Hyundai HX480 SL Service Manual
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Hyundai HX480 SL Service Manual

Hyundai HX480 SL Service Manual

Crawler excavator
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HX480 SL, HX520 SL
CRAWLER EXCAVATOR
SERVICE MANUAL

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Summary of Contents for Hyundai HX480 SL

  • Page 1 HX480 SL, HX520 SL CRAWLER EXCAVATOR SERVICE MANUAL...

  • Page 2: Structure And Function

    Table of Content FOREWORD GENERAL 1. SAFETY HINTS 2. SPECIFICATIONS STRUCTURE AND FUNCTION 1. PUMP DEVICE 2. MAIN CONTROL VALVE 3. SWING DEVICE 4. TRAVEL DEVICE (TYPE 1 & 2) 5. RCV LEVER 6. RCV PEDAL HYDRAULIC SYSTEM 1. HYDRAULIC CIRCUIT 2.

  • Page 3: Troubleshooting

    15. MONITORING SYSTEM 16. FUEL WARMER SYSTEM TROUBLESHOOTING 1. BEFORE TROUBLESHOOTING 2. HYDRAULIC AND MECHANICAL SYSTEM 3. ELECTRICAL SYSTEM 4. MECHATRONICS SYSTEM MAINTENANCE STANDARD 1. OPERATIONAL PERFORMANCE TEST 2. MAJOR COMPONENT 3. TRACK AND WORK EQUIPMENT DISASSEMBLY AND ASSEMBLY 1. PRECAUTIONS 2.
  • Page 4 The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact your HYUNDAI distributor for the latest information. Find manuals at https://best-manuals.com...
  • Page 5 Revised edition mark (①②③…) Any additions, amendments or other changes will When a manual is revised, an edition mark is be sent to HYUNDAI distributors. recorded on the bottom outside corner of the Get the most up-to-date information before you pages.

  • Page 6: Conversion Table

    3. CONVERSION TABLE Method of using the Conversion Table The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. Example Method of using the Conversion Table to convert from millimeters to inches Convert 55 mm into inches.
  • Page 7 Millimeters to inches Millimeters to inches 1mm = 0.03937in 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142 1.181 1.220 1.260 1.299 1.339...
  • Page 8 Liter to U.S. Gallon Liter to U.S. Gallon 1ℓ = 0.2642 U.S.Gal 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019 5.283 5.548 5.812 6.6076 6.340 6.604 6.869 7.133 7.397 7.661 7.925 8.189...
  • Page 9 kgf·m to to lbf lbf·ft ft 1kgf·m = 7.233lbf·ft 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8 217.0 224.2 231.5 238.7 245.9 253.2...
  • Page 10 kgf/cm kgf/cm to to lbf/in lbf/in 1kgf / cm = 14.2233lbf / in 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5 426.7...
  • Page 11 TEMPERATURE TEMPERATURE Fahrenheit-Centigrade Conversion. A simple way to convert a fahrenheit temperature reading into a centigrade temperature reading or vice verse is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.

  • Page 12: Section 1 General

    SECTION 1 GENERAL Group 1 Safety Hints -------------------------------------------------------------------------------------------------------- 1-1 Group 2 Specifications ----------------------------------------------------------------------------------------------------- 1-10...
  • Page 13 SECTION 1 GENERAL GROUP 1 SAFETY HINTS FOLLOW SAFE PROCEDURE Unsafe wor k practices are dangerous. Understand service procedure before doing work; Do not attempt shortcuts. WEAR PROTECTIVE CLOTHING Wear close fitting clothing and safety equipment appropriate to the job. 13031GE01 WARN OTHERS OF SERVICE WORK Unexpected machine movement can cause...
  • Page 14 PREPARE FOR EMERGENCIES Be prepared if a fire starts. Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambulance ser vice, hospital, and fire department near your telephone. 13031GE04 PROTECT AGAINST FLYING DEBRIS Guard against injury from flying pieces of metal or debris;...

  • Page 15: Move And Operate Machine Safely

    KEEP RIDERS OFF EXCAVATOR Only allow the operator on the excavator. Keep riders off. Riders on excavator are subject to injury such as being struck by foreign objects and being thrown off the excavator. Riders also obstruct the operator's view resulting in the excavator being operated in an unsafe manner.

  • Page 16: Support Machine Properly

    SUPPORT MACHINE PROPERLY Always lower the attachment or implement to the ground before you work on the machine. If you must wor k on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load.

