Hyundai HL630 Wheel Loader Operator Manual - PDF Download

Operation and Maintenance Manual

Operation and Maintenance Manual

Content Foreword----------------------------------------------------------------------------2 Safe Precautions-------------------------------------------------------------------4 Purposes and Main Specifications-------------------------------------------- 30 Operation Manual--------------------------------------------------------------- 36 Maintenance Manual------------------------------------------------------------ 59

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Operation and Maintenance Manual

Foreword

This manual provides you with the rules and guide that can help you use this machine safely and efficiently, so, you should always keep the manual handy and read it regularly. If this manual is lost or rendered illegible due to defilement, please request a new copy from a dealer appointed by the company. Provided that you should sell this machine, please be sure to hand over this manual to the new user.

This manual contains safety precautions, operating instructions and notices for lubrication and maintenance.

The items, specifications and graphics contained in this manual are based on the data available at the time of compilation of this manual. The specifications, torques, pressures, measuring and adjusting methods, graphics and any other items may be modified whenever required and these modifications may affect maintenance and repair of this machine. Before you set to work, complete and latest data should be available. If you have any question about your machine and this manual, please contact Hyundai Construction Equipment co., Ltd.. for the up-to-date information.

The section “Safety Precautions” of this manual describes the safety issues that you should pay attention to during operation, routine maintenance and repair of this machine. Most accidents related to operation, maintenance and repair of products are generally due to negligence of basic safety rules or safeguards. Paying attention to the hidden troubles of an accident before its occurrence can prevent it from taking place. The personnel involved must get familiar with these hidden troubles, pass necessary trainings, and command certain skills and can perform troubleshooting using tools. Improper operations, lubrication, maintenance and repair could be

dangerous and may also result in personal injury or death. Do not perform any of above items on your machine before you have read and understood them. Both safety precautions and warnings are listed in this manual and on the product. Negligence of these warnings may result in injury or death of the personnel involved. Hyundai Construction Equipment co., Ltd.. can not forecast every working environment in which hazards exist, so, the warnings in this manual and on the product can not reach every aspect of the matter. If any tool, procedure, working method or operation technique is not specially recommended by Hyundai Construction Equipment co., Ltd.., you should observe whether you and others are safe. You should ensure that the procedure that you select for the operation, lubrication, maintenance or repair will not damage the machine or render it unsafe.

The section “Operation” of this manual describes basic operation techniques and instructs the operators to get familiar with the correct checking, starting, operating and stopping procedures. So, the operators should keep this manual handy and read and study it on a regular basis.

The section “Maintenance” of this manual provides the instructive information on routine maintenance of the machine and it is classified by maintenance cycles.

The maintenance cycles listed in this manual are determined using working hours schedule. If it is more convenient to prepare the maintenance schedules using calendar (day, week, month, etc.) and the results are basically similar to those obtained using working hours schedule, you can substitute the former for the latter. Hyundai Construction Equipment co., Ltd.. recommends that the maintenance work be carried out according to any of the two types of time cycles mentioned above (whichever comes first). Under extremely inclement, dusty or humid working environments, you should carry out the lubrication maintenance more frequently than the conditions specified in the section “Routine Maintenance”. During maintenance, repeatedly perform the maintenance items listed in the former requirements. For example, when you perform the 500 working hours or quarterly maintenance items, carry out the items listed for 250 working hours or monthly, 50 working hours or weekly, and 10 working hours or daily maintenances at the same time.

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Operation and Maintenance Manual

MEMO

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Operation and Maintenance Manual

Safety Precautions Warning Please read and familiarize all safety precautions; otherwise, serious injury and fatal accident will result.

This Safety Precautions section also contains the notices for optional parts and attachments. Descriptions and Attachment Positions of Safety Labels

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Operation and Maintenance Manual

Description of safety labels and attachment positions

Names of components on the machine

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Operation and Maintenance Manual

Safety labels and their attachment positions There are several safety labels on the machine. This section describes their attachment positions and hidden trouble notes. Please take some time to familiarize these safety labels.

Ensure that you can read all safety labels. If you can not clearly read the texts or graphics on them, please replace or use cloth and soapy water to scrub them. Do not scrub them with cleaning agent, gasoline, etc.

If any safety labels are damaged, lost or unable to be read after scrubbing, be sure to replace them.

In case any part to which a safety label is attached will be replaced, note that a new safety label should be attached to corresponding replacement part.  Precautions before start (in cab)

Warning Do not operate this loader or work on it before you have read and understood all instructions and warnings in the practical maintenance manual. Violation of the instructions or disregard of the warnings could result in injury and even death. It is the driver's responsibility to observe the operating rules strictly.

 Do not touch the machine until all its parts come to a full stop.  Keep your hands off the engine fan.  Keep a safe distance from the machine.  Do not stand behind the machine. Caution: Crushing (at left side on rear of the machine).

 Precautions for engine handling (at left and right sides on rear of the machine)

Warning

Do not operate this loader or work on it before you have read and understood all instructions and warnings in the practical maintenance manual. Violation of the instructions or disregard of the warnings could result in injury and even death. It is the driver's responsibility to observe the operating rules strictly.

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Operation and Maintenance Manual

ď Ź No Entry! (located on frame articulation)

Warning No stopping here when turning!

During lift and transfer or when you perform any servicing work at middle part of the loader, be sure to connect front and rear frames of the loader using steering lock lever.

Before resuming operation, release the steering lock lever first and secure it on its holder; otherwise, turning of the loader is not allowed.

ď Ź Do not walk under working device (at each side of boom)

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Operation and Maintenance Manual

Safety rules  Only the trained personnel who have corresponding qualification can operate and service this machine.  Observe all safety rules, precautions and instructions during machine operation and maintenance.  Don’t operate the machine when you feel bad or feel sleepy after taking medicine, or after a drink. This situation will cause your misjudgment and accident.  When you are working together with another operator or the traffic guider on the worksite, ensure that all people understand the hand language signals used.  Observe all safety related rules.

Safety device  Make sure that all protections and hoods are in correct positions; if any of them is damaged, immediately repair.  Use safety devices such as joystick locking device and seat belt properly.  Never remove any safety device and make sure that they are always in good operating condition.  Incorrect use of safety devices may result in serious bodily injury or death.

Be sure to lock it up when you leave the operator’s seat.  When you rise from the operator’s seat, be sure to lock the joystick using the locking device, then pull up the parking brake button and set it to BRAKE position. If you touch the unlocked joystick inadvertently, the working device will abruptly move to cause serious damage.  When you leave the machine, lower the working device to ground completely, lock the joystick using the locking device, then shut down the engine and lock up all equipment with the key. Always take the key with you.

Clothing and personal protective appliances  Do not wear loose clothes, jewelry and long hair.

They could be locked or caught up into the control system or

moving parts, causing serious injury or death.  Never wear oily clothes so as to prevent ignition.  When you operate or service the machine, wear hard material hat and safety goggles, safety shoes, faceshield and gloves. When you throw and sprinkle metal scraps and minute sundries, especially when you nail a pin or use compressed air to clear the foreign substances in the air cleaner, remember to wear safety goggles, hard material hat and thick gloves. In addition, check and keep people off the machine.  Compressed air could result in personal injury. When you clean with compressed air, wear mask, safety clothing and shoes properly. The maximum pressure of the compressed air used for cleaning should be below 0.3Mpa. .  Check all protective appliances for normal functions before use.

Protective appliance

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Operation and Maintenance Manual

Unapproved installation Any refit not approved by Hyundai Construction Equipment co., Ltd.. could result in hazard. Please consult a dealer authorized by Hyundai Construction Equipment co., Ltd.. before machine refit. Hyundai Construction Equipment co., Ltd.. will not be responsible for any injury arising from unapproved refit.

Getting on and off the machine  Before you get on/off the machine, check the handrails or steps. If oil stains, lubricant or mud is found, wipe it up immediately. In addition, repair the damaged parts and tighten the loose bolts.  Never jump on or off the machine. Never get on or off the machine when it is moving.  When you get on or off the machine, face it, pull the handrails, tread on the steps, and keep 3-point contact (two feet and one hand or two hands and one foot) to ensure that your body is safe.  Never grab any joystick when you get on or off the machine.  Do not get on into the cab from the steps on rear of the machine or get off the machine from the tire beside the cab.

Get on the machine.  When you are carrying tools or other articles, do not climb on or off the machine.

Lift the tools needed onto the service platform with rope instead.

Precautions for fire prevention On the loader, fuel and lubricant used in engine, hydraulic oil used in hydraulic system, hydraulic transmission oil and gear oil used in drive system, and brake liquid used in brake system as well as antifreeze used in cooling system can be ignited by open flame. Fuel is especially flammable, so, it is very hazardous. Therefore, the following items must be paid attention to:  Keep flame away from above flammable liquids.  When you fill above flammable liquids, do the job at a ventilated place, shut down the engine, and do not smoke.  Tighten caps of all storage tanks holding above flammable liquids.  Hold above flammable liquids in the vessels with corresponding labels, place them in fixed places and store by sort. Prevent use by non-staffs.  Put oil-permeated wiping cloths or other flammable materials in protected containers and place them in safe places.  Do not perform electric welding or flame cutting to the lines containing flammable liquids. Before electric welding or cutting, use non flammable fluid to clean them up.  Clean up all combustible materials accumulated on the machine, such as fuel, lubricant or other broken objects.

No smoking!

Do not place the machine in flame, flaming bush, etc. In addition, this machine is of general purpose construction machinery and can not work in First-aid kit available flammable and explosive environments.

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Operation and Maintenance Manual

Fire extinguisher and first-aid kit Follow the notices below to take actions in case of injury or fire.  Be sure to get fire extinguishers ready. Carefully read operation instructions and make sure that you know how to use them.  First-aid kit must be available on the job site. Check it regularly; if necessary, add some medicines.  Know how to handle in case of fire or injury.  Select some people’s telephone numbers (e.g. doctors, emergency care centers, fire houses, etc.) for contact in emergency. Post these contact telephone numbers in specified places and make sure that all personnel know these numbers and correct ways of contact.

Prevention from asbestos dust hazard It will be a threat to your health if you inspire asbestos dust.

No asbestos is used in manufacture of the products of Hyundai Construction Equipment co., Ltd.. Please observe the following rules when you need to deal with any material containing asbestos fiber:  Never use compressed gas during cleaning.  Use water to clean, so that the dust will sink.

Use proper mouth mask  It is dangerous when air contains asbestos dust; if possible, operate the machine at uptake.  If needed, use proper mouth mask.

Precautions under high temperature  When a job has just been completed, hydraulic oil, oil and water in the engine and those in the radiator are still very hot; also, pressures still exist. At the time, any attempt to open the fuel tank cap, radiator cap, dump oil or water, or replace filters may result in serious burn.

To perform above operations, wait until the temperatures drop and follow the specified procedures.  To keep hot water from ejection, shut down the engine to allow coolant to cool down. When you open a cap, loosen it slowly to release pressure. (When you check for coolant temperature drop, put your hand close to the front of the water radiator to check air temperature. Take care not to touch it.)  To keep hot oil from ejection, shut down the engine to allow oil to cool down. When you open a cap, loosen it slowly to release pressure. (When you check for oil temperature drop, put your hand close to the front of the hydraulic oil or torque converter oil radiator to check air temperature. Take care not to touch it.)  Do not touch any relay when the machine is hot so as to avoid scald.

Caution, scald!  Do not remove engine oil temperature sensor, coolant temperature sensor, torque converter oil sensor and A/C water pipe when the machine is hot so as to avoid scald.

Prevention from rolling damage or cut off  Do not enter or put your hand, arm or any other part on your body between movable parts, for example, between the working device and the cylinder or the machine and the working device. As the working device moves, the space at the linkage will increase or decrease, so, being close-up could result in serious accident or personal injury. If you need to enter between moving parts of the machine, be sure to shut down the engine and lock the working device.  When you work under the machine, be sure to support equipment or attachments properly. Do not use hydraulic oil cylinder to support. If the control mechanism moves or any hydraulic line leaks, any attachment could drop.

Unless otherwise stated, do not perform any adjustment when the machine is running or the engine is starting.

Prevention from rolling damage or cut off 1. Keep away from all rotating and moving parts.  Ensure that there are no foreign materials between blades of the engine fan because the blades could throw out or cut off the tools and foreign materials falling or thrust between them.

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Operation and Maintenance Manual

Ether (if your machine is equipped with an ether cold start device)       

Ether is a toxic and flammable substance.

Inspiration of ether steam or frequent contact of skin with ether could result in personal injury.

The places where you use ether should be well ventilated.

Do not smoke when you replace ether cylinder.

Take care to prevent fire during use of ether.

Do not store the ether cylinder in a living quarter or inside the cab.

Do not put the ether cylinder in the places where it is directly exposed to sunlight or temperatures higher than 39℃ (120F).  Put discarded ether cylinders in safe places and do not drill or bake them.  Put the ether cylinder in the places where are far away from non-staffs.

Precaution for attachments  When you install and use a spare attachment, please read instructions, manuals and information in the manuals related to the attachment.  Do not use any attachment not approved by Hyundai Construction Equipment co., Ltd.. or a dealer appointed by the company. Use of unapproved attachments may give rise to safety issues which are harmful to normal operation of the machine and will affect its service life.  Hyundai Construction Equipment co., Ltd.. will not be responsible at all for any injury, accident and machine damage arising from use of unapproved attachments.

Keep ventilated during operation in a closed space.

Keep ventilated

 In case you have to start the engine, dispose of fuel or clean parts or paint in a closed or poor-ventilated place, you need to open doors and windows to ensure adequate ventilation so as to prevent gas-induced toxication.  In case adequate ventilation is still unavailable just by opening doors and windows, install a fan.

Lines, hard tubes and hoses  Neither bend or hammer high pressure lines nor install any abnormally bended or damaged hard tube or hose onto the machine.  Repair any loose or damaged fuel and lubricant lines and hard tubes and hoses in the hydraulic system. Leakage could cause fire. Please contact a dealer appointed by Hyundai Construction Equipment co., Ltd.. for proper repair or replacement. Carefully check lines, hard tubes and hoses and tighten all joints to specified torques. Do not check for leakage with naked hand; use a board or cardboard instead. Even the pressure liquid leakage from a pinhole could penetrate muscle, resulting in personal injury or death. If solution is shot on your skin, see a surgeon who is familiar with this kind of wound for treatment within a few hours. In case any of the troubles described below is found, replace the parts involved.

1. A joint is damaged or leaky.

Caution, poisonous gas!

2. Outer layer of a hose is worn or split and its reinforcing steel wires are exposed.

3. Local swell on a hose.

4. Visible torsion or partial crush on a hose.

5. Steel wires in reinforcement of a hose embed into outer layer.

6. An end connector is dislocated.  Ensure that all pipe clips, fenders and heat protection covers are installed properly to avoid shock or overheating caused by friction against other parts.  Keep off open flame when removing connecting lines of A/C compressor; otherwise, poisonous gas will be produced to result in intoxication.

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Operation and Maintenance Manual

I. Before engine start Safety of job site  Before you start a job, check around carefully for any abnormal conditions that may cause hazards.  Check terrain and ground conditions of the worksite and determine the best and safest job method.  Tamp and flatten the ground as firm and level as possible before you start a job. In case the worksite is dusty, sprinkle water before you start a job.  In case you need to operate on a main street, have a staff specially assigned guide traffic or set up fences around the worksite and post “Keep Out!” labels to protect passersby and vehicles.  For the places with such facilities as water pipes, gas pipes and high pressure and cable pipes embedded, contact the company in charge to locate these facilities.

In addition, take care not to damage these facilities during construction.  When you operate in water or pass a sandy bank, check ground condition and water depth and velocity first. Never exceed the allowed water depth, See “Purposes and Main Technical Characteristics and Parameters” for the allowed water depth.

Checks before engine start

 



    

  

Perform the following checks prior to engine start when you start to work. Failure to perform these checks could result in serious injury or damage.

Check around engine and battery for accumulated combustible materials, fuel, lubricant and hydraulic oil for leakage, and rear-view mirror, handrails and steps for contamination by fuel.

Do not leave any part and tool around the operator’s seat. Vibration will be generated during travel and operation, so, these things may fall off to damage the joystick and switches or they will cause the joystick to move and start the working device resulting in accident.

Before you get on this machine, clear mud and fine sand grains adhered to your shoes completely, because sludge will pile up on pivots of accelerator and brake pedals to hamper their reset. In case sludge piles up at these places, immediately clear them.

Check coolant level, fuel level and oil level in engine oil pan; check air cleaner for clogging; and check electric wires for damage.

Adjust the operator’ seat to a position where will facilitate operation and check the seat belt and its anchorage for damage. Be sure to replace the seat belt after 3 years’ use.

Check all meters for normal operation; check if the joystick is in PARK position.

Clear all dirt on window glass and lights of cab to ensure a good visibility.

Adjust position of the rear-view mirror properly to ensure that you can obtain the best field of view on the operator’s seat. Wipe up surface of the rear-view mirror. In case glass of the rear-view mirror has been damaged, replace with a new one.

