Table of Contents

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Foreword ---------------------------------------------------------- 0-1
Before servicing this machine --------------------------- 0-2
EC regulation approved ------------------------------------ 0-3
Table to enter S/No and distribution ----------------------- 0-4
Safety labels ----------------------------------------------------- 0-5
Machine data plate -------------------------------------------- 0-14
Guide(Direction, S/No, Symbol) ------------------------ 0-15
1. Before operating the machine --------------------- 1-1
2. During operating the machine --------------------- 1-16
3. During maintenance ----------------------------------- 1-23
4. Parking ------------------------------------------------------ 1-26
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
8. Recommended oils ------------------------------------ 2-10
1. Cab devices ----------------------------------------------- 3-1
2. Cluster ------------------------------------------------------- 3-2
3. Switches ---------------------------------------------------- 3-14
4. Levers and pedals -------------------------------------- 3-21
5. Air conditioner and heater --------------------------- 3-24
6. Others -------------------------------------------------------- 3-28
1. Suggestion for new machine ---------------------- 4-1
3. Starting and stop the engine ----------------------- 4-3
5. Traveling of the machine ----------------------------- 4-8
6. Efficient working method ---------------------------- 4-14
8. Normal operation of excavator -------------------- 4-21
9. Attachment lowering ----------------------------------- 4-22
10. Storage -------------------------------------------------- ---- 4-23
11. RCV lever operating pattern ----------------------- 4-25
1. Road traveling -------------------------------------------- 5-1
2. Preparation for transportation --------------------- 5-2
3. Dimension and weight -------------------------------- 5-3
4. Loading the machine ---------------------------------- 5-5
5. Fixing the machine ------------------------------------- 5-7
6. Loading and unloading by crane ------------------- 5-8
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 ------------------------------------- 6-15
6. Service instruction -------------------------------------- 6-17
7. Electrical system ---------------------------------------- 6-38
8. Air conditioner and heater --------------------------- 6-41
1. Engine -------------------------------------------------- ----- 7-1
2. Electrical system ---------------------------------------- 7-2
3. Others -------------------------------------------------------- 7-3
1. Selecting hydraulic breaker ------------------------- 8-1
2. Circuit configuration ------------------------------------ 8-2
3. Maintenance ---------------------------------------------- 8-3
5. Quick clamp ----------------------------------------------- 8-6
------------------------------------------------------------- 9-1
CONTENTS

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Summary of Contents for Hyundai R55W-9

  • Page 1: Table Of Contents

    CONTENTS Foreword ---------------------------------------------------------- 0-1 7. Operation in the special work sites ------------- 4-19 Before servicing this machine --------------------------- 0-2 8. Normal operation of excavator -------------------- 4-21 EC regulation approved ------------------------------------ 0-3 9. Attachment lowering ----------------------------------- 4-22 Table to enter S/No and distribution ----------------------- 0-4 10.
  • Page 2: Foreword

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

    The procedures in this manual do not supersede any requirements imposed by federal, state, provin- cial 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 Noise level (EN474-1 : 2006 and 2000/14/EC) are as followings. : 98dB (EU only) : 78dB The value of vibrations transmitted by the operator's seat are lower than standard value of (EN474-1 : 2006 and 2002/44/EC)
  • Page 5 EC Declaration of Conformity 1. HYUNDAI CONSTRUCTION EQUIPMENT EUROPE N.V VOSSENDAAL 11, 2440 GEEL (Belgium), as authorized representative in the European Community of HYUNDAI CONSTRUCTION EQUIPMENT Co. Ltd.(Korea) certifi es 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 Distributor for U.S.A Hyundai Construction Equipment U.S.A, Inc 6100 Atlantic Boulevard Norcross...
  • Page 7: Safety Labels

    SAFETY LABELS 1. LOCATION Always keep these labels clean. If they are lost or damage, attach them again or replace them with a new label. 55W91FW01A Fueling 14 Console box filter 27 Trade mark (boom) Battery accident 15 Machine control (cabin) 28 Swing lock Low sulfur fuel 16 Stay fix (cabin)
  • Page 8 2. DESCRIPTION There are several specific warning labels on this machine please become familiarized with all warn- ing labels. Replace any safety label that is damaged, or missing. FUELING (item 1) This warning label is positioned on the right side of fuel filler neck. Stop the engine when refueling.
  • Page 9 LOW SULFUR FUEL (item 3) This warning label is positioned on the right EPA REGULATION side of fuel filler neck. USE LOW SULFUR EPA Regulation use low sulfur fuel or ultra FUEL OR ULTRA LOW low sulfur fuel only. SULFUR FUEL ONLY 5591FW09 KEEP CLEAR-BOOM/ARM (item 5) This warning label is positioned on both...
  • Page 10 CAUTION-ENGINE ROOM (item 8) This warning label is positioned on the side of radiator. Do not open the engine hood during the engine's running. Escaping fluid under pressure can pene- trate the skin causing serious injury. Study the service manual before service job.
  • Page 11 GENERAL CAUTIONS-CABIN (item 10) This warning label is positioned on the right side window of the cab. Serious injury or death can result from contact with electric lines. An electric shock being received by merely coming into the vicinity of an electric lines, the minimum distance should be kept considering the supply voltage as page 1-7.
  • Page 12 DECAL-CONSOLE TILTING (item 14) This warning label is positioned on the LH console box. Before you get off the machine be sure to tilt the LH console box. R5570FW17 MACHINE CONTROL-CABIN (item 15) WARNING This warning label is positioned on the right THE MACHINE CONTROL PATTERN CAN EASILY BE CHANGEDTO THE "ISO TYPE"...
  • Page 13 FALLING (item 18) This warning label is positioned on the top of the hydraulic tank. Falling is one of the major cause of per- sonal injury. Be careful of slippery conditions on the platforms, steps and handrails when standing on the machine. 14070FW30 NO STEP-ENGINE HOOD (item 19) This warning label is positioned on the...
  • Page 14 BOOM SWING LOCK (item 28) This warning label is positioned on the right side window of the cab. Before operating the machine, be sure to release the swing lock device in the tool box. 55W91FW03 ECM CONNECTOR (item 29) W A R N I N G This warning label is positioned on the battery cover.
  • Page 15 A special air bleed valve is necessary for this operation, so please contact your Hyundai distributor. CHANGE SPEED (item 37) This warning label is positioned on the battery cover.
  • Page 16 CONTROL IDEOGRAM-DOZER (item 38) This warning label is positioned on the RH console box. See page 4-7 for details. Guidlines for using the general dozer blade. Be careful not to apply an excessive load when using a blade. R25Z9A0FW06 Avoid impacts and loads on the bot- tom due to machine modification or excessive working conditions.
  • Page 17: Machine Data Plate