  • Page 17: Beware Of Exhaust Fumes

    BEWARE OF EXHAUST FUMES Prevent asphyxiation. Engine exhaust fumes can cause sickness or death. If you must operate in a building, be positive there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area.

  • Page 18: Stay Clear Of Moving Parts

    SERVICE MACHINE SAFELY Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result. Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.

  • Page 19: Avoid Heating Near Pressurized Fluid Lines

    AVOID HEATING NEAR PRESSURIZED FLUID LINES Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials.

  • Page 20: Prevent Acid Burns

    PREVENT ACID BURNS Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. Avoid the hazard by: 1. Filling batteries in a well-ventilated area. 2. Wearing eye protection and rubber gloves. 3.

  • Page 21: Replace Safety Signs

    DISPOSE OF FLUIDS PROPERLY Improperly disposing of fluids can harm the environment and ecology. Before draining any fluids, find out the proper way to dispose of waste from your local environmental agency. Use proper containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.

  • Page 22: Major Component

    GROUP 2 SPECIFICATIONS 1. MAJOR COMPONENT Tool box Fuel tank Hydraulic tank Main pump Engine Charge air cooler Oil cooler Radiator Tooth Bucket Turning joint Swing motor Main control valve Arm cylinder Boom Boom cylinder Handrail Precleaner Counterweight Swing bearing Bucket cylinder Connecting link Idler...

  • Page 23: Specifications

    2. SPECIFICATIONS HX480S L 7.06 m (23' 2") boom, 3.38 m (11' 1") arm I(I') B(L) 480S2SP02 Description Unit Specification Operating weight kg (lb) 49515 (109160) Bucket capacity (SAE heaped), standard 2.20 (2.88) Overall length 12040 (39' 6") Overall width, with 600 mm shoe 3340 (10' 11") Overall height 3790 (12' 5")
  • Page 24 6.55 m (21' 6") boom, 2.40 m (7' 10") arm I(I') B(L) 480S2SP02 Description Unit Specification Operating weight kg (lb) 49515 (109160) Bucket capacity (SAE heaped), standard 2.20 (2.88) Overall length 12040 (39' 6") Overall width, with 600 mm shoe 3340 (10' 11") Overall height 3790 (12' 5")
  • Page 25 9.00 m (29' 6") boom, 6.00 m (19' 8") arm I(I') B(L) 480S2SP02 Description Unit Specification Operating weight kg (lb) 51155 (112777) Bucket capacity (SAE heaped), standard 1.38 (1.80) Overall length 14010 (46' 0") Overall width, with 600 mm shoe 3340 (10' 11") Overall height 3990 (13' 1")
  • Page 26 HX520S L 7.06 m (23' 2") boom, 3.38 m (11' 1") arm I(I') B(L) 480S2SP02 Description Unit Specification Operating weight kg (lb) 51175 (112820) Bucket capacity (SAE heaped), standard 2.20 (2.88) Overall length 12040 (39' 6") Overall width, with 600 mm shoe 2990/3540 (9' 10"/11' 7") (transport position / working position) Overall height...
  • Page 27 6.55 m (21' 6") boom, 2.40 m (7' 10") arm I(I') B(L) 480S2SP02 Description Unit Specification Operating weight kg (lb) 50865 (112140) Bucket capacity (SAE heaped), standard 2.20 (2.88) Overall length 11780 (38' 8") Overall width, with 600 mm shoe 2990/3540 (9' 10"/11' 7") (transport position / working position) Overall height...
  • Page 28 (3) (3) 10.00 10.00 m (32' 10") boom, 6.85 (32' 10") boom, 6.85 m (22' 6") arm (22' 6") arm I(I') B(L) 520S2SP01 Description Unit Specification Operating weight kg (lb) 51900 (114420) Bucket capacity (SAE heaped), standard 1.00 (1.31) Overall length 10730 (35' 2") Overall width, with 600 mm shoe 2990/3540 (9' 10"/11' 7")