Check if headlights and work lights illuminate normally and repair if any exceptions are found in the inspection result.

Ensure that fire extinguishers are available and you know how to use them well.

Do not park the machine at a place where is very close to an open flame.

Sound horn to warn

During engine start  Go around your machine again before you get on it and check if there is anyone or objects on, under or near the machine. Observe if anyone is in the work area.

Di, Di

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Operation and Maintenance Manual    

Never start the engine in case the warning label “No Operation!” is attached to the joystick.

When you start the engine, sound the horn to warn.

Start and control the engine only when you are seated in the operator's seat. Do not sit on the machine body.

There should be no other people than the operator in the cab. No one is allowed to sit on body of the machine.  Start the engine only when you are in the cab; it is strictly forbidden to start the engine by shorting the starting motor because use of the bypass starting system like this will cause damage to the electrical system of the machine. In addition, this operation is very dangerous.  If a back-up alarm is provided, ensure that it can work normally.

II. After engine start Checks after engine start Detection of abnormal situations will be delayed after engine start without proper checks, which could result in serious injury or machine breakdown. Check the machine at a spacious and unobstructed place and keep people off the machine.  Check operation of instrument and equipment, bucket, boom, braking system, drive system and steering system.  Check if sounds, vibration, heat up, odor or instrument of the machine is normal; check for hydraulic oil, lubricant, gas or fuel leak.  If any abnormal situation is found, immediately repair. Working of the machine under improper conditions could result in serious injury or machine breakdown.  Before travel or start of a job, check that the bumpers on the machine which are used to lock front and rear frames are firmly locked in “LOOSEN” position.

Precautions for start of travel      

Before start of travel, check around the machine again and ensure that there are no people and obstacles in that area.

When the machine starts to travel, you should sound the horn to warn.

Operate the machine only when you are seated in the operator's seat.

Be sure to buckle up.

There should be no other people than the operator in the cab. No one is allowed to sit on body of the machine.

If a back-up alarm is provided, check it for normal operation.

Precautions during travel  Never turn the key in the starting switch to OFF position during travel. It is dangerous if the engine shuts down when the machine is traveling because you will encounter hard steering. In the case of engine shutdown, immediately apply brake to stop the machine. Height of working device during travel  Glancing right and left during operation is dangerous. You should concentrate on working.  It will be dangerous when the machine runs too fast, abruptly starts or stops, sharply turns or travels along a zigzag.  Adjust height of the working device until ground clearance of lower hinge pin of boom is 500~600mm (20~24in) and let the machine travel on flat ground.

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Operation and Maintenance Manual  Drive the machine to a safe place and locate causes if any abnormal situation is found on it (noise, vibration, odor, incorrect meter indication, gas leak, oil leak, etc.) during operation.  Do not operate the joystick of the working device during travel. If you have to operate it, stop the machine first and then do the job.  Do not turn the steering wheel suddenly; otherwise, the working device may touch ground to cause the machine to lose its balance causing machine breakdown or damaging ambient buildings.  When the machine is traveling on a rugged ground, let it run at low speed and avoid sharp turning.  Try to avoid crossing over obstacles during travel. In case the machine has to cross over an obstacle during travel, lower the working device to ground as close as possible and let the machine run at low speed.  During travel or operation, keep proper distances with other machines or buildings so as to avoid collision. Take care when passing bridges!  In case the machine is in water, never exceed the allowed water depth.

See “Purposes and Main Technical Characteristics and Parameters” for the allowed water depth.  When passing a bridge or a building on a private territory, check if it is strong enough to bear weight of the machine first. When the machine is traveling on a public road, comply with the rules of the authorities concerned and observe related regulations first.  Observe traffic rules when the machine is traveling on a public road.

Travel speed of this machine should be lower than normal speeds of vehicles; keep it running along side on the road; remember to leave center of the road to other vehicles.  If you have driven this machine to run continuously at high speed for a long period of time, tires will overheat and their internal pressures will become extremely high. This could cause tire blowup. Tire blowup could produce a huge destructive power, which may cause serious injury or accident.

Checks during direction change To prevent injury or death, be sure to observe the following rules before you move the machine or working device even if the machine is equipped with back-up alarm and rear-view mirror:  Sound the horn to warn the personnel on site.  Check that nobody is close to the machine. Especially, carefully check rear area of the machine because there can not be seen clearly from the operator’s seat.  When you are working at a place where is in dangerous condition and has a poor visibility, appoint a person to guide traffic on the worksite.  Keep unapproved personnel out of the zone in turning or travel direction.  Do not change travel direction under high speed.

Prohibited operations

Overloading is forbidden

To prevent machine rollover or working device damage due to overload, machine load must be maintained within the specified maximum value. It is absolutely not allowed for the machine to exceed its specified capacity during use.  Hyundai Construction Equipment co., Ltd.. shall not assume any liability for any injury, accident or machine damage arising from overloaded use of the machine.

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Operation and Maintenance Manual

Travel on slopes  Take extra care because travel on a slope may cause machine tilt or sideslip.  Keep a 200~300mm ground clearance of bucket when the machine is traveling on a slope. In case of emergency, lower the bucket to the ground rapidly to help stop the machine.  Neither turns on a slope nor travel laterally on it. Instead, drive the machine down to a flat ground to perform these operations.

Take care when going downslope  Never shift or set the transmission to neutral position when the machine is traveling downslope. It is dangerous not to use brake force of Help! the engine. Set the transmission to low gear when the machine starts to travel downslope.  During downslope travel, use brake force of the engine and let the machine run at low speed. If necessary, apply brake pedal while using brake force of the engine so as to control travel speed.  Do not drive at high speed on grass land, defoliation or wet steel Direction of bucket when going upslope/downslope plate because such operation will cause machine sideslip even if it is on a slope of small grade. Therefore, be sure to travel at low speed. When the machine is traveling on a slope, let it go straight upwards or downwards.  Depress the brake pedal to floor immediately to apply brake, lower the bucket to ground and then apply parking brake to fix position of machine in the case of engine shutdown when the machine is traveling on a slope.  If the machine is going upslope or downslope with the bucket loaded, keeps the bucket facing upslope direction (i.e. forward during going upslope and backward during going downslope) during travel.

When the machine is traveling on a slope with its bucket loaded, it will be at risk of tilt with its bucket facing downslope direction.

Keep off high voltage cables

 Keep the machine clear of any overhead cable. Electrical shock could occur even if the machine is only close to a high voltage cable. Keep safe distances between the machine and cables as shown in the table below.  To prevent accident, perform the following properly: 1. When the machine is on a worksite where has potential risk of cable touch, consult the power company before start of the job and check if the action determined in accordance with active laws and regulations related is feasible.

2. Wear rubber boots and gloves. Put a rubber pad on the operator’s seat and take care not to allow any exposed part on your body to touch the metal chassis. Danger! Electric shock.

3. Appoint a signal man who will send out a warning signal when the machine is too close to a cable.

4. If the working device touches a cable, the operator should not leave the cab.

5. When you are working near high voltage cables, keep people off the machine.

Inquire the power company about voltages of these cables before start of the job.

Low voltage High voltage

Voltage 100~200V 6,600V

Minimum safe distance 2m 7ft 2m 7ft

22,000V 66,000V 154,000V 187,000V

3m 4m 5m 6m

10ft 14ft 17ft 20ft

275,000V 500,000V

7m 11m

23ft 36ft

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Operation and Maintenance Manual

Precautions during operation  Take care not to be too close to cliff edge. During banking or filling or dumping earth towards a cliff, you can unload clay into a pile and then use another pile of clay to push the former one.  Load will suddenly turn light when the machine pushes clay off the cliff or push it to peak of the slope. It is dangerous in such a case because travel speed will suddenly increase; therefore, be sure to slow down. When the bucket is fully loaded, never start, turn or stop the machine abruptly. Carry unstable loads When carrying unstable loads such as the objects in round or cylindrical shape or stacked plates, there is a danger that the loads may fall onto top of the cab to cause serious injury or damage if the working device is lifted up. Take care not to lift the working device to a too high position or tilt the bucket back too much when carrying unstable loads.  If the working device drops or stops suddenly, its reaction is likely to make the machine roll over. Be sure to operate the working device with care, especially when it is loaded.  Do not use the bucket or boom in lifting operation.  This machine can undertake the specified jobs only. Other operations beyond the serviceable range could damage the machine. See “Purposes and Main Technical Characteristics and Parameters” for the specified jobs. Lighting  Observe the following points to ensure a good visibility: 1. When you are working at a dark place, turn on work lights and headlights; if needed, install lighting facilities on the worksite.

2. Do not operate in foggy, cloudy, snowy, stormy days or under other conditions in which the visibility is poor. Do not operate until sky turns bright and an adequate visibility is available.  Pay attention to the following points to prevent the working device from collision with other objects: beware of collisions!

1. During operation in tunnels, under bridges, under electric wires, or in any other places with restricted heights, take extra care not to allow the bucket to come into contact with anything.

2. Check that nobody is around the machine when unloading to a tipper.

Take care not to allow the bucket to come into contact with cab of the tipper.

3. To prevent the accidents caused by the machine’s collision with other objects, the machine should work at the speed for safe operation, especially in limited spaces, rooms and the places where other vehicles exist.

Instructions for brake application  Do not put your foot on the brake pedal unless truly necessary.  Do not depress the pedal repeatedly unless truly necessary.  When traveling downslope, use engine as a brake and never shift a gear or set the transmission to neutral position.

Take care to operate in snowy days  When you are working on a snowy or frozen road, even a small grade can cause the machine to sideslip; therefore, let the machine travel at low speed and avoid abrupt start, stop or turning. The risk of slip exists especially when the machine is traveling upslope or downslope.  Travel conditions on frozen roads will become unstable because the ground will soften as temperature rises. In such 16

Operation and Maintenance Manual a case, take extra care to drive.  After a heavy snowfall, the objects on road shoulder and roadside can not be seen clearly because they are buried in snow; therefore, carefully sweep the snow.  When you drive on a road covered by snow, install non-skid chains for tires.  Never apply brake abruptly when you are driving on a road covered by snow. Instead, slow down and use engine as a brake, at the same time, depress the pedal intermittently for several times. If necessary, lower the bucket to ground to stop the machine. Ground adhesion will vary greatly due to effect of snow; therefore, adjust load accordingly to avoid slip of the machine during travel.

Do not work on soft ground  Do not let the machine work on a soft ground; otherwise, it is likely to be trapped in and difficult to come out.  Do not allow the machine to be too close to a cliff edge or hanging part and deep groove. The machine may fall or tilt to cause serious injury or death if these areas collapse due to weight or vibration of the machine. Remember that the soils in these areas will soften after a heavy rain, burst or earthquake.  The clay piled up on ground and that near a channel are soft. These places may collapse under weight and vibration of the machine, which will cause the machine to tilt.  Buckle up when there are dangers of rockfall or machine rollover on the worksite.

Parking the machine  Park the machine on a flat ground and then lower the working device to the ground where there should be no risk of rockfall or landslide. In the case of low terrain, there should be no risk of flood too.  If you need to park the machine on a slope, put wedges under wheels to prevent it from move. Then, lower the working device to the ground.  When you park the machine on a road, set up enclosures, signals, flags or caution lights and place other necessary signals to ensure that passing vehicles can see this machine clearly. In addition, ensure that the machine, enclosures and flags will not disturb traffic.  When you leave the machine, lower the bucket completely to the ground, lock the joystick using the locking device, cut off the engine, and pull up the parking brake switch to set it to BRAKE position. Lock up all devices with the key properly.

When you leave the machine

Take off the key and carry it with you.

Precautions for cold areas  After finish of a job, completely clear the water, snow or sludge adhered to wires, wire connectors, switches or sensors as well as covering panels of these parts. In case you fail to do so, moisture in these parts will freeze to cause machine malfunction at next use, which may result in unexpected failure.  Perform warm-up operation thoroughly. If the machine is not thoroughly warmed up before you start to operate the joystick, it will become unresponsive, which may result in unexpected accident.  Operate all joysticks to allow the hydraulic oil in the hydraulic system to circulate (raise the system pressure up to the setting pressure of the system, then release the pressure and return the oil to the hydraulic oil tank), thus heating

17

Operation and Maintenance Manual up the hydraulic oil. This can ensure that the machine responds well and prevent it from malfunction.  Neither charge the battery nor start the engine using another power supply if the electrolyte in the battery has frozen.

This is dangerous and may cause fire of battery. When you charge the battery or start the engine using another power supply, thaw the electrolyte in the battery and check for leakage before start.

Ⅲ Precautions during transportation Handling the machine  Potential hazards always exist when handling the machine, so, extra care should be taken. When you handle the machine, let the engine run and the machine travel at low speeds.  Handle the machine on a firm and flat ground and keep a safe distance with roadside.  When you handle the machine, always fix wheels of the carrier vehicle properly and put pads under the gang board.  Use the sloping plates that have adequate strength. Ensure that the sloping plate is wide and long enough for safe handling. The included angle between the sloping plate and the ground can not exceed 15º. The distance between the sloping plates should adapt to the wheel track of the machine.  Ensure that the sloping plates are firmly positioned with uniform height at both sides.  Keep surface of the sloping plate clean and free of lubricant, oil stains, ice and loose materials. Clear the dirt on the tires of the machine.  Never turn on the sloping plates. If necessary, drive the machine off the sloping plates and then drive it on them again after a proper direction adjustment.  After loading, wedge tires of the machine and fasten it with cords.

Dispatch  When dispatching this machine using a hauling truck, observe the regulations in national and local laws on weight, height, width, and length of heavy objects. Also, follow all traffic rules related.  When you determine a transport route, take weight, height, width and length of the machine into account.  When passing a bridge or a building on a private territory, check if it is strong enough to bear weight of the machine first. When the machine is traveling on a public road, comply with the rules of the authorities concerned first and observe these regulations.  It may be necessary to divide this machine into several portions during transport. Therefore, please contact a dealer appointed by Hyundai Construction Equipment co., Ltd.. for these jobs when you need to transport this machine.

Ⅳ Precautions for operation and maintenance of the battery Prevention from hazards The electrolyte of the battery contains sulphuric acid and the battery can generate hydrogen. So, incorrect disposal of the battery could result in serious injury or fire. Therefore, absolutely observe the following precautions.  Keep lighted cigarette or open flame off the battery.

18

Operation and Maintenance Manual  When you need to contact the battery during working, wear safety goggles and rubber gloves.  In case the electrolyte in the battery is splashed on your clothes or skin, immediately flush with abundant fresh water.  In case the electrolyte in the battery is splashed into eye, blindness may result. If the electrolyte is splashed into your eye, immediately flush with abundant fresh water and see a doctor at once.  In case you drink some electrolyte inadvertently, drink abundant water or milk, raw eggs or rape oil and immediately call a doctor or an emergency care center for help.  Shut down the engine prior to any battery related operation.  Avoid short circuit between positive (+) and negative (-) terminals of the battery due to inadvertent contact with metal articles (e.g. tools). When you install the battery, connect positive (+) terminal first. When you remove the battery, disconnect the negative (-) terminal (at ground wire side) first.  When you remove or install the battery, differentiate between positive (+) terminal and negative (-) terminal first, and then tighten the nuts firmly.  When you clean top surface of the battery, use cloth to wipe it. Never use gasoline, solvent and any other organic solvent or detergent. Tighten top cover of the battery firmly.  Neither charge the battery nor start the engine using another power supply if the electrolyte of the battery has frozen.

This is dangerous and may cause fire of the battery otherwise. When you charge the battery or start the engine using another power supply, thaw the electrolyte in the battery and check for leakage before start.  Before charging, remove the battery from the machine.

Staring with boosting cable Any fault in connection method of the boosting cable may result in fire, so, comply with the following steps.  The starting operation requires two operators (one is seated in the operator’ seat).  When you start another machine, the two machines are not allowed to contact each other.  When you connect the boosting cable, turn off the starting switches on both the normal machine and the faulted one.  When you install the boosting cable, be sure to connect positive (+) cable first. When you remove the boosting cable, disconnect the ground wire or negative (-) cable first.  Final ground wire connection means connecting ground wire to the engine cylinder block on the faulted machine.

But this could produce sparks; so, keep away from the battery as far as possible during connection operation.  When you remove the boosting cable, take care not to allow mutual contact of the boosting cable clips or contact of the clips with the machine.

Charging the battery The battery may explode if it is handled incorrectly during charging. Therefore, follow the battery handling instructions and the charging related instructions in the manual and observe the following precautions.  Charge at well-ventilated places and remove top cover of the battery to allow hydrogen diffusion and prevent explosion.  Set voltage of the charger until it conforms to that of the battery to be charged. If the voltage is set incorrectly, the charger will overheat and take fire even explode.  Connect positive (+) charging clip of the charger to positive (+) terminal of the battery and then negative (-) charging clip to negative (-) terminal of the battery. Be sure to tighten the both terminals firmly.