    5 Manufacturing year The machine serial number assigned to this particular machine and should be used when request- ing information or ordering service parts for this machine from your authorized HYUNDAI dealer. The machine serial number is also stamped on the frame.
  • Page 18: Guide(Direction, S/No, Symbol)

    GUIDE 1. DIRECTION Forward The direction of this manual indicate forward, back- ward, right and left on the standard of operator when the travel motor is in the rear and machine is on the traveling direction. Left Right Dozer blade Backward 55W91SH01 2.
  • Page 19: 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. A l m o s t ev e r y a c c i d e n t i s c a u s e d b y disregarding the simple and fundamental safety hints.
  • Page 20 Check daily according to the operation manual. Repair the damaged parts and tighten the loosened bolts. 17W31SH05 Check for leakage of engine oil, hydraulic oil, fuel and coolant. Keep machine clean, clean machine regularly. 17W31SH06 Do not operate the machine if it requires repairs. Operate after complete repair.
  • Page 21: Unauthorized Modification

    55W91SH05 ROTATING BEACON ROTATING BEACON Beacon When you operate a machine on a road or beside a road, a rotating beacon is required to avoid any traffic accident. Please contact your Hyundai distributor to install 21071SH03...
  • Page 22: Safety Rules

    Do not use attachments that are not authorized by Hyundai or your Hyundai distributor. Use of unauthorized attachments could create a safety problem and adversely affect the proper operation and useful life of the machine.
  • Page 23: California Proposition

    MACHINE CONTROL PATTERN MACHINE CONTROL PATTERN Check machine control pattern for conformance to pattern on label in cab. If not, change label to match pattern before operating machine. Failure to do so could result in injury. CALIFORNIA PROPOSITION 65 CALIFORNIA PROPOSITION 65 Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other...
  • Page 24: Fire Prevention And Explosion Prevention

    FIRE PREVENTION AND EXPLOSION PREVENTION Regeneration The exhaust gas temperatures during regeneration will be elevated. Follow proper fire prevention instructions and use the disable regeneration function when appropriate. General All fuels, most lubricants, and some coolant mixtures are flammable. To minimize the risk of fire or explosion, the following actions are recommended.
  • Page 25 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 26 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 27 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 28 Fire 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 29 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 30 THE EUROPEAN UNION PHYSICAL AGENTS (VIBRATION) DIRECTIVE 2002/44/EC Vibration Data for Earth-moving Machines Information 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 The highest root mean square value of weighted acceleration to which the whole body is subjected, is less than 0.5 m/s This section provides vibration data and a method for estimating the vibration level for earth moving...
  • Page 31 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 condition X axis Y axis Z axis X axis Y axis...
  • Page 32 Guidelines 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. Maintain machines according to the manufacturer’s recommendations.
  • Page 33 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 Heavy Industries and has been installed according to approved methods described in a publication available from Hyundai Heavy Industries;...
  • Page 34: 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. 17W31SH09 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 35 Provide proper ventilation when operating engine in a closed area to avoid the danger of exhaust gases. 17W31SH13 Check the locations of underground gas pipes or water line and secure the safety before operation. 17W31SH14 The operating near the electrical lines is very dangerous.
  • Page 36 Watch out for obstacles. Be particularly careful to check the machine clearance during the swing. 17W31SH17 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 37 Avoid traveling in a cross direction on a slope as it can cause the danger of rolling over and sliding. 17W31SH21 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 38 The operation on a slope is dangerous. Avoid operating the machine on a slope of over 10 degree. 17W31SH25 Operate the machine after making ground flat when operation is required on a slope. 17W31SH26 The swing on the slope can be danger of rolling over.
  • Page 39 Before traveling the machine, sound the horn to warn nearby personnel. Operate forward and backward correctly with confirming the location of the travel motor. 17W31SH29 Slow down when traveling through obstacles or uneven ground. 17W31SH30 When operating in water or when crossing shallow, check the bed soil condition and depth and flow speed of water, then proceed taking care that water is not above axle center.
  • Page 40: Mounting And Dismounting

    When mounting or dismounting, always face the machine and use the handrails, machine or foot steps. In this case please contact your Hyundai distributor. Do not hold any control levers when getting on or off the machine.
  • Page 41: 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 clus- ter then repair. 17W31SH32 Park on a flat place and stop the engine for inspecting and repairing.
  • Page 42 There is the danger of fire in fuel and oil. Store in cool and dry area, away from any open flames. 13031SH37 Do not touch exhaust pipe, or may cause severe burn. 13031SH38 Do not open the engine hood and covers while the engine is running.
  • Page 43 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. 13031SH41 The antislip protection should be replaced if they have become worn or have been printed...
  • Page 44: 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. 17W31SH43 Park the machine in the flat and safe place. 17W31SH44 Hope you can work easily and safely observing safety rules.
  • Page 45: Specifications

    SPECIFICATIONS SPECIFICATIONS 1. MAJOR COMPONENTS 1. MAJOR COMPONENTS Battery box Swing motor Fuel tank Hydraulic tank Oil cooler Radiator Engine Main pump Tooth Bucket Main control valve Turning joint Arm cylinder Boom Boom cylinder Swing post Muffler Counterweight Dozer cylinder Dozer blade Side cutter Control rod Front axle...
  • Page 46: Specifications

    2. SPECIFICATIONS 2. SPECIFICATIONS 1) 1) 3.0 m m (9'10") MONO BOOM, 1.6 (9'10") MONO BOOM, 1.6 m m (5' 3") ARM WITH BOOM SWING SYSTEM (5' 3") ARM WITH BOOM SWING SYSTEM H(H') B(K) 55W92SP02 Description Unit Specification Operating weight kg (lb) 5550 (12240) Bucket capacity(SAE heaped), standard...
  • Page 47: Working Range

    3. WORKING RANGE 3. WORKING RANGE 1) 1) 3.0 m m (9'10") MONO BOOM WITH BOOM SWING SYSTEM (9'10") MONO BOOM WITH BOOM SWING SYSTEM 55W92SP03 Description 1.6 m (5' 3") Arm 6150 mm (20' 2") Max digging reach 5980 mm (19' 7") Max digging reach on ground Max digging depth 3500 mm (11' 6")
  • Page 48: Weight

    4. WEIGHT 4. WEIGHT R55W-9 Item Upperstructure assembly 2680 5910 Main frame weld assembly 1320 Engine assembly Main pump assembly Main control valve assembly Swing motor assembly Hydraulic oil tank assembly Fuel tank assembly Boom swing post Counterweight Cab assembly...
  • Page 49: Lifting Capacities