  • Page 29: Working Range

    3. WORKING RANGE HX480S L 7.06 m (23' 2") boom 480S2SP04 Description 2.40 m (7' 10") Arm 2.90 m (9' 6") Arm 3.38 m (11' 1") Arm 4.00 m (13' 1") Arm Max digging reach 11200 mm (36' 9") 11620 mm (38' 1") 12040 mm (39' 6") 12600 mm (41' 4") Max digging reach on ground 10980 mm (36' 0") 11410 mm (37' 5") 11840 mm (38'10") 12410 mm (40' 9") Max digging depth...
  • Page 30 6.55 m (21' 6") boom 480S2SP04 Description 2.40 m (7' 10") Arm 2.90 m (9' 6") Arm Max digging reach 10650 mm (34'11") 11070 mm (36' 4") Max digging reach on ground 10430 mm (34' 3") 10850 mm (35' 7") Max digging depth 6420 mm (21' 1") 6920 mm (22' 8")
  • Page 31 9.00 m (29' 6") boom 480S2SP04 Description 6.00 m (19' 8") Arm Max digging reach 16180 mm (53' 1") Max digging reach on ground 16030 mm (52' 7") Max digging depth 12020 mm (39' 5") Max digging depth (8ft level) 11920 mm (39' 1") Max vertical wall digging depth 8510 mm (27'11")
  • Page 32 HX520S L 7.06 m (23' 2") boom 480S2SP04 Description 2.40 m (7' 10") Arm 2.90 m (9' 6") Arm 3.38 m (11' 1") Arm 4.00 m (13' 1") Arm Max digging reach 11200 mm (36' 9") 11620 mm (38' 1") 12040 mm (39' 6") 12600 mm (41' 4") Max digging reach on ground 10950 mm (35'11") 11380 mm (37' 4") 11810 mm (38' 9") 12380 mm (40' 7") Max digging depth...
  • Page 33 6.55 m (21' 6") boom 480S2SP04 Description 2.40 m (7' 10") Arm 2.90 m (9' 6") Arm Max digging reach 10650 mm (34'11") 11070 mm (36' 4") Max digging reach on ground 10390 mm (34' 1") 10820 mm (35' 6") Max digging depth 6270 mm (20' 7") 6770 mm (22' 3")
  • Page 34 (3) (3) 10.00 10.00 m m (32' 10") boom (32' 10") boom 520S2SP02 Description 6.85 m (22' 6") Arm Max digging reach 18170 mm (59' 7") Max digging reach on ground 18020 mm (59' 1") Max digging depth 13080 mm (42' 11") Max digging depth (8ft level) 13000 mm (42' 8") Max vertical wall digging depth...
  • Page 35 4. WEIGHT HX480S L HX480S L Item Upperstructure assembly 20120 44360 Main frame weld assembly 4640 10230 Engine assembly 2070 Main pump assembly Main control valve assembly Swing motor assembly Hydraulic oil tank assembly Fuel tank assembly 6.55 m, 7.06 m boom 10200 22490 Counterweight...
  • Page 36 HX520S L HX520S L Item Upperstructure assembly 21180 46690 Main frame weld assembly 4640 10230 Engine assembly 2070 Main pump assembly Main control valve assembly Swing motor assembly Hydraulic oil tank assembly Fuel tank assembly Counterweight 6.55 m, 7.06 m boom 10700 23590 Cab assembly...

  • Page 37: Lifting Capacities

    The difference between the weight of a work tool attachment must be subtracted. Consult your Hyundai dealer regarding the lifting capacities for specific work tools and attachments. Failure to comply to the rated load can cause possible personal injury or property damage.
  • Page 38 Unit : mm Boom Boom Counterweight Shoe Dozer Outrigger Model Type Length Length Weight (kg) Width Front Rear Front Rear HX480S L Mono 6550 2900 10200 · · : Rating over-front : Rating over-side or 360 degree Lift-point radius (B) At max.
  • Page 39 Unit : mm Boom Boom Counterweight Shoe Dozer Outrigger Model Type Length Length Weight (kg) Width Front Rear Front Rear HX480S L Mono 7060 3380 10200 · · : Rating over-front : Rating over-side or 360 degree At max. reach Lift-point radius (B) Lift-point 3.0 m (9.8 ft) 4.5 m (14.8 ft) 6.0 m (19.7 ft) 7.5 m (24.6 ft) 9.0 m (29.5 ft)
  • Page 40 Unit : mm Boom Boom Counterweight Shoe Dozer Outrigger Model Type Length Length Weight (kg) Width Front Rear Front Rear HX480S L Mono 7060 2400 10200 · · : Rating over-front : Rating over-side or 360 degree At max. reach Lift-point radius (B) Lift-point 3.0 m (9.8 ft) 4.5 m (14.8 ft) 6.0 m (19.7 ft) 7.5 m (24.6 ft) 9.0 m (29.5 ft)
  • Page 41 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...

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