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Operation and Maintenance Manual  In case the charging rate of the battery is below 1/10, perform a fast charge and set the hash value below the rated capacity of the battery. Too heavy charging current can cause electrolyte leak or evaporation, which may result in fire or explosion.

Ⅴ Towing During towing Towing an immobile machine incorrectly or improper selection of hoisting cables could result in injury or death, so, observe the following precautions.  Refer to vehicle towing related instructions in this “Operation and Maintenance Manual” to operate.  When you handle the hoisting cables, wear leather gloves.  When you prepare for the towage together with other workers, arrange the signals to be used before start of the job.  In case the engine on the faulted machine can not start or the braking system is malfunctioning, please contact a dealer appointed by Hyundai Construction Equipment co., Ltd.. for repair.  It is dangerous to tow a machine on a slope; choose a place with a mild grade instead. If such a place is unavailable, choose a place with a grade as small as possible to carry out the job.  If the faulted machine is towed by another machine, the hoisting cables used must be strong enough to bear weight of the faulted machine.  The hoisting cables used should have no broken strands, kinks or reduced diameters.  Do not straddle to stand on the towing cables or hoisting cables.  When you connect the machine to be towed, keep people out of the area between the towing machine and the one to be towed.  Align the car body coupler on the machine to be towed with the towing portion on the towing machine and ensure that they are in place.

Precautions for maintenance I. Before maintenance Failure notice Maintenance items not contained in this “Operation and Maintenance Manual” may cause unexpected failure, so, please contact a dealer appointed by Hyundai Construction Equipment co., Ltd.. for repair.

Warning labels  When the operator is servicing the machine or filling it with oil, starting the engine or operating the joystick by others will cause the operator’s serious injury or death.  Post a warning label on the joystick in the cab to remind others that you are servicing the machine. If necessary, post warning labels around the machine too.

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Operation and Maintenance Manual

Cleaning prior to servicing and maintenance  Clean the machine prior to servicing and maintenance. This can not only keep dirt out of the machine but also ensure safe performance of the maintenance work.  If the machine is still dirty when it is being serviced and maintained, the troubles will be difficult to locate, dirt or sludge may be splashed into eyes, and the dangers of slip and injury will exist.

Pay attention to the following points during machine cleaning: 1. Wear non-slip shoes to prevent slip on wet and slippery surfaces.

2. Wear protective clothing when you flush the machine using high-pressure water. This will protect you from shock of high-pressure water, skin stab or invasion of splashed dirt or sludge into eyes.

3. Don’t directly spray water onto components of electric system (such as sensor and connection plugs of electric wire).

Entry of water into the electrical system may cause operation failure.

Keep worksite clean and tidy  Do not leave any servicing and maintenance tools around the worksite. Wipe up all grease, lubricant or other things that can make people slip. Always keep worksite clean and tidy to allow safe operation.  Failure to do so may make people stumble, slip or trip resulting in injury.

Appoint a person in charge when working together with others  Appoint a person in charge who is in command of the personnel during operation when repairing the machine or handling the working device.  When working together with others, misunderstanding each other could result in serious accident.

Coolant level in the radiator When checking coolant level in the radiator, shut down the engine and do not operate until the engine and radiator have cooled down. Under normal condition, do not open the top cover of the radiator.

If you need not to open the top cover of the radiator, operate as follows: Wait until temperature of the coolant in the radiator has dropped before coolant level check. (When checking if coolant temperature has dropped, put your hand close to the engine or radiator to check air temperature. Take care not to touch the engine or radiator so as to avoid scald.)

1. Wait until the coolant filler has cooled to an extent that you can open it with naked hand, and then loosen the filler cap slowly to release internal pressure.  If you need to open the top cover of the radiator, wait until temperature of the coolant in the radiator has cooled down. Release internal pressure before opening the top cover.

Cut off the engine prior to servicing and maintenance  When carrying out servicing and maintenance, park the machine on a flat ground where there should be no risk of rockfall or landslide. In the case of low terrain, there should be no risk of flood too.

Cut off the engine.

 After the engine shuts down, set the joystick of the working device to “LIFT” and “FALL” positions for several

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Operation and Maintenance Manual times to release residual pressure in the hydraulic circuit.

Lower the working device to the ground and then lock the joystick using the locking device.  Pull up the parking brake switch to apply brake and then put wedges under the tires. Set joystick to “neutral position”  Lock front and rear frames with bumpers.  Take extra care during maintenance work and avoid being touched or hitched by moving parts.

Support of the working device  Set the joystick to “neutral position” and then lock it using the locking device.  During servicing and maintenance with the bucket lifted, remember to lock the safety support on the piston rod of the boom cylinder firmly to limit retraction of the cylinder and prevent the working device from falling.

Appropriate tools Use the tools suitable for the job tasks only. Use of the tools damaged, of inferior quality, defective or as temporary substitutes may cause personal injury.

Periodic replacement of safety and critical parts Hoses and other parts in fuel, hydraulic and braking systems are the critical parts for safety assurance, so, they must be replaced periodically. Replacement of safety and critical parts requires command of certain skills. You should contact a dealer appointed by Hyundai Construction Equipment co., Ltd.. for the replacement.

These components should be replaced with new ones periodically whether they are malfunctioning or not.  These components will age with time elapse and serious accidents may arise due to oil leaks or failures in the working device system.  If any fault is found on these components, replace or repair even if the schedule time is not reached yet.

Refer to “Contents and Change Periods of Safety and Critical Parts” for periodic replacement of these components.

Use of lighting  When checking fuel, lubricant, battery electrolyte or window glass washer fluid, use the lighting facilities with explosion protection function. Not using such lighting facilities will cause danger of explosion.  Working at dark places without lighting may cause injury; so, install appropriate lighting facilities.  Do not use a lighter or open flame as lighting even if in dark places. This could cause fire hazard: explosion may take place when the gas given off by the battery meets fire.  Observe the instructions in this “Operation and Maintenance Manual” when the machine is used as a lighting power supply.

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Operation and Maintenance Manual

Fire prevention The gas given off by fuel and battery may take fire during maintenance, so, the following precautions should be observed during servicing and maintenance.  Keep storages of fuel, lubricant and other flammable materials away from open flame.  Use nonflammable materials as cleaning agents for part cleaning. Do not use diesel oil or gasoline as they may cause fire hazard.  When carrying out servicing or maintenance, do not smoke. Smoke only at the specified places.  When checking fuel, lubricant or battery electrolyte, use the lighting facilities with explosion protection function.

Never use a lighter or match as lighting.  When performing grinding or electric welding on the frame, move all flammable materials to a safe place.  Fire extinguishers must be available at the job site of servicing and maintenance.

II. During maintenance Personnel  Only the personnel who have corresponding qualification can maintain and repair this machine. Keep the personnel not involved in the ongoing maintenance and repairing work out of the work area. If necessary, someone can be appointed specially to keep watch the area.  Take extra care during grinding, electric welding or use of mash hammer.

Attachments “No entry!” label  Appoint a person in charge before start of an attachment removal or installation exercise.  Keep all non-staffs off the machine or attachment.  Place the attachment removed from the machine in a safe place and ensure that it will not fall. Set up handrails around the attachment and hang the “No entry!” labels to keep the unapproved men off.

Working under the machine

Fix tires using wedges

Park the machine on a firm and flat ground and lower all working devices to the ground before you start a maintenance work or repair under the machine.  Fix tires using wedges.

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Operation and Maintenance Manual Do not work under a poorly supported machine.  It is very dangerous when you work under the machine with tires off ground and the machine supported only by the working device. Never work under a poorly supported machine.

Maintenance with the frame jacked up  When working with the working device or frame lifted, lock front and rear frames using bumpers. Set the joystick to “neutral position” and lock it using the locking device. Wedge the working device and frame with wedges.  Before jackup, wedge wheels from the opposite side. Before jackup, put pads under the machine.

Working on top of the machine  Keep your foothold clean and free from obstacles when you are carrying out a maintenance work on top of the machine. In addition, observe the following precautions to protect yourself from falling.

1. Keep free from splashed lubricant or grease.

2. Do not place tools around.

3. Pay attention to your paces during walk.  Never jump off the machine. When you get on and off the machine, be sure to use steps and handrails and always keep 3-point touch (two feet and one hand or two hands and one foot).  If needed, use protective equipment.  Do not stand on top of the engine hood as it is slippery and dangerous.  Do not stand on top of any tire as it is slippery and dangerous.  Stand on the mudguard of the front frame when cleaning the front glass of the cab.

Do not allow foreign materials to fall into the machine  When you open the inspection window or oil tank filler to carry out a repair work, take care not to allow any foreign object (e.g. nut, bolt, cotton yarn or tool) to fall into the machine. Falling of these things into the machine could cause engine damage, operation errors and other failures. If any foreign object falls into the machine, be sure to take it out.  Do not carry any unnecessary tools and parts in your pockets during a repair work.

Caution, fan!

Maintenance work when the engine is running To prevent injury, do not carry out any maintenance work when the engine is running. If you have to do so with the engine running, observe the following precautions.  Appoint a worker who is seated on the operator's seat to get ready for cutting off the engine whenever necessary. Any worker must keep in touch with others.  When a job site is close to rotating parts the danger of being caught by them will exist, so, extra care should be taken.

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Operation and Maintenance Manual

 Never allow any tool or any part on your body to touch the fan blade or belt. This can cause serious wound.  When you clean inside of the radiator, lock the joystick using the locking device to prevent the working device from move. In addition, pull up the parking brake switch to apply brake.  Do not touch any joystick. If you have to operate the joystick, signal other workers to advise them to walk to safe places.

Precautions for use of hammers  When you use a hammer, be sure to wear safety goggles, safety helmet, and other protective clothing and put a copper bar between the hammer and the area to be hammered.  In case you hammer a hard part, e.g. a pin or bearing, debris may fly into eyes to cause injury.

Repair welding Electric welding operation should be carried out by qualified welders at the places where is equipped with appropriate equipment. Electric welding could generate gas and hazards of fire and electric shock exist during the operation, so, never allow unqualified persons to operate. A qualified welder must observe the following precautions:  Disconnect the terminals of the battery to prevent it from explosion.  Remove paint in the areas to be welded so as to prevent generation of harmful gas.  Electric welding operation on hydraulic equipment or piping or at the places where are very close to there will generate flammable steam and sparks which could cause fire hazard. Therefore, avoid electric welding in such places.  In case the sparks splashed during electric welding can fall on rubber hose, wires or pressurized piping, these pipes may burst and the insulating layers of these wires could be damaged, so, they must be covered using fire dampers.  Wear protective clothing during electric welding operation.  Keep electric welding job site well ventilated.  Clear all flammable materials and be sure to provide the job site with fire extinguishers.

Battery related precautions When repairing the electrical system or carrying out electric welding operation on the machine, remove the negative (-) pole of battery or turn off the general power switch to prevent current flow.

When any abnormal location is found  If any abnormal situation is found during servicing, repair. Especially, any abnormal situation in braking system, steering system or working device system during machine operation may result in serious accident.  Please contact a dealer appointed by Hyundai Construction Equipment co., Ltd.. for repair according to fault type.

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Operation and Maintenance Manual

Regulations that you must observe during fuel or lubricant fill All fuel, lubricant, hydraulic oil, antifreeze, brake liquid and window glass washer fluid can be ignited by open flame. Observe the following provisions:  Shut down the engine during fuel or lubricant fill.  No smoking!  Wipe up spillage of fuel, lubricant, hydraulic oil, antifreeze, brake fluid or window glass washer fluid immediately.  Tighten top covers of the vessels holding fuel, lubricant, hydraulic oil, antifreeze, brake fluid or window glass washer fluid.  The places for adding or storing fuel, lubricant, hydraulic oil, antifreeze, brake fluid or window glass washer fluid should be well ventilated.

Treatment of high-pressure hoses  Leaky high-pressure hoses may cause operation failure, personal injury or equipment damage. Stop work if any hose is found damaged or any bolt is found loose. Contact a dealer appointed by Hyundai Construction Equipment co., Ltd.. for repair issues.  Replacement of high-pressure hoses requires command of high skills and mounting torques should be determined according to types and sizes of hoses. Therefore, do not repair them by yourself. Instead, have a dealer appointed

by Hyundai Construction Equipment co., Ltd.. do the job.

Precautions for high-pressure oil When you service or replace pipes in the hydraulic system, check if system pressure has been released.

Residual pressure in the line could result in serious injury or damage, so, the following procedure should be followed.  Refer to “Please cut off engine before servicing and maintenance” in “Precautions for Maintenance” for details of pressure release. Never carry out servicing or replacement before the pressure is completely released.  Wear safety goggles and leather gloves.  It oil leaks from a pipe, the pipe and the area around it will become wet; so, check steel tubes or hoses for cracks and hoses for swell. If it is difficult to locate the leaky places, please contact a dealer appointed by Hyundai Construction Equipment co., Ltd.. for repair issues.  Do not check for leakage with naked hand; use a board or cardboard instead.  If shot by ejected high-pressure oil, contact a doctors for treatment immediately.

Precautions for servicing under high temperature or pressure  When a job has just been stopped, water coolant and oil in all parts of the engine are under high temperature and pressure. Opening engine hood, or draining oil or water, or replacing a filter at the time will result in burns or other injuries. Wait until the temperature has dropped and then carry out the repair work according to the steps specified in this “Operation Manual”.  Refer to “Periodic Maintenance” and the related items in this “Operation and Maintenance Manual” for other check items.

Wastes The following procedure must be observed to prevent pollution, especially in the places where human or animals reside in.

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Operation and Maintenance Manual  Never pour waste oil in such places as sewers and rivers.  Hold the oil discharged from the machine in a vessel. Never discharge oil directly to the ground.  Abide by related laws and regulations when disposing of harmful matters such as lubricant, fuel, coolant, solvent, filter, battery and other substances.

Checks after servicing and maintenance Unexpected troubles may arise and even personal injury or machine damage may be caused in the case of failure to carry out a total servicing and maintenance or check functions of each portion serviced, so, always pay attention to the following issues.  Checks when the engine is shut down.

1. Have all places requiring servicing and maintenance been checked?

2. Have all servicing and maintenance items been carried out correctly?

3. Has any tool or part fallen into the machine? It is especially dangerous when there is any tool or part on the linkage of the joystick, so, be sure to check specially.

4. Have all water or oil leak troubles been cleared? Have all bolts been tightened?  Checks during engine operation Refer to “Maintenance work during engine operation” in “Precautions for Maintenance” for details on checks during engine operation. Take extra care to ensure safety and pay attention to the following issues: 1. Are the parts requiring servicing and maintenance working normally?

2. Is oil leaking from the hydraulic system when speed of the engine is increased and a load is applied? Ⅲ

Tires

Tire treatment A tire may blow up or burst and a rim may burst and get loose to cause serious injury and even result in death if they are treated incorrectly.

To ensure a safe maintenance work, the following precautions should be observed:  Maintenance, removal, repair and installation of tires and rims require special-purpose equipment and professional skills, so, have the jobs done by a tire mendery.  Use the specified tires and charge them to the specified pressure only. Refer to “Purposes and Main Technical Characteristics and Parameters” for the specified tires and pressures.  When inflating tires, check and keep others out of the work area. Stand at side of the tire, use selfhold clamping head, and check inflation pressure to ensure it will not become too high on a regular basis.  Rims may be broken or get loose after tire inflation if they are installed incorrectly, so, be sure to place guard plates around tires and work at side of tires instead of inside of rims.  Both abnormal drop in inflation pressure and off normal fit between a tire and a rim indicate a tire or rim malfunction. In such a case, have them repaired by a tire mendery.  After a high-speed travel or loading operation, do not adjust inflation pressure.

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Operation and Maintenance Manual  Gas-filled tires may blow up due to the gas inside them being heated or gas combustion. Gas being heated is generally resulted from heating up or electric welding to rims, external flames or excessively frequent brake applications causing gas to expand or combust due to being heated.  Power of tire blowup is by far greater than that of air bleed. The blowup may cause tires, rims and parts of final drive to fly as far as more than 500m away from the machine. The blasting power and debris may cause personal injury and property damage.  It is recommended that you use dry nitrogen (N2) to fill tires. In case a tire is charged with air originally, we recommend that you use nitrogen to adjust its pressure. Nitrogen can mix with atmospheric gas. Nitrogen charged tires are less likely to blow up because nitrogen is nonflammable. Also, nitrogen helps prevent oxidation, rubber aging and corrosion of rim parts and components.  Appropriate equipment and personnel training should be provided to avoid over inflation, because air leak or rim damage is due to use of incorrect inflation equipment or improper operation.

Precautions for tire storage  As a basic rule, tires should be stored in a warehouse where the unapproved personnel are kept out.. If some tires are to be stored outdoors, set up fences around them and hang the “No entry!” signs.  Erect the tire on a level ground and wedge it with wedges firmly to ensure that it will not fall down even when touched by an unapproved person. If the tire is upended with its flank touching down, it will be crushed causing its quality drop.

Wedge tires using wedges

 Stand aside as quickly as possible if the tire is about to fall down. All tires on engineering machinery are very heavy and any attempt to buttress it may on the contrary cause serious injury.