    5. LIFTING CAPACITIES 5. LIFTING CAPACITIES 3.0 m m ( 9'10") boom, 1.6 ( 9'10") boom, 1.6 m( 5' 3") arm equipped with 0.18 ( 5' 3") arm equipped with 0.18m (SAE heaped) bucket and the (SAE heaped) bucket and the dozer blade down.
  • Page 50: Bucket Selection Guide

    6. BUCKET SELECTION GUIDE 6. BUCKET SELECTION GUIDE 0.07m 0.18 m heaped bucket heaped bucket Recommendation Capacity Width 3.0 m (9' 10") boom Weight CECE Without With 1.6 m (5' 3") arm heaped heaped side cutter side cutter 315 mm 360 mm 115 kg 0.07 m...
  • Page 51: Specification For Major Components

    7. SPECIFICATIONS FOR MAJOR COMPONENTS 7. SPECIFICATIONS FOR MAJOR COMPONENTS ENGINE ENGINE 1) 1) Item Specification Model Yanmar 4TNV98-EPHYBU Type 4-cycle diesel engine, low emission 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 Cylinder bore×stroke...
  • Page 52: Main Control Valve

    3) 3) GEAR PUMP GEAR PUMP Item Specification Type Fixed displacement gear pump single stage Capacity 16.2/6.5 cc/rev Maximum pressure 220/30 kgf/cm (3130/430 psi) Rated oil flow 38.9/15.6ℓ/min (10.3/4.1 U.S. gpm/8.6/3.4 U.K. gpm) 4) 4) MAIN CONTROL VALVE MAIN CONTROL VALVE Item Specification Type...
  • Page 53: Power Train

    SAE heaped CECE heaped Without side cutter With side cutter 670 mm (26.4") 740 mm (29.1") 0.18 m (0.24 yd 0.15 m (0.20 yd R55W-9 315 mm (12.4") 360 mm (14.2") 0.07 m (0.09 yd 0.06 m (0.08 yd...
  • Page 54: Recommended Oils

    8. RECOMMENDED OILS Use only oils listed below or equivalent. Do not mix different brand oil. Ambient temperature C ( F) Capacity Service point Kind of fluid (U.S. gal) (-4) (14) (32) (50) (68) (86) (104) SAE 30 SAE 10W Engine oil pan Engine oil 11.6 (3.1)
  • Page 55: 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 56: Cluster

    2. CLUSTER 2. CLUSTER The cluster consists of gauges and lamps as shown below, to warn the operator in case of abnormal machine operation or conditions for the appropriate operation and inspection. · Gauges : Indicate operating status of the machine. ·...
  • Page 57: Gauges And Displays

    1) 1) GAUGES AND DISPLAYS GAUGES AND DISPLAYS LCD display LCD display (1) (1) ① Service meter Service meter : This meter shows the total operation hours of Service meter the machine. ※ Always ensure the operating condition of the meter during the machine operation.
  • Page 58 2) 2) WARNING AND PILOT LAMPS WARNING AND PILOT LAMPS (1) (1) Fuel low level warning lamp Fuel low level warning lamp ① This lamp blinks and the buzzer sounds when the level of fuel is below 18ℓ(4.8 U.S. gal). ②...
  • Page 59 (6) (6) Battery charging warning lamp ① This lamp blinks and the buzzer sounds when the starting switch is ON, it is turned OFF after starting the engine. ② Check the battery charging circuit when this lamp blinks during engine operation. R5573CD16 (7) (7) Warming up pilot lamp...
  • Page 60 (11) (11) Auto idel pilot lamp Auto idel pilot lamp ① If the control lever and pedal are not moved for several seconds with auto idle switch pressed, the indicator illuminates and engine speed is decelerated. ② If the auto idle switch is pressed once more or the control lever or pedal is moved, the indicator turns off and the number of engine revolution is turned to the previous condition.
  • Page 61 (16) (16) Ram lock pilot lamp Ram lock pilot lamp ① This pilot lamp lights ON when ram lock switch is rear position. ② Also, the pilot lamp lights ON when the parking switch is ON or service brake is applied. 20W73CD37 (17) (17)
  • Page 62: Switches

    3) 3) SWITCHES SWITCHES Auto idle switch Auto idle switch (1) (1) ① This switch is used to actuate or cancel the auto idle function. ② When the switch actuated and all control levers and pedals are at neutral position, engine speed will be lowered automatically to save fuel consumption.
  • Page 63 (5) (5) Menu and enter switch Menu and enter switch ① Menu Enter These switches are used to set time or set ESL (Engine Start Limit) function. The Enter button ( ) is used to select a function. The Menu button ( ) is used to select a menu or return to the time display menu.
  • Page 64 ⑤ Change password Change password Selct ESL function to YES and press the Menu button ( the display is shifted to the password change menu. · Input a new password (Sn : - - - -) after enter the current password successfully (SC : - - - -).
  • Page 65 ⑦ Machine fault code Machine fault code Fault code Description HCESPN Working pressure sensor data above normal range (or open circuit) Working pressure sensor data below normal range Working pressure sensor data error Working pressure sensor circuit - voltage below normal, or shorted to low source Working pressure sensor circuit - special instructions Working pressure sensor circuit - voltage valid but above normal operational range Working pressure sensor circuit - voltage valid but below normal operational range...
  • Page 66 ⑧ Engine fault code Engine fault code Fault code Description YANMAR SPN FMI Engine fuel rack position sensor : shorted to low source 1210 Engine fuel rack position sensor : shorted to high source Accelerator pedal position sensor “A” : shorted to low source Accelerator pedal position sensor “A”...
  • Page 67 Fault code Description YANMAR SPN FMI Cold start device : open circuit 522242 Cold start device : short circuit Cold start device : intermittent fault EGR stepping motor “A” : open circuit 522251 EGR stepping motor “A” : short circuit EGR stepping motor “B”...
  • Page 68: Starting Switch

    3. SWITCHES 3. SWITCHES Head light switch Quick clamp switch Boom offset switch Work light switch Auto cruise switch Travel alarm switch Auto ram lock switch Cab light switch Beacon switch Master switch Breaker selection switch Start switch Switch panel 2 Switch panel 1 Breaker operation switch...
  • Page 69 2) 2) ACCEL DIAL ACCEL DIAL There are 10 dial setting. Setting 1 is low idle and setting 10 is high idle. ·By rotating the accel dial to right : Engine speed increased. ·By rotating the accel dial to left : Engine speed decreased. 21073CD34 3) 3) HEAD LIGHT SWITCH...
  • Page 70: Beacon Switch

    7) 7) BEACON SWITCH BEACON SWITCH (option) This switch turns ON the rotary light on the cab. The below indicator lamp is turned ON when operating this switch. 555C93CD30 8) 8) BREAKER SELECTION SWITCH BREAKER SELECTION SWITCH (option) This switch is used to operate breaker. ※...
  • Page 71: Parking Brake Switch

