPLACE OF OUTER FILTER ※ Always stop the engine before servicing. Always stop the engine before servicing. Open the door, loosen the wing bolt and remove the outer filter.
  • Page 225 3) 3) PRECAUTIONS FOR USING AIR CONDITIONER PRECAUTIONS FOR USING AIR CONDITIONER When using the air conditioner for a long time, open the window once every one hour. Be careful not to overcool the cab. The cab is properly cooled if the operator feels cool when entering there from outside (about 5˚C lower than the outside temperature).

  • Page 226: 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 possibil- ities are listed. Trouble Service Remark · Engine oil pressure lamp fails to go Add the oil to the specified level. off immediately after the engine is ·...

  • Page 227: Electrical System

    2. ELECTRICAL SYSTEM 2. ELECTRICAL SYSTEM Trouble Service Remark · Voltmeter fluctuates largely even Check for loose terminals open-circuit wiring. with the engine running at a constant · Adjust belt tension. speed. Lamp does not glow brightly even when engine runs at high speed. Lamp flickers while engine runs.

  • Page 228: Power Train System

    3. POWER TRAIN SYSTEM 3. POWER TRAIN SYSTEM Trouble Service Remark · Engine is running but machine Release parking brake. will not move. · Put gear selector lever in position properly. · Add oil to transmission case to the specified level. ·...

  • Page 229: Hydraulic System

    4. HYDRAULIC SYSTEM 4. HYDRAULIC SYSTEM Trouble Service Remark · Bucket lacks lifting power. Check the hydraulic oil level and add if necessary. Bucket lifting speed is slow. · Replace filter in hydraulic tank. Bubbles in oil. · Replace with specified oil. ·...

  • Page 230: Others

    OTHERS OTHERS 1. CENTRAL GREASE LUBRICATION SYSTEM 1. CENTRAL GREASE LUBRICATION SYSTEM 1) 1) MAJOR COMPONENT MAJOR COMPONENT Minimum level Cab ceiling LH side To rear axle and To attachment steering cylinder and flange bearing 7809A8CG01 Grease tank Central grease lubrication switch Grease pump Pump element Control unit...

  • Page 231: Electronic Control Unit

    2) 2) ELECTRONIC CONTROL UNIT ELECTRONIC CONTROL UNIT EA/PA Controller Type S-EP 4 Push button Lubricating period (min.) Control Pause period (hr) 8007A8CG18 (1) (1) Lubricating period setting dial Lubricating period setting dial ① This dial use to set the greasing period from 1 to 16 minutes. ②...
  • Page 232 4) 4) FILLING THE GREASE TANK FILLING THE GREASE TANK Standard filling via lubrication nipple with manual or pneumatic grease gun. ※ Lubricate the grease until it flows out to Lubricate the grease until it flows out to Grease vent Gerase tank the grease vent.

  • Page 233: Repair Instructions

    5) 5) REPAIR INSTRUCTIONS REPAIR INSTRUCTIONS Case of system blockage Case of system blockage (1) (1) ① A creased or clogged lubricant pipe ② Grease points overfilled or clogged by lubricant ③ Lubricant not suitable for central lubrication system ④ Distributor outlet closed ⑤...

  • Page 234: Troubleshooting

    6) 6) TROUBLESHOOTING TROUBLESHOOTING Category Applications Service Pump does not work Defective electronic control unit Replace the control unit Electric cable is broken Renew the electric cable Pump is defective Replace the pump Pump is working, but does Bleed the pump Air in the feed piston filling not supply of lubrication Refill the grease tank...

  • Page 235: Quick Coupler

    2. QUICK COUPLER FIXING BUCKET WITH QUICK COUPLER Release the lock pins by pressing the attachment unlock switch. 9558QC01-1 Tilt quick coupler forward and align the upper attaching points of the quick coupler Bucket with upper attaching points on the bucket. Raise the boom until the bucket rests in Boom the quick coupler and tilt the quick coupler...
  • Page 236 REMOVE BUCKET FROM QUICK COUPLER The attachment should be in a level position on the ground. Release the lock pins by pressing the switch. Lower the boom so that it disengage from the attachment. Reverse away from the attachment. PRECAUTION OF USING QUICK COUPLER When operating the machine with quick coupler, confirm that the attachment lock switch is lock position.

  • Page 237: Index

    INDEX INDEX Loading and unloading -------------------------------------- 5-6 Lubrication -------------------------------------------------------- 6-40 Air cleaner ------------------------------------------------------- 6-24 Air conditioner & heater ----------------------------------- 3-43 Air conditioner filter ------------------------------------------ 6-48 Machine control unit (MCU) ------------------------------- 3-49 Axle oil ------------------------------------------------------------- 6-39 Maintenance chart --------------------------------------------- 6-13 Maintenance check list -------------------------------------- 6-10 Major components --------------------------------------------- 2-1 Battery ------------------------------------------------------------- 6-45 Master switch ---------------------------------------------------- 3-48...

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