Wedge

Contents and change periods of safety and critical parts  To ensure safety of the loader during operation, customers must always carry out periodic maintenance. In addition, to further increase safety, users should also replace the parts given in the table periodically because they are very important for safety and fire prevention.  Materials of these parts will deteriorate or become more liable to wear and corrosion as time elapses. In addition, it is very difficult to judge their conditions simply by routine maintenance. Therefore, all these parts should be replaced periodically in spite of their service conditions. This is necessary for ensuring their service performances.  If they are found malfunctioning before the replacement time is reached, repair or replace immediately. If any damage, deformation or crack is found on a pipe clip securing a hose, replace it together with the hose.  When replacing a hose, be sure to replace the O-ring, gasket and other parts like at the same time.  Please contact a dealer appointed by Hyundai Construction Equipment co., Ltd.. for replacement of the safety and critical parts so as to ensure safety.

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Operation and Maintenance Manual

Periodic replacement of safety and critical parts SN

Critical parts to be replaced periodically

Quan

Change period

tity 1

Filter element of hydraulic oil tank

1

Semiyearly or 1000h (whichever comes first).

2

Fuel pipe (fuel tank-diesel oil prefilter)

1

3

Fuel pipe (diesel oil prefilter-oil transfer pump)

1

4

Fuel pipe (oil transfer pump-diesel oil filter)

1

5

Fuel pipe (diesel oil filter-high-pressure pump)

1

6

Fuel pipe (fuel return pipe)

1

7

Hose assembly (pump-priority valve)

1

8

Hose assembly (priority valve-steering gear)

1

9

Hose assembly (steering gear-steering cylinder)

4

10

Steering cylinder seal

2

11

Steel tube (air compressor-relief valve)

1

Biyearly or 4000h

12

Hose (relief valve-air reservoir)

1

(whichever comes first).

13

Hose (air reservoir-foot brake valve)

1

14

Hose (foot brake valve-font/rear booster pump)

2

15

Hose (foot brake valve-hand brake valve)

1

16

Hose (hand brake valve-brake chamber)

1

17

Seal in brake chamber

1

18

High-pressure hose (booster pump-front axle steel

1

tube) 19

High-pressure hose (booster pump-rear axle steel

1

tube) 20

Air reservoir

1

Every

three

years

or

6000h

(whichever comes first).

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Operation and Maintenance Manual

Purposes and Main Specifications Notices The content in this section is very important for correct operation, maintenance and servicing of this machine.

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Operation and Maintenance Manual

Purposes This loader is a single bucket, front end working, articulated steering wheel loader. As a type of efficient construction machinery, it applies to such jobs as loading, mounding, shoveling, hoisting and towing in such places as mines, fundamental construction, road construction, enterprises, ports and freight yards.

Requirements to working environment: 1.

Elevation: ≤3000m

2.

Ambient temperature: -15℃~40℃

3.

Fordable depth: ≤630mm This loader is a type of general-purpose construction machinery which does not apply to flammable, explosive, highly dusty or poisonous gas containing environments.

Prohibited operations: 1.

Overloaded use.

2.

Lifting heavy objects with hoisting cables hung on bucket teeth directly.

3.

Digging above the machine with bucket lifted.

Notices The precautions in operation, maintenance and safety operation rules given in this manual apply only to the specified purposes of this machine. Hyundai Construction Equipment co., Ltd.. will not assume any safety liability when a customer uses this machine for the purposes beyond the serviceable range specified in this manual and all safety liabilities arising from such operations shall be assumed by the customer solely. In no event can any customer perform the operations forbidden in this manual.

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Operation and Maintenance Manual

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Operation and Maintenance Manual

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Operation and Maintenance Manual

MEMO

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Operation and Maintenance Manual

MEMO

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Operation and Maintenance Manual

Operation Manual

Notices Before operating this machine to carry out a job, carefully read and understand the content of this manual so that you can operate this machine correctly.

Correct operations are very important for safety control, obtaining of high working efficiency and extension of service life of the machine.

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Operation and Maintenance Manual

Control facilities and monitoring system Steering wheel This machine uses a fully hydraulic coaxial flow-amplified steering system in which the steering wheel is located in the cab and connected with the steering gear. When the machine operates normally, turn the steering wheel clockwise and the machine will turn right; turn it counterclockwise and the machine will turn left.

The steering characteristics are as follows: 1. The angle the steering wheel turns is not equal to the steering angle of the machine. You can continuously turn the steering wheel to increase the steering angle until the desired steering position is reached.

2. The quicker the steering wheel is turned, the higher the steering speed of the machine will be.

3. The steering wheel will not return automatically after turned and the steering angle of the machine will keep constant. Therefore, after machine turning is completed, turn the steering wheel in reverse direction to allow the machine to travel in a straight direction.

Steering wheel

Machine power switch

Machine power switch The machine power switch is installed on right rear part on rear frame.

It is a little different from the starting switch. The vehicle electrical system can be turned off by turning off the machine power switch. However, the battery is still connected with the vehicle electrical system when the starting switch is turned off, so, some electrical components can still work. There is also a general power switch at left side of the starting switch.

Starting switch The starting switch (also called electro lock) is located on the control panel at right side of the driver’s seat and has 4 positions from left to right respectively. It is enabled only when the red button (general power switch) in the figure is turned on first.

Starting switch

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Operation and Maintenance Manual 1. STOP-A position that the starting switch key stops in after the key is inserted and then turned counterclockwise.

Electric shutdown will be enabled when the key is turned to this position.

2. OFF-In this position, the machine power supply circuit will be cut off.

Notices Only in “OFF” position, you can insert or draw out the starting switch key.

3. ON-The first position that the starting switch key will stop in after the key is inserted and then turned clockwise.In this position, the vehicle electrical system is power on and works normally.

4. START-The second position that the starting switch key will stop in after the key is inserted and then turned clockwise. In this position, the starting motor is energized to start the engine. Please release the starting switch key immediately after a successful engine start. Selfhold function is not available in this position and the starting switch key will return automatically to its “ON” position after released.

Notices

Warning Before engine start, please confirm that the negative switch is ON and that the gearshift lever is in neutral position. If the engine fails to start up, you must turn the starting switch to “OFF” position before another attempt; otherwise, the switch may be damaged!

The duration of each attempt should not exceed 15s; the time interval between two attempts should be least 30s; and the number of successive attempts can not exceed 3. After 3 attempts, do not continue to try until the starting motor and cut-off electromagnet have fully cooled down; otherwise, service life of the battery may be cut, at the same time, the starting motor and cut-off electromagnet may be damaged!

When starting on a steep slope, do not use the power cut function so as to ensure safety.

Parking brake lever The parking brake lever is located near left armrest of the driver's seat. Pull it up and the parking brake will engage to apply brake; put it down and the parking brake will be released to cancel brake.

The parking brake can also be used as an emergency brake. In case of emergency when the machine is working, pull up the parking brake lever manual to apply emergency brake.

Cut-off switch The starting switch is also a cut-off switch. When you park the vehicle, turn the key counterclockwise to “STOP” position and the engine will shut down. (The key will return automatically) Parking brake lever Cut-off switch

Service brake pedal The service brake pedal is located at front left of the driver’s seat. The service braking system on this machine is a single-pedal dual-circuit system. In case one circuit is malfunctioning, normal working of the other circuit will not be affected, so that part of braking capacity of the machine will be maintained to ensure driving safety. When the braking 38

Operation and Maintenance Manual system is malfunctioning, repair it immediately to ensure adequate braking capacity of the machine.

Depress the service brake pedal and the rim brakes of front and rear drive axles will apply brake. At the same time, the brake light switch will be turned on and the brake light will come on. Loosen the service brake pedal and the service brake will be released simply.

Accelerator pedal The accelerator pedal is located at front right of the driver’s seat. When it is in natural position, the engine will be in idle state. Depress the accelerator pedal and fuel supply quantity of the diesel engine will be increased to raise its power output.

Engine shutdown of this machine is enabled by electric cut-off. When the engine is running, turn the starting switch key counterclockwise to “STOP” position and the engine will shut down.

Service brake pedal Accelerator pedal

Gearshift lever It is installed below the steering wheel.

The forward I gear, forward II gear, reverse gear and neutral position of the vehicle can be controlled respectively by moving the lever forward and backward.

Notices When the shift control system of the vehicle is malfunctioning, please do not remove it without permission!!!

In the case of troubleshooting failure, please contact an authorized service station or after service company of Hyundai Construction Equipment co., Ltd.. for servicing issues.

Gearshift lever Control lever

Control lever The working device control lever is installed at right side of the driver’s seat to control working of the device.

Moving the inside lever to the forward or backward can control movement of the bucket; moving the outside lever forward and backward can control movement of the boom; When the engine is running, push the inside lever to the forward and the bucket will tilt forward; push it to the back and the bucket will tilt backward. Pull the outside control lever back, the boom will lift; push it forward, the 39

Operation and Maintenance Manual boom will fall; continue to push it forward, the boom will enter floating position. (Neutral position is the initial relative position)

Warning Before operating the boom and bucket, you must confirm that obstacles or persons are kept out of the areas around, on and under the vehicle in spite of its state; otherwise, equipment damage even personal injury and death may result!!!

Electric appliances, light fittings and switches The light fittings on the machine fall into front combined light (each at LH/RH), rear combined light (each at LH/RH), interior light, work light (each at LH/RH), and rear work light (each at LH/RH).

In the arrangement, the front combined light includes headlight and front turn light while rear combined light includes rear turn light and brake light.

The turn lights are controlled by the combined switch under the steering wheel.

In addition, the machine electric appliances also include fan, wiper, radio and flashing caution light, etc.

Front combined light, work light and fog light

Interior light

Rear combined light

Rear work light

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Operation and Maintenance Manual Flashing caution light

Fan

Radio

Wiper

Combined switch

Rocker switch assembly and instrument assembly

Functions of rocker switch (from left to right as shown in above instrument panel) 1. Front work light switch The front work light switch controls left and right front work lights to come on or go out simultaneously.

2. Front fog light switch The front fog light switch controls left and right front fog lights to come on or go out simultaneously.

3. Rear work light switch The rear work light switch controls left and right rear work lights to come on or go out simultaneously.

4. Interior dome light switch The interior dome light switch controls the cab interior dome light to come on or go out.

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Operation and Maintenance Manual 5. Flashing caution light switch The flashing caution light switch controls the flashing caution light on top of the cab to come on or go out.

6. Electric fan switch The electric fan switch controls turn on or off of the fan on right side of the cab.

7. General power switch The general power switch controls turn on or off of machine power supply.

8. Electro lock The electro lock controls start and shutdown of the diesel engine.

9. In addition, 4 switch hole sites are reserved for later extension as needed.

Instrument assembly The instrument assembly comprises 6 pointer type indicating instruments: (as shown in above figure, from left to right) power machine oil pressure gauge, power machine coolant temperature gauge, torque converter oil temperature gauge, transmission oil pressure gauge, braking system air pressure gauge, and working hourmeter.

1. Power machine oil pressure gauge : Normal working range: 0.25Mpa ~ 0.4Mpa. 2. Power machine coolant temperature gauge Normal working range: 60℃ ~ 100℃. When the coolant temperature is above 100℃, the pointer will point to the red warning zone.

Notices When indicated value of engine coolant temperature is a little high, please park your vehicle at a safe place where is convenient for servicing, and then check engine radiator fan, belt and coolant level in radiator. You can not continue to drive or work until the trouble is cleared.

3. Torque converter oil temperature gauge Normal working range: 40℃ ~ 120℃. When the oil temperature is above 120℃, the pointer will point to the red warning zone.

Notices When indicated value of torque converter oil temperature is a little high, please park your vehicle at a safe place where is convenient for servicing, and then check transmission and transmission oil level. You can not continue to drive or work until the trouble is cleared.

4. Transmission oil pressure gauge Normal working range: 1.1Mpa ~ 1.5Mpa.

Notices When indicated value of transmission oil pressure is a little high, please park your vehicle at a safe place where is convenient for servicing, and then check transmission and transmission oil level.

If oil is insufficient, immediately add. You can not continue to drive or work until the trouble is cleared.

5. Braking system air pressure gauge Normal working range: 0.4-0.8MPa. When the air pressure is below 0.4MPa, the pointer will point to the red warning zone.

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Operation and Maintenance Manual

Warning When indicated value of brake pressure is a little low, please stop your vehicle immediately to check; otherwise, accident may occur due to braking failure.

Do not continue to work or drive until the trouble is cleared.

6. Left turn indication When the vehicle turns left, the turn light will come on and so will the indicator light.

7. Right turn indication When the vehicle turns right, the turn light will come on and so will the indicator light.

8. Working hourmeter Combined switch Overtake High beam

Wash

Low beam

Right direction Wiper control switch OFF position Turn light control switch Left direction

Low Speed position High Speed position

The combined switch is located below the dashboard and its controls are shown in above figure. Such functions as left and right turn indications of the turn lights as well as “HIGH”, “LOW” and “WASH” of the wiper can be controlled through the shift lever; high and low beams of front combined headlight can be controlled through the selector lever.

Fuse box The fuse block is located on middle lower part of the instrument panel shown above. There are 8 groups of resistance wires having different rated currents in the box for overload protection of machine electric appliances.

Indicator lights The indicator lights are located exactly above the fuse box. There are 4 groups of indicator lights in total with 2 lights in each group. They are (from left to right): 1. Upper-Left turn indication 2. Upper-High beam indication

3. Upper-Spare

1. Lower-Brake indication

3. Lower-Filter element clogging indication

2. Lower-Charge indication

4. Upper-Right turn indication

4. Lower-Hand brake indication

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Operation and Maintenance Manual

Horn switch The horn switch on this machine is located at center of the steering wheel. It will sound after depressed.

Heater unit This machine is provided with an air conditioning on which you can select cooling and heating as needed.

Depress the button and the A/C will start to work.

A/C switch and cooling/heating selecting switch

A/C condenser

Adjustment of longitudinal separations of driver’s seat There is a handle on left lower side of the driver’s seat. Pull the handle towards outside of the driver’s seat and then the seat can be moved longitudinally, during which you can feel obvious locking positions. Loosen the handle and the seat will be fixed in a locking position. The seat on this machine can be moved forward or backward and its angle can also be adjusted, but it can be fixed in a locking position only.

Adjusting handle

Use of entrance door lock The keys for left and right entrance door locks of the cab on this machine are same. If the entrance door lock is in LOCK position, the lock core can not be depressed. To open the door at the time, insert the key, turn it 180° clockwise before drawing it out, hold the door lock by hand, and then press down the lock core with your thumb while pulling the door outwards. To lock the entrance door lock, close the vehicle door first, then insert the key and turn it 180° counterclockwise before taking it out.

44

Operation and Maintenance Manual Use of entrance door lock

Positioning lock

Use of positioning lock When left/right door is opened 180°, the positioning lock on the door will touch the lock catch at outside of the cab and get stuck so that the door will be fixed in this position. The control lever of the positioning lock is on right part of the door. When the positioning lock is in locked position, press the lever down once and the positioning lock will loosen. Then, you can close the door simply.

Warning When the driver operates this machine to work, he/she must close both left and right doors to ensure safety.

Rear-view mirror adjustment There is a rear-view mirror above the cab at each side of this machine. Before operating this machine to work, both rear-view mirrors must be adjusted to ensure that the driver has a good rear visibility.

Unscrew the bolt connecting the rear-view mirror support with the cab, and then turn the support to adjust the position of the rear-view mirror relative to the cab; unscrew the bolt connecting the rear-view mirror with its support, and then turn the rear-view mirror to adjust its elevation angle. After above adjustment is completed, tighten the bolts.

Rear-view mirror

Interior rear-view mirror

Use of wiper This machine is equipped with a wiper of which the control switch is located on right lower side of the cab front desk. After depressed, the wiper will start to work.

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Operation and Maintenance Manual

Use of electric fan The electric fan button on this machine is installed on right lower side of the cab.

Electric fan button

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Operation and Maintenance Manual

Running-in of a new vehicle Running-in of a new vehicle is very important for prolonging a machine’s service life, eliminating potential failures and avoiding major failures. Customers must operate, service and maintain their machines in accordance with the provisions on running-in of new vehicles in this manual after their purchases before normal use.

Requirements for running-in of a new vehicle 1. The duration of running-in for a new vehicle is 12h in total.

2. During the running-in period, even running-in should be arranged in each of forward I and II gears and reverse gear.

3. The vehicle should start smoothly at low speed with a small throttle opening and then accelerate step by step.

Unless in emergency, you should avoid sudden start, acceleration, turning and braking.

4. Within the running-in period, it is advisable that the vehicle should load loose materials and not be too hard and fast during operation. Within the running-in period, the vehicle’s loaded weight can not exceed 70% its rated payload and its travel speed can not exceed 70% its rated maximum vehicle speed.

5. Pay attention to lubrication condition of the machine and change or add lubricant and grease at the specified time intervals.