    AUTO AUTO RAM LOCK SWITCH RAM LOCK SWITCH (machine serial No. : #1363~) This switch activate front axle oscillation cylinder to locking position for increase of stability. ·ON : Set front axle to locking position for excavation work or travels even ground. Also, the ram lock pilot lamp comes ON at the travel pilot lamp.
  • Page 72 BREAKER OPERATION SWITCH BREAKER OPERATION SWITCH On pressing this switch, the breaker operates only when the breaker Breaker operation switch selection switch on the switch panel is selected. RH RCV lever 5593CD32 RH MULTI FUNCTION SWITCH RH MULTI FUNCTION SWITCH FNR lever FNR lever (1) (1)
  • Page 73: Wiper Switch

    LH MULTI FUNCTION SWITCH LH MULTI FUNCTION SWITCH Direction indication lamp switch Direction indication lamp switch (1) (1) ① This switch is used to warn or signal the turning direction of the Right turning machine to other machines or equipment. ②...
  • Page 74: Hazard Switch

    HAZARD SWITCH HAZARD SWITCH Use for parking, or roading machine. LH and RH turn signal lamps come ON at the same time by this switch. ※ If the switch is left ON for a long time, the battery may be dis- If the switch is left ON for a long time, the battery may be dis- charged.
  • Page 75: Levers And Pedals

    4. LEVERS AND PEDALS 4. LEVERS AND PEDALS Dozer control lever RH control lever LH control lever Steering wheel Safety lever Seat & console box control lever Acceleration pedal Brake pedal Swing lock pin 55W93CD04 1) 1) LH CONTROL LEVER LH CONTROL LEVER This joystick is used to control the swing and the arm.
  • Page 76: Brake Pedal

    3) 3) SAFETY LEVER SAFETY LEVER All control levers and pedals are disabled from operation by locating the lever to lock position as shown. ※ Lock Be sure to raise the lever to LOCK position and tilt LH console Be sure to raise the lever to LOCK position and tilt LH console box when leaving from operator's seat.
  • Page 77: Dozer Control Lever

    7) 7) DOZER CONTROL LEVER DOZER CONTROL LEVER This lever is used to operate the dozer blade. Dozer control lever If the lever is pushed forward, the dozer blade will be going down. If the lever is pulled back, the dozer blade will be going up. R5573CD41 8) 8) STEERING WHEEL...
  • Page 78: Air Conditioner And Heater

    5. FULL AUTO FULL AUTO AIR CONDITIONER AND HEATER 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. · Location of air flow ducts Location of air flow ducts Fresh air switch Mode switch...
  • Page 79: Auto 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 In/outlet Temperature Mode Value Inlet OFF Previous sw OFF Previous sw OFF...
  • Page 80 5) 5) TEMPERATURE CONTROL SWITCH TEMPERATURE CONTROL SWITCH Setting temperature indication (17~32˚C, scale : 1˚C) Max cool and max warm beeps 5 times. The max cool or the max warm position operates as following table. Temperature Compressor Fan speed In/Outlet Mode Max cool Max (Hi)
  • Page 81: Self Diagnosis Function

    8) 8) SELF DIAGNOSIS FUNCTION SELF DIAGNOSIS FUNCTION Procedure Procedure (1) (1) 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)
  • Page 82: Others

    6. OTHERS 6. OTHERS Handsfree 12V socket Speaker Cigar lighter Remote controller Radio & CD/MP3 player Fuse box Seat 55W93CD06 1) 1) CIGAR LIGHTER 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 83 3) 3) 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) Forward/Backward adjustment (A) Forward/Backward adjustment (A) Pull lever A to adjust seat forward or backward. The seat can be moved forward and backward over 130 mm (5.1") in 13 steps.
  • Page 84 4) 4) HANDSFREE HANDSFREE Allow you to dial a call or to have a conversation without holding your handset. Use the remote controller when making and answering a calls or ring off. Indicator lamp Private call jack socket Handsfree jack socket USB socket Mobile phone stroage box Service socket...
  • Page 85 (4) (4) Handsfree jack socket Handsfree jack socket ① Connect the jack cable when call by handsfree. ② Use the special adapter when jack cable is not interchangeable. ③ Check the jack type of mobile phone before use. 21093CD51D (5) (5) Indicator lamp Indicator lamp ①...
  • Page 86: Remote Controller

    5) 5) REMOTE CONTROLLER REMOTE CONTROLLER Handsfree jack MIC Power/Volume switch SEEK Seek button MODE MUTE Mode button Mute button Call button Mode change button CALL 21093CD52 (1) (1) Power and volume switch Power and volume switch ① This switch is used to turn the audio or handsfree ON or OFF. ②...
  • Page 87 (4) (4) Handsfree MIC Handsfree MIC ① This MIC transfers user voice to receiver of the call when making a call by handsfree. SEEK MODE MUTE 21093CD52D (5) (5) Seek button Seek button ① If this button pressed, the radio automatically stops at the next frequency of broadcasting for your listening.
  • Page 88 At this time, you can hear beep sounds three times. Next, the mobile phone finds bluetooth named "HYUNDAI". Select "HYUNDAI" and set "Connect with bluetooth on the mobile phone". For the connection, the password is, by default, set as "0000".
  • Page 89 6) 6) FUSE BOX FUSE BOX The fuses protect the electrical parts and wiring from burning out. WORK START LAMP The fuse box cover indicates the capacity of each FUEL PUMP CASSETTE HORN CLUSTER fuse and circuit it protects. ※ Replace a fuse with another of the same Replace a fuse with another of the same CIGAR LIGHT...
  • Page 90 8) 8) RADIO AND CD/MP3 PLAYER RADIO AND CD/MP3 PLAYER (machine serial No. : -#1438) (machine serial No. : -#1438) CD inserter 21093CD70 ■FRONT PANEL PRESENTATION FRONT PANEL PRESENTATION -------- Power and volume switch -------- Preset memory button 1 REW ----------- Fast rewind (CD) PWR ----------- Press to power on/off -------- Preset memory button 2 VOL ------------ Turn right/left to adjust the volume...
  • Page 91: Power On/Off

    ■RADIO RADIO (1) (1) Power and volume switch ower and volume switch ① Power ON/OFF Power ON/OFF This switch is used to turn the audio ON or OFF. ② Volume Volume This switch turned to right or left, the sound is increased or decreased.
  • Page 92 (6) (6) Preset memory button Preset memory button ① Manually storing stations in a preset Manually storing stations in a preset Six stations per band can be stored and recalled using the preset keys (1 to 6). · Tune in to the desired station. ·...
  • Page 93 ■CD/MP3 CD/MP3 PLAYER PLAYER (1) (1) CD playback button playback button ① It is possible to change CD playback during broadcasting. ② If there was no CD on audio, "NO DISC" displays on LCD during 5 seconds. 21093CD80 (2) (2) Track button Track button ①...
  • Page 94: Cd Eject Button