6. Be sure to check transmission, torque converter, front/rear axle, wheel hub, parking brake, and intermediate support shaft as well as temperatures of hydraulic oil, engine coolant, and engine oil on a regular basis. If overheat is found, locate the causes and troubleshoot.

7. Check tightening of bolts and nuts on all components.

After 8h running-in for a new vehicle, carry out the following items: 1. Check tightening of bolts and nuts on all components thoroughly.Especially, check all of diesel engine cylinder head bolts, exhaust pipe bolts and front/rear axle retaining bolts, rim nuts, propeller shaft joint bolts, diesel engine retaining bolts, transmission retaining bolts, bolts at front/rear frame articulation, etc. once.

2. Check tightness of fan belt, generator belt, and A/C compressor belt.

3. Check transmission oil level, drive axle oil level and diesel engine oil level.

4. Check leak tightness of hydraulic system and braking system.

5. Check connection and fixation of all control rods and the accelerator rod.

6. Check temperature and connection of each component in the electrical system, power supply state of the generator, and operation of light illumination and the directional signals, etc.

Notices When checking levels of various oils, follow related working regulations.

Perform the following items after finish of the running-in for a new vehicle: 1. Check tightening of bolts and nuts on all components thoroughly. Especially, check all of diesel engine cylinder head bolts, exhaust pipe bolts and front/rear axle retaining bolts, rim nuts, propeller shaft joint bolts, diesel engine retaining bolts, transmission retaining bolts, bolts at front/rear frame articulation, etc. once.

2. Check tightness of fan belt, generator belt, and A/C compressor belt.

3. Check leak tightness of hydraulic system and braking system.

4. Change transmission oil and drive axle lubricant.

5. Replace elements of transmission oil filter, diesel engine oil filter and diesel oil filter.

6. Clean oil return filter element of hydraulic oil tank.

Notices When changing transmission oil, drive axle lubricant and diesel engine oil, follow related operating rules.

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Operation and Maintenance Manual

Machine operation Checks before engine start 1.

2.

3.

4.

5.

Check engine coolant level Check engine oil level.

Check oil level in hydraulic oil tank.

Check leak tightness of all oil pipes, water pipes and components.

Check battery wiring. If connections between battery poles and cables are found loose, please tighten them immediately.

6. Check for normal tire pressure.

Engine start 1. Ask the personnel around the loader to leave and the obstacles in the travel direction should be cleared; observe if any repairman is under the vehicle; no one is allowed to stand on any part of the machine or sit in the cab, except that the driver can sit in the cab to operate.

2. Confirm that the negative switch is ON. 3. Walk up/down the staircase in accordance with related safety rules.

4. Adjust the rear-view mirror so that you can obtain a good rear visibility and it is as close to the machine as possible.

5. Close left and right doors of the cab properly.

6. Confirm if the gearshift lever is in neutral position.

7. Confirm if the working control gear is in neutral position.

8. Check if the hand brake gear is in disengaged position.

9. Depress the power switch, insert the key into the electro lock and turn it for one stop clockwise to turn on machine power supply, then sound the horn to “announce� that this machine is about to start and keep others off.

Power switch and electro lock Hand brake gear is in disengaged position

10. Check oil quantities.

11. Depressing the accelerator pedal slightly and then turning the key further for another stop clockwise will turn on the starting motor of the diesel engine. Under normal conditions, the engine will get started to work within 10s, and then you should release the key immediately to allow the electro lock to return.

Notices The duration for one start should not exceed 15s (the continuous working time of the starting motor should not exceed 15s). After that, if the engine still can not work normally, release the starting switch immediately and 48

Operation and Maintenance Manual wait more than 30s before another attempt. If the engine fails to start after successive 3 attempts, check and troubleshoot, and then wait at least 3 minutes before another attempt.

12. After the engine is started, warm it up under idle speed (600~750r/min). Wait and do not allow it to run under full load until engine coolant temperature reaches 55℃ and engine oil temperature reaches 45℃.

13. When the engine is running at low speed, listen attentively to whether it runs and the transmission works normally.

14. Check all meters and equipment for normal operation.

Notices Pay extra attention to indicated value of engine oil pressure. The value should not be below 0.07Mpa (under idle speed); if under this value, stop the vehicle to check the engine for malfunction.

15. In severe cold seasons, warm up the hydraulic oil. Pull the bucket control lever back and hold 4~5 minutes, at the same time, accelerate to lean the bucket stopper against the boom to make hydraulic oil overflow so that hydraulic oil temperature will rise rapidly.

16. Check the service braking and parking braking systems for normal operation.

17. If there are no obstacles around the machine, turn the steering wheel slowly and observe the machine for left/right turn actions.

Machine driving operation 1. Operate the working device control lever to tilt back the bucket until its limit position; lift the boom to carry position, i.e. a position when the ground clearance of the boom lower hinge point is about 400mm.

Bucket in carry position

2. Depress the service brake pedal, at the same time, confirm that the hand brake is OFF and the parking brake is in released state. Loosen the service brake pedal slowly while observing if the machine can move.

Warning If the machine moves, please depress the service brake pedal immediately and then pull up the parking brake lever to apply brake. Then, check the shift control system on this machine for malfunction. If the machine is on a slope, please block the wheels first to prevent the machine from move and then check the machine.

3. Push the gearshift lever forward to forward I gear or pull it back to reverse gear, at the same time, depress the accelerator pedal, and then the machine can advance or back up.

4. Drive the machine to an open and flat ground. If steering behavior check is not performed during the operations in last stage due to narrowness of site, then you should turn the steering wheel to check if the machine can turn left 49

Operation and Maintenance Manual and right in situ.

5. Check service braking performance. On an open and flat ground, drive the machine to travel at forward I or II gear speed, then loosen the accelerator pedal first and depress the service brake pedal gently, at the time, the machine should decelerate visibly and come to a stop.

Notices If you can not feel that the machine is decelerating visibly after the service brake pedal is depressed, please use the hand brake gear immediately to apply emergency brake. At the same time, operate the boom control lever to lower the boom to its lowest position and tilt the bucket forward until the bucket teeth or edge cuts in or hold the ground to ensure safety.

6. Check engagement in each gear. Drive the machine to an open and flat ground, and then engage each gear respectively to check shift response of the machine.

7. Steering operation of the machine.

When turning is required because a bend appears ahead in the travel direction of the machine, please follow related local laws and regulations to operate.

When the machine is about to turn, set the turn light switch to corresponding position first. As shown in the figure below, at the time, the front and rear turn lights at the corresponding side of the machine and the corresponding turn indicator light on the instrument assembly will come on to warn the adjacent vehicles and passersby ahead and behind that this machine is about to turn. Then, when you turn the steering wheel towards the side to which the machine will turn, a machine turning will begin.

Steering operation

The machine uses a fully hydraulic coaxial flow-amplified steering system, in which the angle the steering wheel turns is not equal to the steering angle of the machine. You can turn the steering wheel continuously to increase the steering angle until the desired steering position is reached. The quicker the steering wheel is turned, the higher the steering speed of the machine will be.

The steering wheel will not return automatically after turned and the steering angle of the machine will keep constant. Therefore, after a machine turning is completed, you should turn the steering wheel reversely to eliminate the relative angle between front and rear frames of the machine enabling it to travel in a straight direction. After a steering operation is completed, set the turn light switch to neutral position, and then the turn lights and turn indicator light will go out. Before a steering operation under high travel speed, you must loosen the accelerator pedal first.

When necessary, slow down first before turning so as to ensure safety.

Warning Turning on a slope is strictly forbidden.

8. Machine braking When you arrest the machine, loosen the accelerator pedal first, and then depress the brake pedal gently to apply service brake.

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Operation and Maintenance Manual

Warning When the machine is running under high speed, unless in emergency, do not depress the brake pedal to the floor suddenly so as to avoid the safety accidents and machine damages caused by sharp braking.

Machine parking 1.

2.

3.

4.

5.

6.

7.

Drive the machine to a flat ground where should have no hazards of rockfall, landslide or floor.

Apply service brake to stop the machine.

Set the gearshift lever to neutral level.

Pull up the parking brake control lever to apply parking brake.

Operate the lever to lower the boom and place the bucket flatly on the ground, and then depress the bucket slightly.

Run the engine at idle speed for 5 minutes to allow all parts to cool evenly.

Shut down the engine, turn the electro lock key to “OFF” position to cut off machine power supply, and then draw out the key.

8. Turn general power switch to “OFF” position all other switches to neutral position or “OFF” position.

9. Close left and right doors properly and then walk down the staircase in accordance with related regulations.

10. If the machine is to be parked for an extended period of time (i.e. overnight), open back door of engine hood to turn the power supply negative switch to OFF. 11. If no antifreeze is added at delivery of the machine, after parking in winter, open all water drain valves on the engine immediately to drain all coolant in evaporators of cooling system and A/C system so as to prevent engine body from frost cracks. If the machine has been filled with antifreeze at delivery, please follow related instructions.

12. Lock up all devices properly, and then take off the key and carry it with you.

Notices Park the machine on a flat ground. If you have to park the machine on a slope, hold wheels using wedges to prevent the machine from move.

If the machine requires a long-term storage, follow the requirements below to operate: 1) Before storage  Clean each portion of the vehicle, air-dry and then store them in a dry storeroom. If the vehicle has to be stored in open air, park it on a concrete ground where is easy to discharge water, and then cover it with canvas.  Before storage, fill the fuel tank, fill each moving pin driving shaft with grease, and change hydraulic oil.  Set the gearshift lever to neutral level.  Pull up the parking brake control lever to apply parking brake.  Place the bucket on the ground flatly, and turn the control lever to neutral position.  Turn each switch to neutral position or “OFF” position, and lock all doors properly.  Coat the exposed portion of the hydraulic cylinder piston rod with a thin layer of grease.  Remove the battery from the vehicle and store it separately.  If air temperature is likely to drop to below 0℃, add antifreeze in engine coolant and ensure that the antifreeze can reach the engine body and the evaporator in the A/C system. Or you can drain the water in the cooling system; remember to drain the water in the evaporator of the A/C system too.  Use the frame fixing bumper to fasten front and rear frames.

2)

During storage

 Start the vehicle monthly to run each system and fill each moving pin and driving shaft with grease so as to lubricate 51

Operation and Maintenance Manual all moving parts. At the same time, the battery will be charged.  Before vehicle start, wipe off the grease on the hydraulic cylinder piston rod. After the operations are finished, apply a thin layer of grease again.  Coat the corrosion susceptible places with antirust.

Notices If using antirust indoors, open doors and windows to keep ventilated so as to discharge poisonous gas.

3)

After storage After a long-term storage of the machine is finished, operate as follows:

 Change lubricants in engine, transmission and drive axle as well as hydraulic oil and antifreeze.  Fill all moving pins and driving shafts with grease.  Before vehicle start, wipe off the grease on the hydraulic cylinder piston rod.

Machinery operation 1. Preparation before a job Before working, first use this machine to level off the job site, delete bosses, fill and level up pits, eradicate wet and slippery ground surface layer, and clean up big and sharp stones on the ground to avoid tire scratches.

If the machine is used to load trucks or bunkers with materials or unload materials from them, adjust the boom lift limiter (if equipped) according to heights of the trucks or bunkers so as to ensure that the loader’s bucket can get in and out them safely without causing the damages resulted from shock of the materials due to unloading clearance excess to them.

2. General techniques  General digging and loading method The General digging and loading method is suitable for digging and loading loose materials.

Let the loader approach to the material at forward II gear speed and aim middle part of the bucket at the material pile.

Then, the driver should hold the steering wheel with left hand while operating the boom control lever to lower the boom until its ground clearance is 500mm.

When the machine is around 1m from the material pile, lower the boom again to allow the bucket to touch down, and then shift the machine from forward II gear to forward I gear.

Notices When the bucket touches down, avoid it applying excessive pressure to ground which could generate unnecessary advance resistance. In addition, front and rear frames of the loader should be placed straightly without leaving an included angle between them.

Depress the accelerator pedal, let the bucket cut in the material pile at full tilt; when the machine can not advance further, the driver should pull the control lever to the left once to allow the bucket to tilt back slightly, and then push the control lever back to neutral position to allow the machine to cut in the material pile forward further. Repeat such cut in and bucket tilt operations until the bucket is filled with material.

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Operation and Maintenance Manual  Bucket cuts in and tilts back loading method)

Bucket cuts in, lifts and tilts back (joint digging and

 Joint digging and loading method The joint digging and loading method is suitable for digging and loading hard or highly viscous materials.

The operations before the bucket cuts in the material are the same as those in general digging and loading method.

When the bucket can not advance further after cutting in the material pile, the driver should pull the control lever back once with right hand and then push it back to neutral position to lift the bucket slightly allowing the bucket to cut in forward for another length. Then, the driver should pull the control lever to the left once and then push it back to neutral position allowing the bucket to tilt back slightly to continue cut in forward. Repeat such cut in, bucket lift, cut in and bucket tilt operations until the bucket is filled with material.  Exiting from material pile After the bucket is filled with material, the driver should operate the control lever to tilt the bucket back until the stopper on the bucket touches the boom and then pull the control lever back to neutral position. At the time, the maximum rollback angle of bucket is obtained.

When backing up the machine with the boom lifted to a certain height, the bucket can avoid the material pile.

The driver can hold the steering wheel with right hand and pull the gearshift lever to reverse position with left hand to control the machine to back up.

After the machine withdraws from the material pile, the driver should operate the control lever to lower the boom until the ground clearance of the boom lower hinge point is around 400mm.  Material conveyance In any of the following cases, self-carry is applicable: 1) On a soft road surface or not leveled off ground where motor trucks are inapplicable.

2) Carry distance is within 500m, so, transport using a motor truck is uneconomical.

During carry, keep the boom lower hinge point in carry position (ground clearance: approx 400mm) and tilt the bucket back to its limit position (bucket stopper touches the boom) so as to ensure smooth and safe carry and reduce occurrences of material sprinkle.

The vehicle speed for carry is determined according to carry distance and road surface conditions. When the machine gets across a pit or boss, ease up on the accelerator pedal and, when necessary, use service brake to “snub” to get across the obstacle slowly at reduced vehicle speed so as to reduce impact on the machine and occurrences of material sprinkle.

Warning Carry operation with bucket lifted to a high position is forbidden; otherwise, machine turnover may result.  Unloading 1) Unloading to a truck or skip When the material-laden loader is 15m from the truck or bunker, ease up on the accelerator pedal and, when necessary, use service brake to “snub” so that the machine can approach to the truck or bunker at reduced travel speed. At the same time, the driver should pull the control lever back to extreme position, and the boom will keep on rising. After the boom reaches its limit height, pull the control lever back to neutral position, and the boom will stop rising. During this course, the driver should drive the machine with care, observe movement of the bucket 53

Operation and Maintenance Manual carefully when it approaches to the truck or bunker and not allow them to collide with each other.

When the bucket is exactly above the truck or bunker, the driver should depress the brake pedal to stop the machine. Then, push the control lever to the left to allow the bucket to tip forward dumping the material into the truck or bunker. At the time, the driver should observe movement of the bucket carefully and not allow the bucket to collide with edge of the truck or bunker. If the material is highly viscous, push the control lever to the left or right repeatedly to allow the stopper on the bucket to strike on the boom again and again making the material adhering to the bucket fall off.

If the body length of the truck is greater than double width of the bucket, unloading should begin at fore part of the body.

Unload to a truck

Notices When unloading, the striking force between the stopper of the bucket and the boom should not be too big and there should be no too many impacts, so as to avoid machine damage.

After machine unloading is finished, the driver should pull the control lever to the left to extreme position to allow the bucket to roll back continuously until horizontal position and then push the control lever to neutral position. Then, the driver should pull the gearshift lever to reverse position and then loosen the brake pedal to allow the machine to leave the truck or bunker. When the machine leaves the truck or bunker, the driver should drive the machine with care and observe departure of the bucket from the truck or bunker and not allow them to collide with each other. After the bucket disengages from the truck or bunker completely, the driver can lower the boom while driving the machine to prepare for the next job cycle.

2) Unloading at low position During material carry between sites, sometimes low-position unloading, i.e. unloading with a small ground clearance of bucket, is required. At the time, after unloading is finished, roll back the bucket until horizontal position first and then lift the boom; otherwise, it is unlikely to be lifted up due to interference with the working device linkage. ď Ź Pushing operation Let the bucket snug flatly with ground, set the gearshift lever to forward I gear, and depress the accelerator pedal to enable the machine to push forward. During pushing, if any obstacle that hampers advance of the machine is found, move on with the boom lifted slightly. When controlling the boom to rise and fall, move the control lever between FALL and RISE and do not set it to any of the two positions so as to ensure that the pushing operation can be carried out in a smooth way.

Pushing operation Striking off operation

ď Ź Striking off operation Lift the boom and tilt the bucket forward until the blade touches down with the included angle between the blade and the ground maintained at around 64Âş. In the case of hard road surfaces, the control lever should be set to FLOAT position; in the case of soft road surfaces, the control lever should be set to neutral position. Pull the shift lever to reverse gear and depress the accelerator pedal to back up the machine while striking off the ground with the blade.