    (7) (7) Repeat track button Repeat track button (CD) ① Press this button to activate repeat current track playback. ※ The LCD displays "RPT". The LCD displays "RPT". ② It is canceled press one more this button. 21093CD84 (8) (8) Mark button Mark button (MP3) ①...
  • Page 95 RADIO AND USB PLAYER ( RADIO AND USB PLAYER (machine serial No. : #1439- machine serial No. : #1439-) ■BASIC FUNCTIONS BASIC FUNCTIONS 2209S3CD70 1 Power (PWR) button 4 Radio (FM/AM) selection button 2 Volume/Sound setting button 5 USB slot 3 Mode selection button 6 AUX terminal (1) (1)
  • Page 96 ·Sound setting Sound setting ① Press the SELECT button to conduct sound setting. SELECT PUSH Each press of the button will change the sound setting in the fol- lowing order. BASS → MIDDLE → TREBLE → BALANCE → EQ → BEEP 2209S3CD70C ②...
  • Page 97 (3) (3) MODE selection button MODE selection button ① Pres the MODE button to change to RADIO/USB/AUX/iPod modes. MODE However, the mode can be selected only when the respective media is connected. ② If iPod is connected to the audio, the mode will change in the following order.
  • Page 98 ■RADIO RADIO 2209S3CD71 1 Radio (FM/AM) selection button 4 LCD display 2 TRACK/SEEK button 5 BSM (Best Station Memory) button 3 Broadcast manual search (FLDR) button 6 Saving broadcast frequencies to PRESET numbers (1) (1) Radio Radio (FM/AM) selection button (FM/AM) selection button ①...
  • Page 99 (2) (2) TRACK/SEEK button TRACK/SEEK button ① As buttons used to automatically search broadcasts, pressing the button will automatically search and stop at a frequency with supe- TRACK rior reception. TRACK ∧ : Searches frequencies higher than current frequency SEEK SEEK ∨: Searches frequencies lower than current frequency 2209S3CD71B ※...
  • Page 100 (6) (6) Saving broadcast frequencies to PRESET numbers Saving broadcast frequencies to PRESET numbers Up to 18 FM broadcasts and 6 AM broadcasts can be saved. ① Use the auto/manual search buttons to find the desired frequency. ② Select the preset button (1REW~ 6INFO) to which you wish to save the selected frequency.
  • Page 101 ■USB USB CONNECTION CONNECTION 2209S3CD72 1 USB selection button 7 Scroll (SCR) button 2 TRACK UP/SEEK DOWN button 8 View music info (INFO) button 3 FLDR UP/DOWN button 9 Scan button (BSM) 4 FF/REW button 10 Finding and playing file (SELECT) button 5 RPT/FOLDER RPT button 11 LCD display 6 RDM/FOLDER RDM button...
  • Page 102 (3) (3) FLDR UP/DOWN button FLDR UP/DOWN button ① If there are more than 2 folders in the USB, pressing the FLDR UP/ DOWN button will move to the previous or next folder. FLDR ② If there are no folders in the USB, then pressing the button will move FLDR up/down within the folder in 10 file increments.
  • Page 103 (8) (8) View music info iew music info (INFO) (INFO) button button ① Each time the INFO button is pressed, the info on the currently playing song will be displayed in the following order. FILE NAME → TITLE → ARTIST → ALBUM → DIR 2209S3CD72E (9) (9) Scan button...
  • Page 104 ■iPOD CONNECTION POD CONNECTION 2209S3CD73 1 iPod selection button 5 Random play (RDM) button 2 TRACK UP/SEEK DOWN button 6 Scroll (SCR) button 3 FF/REW button 7 View music info (INFO) button 4 Repeat (RPT) button 8 Finding and playing file (SELECT) button ·...
  • Page 105 (3) (3) FF/REW FF/REW button button ① While an iPod is operating, press and hold the FF button to fast- for- ward the song. ② When fast-forward is complete, the next song will properly play from the beginning even if you continue holding the button. Press and hold the REW button to rewind the song.
  • Page 106 (8) (8) Finding and playing file (SELECT) button Finding and playing file (SELECT) button ① While iPod is playing, press and hold the SELECT button for over 3 SELECT PUSH seconds to enter CATEGORY mode and search for desired files. ②...
  • Page 107 ■AUX connection AUX connection 2209S3CD74 · Operates only when an external device is connected to AUX. Connecting an AUX device to the audio using the AUX cable will automatically convert to AUX mode. · When an external device is connected, only the PWR, FM/AM, MODE, and VOL buttons can be operated.
  • Page 108: 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. Service meter Load Avoid excessive operation for...
  • Page 109: Check Before Starting The Engine

    2. CHECK BEFORE STARTING THE ENGINE Look around the machine and under the machine to check for loosen nut or bolts, collection of dirt, or leakage of oil, fuel or coolant and check the Check before starting condition of the work equipment and hydraulic system.
  • Page 110: 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 lever is on the neutral position. Turn the starting switch to the ON position, and START check following.
  • Page 111 2) 2) STARTING ENGINE STARTING ENGINE ※ Sound hor n to war n surroundings after Sound hor n to war n surroundings after checking if there are obstacles in the area. checking if there are obstacles in the area. ※ Replace the engine oil and fuel referring to Replace the engine oil and fuel referring to recommended oils at page 2-10.
  • Page 112: Warming-Up Operation

    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 normal level? Are there leakages of oil or water? Are all the warning lamps OFF (2~7)? Is the indicator of engine coolant temperature gauge (1) in the normal zone? Is the engine sound and the color of exhaust gas...
  • Page 113: To Stop The Engine

    5) 5) 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 5 minutes shortened.
  • Page 114: Operation Of The Working Device

    4. OPERATION OF WORKING DEVICE 4. OPERATION OF WORKING 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. When you release the control lever, control lever returns to neutral position automatically.
  • Page 115: Traveling Of The Machine

    5. TRAVELING OF THE MACHINE 5. TRAVELING OF THE MACHINE 1) 1) BASIC OPERATION BASIC OPERATION Traveling position (1) (1) Traveling position Traveling position It is the position which the dozer and rear axle is in the rear and the working device is forward. Travel directions will be reversed if lower Travel directions will be reversed if lower structure is positioned with dozer in front...
  • Page 116 Changing direction Changing direction (forward/reverse) Forward ① Be sure to stop the machine Be sure to stop the machine when changing the direction forward or backward while traveling. ② Put the levers in the desired position to change Reverse direction. ※...
  • Page 117: Parking The Machine