54

Operation and Maintenance Manual  Towage A 20t towing flat wagon can be provided for towed carry. Steps: 1)

Connect the towing flat wagon to the traction pin of this machine firmly.

2)

A high-performance braking system should be equipped on the towing flat wagon.

3)

Set the bucket in carry position.

4)

It is required that you operate gently during starting and parking and remember to apply brake before driving downslope.

Notices When applying brake, do this to the towing flat wagon first and then this machine.

3. Operation methods  V-shaped operation method As shown in the figure below, let the loader face against the material pile with a 60º included angle formed between the truck and the loader’s travel direction and keep still at a place 12~15m from the material pile. After the loader is filled with material, back it up directly to a place 12~15m from the material pile, and then make a turn while driving towards the truck; at the same time, you can lift the bucket. After material unloading is completed, move back to the original position, and then start the next operation.

V-shaped operation method

Shuttling operation method

 Shuttling operation method The shuttling operation method is mainly used in teamwork between the loader and a fleet. As shown in the figure below, after the loader is filled with material, back it up until a distance of 2~3 truck widths is left. Then, drive from one side to front area of the loader and stop. Let the loader advance further and lift the boom. After unloading is completed, back up the loader to its home position. If the truck is still not laden, let it go forward for a parking stall.

When the loader backs up to its home position after its next digging and loading, the truck not laden will withdraw to front area of the loader which will carry out another unloading. Repeat thus until the truck is laden and loading of next truck will begin. This operation method requires experienced cooperation between the driver of the loader and the drivers of the trucks. They should use horns, lights and gestures to communicate each other when necessary.

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Operation and Maintenance Manual

Operations in cold weather Precautions under low temperature If ambient temperature is too low, the engine will be difficult to start up and the radiator may get frozen. Therefore, the following points should be observed: 1.

Use less viscous fuel, hydraulic oil and lubricant to all parts and add antifreeze in water coolant. Refer to “Oil Specifications” in the “Operation and Maintenance Manual” for brands of the specific oils applicable.

2.

Precautions for use of antifreeze:

 Do not use any antifreeze containing methanol, ethanol or propanol.  Never use leak preventive whether it is used separately or together with antifreeze.  Hybrid use of antifreezes of different brands is not allowed.  When changing antifreeze, please refer to the instructions on the name plate at vehicle tail for use of the antifreeze.

Notices Keep antifreeze away from open flame and do not smoke during antifreeze fill.

3.

Precautions for use of battery:

 As ambient temperature drops, battery capacity will also decrease. If charging rate of a battery is low, its electrolyte may get frozen. Keep charging rate as close to 100% as possible and preserve heat to the utmost so that the engine can be started easily in the next day.  In high-cold areas, use high-cold resistant battery.

Precautions after finish of daily work To prevent the sludge, water or snow adhered to the machine from freezing which will affect vehicle start in the next day, do the following: 1. Clean up the sludge, water and snow on the machine thoroughly. Avoid damage to sealing performance caused by entry of sludge, water or snow into seals and freezing there.

2. Park the vehicle on a dry and hard ground. If impossible, park it on a wood board. Use of wood board can prevent the vehicle from being frozen on the ground so that vehicle start in the next day will become easier.

3. Under low temperature, battery capacity will drop significantly with extension of parking period; so, cover the battery or move it to a warm place and install it during operation in the next day.

After cold weather After weather warms with seasonal change, do the following: 1. Replace fuel, hydraulic oil and lubricant of all components with semi viscous oils. Refer to “Oil Specifications” in the “Operation and Maintenance Manual” for brands of the specific oils used.

2. If permanent antifreeze is not used, be sure to drain all water in the cooling system, clean the system, and replace with fresh water coolant.

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Operation and Maintenance Manual

Machine transport Before shipment, survey heights, widths and throughput payloads of the channels in the transport route. The total height, width and weight, etc. after this machine is placed on the transport vehicle can not exceed related regulations.

In the case of height or width excess, please consult Hyundai Construction Equipment co., Ltd.. or an agent of the company for solution.

To prevent safety accidents caused by slip of the machine during shipment, clear docks and train wagons of ice and snow and other slippery materials before the shipment.

Notices When shipping, please observe related national and local laws and regulations on height, width, length and weight of the shipment.

The shipment shall be made in accordance with the following procedure: 1. Before shipment, block wheels of the towing vehicle or truck with wedges properly (the towing vehicle is shown in the figure).

Block wheels of towing vehicle with wedges properly

2. When you drive the machine onto the towing vehicle or truck, halfway steering operation is not allowed. If you have to carry out the operation, back up the vehicle to a flat ground, and then perform the steering operation.

3. After the machine is parked properly, use the frame fixing bumper to fasten front and rear frames.

4. Place the bucket flatly on the transport vehicle and set the gearshift lever to neutral position.

5. Pull up the parking brake lever to apply parking brake.

6. Shut down the engine and turn all switches to neutral position or “OFF” position. Take out the electro lock key.

7. Close and lock all doors properly, and take out the key.

8. Turn the power supply negative switch to open (“OFF”) position.

9. When the machine is transported using a truck or towing vehicle, block wheels with wedges and fix the machine with wire cables properly to prevent it from move during transport.

Hoisting the machine 1. Have the job directed and handled by the professionals who possesses hoisting knowledge.

2. To ensure hoisting safety, check and calculate maximum hoisting weight of the crane and bearing capacity of the sling (hoisting weight of this machine is 17300±5%kg). Also, lengths of the four hooks on the sling should be equal so as to ensure that the hooks will receive forces uniformly during hoisting.

3. Before hoisting, do the following preparations properly:  Set the gearshift lever to neutral position.  Place the boom and bucket to lowest position.  Pull up the parking brake lever to apply parking brake.

57

Operation and Maintenance Manual Cut off the engine and take out the electro lock key.  Close and lock all doors properly.  Turn the power supply negative switch to open (“OFF”) position.  Keep the machine from turn by fastening front and rear frames with frame fixing bumper.

4. Secure the sling firmly on the hangers on the machine where are indicated using hoisting labels.

Warning Incorrect hoisting may cause machine offset resulting in personal injury and loss.

Towing a faulted machine 1. Unless in emergency, this machine can not be towed. Towing is used to haul this machine to a place where it can be serviced only and does not apply to long-distance move. Trail distance of this machine should not exceed 10km and its speed should not exceed 10km/h during towing; otherwise, the transmission will be damaged due to insufficient oil supply. If a long-distance move is a must, use a special-purpose towing vehicle.

Warning

2.

3.

4.

5.

6.

7.

8.

9.

Towing an inoperative machine incorrectly will result in personal injury and death. Towing a faulted vehicle on a bad road surface will cause it to be damaged seriously further.

Brakes will be inoperative if braking system is malfunctioning, then extra care should be taken during towing.

Notices Before releasing the parking brake, block wheels of the machine with wedges properly to prevent it from move. If the machine is not blocked properly, it will slip. Do not remove the wedges until start of the towage.

No one is allowed to sit on the machine towed, unless the driver can control direction and brakes.

Before towage, ensure that the towline or towbar is in good condition and is strong enough to tow the machine.

Strength of the towline or towbar used should at least be 1.5 x gross weight of the machine towed so that it can pull the machine out of a slob or up a downslope.

Maintain the minimum angle of the towline. The position angle between a towline and the exact frontage should not be greater than 30°.

Too high travel speed of the machine will cause the towline or towbar to break. Moving the machine slowly and smoothly ensures better working effect.

When towing, keep people away from both sides of the towline to prevent the injury caused by broken towline.

Under normal conditions, size of the towing vehicle should be equal to that of the machine towed. Ensure that the towing vehicle has enough braking capacity, weight and power to control runup and travel distance, etc. of the two machines.

When the machine towed goes downslope, to ensure enough control and braking capacity, a major towing vehicle or other machine should be connected to rear of the machine towed so as to prevent the machine towed from rolling off in the case of out of control.

If direction of the machine towed can be controlled by the driver, he/she must steer along direction of the towline.

58

Operation and Maintenance Manual

Maintenance Manual

Notices During use of this machine, please maintain it according to the maintenance periods and procedures specified in this manual. Good maintenance to the machine is very important for extension of service life of the machine and assurance of operation safety.

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Operation and Maintenance Manual

Periodic maintenance The maintenance cycles listed in this manual are determined using work or calendar (day, week, month, etc).

Hyundai Construction Equipment co., Ltd.. requires that the maintenance work be carried out according to any of the two types of time cycles mentioned above (whichever comes first). Under extremely inclement, dusty or humid working environments, you should carry out the lubrication maintenance more frequently than the conditions specified in the section “Routine Maintenance�. During maintenance, repeatedly perform the maintenance items listed in the former requirements. For example, when you perform the 600 working hours or quarterly maintenance items, carry out the items listed for 300 working hours or monthly, 100 working hours or weekly, and 10 working hours or daily maintenances at the same time.

Every 10 working hours or daily maintenance 1. Check engine oil level.

2. Check coolant level.

3. Check hydraulic oil level.

4. Check fuel level and the clear water and foreign substances in the fuel prefilter and that on the engine.

5. Visually inspect around the machine to check all systems for abnormal situations and leakage.Visually check engine fan and the drive belt.

6. Check operation of lights, instruments, switches, pedals, levers and buttons.

7. Check tire pressure and damage.

8. Check operation of the back-up alarm.

9. Check and adjust travels of throttle, brake control lever, working and shift control cables; check for smart operations.

10. Grease all driving shafts.

Every 100 working hours or weekly maintenance Perform the inspection and maintenance items described above first.

1. Check transmission oil level.

2. At the first 100 working hours, check clearance between parking brake and brake disc; if inappropriate, adjust.

After that, check every 300 working hours.

3. Tighten coupling bolts of all driving shafts.

4. Keep terminals of battery clean and apply Vaseline on them to protect from corrosion caused by acid fog.

5. Check lubrication status of all lubrication points and grease them according to the instructions on the machine lubrication diagram posted on the machine.

6. On the work day when the first 100 hours are reached, clean transmission oil filter and change transmission oil, torque converter oil and radiator oil. After that, change transmission oil every 1200 working hours. If the specified working hours are not reached, transmission oil should also be changed at least yearly.

7. Change drive axle gear oil on the work day when the first 100 hours is reached. After that, change drive axle gear oil every 1200 hours. If number of working hours does not reach that value, drive axle gear oil should also be changed at least yearly.

8. Clean up engine cylinder end.

9. Clean up radiator panel.

10. Clean filler strainer of diesel oil tank.

11. Check oil level in brake booster.

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Operation and Maintenance Manual

Every 300 working hours or monthly maintenance Perform the inspection and maintenance items described above first.

1. Check tightening torques of rim retaining bolts and axle bolts.

2. Check tightening torques of mounting bolts of transmission and engine.

3. Check all stressed weld joints and retaining bolts on working device and front and rear frames for cracks and looseness.

4. Check oil levels in front and rear axles.

5. Visually check service indicator of air cleaner. If the yellow piston of the indicator rises into the red area, clean or replace the air cleaner element.

6. Check engine intake system.

7. Replace engine oil and oil filter.

8. Replace engine coolant filter.

9. At the first 300 working hours, clear the return oil filter element in the hydraulic system.After that, replace the return oil filter element in the hydraulic system every 1200 working hours.

10. Check tension and damage of engine drive belt and A/C compressor belt.

11. Test service braking and parking braking capacities. Remember to drain water from air reservoir daily.

12. Check oil level in brake booster.

Every 600 working hours or quarterly maintenance Perform the inspection and maintenance items described above first.

1. Check concentrations of antifreeze and coolant additive.

2. Replace fuel prefilter in diesel oil tank and primary and secondary fuel filters on engine.

3. Tighten the bolts connecting front and rear axles with frame.

4. Check retaining bolts of frame articulation pin for looseness.

5. Replace transmission oil and oil filter.

6. Check structures, hood and cab for cracks.

7. Check wear of all hinge points; check if grease fill is unobstructed.

8. Check for normal tire pressure.

9. Clean brake master cylinder, service booster pump, and change brake oil (hybrid use of two types of oils is not allowed).

10. Check wear of brake disc and brake block (≤2/3).

11. Refill steering gear with lubricant; test steering system pressure.

12. Check oil level in brake booster.

Every 1200 hours or semiyearly maintenance Perform the maintenance items described above first.

1. Adjust engine valve clearance.

2. Check engine tensioner bearing and fan shaft casing.

3. Change drive axle gear oil.

4. Clean hydraulic oil tank, change hydraulic oil, and replace return oil filter element in hydraulic system.

5. Clean fuel tank.

6. Tighten all retaining bolts of battery and clean battery top.

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Operation and Maintenance Manual

Every 1800 hours or yearly maintenance Perform the maintenance items described above first.

1. Check engine cushion.

2. Replace coolant and coolant filter and clean cooling system. If working hours are inadequate, coolant should also be changed at least biyearly.

3. Change hydraulic oil, clean oil tank and check oil suction pipe.

4. Check operation of service braking system and parking braking system; when necessary, disassemble to check wear of friction plate.

5. Check leak tightness of distributing valve and working cylinder by measuring natural sink of cylinder.

6. Check mobility of steering system.

Important maintenance procedure Engine coolant maintenance Proper maintenance to engine cooling system is very important. Overheating, supercooling, pitting corrosion, cavitation erosion, cylinder end cracks, piston seizure and radiator clogging are common faults in the cooling system.

These faults could not only reduce the engine’s working efficiency but also cause serious damage to the engine.

Composition of coolant Engine coolant is a mixture mainly composed of cooling water, antifreeze and additives.

Cooling water The cooling water used in the coolant must be “soft water”, e.g. main water or distilled water. After mixing of hard water or the water with high calcium ion and manganese ion content with silicon and phosphorous in the coolant, insoluble chemical compound is likely to be generated to clog water passage or form water scale to reduce cooling performance. Moreover, the water with high sulfate or chloride content could cause corrosion.

Antifreeze The main function of the antifreeze is to decrease solid point and increase boiling point of engine coolant. Therefore, when the machine is used under low temperature, use antifreeze to prevent coolant from freezing which may damage engine cooling system. Use of antifreeze is also recommended in normal temperature applications because it can increase boiling point of engine coolant, at the same time, the additives contained in it can reduce occurrences of engine body corrosion and cracks. As concentration of antifreeze in coolant increases, boiling point of coolant will rise while its solid point will drop. But concentration of the antifreeze can not exceed 68%; otherwise, solid point of the coolant will rise instead and silica gel is likely to develop. The normal range of the concentration is 40%~60%.

Use of the coolant containing 50% concentration antifreeze is recommended; then, boiling point of the coolant is 110℃ and its solid point is -36℃.

Notices Antifreeze is an inflammable substance; so, keep it away from open flame.

Brands and performances of the antifreezes recommended by Hyundai Construction Equipment co., Ltd.. are as follows: 62

Operation and Maintenance Manual Lowest applicable ambient temperature (℃)

Mobil antifreeze (enriched type)

—46

56

—40

51

—33

45

—25

40

—20

38

—15

33

—10

28

0

0

Proportion (%)

When changing antifreeze, please use best quality antifreeze and fill according to its direction for use.

Additives All water is corrosive under operating temperature of the engine, so, the coolant must contain additives (SCA).

Additives can protect the engine parts in touch with the coolant from rust, encrust, pitting and corrosion. Concentration of the additives in the coolant should be maintained at approx 3%. Additives have been included in the antifreeze, but they will be consumed during use of the engine. Check concentration of the additives every 500 working hours or semiyearly and add them by replacing the coolant filter periodically. Please refer to the engine operation and maintenance manual for the concentration test method for the additives and particular regulations on additive refill.

Coolant level inspection method 1.

2.

3.

4.

5.

Water radiator filler

The water radiator is located at tail of the machine.

Be sure to wait until temperature of engine coolant drops below 50℃, and then screw off the filler cap of the water radiator slowly to release pressure so as to avoid being scalded by high-pressure steam or spattered high-temperature coolant.

Check whether the coolant level is within 1cm from the filler; when necessary, add coolant.

Check seal of water radiator filler cap; if damaged, replace.

Tighten water radiator filler cap properly.

If coolant refill is needed at each check, check engine cooling system for leakage. If leakage is found, clear the trouble and add antifreeze to corresponding level.

Adding coolant When adding coolant to the engine on a new machine or an engine of which the cooling system has just been cleaned, first select concentration of the antifreeze contained in the coolant according to the lowest local air temperature occurred ever (or 10℃ below the lowest air temperature is preferable) and then work out quantity of the antifreeze needed according to total volume of the engine cooling system (total volume of the cooling system on this machine is 45L).

Notices Never use water as coolant separately. The damage caused by corrosion is a consequence of using water as coolant separately.

The operating procedure for adding coolant is as follows: 1. Be sure to mix water and antifreeze completely beforehand according to the coolant proportioning selected.Filling antifreeze in the engine before it mixes with water completely will cause engine overheating because antifreeze 63

Operation and Maintenance Manual absorbs less heat from the engine than water does.