    TRAVELING ON A SLOPE TRAVELING ON A SLOPE Never travel down a slope in neutral. Lower the bucket 20 to 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 118: Towing The Machine

    4) 4) TOWING THE MACHINE TOWING THE MACHINE Except for an emergency, do not tow this machine. If it is inevitable to tow this machine, observe the following. (1) (1) General General ① Parking brake cylinder of the machine is operated by the spring force and released by hydraulic pressure.
  • Page 119 Towing the machine Towing the machine ① When moving the machine or in case of an Locking emergency towing, the power flow between screw Spacer final drive (spur gear drive) and travel motor will be interrupted. Both side ② For this purpose, loosen the locking screw and remove the spacer of rear axle.
  • Page 120: Precautions For Operation

    A f t e r u s i n g t h e p a r k i n g b r a ke a s a n emergency brake, ask Hyundai dealer to emergency brake, ask Hyundai dealer to check complete brake system.
  • Page 121: Efficient Working Method

    6. EFFICIENT WORKING METHOD 6. EFFICIENT WORKING METHOD Do the digging work by arm. Use the pulling force of arm for digging and use together with the digging force of the bucket if necessary. 555W94OP20 When lowering and raising the boom operate softly for the beginning and the end.
  • Page 122 Dig slowly with keeping the angle of boom and arm, 90-110 degree when maximum digging force is required. 90~110 555W94OP23 Operate leaving a small safety margin of cylinder Margin stroke to prevent damage of cylinder when working with the machine. 55W94OP12 Keep the bucket to the dumping position and the arm horizontal when dumping the soil from the...
  • Page 123 If the excavation is in an underground location or Incorrect in a building, make sure that there is adequate overhead clearance and that there is adequate ventilation. 55W94OP17 Do not use the dropping force of the work Incorrect equipment for digging. The machine can be damaged by the impact.
  • Page 124 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. 55W7A4OP30 4-17...
  • Page 125: 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 bucket teeth. Hook Lifting loads with the wire rope wrapped directly around the boom or arm.
  • Page 126: Operation In The Special Work Sites

    7. OPERATION IN THE SPECIAL WORK SITES 7. 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 50 C coolant.
  • Page 127 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 128: Normal Operation Of Excavator

    8. NORMAL OPERATION OF EXCAVATOR 8. NORMAL OPERATION OF EXCAVATOR Followings may occur during operation due to the nature of a hydraulic excavator. When rolling in the arm, the roll-in movement stop momentary at point X in the picture shown, then recovers speed again after passing point X.
  • Page 129: 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 55W94OP14 distributor.
  • Page 130: Storage

    10. STORAGE 10. STORAGE Maintain the machine taking care of following to prevent the deterioration of machine when storing the machine for a long time, over 1 month. BEFORE STORAGE BEFORE STORAGE (1) (1) Cleaning the machine Cleaning the machine Clean the machine and dried.
  • Page 131: During Storage

    Remove the drain port plug and drain the water until the gear oil comes out and then tighten the drain plug. 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 Hyundai dealer for service. 4-24...
  • Page 132: Rcv Lever Operating Pattern

    3 Swing right ① 4 Swing left ④ 5 Boom lower ② 6 Boom raise Right ① 7 Bucket out Hyundai ③ 8 Bucket in ② 1 Boom lower A Type ④ 2 Boom raise Left ③ 3 Swing right ①...
  • Page 133 RCV LEVER OPERATING PATTERN (option, A type) Multimode selector valve Terminal 5594OP14 Operation Hose connection (port) Pattern Control function Left Right RCV lever MCV port ② 1 Boom lower ④ 2 Boom raise Left ③ 3 Bucket out ① 4 Bucket in A ype ④...
  • Page 134: Transportation

    TRANSPORTATION TRANSPORTATION 1. ROAD TRAVELING 1. ROAD TRAVELING As this machine can run at the maximum speed of 30.5km/h, it is not necessary to transport the machine on trailer in a short distance. But the transportation by the trailer is convenient in a long distance.
  • Page 135: Preparation For Transportation

    2. PREPARATION FOR TRANSPORTATION 2. PREPARATION FOR TRANSPORTATION When transporting the machine, observe the various road rules, road transportation vehicle laws and vehicle limit ordinances, etc. Overall width Select proper trailer after confirming the weight and dimension from the chapter 2, specification. Check the whole route such as the road width, the height of bridge and limit of weight and etc., which Overall...
  • Page 136: Dimension And Weight

    3. DIMENSION AND WEIGHT 3. DIMENSION AND WEIGHT 1) 1) Base machine Base machine Mark Description Unit Specification Length mm (ft-in) 3580 (11' 9") Height mm (ft-in) 2850 ( 9' 4") Width mm (ft-in) 1925 ( 6' 4") Weight kg (lb) 4760 (10490) ※...
  • Page 137 5) 5) Boom cylinder Boom cylinder Mark Description Unit Specification Length mm (ft-in) 1210 ( 3'12") Height mm (ft-in) 150 ( 0' 6") Width mm (ft-in) 280 ( 0'11") Weight kg (lb) 70 (155) ※ Included piping. 13035TA06 6) 6) Cab assembly Cab assembly Mark...
  • Page 138: Loading The Machine

    4. LOADING THE MACHINE 4. LOADING THE MACHINE Load and unload the machine on a flat ground. Use the gangplank with sufficient length, width, thickness and gradient. Place block tires of the truck and the trailer not to move the trailer. Place the swing lock device to the LOCK LOCK position before fixing the machine at the bed of trailer and...
  • Page 139 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 140: Fixing The Machine

    5. FIXING THE MACHINE 5. FIXING THE MACHINE Place the swing lock pin on the LOCK position. Place the parking switch to the parking position. Select switch Starting switch Keep the safety lever on the SAFETY position. Turn OFF all the switches and remove the key. Safety lever Swing lock pin 55W95TA02...
  • Page 141: Loading And Unloading By Crane

    6. LOADING AND UNLOADING BY CRANE 6. 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. Stay Use long wire rope and stay to keep the distance with the machine as it should avoid touching with the machine.
  • Page 142: 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 143: 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, safety hints.
  • Page 144 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 r ight after the loosening the cap or hose r ight after the operating of machine as the machine or oil is on operating of machine as the machine or oil is on the high pressure on the condition.
  • Page 145 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 146 6) 6) 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 147: 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 148 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 149 TIGHTENING TORQUE OF MAJOR COMPONENT TIGHTENING TORQUE OF MAJOR COMPONENT Torque Descriptions Bolt size kgf·m lbf·ft M10 × 1.5 Engine mounting bolt (engine-Bracket) 6.9±1.0 50±7.2 M16 × 2.0 Engine mounting bolt (bracket-Frame) 25±2.5 181±18.1 M10 × 1.5 Radiator mounting bolt, nut 6.9±1.4 50±10.0 Engine...
  • Page 150: Fuel, Coolant And Lubricants

    New machine used and filled with following lubricants. Description Specification Engine oil SAE 15W-40 (API CH-4) Hyundai genuine long life hydraulic oil (ISO VG32, VG46, VG68) Hydraulic oil Conventional hydraulic oil (ISO VG15) Swing reduction gear oil SAE 85W-140 (API GL-5)
  • Page 151 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) (-4) (14) (32) (50) (68) (86) (104) SAE 30 SAE 10W Engine oil pan Engine oil 11.6 (3.1) SAE 10W-30...
  • Page 152: 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 Fuel tank Check, Refill 6-24 Hydraulic oil level Check, Add 6-26 Engine oil level Check, Add 6-17 Coolant level Check, Add...
  • Page 153: Initial 50 Hours Service

    3) 3) INITIAL 50 HOURS SERVICE INITIAL 50 HOURS SERVICE Check items Service Page Engine oil Change 6-17, 18 Engine oil filter Replace 6-17, 18 Prefilter (water, element) Replace 6-25 Fuel filter Replace 6-25 Bolts & Nuts Check, Tight ·Power train mounting bolts ·Swing motor mounting bolts ·Swing bearing mounting bolts ·Engine mounting bolts...
  • Page 154: Every 250 Hours Service

    7) 7) EVERY 250 HOURS SERVICE EVERY 250 HOURS SERVICE Check items Service Page Battery electrolyte Check 6-38 Front axle steering case grease Lubricate 6-30 Front & rear axle gear oil Check, Add 6-32 Aircon & heater fresh air filter Check, Clean 6-41 Swing bearing grease...
  • Page 155: When Required

    ★ Change 6-26 Hydraulic oil ★2 Hyundai genuine long life hydraulic oil ★ Change oil every 1000 hours of continuous hydraulic breaker operation. Change oil every 1000 hours of continuous hydraulic breaker operation. WHEN REQUIRED WHEN REQUIRED Whenever you have trouble in the machine, you must perform the service of related items, system by system.
  • Page 156: Maintenance Chart

    5. MAINTENANCE CHART 5. MAINTENANCE CHART 9 11 12 19 30 4 55W96MA02 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. 4.
  • Page 157 28 Air cleaner element(Primary, safety) Check, Replace ★1 ★2 Conventional hydraulic oil Hyundai genuine long life hydraulic oil ★ Severely dusty area operation only. Severely dusty area operation only. ※ Oil symbol Oil symbol Please refer the recommended lubricants for specification.
  • Page 158: Service Instruction

    6. SERVICE INSTRUCTION 6. SERVICE INSTRUCTION 1) 1) CHECK ENGINE OIL LEVEL CHECK ENGINE OIL LEVEL Filler port Check the oil level with the machine on a flat ground before starting engine. Pull out the dipstick and wipe with a clean cloth. Check the oil level by inserting the dipstick completely into the hole and pulling out again.
  • Page 159 Apply a light film of lubricating oil to the gasket sealing surface before installing the filters. R5576MA50 Install the filter to the filter head. Remove the quick coupler hose. ※ Mechanical over-tightening may distort the Mechanical over-tightening may distort the Engine oil filter threads or damage the filter element seal.
  • Page 160: Check Coolant

    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 161 Wait until the temperature is below 50 Wait until the temperature is below 50˚C (122 (122˚F ) before removing the coolant system ) before removing the coolant system pressure cap. pressure cap. Water drain plug Failure to do so can cause personal injury Failure to do so can cause personal injury from heated coolant spray.
  • Page 162 Operate the engine for 5 minutes with the coolant temperature above 80˚C (176˚F) . Shut the engine off, and drain the cooling system. If the water being drained is still dirty, the system must be flushed again until the water is clean.
  • Page 163: Fan Belt Tension

    5) 5) CLEAN RADIATOR AND OIL COOLER CLEAN RADIATOR AND OIL COOLER NOT OK Check, and if necessary, clean and dry outside of radiator and oil cooler. After working in a dusty place, clean radiator more frequently. Visually inspect the radiator for clogged radiator fins.
  • Page 164: Cleaning Of Air Cleaner

    INSPECTION OF COOLING FAN INSPECTION OF COOLING FAN Personal injury can result from a fan blade fail- Personal injury can result from a fan blade fail- ure. Never pull or pry on the fan. This can ure. Never pull or pry on the fan. This can damage the fan blade and cause fan failure.
  • Page 165 FUEL TANK FUEL TANK Fill fuel fully when system the operation to minimize water condensation, and check it with fuel gauge before starting the machine. Drain the water and sediment in the fuel tank by Fuel gauge opening the drain cock. ※...
  • Page 166: Replacement Of Fuel Filter

    REPLACEMENT OF FUEL FILTER REPLACEMENT OF FUEL FILTER Clean around the filter head, remove the filter with a filter wrench and clean the gasket surface. Apply a small amount of fuel to the O-ring of new cartridge. Install the new fuel filter manually turning until it Cartridge comes into contact with the mounting surface and tighten it further to 1/2 of a turn using a filter...
  • Page 167: 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 on the ground at a flat location as in the Level gauge illustration. Check the oil level at the level gauge of hydraulic oil tank.
  • Page 168 CLEAN SUCTION STRAINER CLEAN SUCTION STRAINER Clean suction strainer as follows paying attention Air breather to 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) Pull out the strainer in the tank.
  • Page 169 REPLACEMENT OF ELEMENT IN HYDRAULIC REPLACEMENT OF ELEMENT IN HYDRAULIC TANK BREATHER TANK BREATHER Loosen the cap and relieve the pressure in the Cover tank by pushing the top of the air breather. Element Loosen the lock nut and remove the cover. Pull out the filter element.
  • Page 170 CHANGE SWING REDUCTION GEAR OIL CHANGE SWING REDUCTION GEAR OIL Filling port plug Raise the temperature of oil by swinging the machine before replace the oil and park the machine on the flat ground. Loosen the plug of the drain port. Drain into a proper container.
  • Page 171 LUBRICATE RCV LEVER LUBRICATE RCV LEVER Remove the bellows and with a grease gun grease the joint part (A) and sliding parts (B). 36076MA25 LUBRICATE LUBRICATE Drive shaft Drive shaft ① Front drive shaft : 3 point ② Rear drive shaft : 3 point 17W36MI63 (2) (2) Front axle...
  • Page 172 (4) (4) Dozer blade Dozer blade : 4 point 55W76MA34 TIRE TIRE Air pressure Air pressure (1) (1) It is important to keep air pressure properly for maximizing tire life. Both excessive and insufficient air pressure of tires should be avoided not to damage tires.
  • Page 173 ③ Position change of tire Position change of tire Front · Tire is worn out differently par t by par t according to installing position, so change position regularly as figure. Keep air pressure at standard. Keep air pressure at standard. Use same pattern of groove and same Use same pattern of groove and same maker's tire.
  • Page 174 CHANGE THE AXLE OIL CHANGE THE AXLE OIL Air breather Place a drain box under drain plug to catch oil. Drain box Remove the air breather to relieve internal pres- Drain plug sure. Drain oil into the differential gear Drain oil into the differential gear (3) (3) ①...
  • Page 175: Change The Gear Box Oil