2. Turn on the power supply negative switch, insert the key into the starting switch and turn it to the first position clockwise, then turn on vehicle power supply and turn shift switch of the A/C system to heating position (HEAT).

3. Turn the manual valve on the engine water inlet pipe to on position (in this position, the valve hand is in line with the route direction of the line).

Turn on warm water valve of A/C system

4. Open the water radiator filler cap, add coolant slowly until the coolant level is within 1cm from the water radiator filler and keeps stable within 10 minutes.

Notices When adding coolant, be sure to bleed air from the engine cooling system line.

5. Keep the water radiator filler cap open, start the engine, run it under low idle speed for 5 minutes first and then under high idle speed for another 5 minutes to enable coolant temperature to reach above 85℃.

6. Check the coolant level again; if necessary, continue to add coolant until its level is within 1cm below the water radiator filler.

7. Check seal of the water radiator filler cap; if damaged, replace.

Warning Do not refill high-temperature engine with cold coolant; otherwise, engine body damage could result.

Instead, wait until engine temperature is below 50℃, and then do the job.

Notices Hyundai Construction Equipment co., Ltd.. will not assume any liability for any loss due to antifreeze temperature drop caused by coolant leak resulted from improper use of customers.

Cleaning cooling system Every 2000 working hours or 2 years (whichever comes first), change the coolant in the cooling system and clean the system thoroughly.

Before these conditions are met, if the coolant is contaminated, the engine overheats, or foams appear in the radiator, clean the cooling system.

The procedure for cleaning the cooling system is as follows: 1. Turn on the power supply negative switch, insert the key into the starting switch and turn it to the first position clockwise, then turn on vehicle power supply and turn shift switch of the A/C system to heating position (HEAT).

64

Operation and Maintenance Manual 2. Turn the manual valve on the engine water inlet pipe to on position (in this position, the valve hand is in line with the route direction of the line).

3. Start the engine, run it under idle speed for 5 minutes, and then shut it down. After that, turn the starting switch to the first position to turn on vehicle power supply. Set the shift switch of the A/C system to heating position; set the A/C solenoid water valve to open position.

4. Be sure to wait until coolant temperature drops below 50℃, and then screw off the water radiator filler cap slowly to release pressure.

5. Open the drain valve at bottom of the water radiator and the discharge valve of the engine oil cooler, then drain engine coolant and hold it with a vessel.

Drain valve of water radiator

6. After the engine coolant has been drained completely, close the drain valve at bottom of the water radiator and the discharge valve of the engine oil cooler.

7. Check all water pipes and pipe clips in the cooling system for damage; if necessary, replace. Check the water radiator for leakage, damage and dirt accumulation, and then clean and repair as needed.

8. Add the cleaning solution prepared by mixing water and sodium carbonate (mixing ratio: 0.5kg sodium carbonate per 23L water) to the engine cooling system. The liquid level should reach that for normal use of the engine and keep stable within 10 minutes.

Notices When adding the cleaning solution to the cooling system, be sure to bleed air from the engine cooling system line.

During the whole cooling system cleaning process, never cover the water radiator filler cap when the engine is running.

9. Start the engine with the water radiator filler cap open. When the coolant temperature rises to above 80℃, run the engine for another 5 minutes.

10. Cut off the engine and discharge the cleaning solution.

11. Add clean water to the engine cooling system until the liquid level for normal use which should keep unchanged for 10 minutes. Start the engine with the water radiator filler cap open. When the coolant temperature rises to above 80℃, run the engine for another 5 minutes.

Warning Engine coolant is toxic, so, it is undrinkable. Please dispose of it according to local laws and regulations related.

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Operation and Maintenance Manual

Engine air filter maintenance Notices When you service the air filter, shut down the engine to prevent damage.

Maintenance and replacement of main cartridge of air cleaner If the yellow piston of the air cleaner service indicator rises into the red zone when the engine is idling at high speed, the air filter should be serviced. The operating procedure is as follows: Air cleaner service indicator

Remove inner and outer covers of air cleaner

1. Turn off the engine and open the engine hood.

2. Remove inner and outer covers of the air cleaner.

3. Remove the nut on top of the main cartridge and then take out the cartridge.

Nut on top of main cartridge

Clean inwall of air cleaner case

4. Clean inwall of the air cleaner case.

5. Clean the main cartridge. Use compressed air (pressure ≼ 300kPa) to scour outwards along the folds at inside of the main cartridge first, and then scour repeatedly along the folds from outside and inside of the main cartridge respectively.

Notices Do not knock on the main cartridge when cleaning it; otherwise, the engine may be damaged.

66

Operation and Maintenance Manual Clean main cartridge

Check main cartridge

6. After clearing the main cartridge, check it under an electric lamp. If any orifices or particles are found on it and its washer or seal is damaged, replace with a new main cartridge.

7. Install the clean main cartridge into the air cleaner case and ensure that the seal at end of the main cartridge contacts evenly. Hand-tighten the nut on top of the main cartridge. Do not use any tool so as to avoid damage to the main cartridge.

8. Clean and install the cover of the air cleaner and ensure that the gasket of the air cleaner inner cover and the air cleaner case come into contact with each other evenly.

9. Depress the reset key at bottom of the service indicator to reset the indicator.If the yellow piston of the air cleaner service indicator still rises into the red zone or black smoke is still given off when the engine is started after a main cartridge cleaning, replace with a new safety filter element.

The main cartridge should be replaced after 6 cleaning operations. Replace it yearly even that number is not reached. When replacing the main cartridge, replace the safety filter element at the same time.

Replacing safety filter element of the air cleaner Safety filter element 1.

2.

3.

4.

5.

6.

7.

8.

Shut down the engine and open its hood.

Remove the inner and outer covers of the air cleaner.

Remove the main cartridge.

Screw off the nut on top of the safety filter element, and then remove the element.

Clean up inwall of the air cleaner.

Install a new safety filter element. Ensure that the gasket on end face of the safety filter element contacts evenly and functions well. Hand-tighten the mounting nut of the safety filter element only and do not use any tool.

Install the new main cartridge and the inner and outer covers of the air cleaner. Hand-tighten the nut on top of the main cartridge only. Do not use any tool.

Depress the reset key at bottom of the service indicator to reset the indicator.

Notices The safety filter element can be replaced with a new one only. Reuse after clearing is not allowed.

When replacing the main cartridge, replace the safety filter element at the same time.

If the yellow piston of the air cleaner service indicator still rises into the red zone or black smoke is still given off after a main cartridge cleaning, replace with a new safety filter element.

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Operation and Maintenance Manual

Oil specifications During refill and change of each type of oil used on this machine, use the specification and variety specified in the table below to ensure normal use of the machine.

1. Oils used in plain areas Designation

Type

Summer use

Grease

●3# molybdenum disulfide lithium base grease

Torque converter oil

6# hydraulic transmission oil

Hydraulic oil

● HM46 hydraulic oil

Engine oil

Supercharged

Engine fuel

South North

antiwear

● SAE/CF15W-40, CD15W/40 0# light diesel oil

Application location

Winter use

All rolling bearings, sliding bearings, working device pins, steering cylinder pins, frame pins, rear axle articulated frame, driving shaft splines, universal joints, water pump shaft, etc.

Torque converter and power shift transmission.

HV46 low temperature antiwear hydraulic oil

Working device hydraulic system and steering hydraulic system.

SAE/CF5W-40, CD15W/40

Diesel engine

● 0# light diesel oil

Diesel engine

-20# light diesel oil

Gear oil

● SAE80W-90 (API GL-4) heavy-duty automobile gear oil

In-axle main drive and hub reducer

Brake oil

DOT3 or 719 synthetic brake fluid

Braking system booster

Note: The oil added at delivery of the machine is marked with a “●”.

2. Oils used in plateaus and high-cold areas Type

Grease

Torque converter oil

Designation Summer use

Winter use

2# molybdenum disulfide lithium base grease

Application location All rolling bearings, sliding bearings, working device pins, steering cylinder pins, frame pins, rear axle articulated frame, driving shaft splines, universal joints, water pump shaft, etc.

SAE15W-40

Torque converter and power shift transmission.

HV46 low temperature antiwear hydraulic oil

Working device hydraulic system and steering hydraulic system.

Engine oil

SAE/CF5W-40

Diesel engine

Engine fuel

-35# light diesel oil

Diesel engine

Gear oil

SAE80W-90 (API GL-4) heavy-duty automobile gear oil

In-axle main drive and hub reducer

Brake oil

DOT3 or 719 synthetic brake fluid

Braking system booster

Hydraulic oil

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Operation and Maintenance Manual

Notices 1. Hybrid use of the oils of same specification but different brands is not allowed. If the oil of another brand must be used for a certain reason, please clean up the system first.

2. If the machine is to be used in low-temperature and high-cold areas for an extended period of time, use HV46 low temperature antiwear hydraulic oil as hydraulic oil and 6# hydraulic transmission oil as transmission oil.

3. Change lubricants on schedule. Through clean, oils may deteriorate after a long-term storage.

4. Select fuel according to the lowest local air temperature when the machine is in use.

Use and related maintenance of fuel Diesel oil tank With a volume of 180L, the diesel oil tank on this machine is located at bottom of the counterweight.

Take off the filler cap and then you can fill diesel oil. When opening the filler cap, turn it counterclockwise until it loosens, and then move it outwards simply. Please do not take out the strainer at the filler during diesel oil fill.

Clean the filler strainer and diesel oil tank periodically. You can follow the steps below to do the cleaning job: Remove the blind flange at bottom of the diesel oil tank and then flush inside surface of the tank with clean diesel oil repeatedly until the oil discharged becomes clean.

Diesel oil tank Clean diesel oil tank

Clearing moisture and foreign substances from diesel oil The fuel pump and injection nozzles are very precise units. They could become malfunctioning and be worn more rapidly if water or dirt is entrained in diesel oil. Proper measures should be taken to remove the water and foreign substances in the diesel oil. The procedure is as follows: 1. If possible, settle the diesel oil for 24h before adding it into the fuel tank.

2. Before fuel fill, screw off the drain plug at bottom of the diesel oil tank weekly to discharge the water and foreign substances there.

3. After finish of daily work, fill with diesel oil to bleed the wet air in the diesel oil tank.

4. Each time the diesel oil tank is filled up, stay for 5~10 minutes and then start the engine to allow the moisture and foreign substances in the diesel oil to settle at bottom of the tank.

5. After daily work, unscrew the drain plugs at bottom of the diesel oil/water separator and primary diesel oil filter to discharge moisture and foreign substances.

Screw off drain plug of diesel oil/water separator Primary diesel oil filter

69

Operation and Maintenance Manual Refill after the oil in the diesel oil tank has been used up will cause the engine to shut down. In addition, the diesel oil at bottom of the tank contains more moisture and foreign substances which could affect normal operation of the engine.

Sulphur content of diesel oil Sulphur content percentage of diesel oil will affect choice and change period of engine oil. During combustion process, sulphur will form sulfuric acid and sulfurous acid through chemical change. These acids can corrode metal surfaces. Therefore, select the diesel oil of low sulphur content.

Some additives in lubricants contain alkaline compound which can neutralize acid. Therefore, change period of engine oil should be adjusted according to sulphur content of diesel oil: 1. If the sulphur content is less than 0.50%, change oil at the time interval specified in “Routine Maintenance” of the manual.

2. If the sulphur content is between 4.50%-1.5%, change oil at 1/2 time interval specified in “Routine Maintenance” of the manual.

3. If the sulphur content is greater than 1.5%, change oil at 1/4 time interval specified in “Routine Maintenance” of the manual.

Diesel oil filter replacement 1. Clean up the area around the filter and its mounting base.

2. Remove the filter from its mounting base using a belt wrench.

Remove filter Clear sealing surface of mounting base

3. Remove the gasket on the screwed connection of the mounting base. Clean up the sealing surface of the mounting base with fiber-free cloth.

4. Install a new gasket to the screwed connection of the filter mounting base; apply a layer of engine oil on the sealing surface of the filter; fill the filter with clean diesel oil.

5. Screw the filter on the mounting base and then tighten another 1/2-3/4 turn simply after the gasket of the filter just comes in contact with the mounting base. Do not overtighten mechanically so as to avoid damage to the filter.

Install an oil filter

Prepare a new filter

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Operation and Maintenance Manual Diesel oil warm-up If diesel oil warm-up is required because air temperature is low, do not allow diesel oil temperature to exceed 35℃; otherwise, engine power loss will occur.

Engine oil maintenance Check engine oil level.

1. Drive the machine to a flat ground, shut down the engine, and pull up the parking brake lever.

2. Wait 10 minutes after engine shutdown to allow the engine oil in the crankcase to flow back to the engine oil sump fully.

3. Open engine hood and you will find that both oil dipstick and filler are located at right side of the engine.

Oil dipstick

Oil filler

4. Draw out the oil dipstick, wipe it up with a clean cloth, reinsert it into the engine oil level opening until extreme position, and then draw it out again to check. The oil level should be between the “L” and “H” scales on the oil dipstick.

5. If the oil level is below the “L” scale, add engine oil; if the oil level is above the “H” scale, please unscrew the drain plug at bottom of the oil sump to drain part of the engine oil.

Notices Both excess and lack of engine oil could cause engine damage.

Engine oil change When the specified oil change period comes, change engine oil.

Park your machine on a flat ground, run the

engine until coolant temperature reaches 60℃, and then shut down the engine. Pull up the parking brake lever. Remove the drain plug at bottom of the engine oil sump to drain the oil and hold it properly with a vessel. Replace oil filter.

Change engine oil

Appropriate range of engine oil

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Operation and Maintenance Manual Screw on the drain plug and then add clean engine oil from the engine oil filler until the “H” scale of the oil dipstick. Run the engine under idle speed and check the oil filter and drain plug for leakage.

Shut down the engine and wait approx 10 minutes to enable the oil to flow back to the oil sump fully, and then check the oil level again. If oil is insufficient, please add engine oil until the “H” scale of the oil dipstick.

Check engine oil level

Notices Within 15 seconds after the engine starts, reading on oil pressure gauge should be seen. If no reading is seen, please shut down the engine immediately to avoid damage to it. Also, check whether the oil level is in appropriate position.

Engine oil filter replacement 1. Clean up the area around the mounting base of the oil filter.

2. Remove the oil filter using a belt wrench.

3. Clean up the contact surface of the gasket on the mounting base with a clean cloth. If the used O-ring is adhered to the mounting base, remove it.

Clean up mounting base

Install a new oil filter

4. Install a new O-ring, fill the oil filter with clean engine oil, and apply a layer of clean engine oil on the surface of the gasket.

Notices If an empty oil filter is installed, the engine may be damaged due to lubricant shortage.

5. Install the oil filter on its mounting base, hand-tighten until the surface of the oil filter gasket comes into contact with the mounting base, and then tighten the oil filter to the specified torque requirement using a belt wrench.

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Operation and Maintenance Manual Notices Mechanical overtightening may damage threads or seal of oil filter element.

Transmission maintenance Checking transmission oil level The transmission oil filler is located at right side of the frame. Check transmission oil level at the specified intervals to ensure oil quantity. You can check the oil level through the oil level cock installed beside the filler pipe.

Transmission oil filler

Check transmission oil level as follows: 1. Before a cold start, check cold oil level first to ensure adequate oil quantity when starting. It is more important for a loader that has not been out of operation for a quite long period.

2. Before engine start, open the oil level cock. If oil flows out, it indicates that the engine can be started. If no oil flows out, fill up before starting the engine.

3. Park the machine on a flat ground, set the gearshift lever to neutral position, pull up the parking brake button, and install the frame fixing bumper to prevent the machine from move and turn. Run the engine under idle speed.

Start the engine, run it for approx 5 minutes and then shut it down. Open the oil level cock and the transmission oil level should be at the height limited by the oil level cock.

Notices Either high or low transmission oil level could cause transmission damage. Please maintain transmission oil level at correct position.

During transmission oil level check and transmission oil change, be sure to pay full attention to cleanliness and do not allow dirt to enter the transmission system causing transmission damage.

Transmission oil change The oil in the transmission, on one hand, serves as working medium of the torque converter-transmission hydraulic system, on the other hand, is used for cooling and lubrication of the parts and components in the torque converter-transmission. Therefore, the brand of the oil used in the transmission should be satisfactory and the oil should be changed according to the specified change period; otherwise, service life of the transmission may be reduced.

The operating procedure for transmission oil change is as follows: 1. Start the engine and then operate the machine to work for several hours enabling dirt, metal powder and deposits to float in the oil.

2. Park the machine on a flat ground, set the gearshift lever to neutral position, and pull up the parking brake lever to prevent the machine from move.

3. Shut down the engine, screw off the drain plug on left lower part of the transmission to drain oil and hold it with a vessel.

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Operation and Maintenance Manual

Warning At the time, transmission oil is still hot, so, you should wear protective appliances properly and operate with care to avoid personal injury.