    CLEANING AXLE BREATHER CLEANING AXLE BREATHER Air breather Remove dust or debris around the breather. Air breather Remove the breather and wash it with cleaning for brake oil. 55W76MA36 CHECK AND SUPPLYING GEAR BOX OIL CHECK AND SUPPLYING GEAR BOX OIL Air breather Move the machine to flat ground.
  • Page 176: 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 177 REPLACEMENT OF BUCKET TOOTH REPLACEMENT OF BUCKET TOOTH Timing of replacement Timing of replacement Tooth adapter ① Check wearing condition as shown in the illus- Tooth tip tration and replace tooth tip before adapter starts to wear. ② If excessive use, tooth adapter has worn out, replacement may become impossible.
  • Page 178 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 upper frame Boom connection pin Boom cylinder pin Arm cylinder pin...
  • Page 179: Electrical System

    7. ELECTRICAL SYSTEM 7. ELECTRICAL SYSTEM 1) 1) WIRING, GAUGES WIRING, GAUGES Check regularly and repair loose or malfunctioning gauges when found. 13036MI29 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 180 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 ※ Use the same capacity of battery for starting. Use the same capacity of battery for starting.
  • Page 181 Welding repair Welding repair Before start to welding, follow the below proce- Cluster Master switch dure. ① Shut off the engine and remove the starting switch. ② Disconnect ground cable from battery by mas- ter 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 (cluster etc).
  • Page 182: Air Conditioner And Heater

    8. AIR CONDITIONER AND HEATER 8. AIR CONDITIONER AND HEATER 1) 1) CLEAN AND REPLACE OF THE CLEAN AND REPLACE OF THE CIRCULATION FILTER CIRCULATION FILTER ※ Always stop the engine before servicing. Always stop the engine before servicing. Remove the screw (1) and cover (2) on the seat base.
  • Page 183 Clean the recirculation filter using a pressurizes are (Below 2 kgf/cm , 28psi) or washing with water. When using pressurized air, be sure to wear When using pressurized air, be sure to wear safety glasses. safety glasses. Inspect the filter after cleaning. If it is damaged or badly contaminated, use a new filter.
  • Page 184: 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- This guide is not intended to cover every conditions, however many of the more common possibil- ities are listed.
  • Page 185: 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 Check the alternator.
  • Page 186: Others

    3. OTHERS 3. OTHERS Trouble Service Remark · Adjust tension of track. Track slip out of place. Excessive wear of the sprocket. Bucket either rises slowly or not at · Add oil to specified level. all. · Add oil to specified level. Slow speed of travel, swing, boom, arm and bucket.
  • Page 187: Hydraulic Breaker And Quick Clamp

    Become familiar with the manual and select breakers suitable to machine specifications. Make careful selection in consideration of oil quantity, pressure and striking force, to enable satisfied performance. When apply a breaker to the machine, consult your local dealer of Hyundai for fur ther explanation.
  • Page 188: Circuit Configuration

    One of spool of the main control valve should be connected to the tank. Select the size of pipe laying considering the back pressure. Shimless tube should be used for the piping. The hose and seal should be used Hyundai genuine parts.
  • Page 189: Maintenance

    ★1 : Conventional hydraulic oil may easily go out of order. ★2 : Hyundai genuine long life hydraulic oil Inspect and maintain hydraulic oil and 3 kinds of ● Replace following filter same time Replace following filter same time filter elements in particular, in order to prolong ·Hydraulic return filter : 1 EA...
  • Page 190: Precaution While Operating The Breaker

    4. PRECAUTIONS WHILE OPERATING THE BREAKER 4. PRECAUTIONS WHILE OPERATING THE BREAKER 1) 1) 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 191 DO NOT CONTINUE TO WORKING OVER DO NOT CONTINUE TO WORKING OVER Incorrect ONE MINUTE AT SAME POSITION OF BOOM ONE MINUTE AT SAME POSITION OF BOOM For one For one AND ARM AND ARM minute minute This will increase the temperature of the oil, and cause problem in the accumulator and seals.
  • Page 192: Quick Clamp

    5. QUICK CLAMP 5. QUICK CLAMP FIXING BUCKET WITH QUICK CLAMP FIXING BUCKET WITH QUICK CLAMP Quick clamp switch Before fixing bucket, remove safety pin of the moving hook. Safety button Pulling safety button, press the quick clamp switch to unlock position. Then, the moving hook is placed on release position.
  • Page 193 ※ HYUNDAI will not be responsible for HYUNDAI will not be responsible for any injury or damage in case that safety any injury or damage in case that safety pin is not installed properly.
  • Page 194: Index

    INDEX INDEX Accel dial switch ---------------------------------------------- 3-15 Gauge -------------------------------------------------------------- After engine start -------------------------------------------- Gear box oil ------------------------------------------------------ 6-34 Air breather element --------------------------------------- 6-28 Air cleaner filter ----------------------------------------------- 6-23 Handsfree -------------------------------------------------------- 3-30 Air conditioner & heater ---------------------------------- 3-24 Hydraulic breaker --------------------------------------------- Air conditioner filter ----------------------------------------- 6-41 Hydraulic oil changing -------------------------------------- 6-26 Attachment lowering --------------------------------------- 4-22...
  • Page 195 Remote controller --------------------------------------------- 3-32 Return filter ------------------------------------------------------ 6-27 Road traveling -------------------------------------------------- Safety hints ----------------------------------------------------- Safety labels --------------------------------------------------- Safety parts ---------------------------------------------------- Seat ---------------------------------------------------------------- 3-29 Service meter ------------------------------------------------- Speciation for major component -------------------- Specifications ------------------------------------------------- Start switch ----------------------------------------------------- 3-14 Storage ----------------------------------------------------------- 4-23 Suction strainer ----------------------------------------------- 6-27 Swing bearing grease ------------------------------------ 6-29 Swing gear ----------------------------------------------------- 6-29...

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