Torque converter oil radiator

4. Clean up the iron chips adhered to the drain plug and those on inwall of the transmission with a magnet.

5. Install the transmission drain plug and corresponding seal properly.

6. Screw off the transmission filler cap and add clean transmission oil from the filler pipe. The transmission oil level should be at the highest position limited by the oil level cock. Start the engine, run it for approx 5 minutes before shutdown, and then open the oil level cock. Check the oil level and it should be at a position limited by the oil level cock. In the case of oil shortage, please add; in the case of excessive oil, drain part of the oil.

7. Tighten the filler cap clockwise.

Notices Before transmission oil change, take care to cover the parking brake properly so as to prevent it from being contaminated by oil which will reduce braking performance.

Drive axle maintenance Check oil level and change drive axle oil on schedule in accordance with related provisions in “Routine Maintenance�.

Checking drive axle oil level 1. Drive the machine to a flat ground, move it slowly with small throttle opening until the drain plug on the rim end face of front drive axle is in horizontal position. Oil levels in front and rear drive axles should be checked in twice because it is impossible for the drain plugs on the axles to be in horizontal position at the same time.

2. Set the transmission control lever to neutral position and pull up the parking brake lever to prevent the machine from move.

3. Clean up the area near the drain plug on the rim at each side of the drive axle and then remove the plug to observe.

The oil level inside the drive axle should be at the lower edge of the oil drain. If the oil level is below the lower edge of the oil drain, add clean drive axle oil. After oil fill, observe for approx 5 minutes. It is OK if the oil level keeps stable.

4. Screw on the drain plug.

5. Follow above steps to check the oil level in rear drive axle.

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Operation and Maintenance Manual Drive axle oil change 1. Drive the machine to run for a period of time first to allow the foreign substances settled in the axle housing to float up fully. . Then, drive the vehicle to a flat ground and then move it slowly with small throttle opening until the drain plug on the rim end face of front drive axle is in its lowest position. Oils in front and rear drive axles should be changed in twice because it is impossible for the drain plugs on the axles to be in horizontal position at the same time.

2. Shut down the engine, set the gearshift lever to neutral position, and then pull up the parking brake button to prevent the vehicle from move.

3. Screw off the drain plugs on both end faces of front drive axle rims and that at middle part of the axle housing to drain oil and hold it with a vessel properly.

Warning At the time, transmission oil is still hot, so, you should wear protective appliances properly and operate with care to avoid personal injury.

Inspection and drain plug at middle part of drive axle Inspection and drain plug on rim

4. Screw on the drain plug at middle part of front drive axle.

5. Start the engine and depress the parking brake button to release the parking brake. Shift transmission to I gear and then move the vehicle slowly with small throttle opening until the drain plug on the rim end face of front drive axle is in horizontal position. Then, shut down the engine, shift transmission to neutral position, and pull up the parking brake button.

6. Add clean drive axle oil from the oil drain on each end face of front axle rim until the oil level reaches the lower edge of the oil drain there. After oil fill, observe for approx 5 minutes. It is OK if the oil level keeps stable.

Liquid level gauge on hydraulic oil tank

7. Screw on the drain plugs at both ends of front drive axle rims.

8. Follow a procedure similar to above one to change the oil in rear drive axle.

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Operation and Maintenance Manual Hydraulic system maintenance Check oil level and change hydraulic oil in accordance with related provisions in “Routine Maintenance�.

Checking hydraulic oil level 9. Located at left side of the cab, the hydraulic oil tank is equipped with a liquid level gauge at its front end for indication of hydraulic oil level.

When checking the hydraulic oil level, park the vehicle on a flat ground, place the bucket flatly on the ground, and align front and rear frames without leaving any included angle. At the time, the hydraulic oil level should reach center of the liquid level gauge.

Periodic change of hydraulic oil Change hydraulic oil every 1800 working hours or yearly. The procedure is as follows:

Warning During oil change, the machine should carry out various operations. Follow related safety specifications to operate and take care.

During oil change, pay full attention to cleanliness of hydraulic oil and do not allow dirt to enter the hydraulic system.

1. Clear the bucket of foreign materials, park the machine on a flat and open ground, set the gearshift lever to neutral position, and pull up the parking brake lever. Start the engine and run it under idle speed for 10 minutes, during which carry out such actions as boom lift and fall and bucket tilt and rollback repeatedly for several times.

2. Finally, lift the boom to its highest position, roll back the bucket to its maximum position, and then shut down the engine.

3. Push the control lever of the pilot control valve to the right forward to tilt the bucket forward under the action of its dead weight so as to discharge the oil in the tilt cylinder; after the bucket has rotated in place, push the pilot valve control lever forward to lower the boom under the action of its dead weight so as to discharge the oil in the boom cylinder.

4. Clear the oil drain on underside of the hydraulic oil tank, and then screw off the drain plug to drain the hydraulic oil and hold it with a vessel. At the same time, screw off the filler cap to pick up the oil drain process.

Warning At the time, transmission oil is still hot, so, you should wear protective appliances properly and operate with care to avoid personal injury.

Filler cap of hydraulic oil tank

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Operation and Maintenance Manual 5. Disconnect the oil pipe of the hydraulic oil radiator to drain the residual hydraulic oil in the radiator.

6. Remove the hydraulic oil return filter end cover from the hydraulic oil tank, take out the return filter element and replace it with a new one. Remove the hydraulic oil suction filter end cover, take out the suction filter element and replace it with a new one. Open the filler cap, take out the filler strainer and clean it.

7. Remove the blind flange on the cleaning port under the oil tank and flush bottom and four walls of the hydraulic oil tank with diesel oil. Finally, mop up the tank with a clean cloth.

Return and suction ports on hydraulic oil tank (the righe one is return port)

8. Install drain plug of hydraulic oil tank, return filter and its end cover, filler strainer, blind flange of oil tank cleaning port, and oil pipes of hydraulic oil radiator properly.

9. Add clean hydraulic oil from the filler on the hydraulic oil tank until the oil level reaches the upper scale on the hydraulic oil level gauge, and then tighten the filler cap properly.

10. Operate the multi-way valve to perform 2~3 combinations of boom lift and fall, bucket tilt and rollback, and left and right turn to maximum angle so as to fill oil cylinders and pipes with hydraulic oil. Then, run the machine under idle speed for 5 minutes to bleed the air in the system.

11. Shut down the engine, open the filler cap of the hydraulic oil tank, and then add clean hydraulic oil until 2/3 scale of the liquid level gauge on the tank.

Change of seriously contaminated hydraulic oil If the hydraulic oil is deteriorated (e.g. blackening and foaming) due to severe working conditions or serious contamination, please change it immediately.

1. Clear the bucket of foreign materials, park the machine on a flat and open ground, set the gearshift lever to neutral position, and pull up the parking brake button. Start the engine and run it under idle speed for 10 minutes, during which carry out such actions as boom lift and fall and bucket tilt and rollback repeatedly for several times.

2. Finally, lift the boom to its highest position, roll back the bucket to its maximum position, and then shut down the engine.

3. Push the bucket control lever forward to tilt the bucket forward under the action of its dead weight so as to discharge the oil in the tilt cylinder; after the bucket has rotated in place, push the boom control lever forward to lower the boom under the action of its dead weight so as to discharge the oil in the boom cylinder.

4. Clear the oil drain on underside of the hydraulic oil tank, and then screw off the drain plug to drain the hydraulic oil and hold it with a vessel. At the same time, screw off the filler cap to pick up the oil drain process.

5. Disconnect one end of each pipe to discharge the residual hydraulic oil in steering cylinder, hydraulic oil radiator and various pipes.

6. After finish of oil discharge, install the drain plug on underside of the hydraulic oil tank and all disconnected pipes.

7. Open the filler cap of the hydraulic oil tank and then add clean hydraulic oil until the upper scale of the liquid level gauge.

8. Perform another oil change in accordance with the procedure in “Periodic Change of Hydraulic Oil� described

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Operation and Maintenance Manual above, at the same time, replace return and suction filter elements and clean filler strainer and hydraulic oil tank.

Tire maintenance and inflation know-how

Warning If a tire or rim is handled incorrectly, the tire may blow up or break and get loose to cause serious injury even death.

Maintenance, removal, repair and installation of tires and rims require special-purpose equipment and professional skills, so, have the jobs done by a tire mendery or the personnel specially trained. In addition, observe all safety rules related.

It is recommended that you use dry nitrogen (N2) to inflate tires. In case a tire is charged with air originally, we recommend that you use nitrogen to adjust its pressure because nitrogen can mix with atmospheric gas. Nitrogen charged tires are less likely to blow up because nitrogen is nonflammable. Also, nitrogen is helpful to avoid oxidation, aging of rubber, and corrosion of wheel rim parts.

Checking and adjusting tire inflation pressure should be carried out after the tire has cooled down fully. The pressure of a tire inflated with nitrogen is the same as that of one inflated with air. Hyundai Construction Equipment co., Ltd.. recommends that you select inflation pressure of tires according to service condition of you machine: Front wheel Rear wheel Handling operation: 0.42±0.01 MPa 0.32±0.01MPa Long distance no-load travel: 0.32±0.01 MPa 0.32±0.01MPa

Notices If the machine is on the road for a long-distance travel at high speed, stop and wait 30 minutes every 45km to allow tires to fully cool down.

Parking braking performance check Parking braking performance check Check parking braking performance of the machine on a regular basis to ensure parking safety and the braking capacity during emergency braking.

1. Adjust tire pressure of the machine to the specified value, place the bucket flatly with a ground clearance of approx 300mm, and confirm that the machine has good service braking performance.

2. Start the engine, align the machine dead against an 18% (included angle: 10º12') slope and then drive straight upslope. The road surface should be flat and dry.

3. Depress the service brake pedal to allow the machine to come to a full stop. Set the gearshift lever to neutral position and then shut down the engine.

4. Pull up the parking brake button, slowly loosen the service brake pedal, and check whether the machine is still in its home position.

Service braking performance check Before checking service braking performance, ensure that the parking braking system on the machine operates normally so that you can use parking brake to apply emergency brake in case of emergency.

When the machine is traveling on a straight, dry cement road surface at a speed of 32 km/h, depress the service brake pedal to apply full brake. After the machine stops, push the gearshift lever to neutral position and pull up the parking brake button first, and then loosen the service brake pedal. Check braking length of the machine and the value should not be greater than 15m.

Drive the machine at a speed of 32 km/h and snub, then braking action should take place rapidly without causing 78

Operation and Maintenance Manual the machine to pull to one side.

Replacement of bucket teeth 1. Start the engine and lift the bucket. Put a pad under the bucket, and then place the bucket flatly on the pad. Height of the bucket pad should not exceed that required by bucket teeth replacement. You can also place the bucket at the height shown in the figure. Shut down the engine and pull up the parking brake button.

2. Screw off the nuts and take off the bucket teeth.

3. Clear tooth bodies, screws and nuts, install new bucket teeth, and then tighten the nuts properly.

Bucket and bucket teeth

Welding operation When you perform welding operation on this machine, follow the regulations below to operate so as to avoid machine damage or safety accident.

1. Before welding operation, be sure to read and understand relevant safety rules concerning welding operation on this machine.

2. Before welding operation, turn on the engine starting switch and turn off the power supply negative switch.

3. Before welding operation, be sure to remove the console connector to avoid console damage. This also can be done by disconnecting the cab wiring harness (on right lower part of the cab and near the frame articulation) from the vehicle wiring harness.

Cab wiring harness

4.

5.

6.

7.

8.

Do not apply voltages higher than 200V continuously.

The distance between the weld zone and the ground cable should be within 1m.

Keep gaskets and bearings out of the area between the weld zone and the ground cable.

Never weld or cut the pipes and vessels containing fuel, engine oil and hydraulic oil.

Never weld or cut sealed or poorly ventilated vessel.

General torque specifications Unless otherwise stated, the bolts used on this machine should be tightened according to the torque requirements 79

Operation and Maintenance Manual in the table below.

1. Standard torques for metric threads Standard torque(N.m)

Thread size

Class 8.8 strength

Class 10.9 strength

M6

10.5±1.5

M8

26±4

M10

52±7

72±6

M12

90±12

120±10

M14

145±20

195±15

M16

225±35

305±25

M18

310±45

415±35

M20

410±50

600±50

M22

600±80

800±40

M24

760±100

1020±100

M27

1100±150

1500±100

M30

1500±200

1850±150

M33

2050±300

2900±400

M36

2650±350

3100±250

2. Standard torques for inch threads Thread size

Standard torque(N.m)

1/4

12±4

5/16

25±7

3/8

45±7

7/16

70±15

1/2

100±15

9/16

150±20

5/8

200±25

3/4

360±50

7/8

570±80

1

875±100

Charge specifications for maintenance-free batteries The battery used on this machine is of maintenance-free type and the following operating rules must be observed during use.

Causes of battery capacity loss 1. Abnormal uses such as extended on time of on-vehicle electric appliances with the vehicle not started.

2. Battery electric energy is exhausted due to long-term stop, heavy leakage current of vehicle, or additional electric appliances. .

3. Frequent starts of vehicle.

4. Troubles in vehicle charging system such as malfunction of generator and its electronic components, low charging voltage set for generator voltage regulator, loose generator drive belt, etc., which result in abnormal charge of the battery causing battery capacity loss, blackish battery magic eye (charge indicator), and even vehicle start failure.

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Operation and Maintenance Manual 5. Storage period of off-board batteries exceed 6 months.

Batteries with capacity loss caused by above situations can be restored through timely and correct recharge.

Check battery appearance before charge.

1. Batteries with broken cases or acid leakage can not be recharged. They should be replaced after the causes are found.

2. Batteries with broken terminals can not be recharged. They should be replaced after the causes are found.

3. Do not recharge the batteries with whitish magic eyes. Instead, replace them.

4. Before recharge, clean terminals and remove the scales on their surfaces.

Precautions during charge 1. Wear safety goggle.

2. Keep ventilation in the environment during charge. Charge under normal temperature.

3. Smoking is strictly forbidden during charge. In addition, avoid introduction of kindling sparks.

4. When connecting wires after charge, connect positive wire first; when disconnecting wires before charge, disconnect negative wire first.

Operating rules for battery charge 1. Confirm that the battery terminals are clean and the charging current is in good connection.

2. Connect positive pole of the charger with that of the battery; connect negative pole of the charger with that of the battery. Never charge the batteries connected in series (24V).

3. It is recommended that you use a constant-voltage 16.0V (10.2V maximum. If exceeding this value, a mass of water will be electrolyzed to cause liquid level drop, whitish magic eye and battery scrap) charger (current limit: 25A) to charge the battery until its magic eye becomes greenish. Greenish battery magic eye indicates that the battery has been charged fully.

4. You can perform constant-current charge according to the following specifications if constant-voltage mode is infeasible: 1) Select 1/8~1/10A of rated capacity as charging current (for battery 37B0108; 12~15A; for battery 378B077; 10~12A). At terminal stage of charge, the voltage should reach but not exceed 16V (voltage at terminal stage below 16V is likely to cause the magic eye to keep blackish after finish of charge). When the charger can not ensure that the charging voltage can be limited below 16V, be sure to manually monitor the terminal voltage of the battery charged hourly; otherwise, battery dehydration due to over-voltage charge will occur to affect battery life even render it inoperative.

2) See the table below (for reference) for the corresponding relation between charging time and voltage of battery before charge.

12.55 12.45 12.35 12.20 12.05 11.95 11.80 11.65 11.50 11.30 Below Battery ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ 11.00V voltage 12.45V 12.35V 12.20V 12.05V 11.95V 11.80V 11.65V 11.50V 11.30V 11.00V Charging 2h 3h 4h 5h 6h 7h 8h 9h 10h 12h 14h time

3) After finish of charge, check color of battery magic eye. If the magic eye renders green, it indicates that the battery has been charged fully. If the magic eye renders black, check if charging wires are connected firmly, junctions are clean, and voltage at terminal stage of charge reaches 16V. Measure voltage after 24h placement, and then continue to recharge referring to the relation between voltage and recharging time.

4) If the magic eye is found whitish, bubbles may exist in it. Then, you can joggle the battery to drive the bubbles away. If the magic eye is still found whitish after you joggle the battery, it indicates that electrolyte loss has taken place and this battery has become disabled and should be replaced.

5. For a battery with voltage below 11.0V, “electricity refuse� of battery may occur at initial stage of charge because specific gravity of the sulfuric acid inside a battery with heavy capacity loss has been close to that of water so that internal resistance of the battery becomes very high. At the time, you can reduce charging current or replace with another charger of higher power. With progress of battery charge, specific gravity of the sulfuric acid inside the battery will rise, and then you can allow charging current of the battery to resume normal value step by step.

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Operation and Maintenance Manual 6. If a large amount of acid jets through the vent hole of the battery during charge, stop charge immediately to locate the causes.

7. When battery temperature exceeds 45℃ during charge, stop charge, and then continue charge with halved charging current after battery temperature drops to room temperature.

8. During battery charge, check state of magic eye hourly. Green battery magic eye indicates that the battery has been charged fully, and then you can stop charge.

9. After the charge process is finished and the battery has passed related tests, it is recommended that you coat the terminals with Vaseline to prevent occurrence of electrical erosion.

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