Hyundai HL930A Operation & Maintenance Manual Download

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WHEEL LOADER

OPERATION & MAINTENANCE

MANUAL

HL930A

HL930A XT

Serial No.

Summary of Contents for HL930A

Page 1: ...WHEEL LOADER OPERATION MAINTENANCE MANUAL HL930A HL930A XT Serial No ...

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Page 3: ... engine 4 2 3 Starting and stopping the engine 4 3 4 Warming up operation 4 7 5 Operation of working device 4 8 6 Travelling of the machine 4 9 7 Efficient working method 4 14 8 Adjustment of the work equipment 4 20 9 Operation in special work sites 4 21 10 Storage 4 22 11 Exhaust system cleaning 4 24 12 Attachment manually lowering En gine stopped 4 26 TRANSPORTATION 1 Road travelling 5 1 2 Prepa...

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Page 5: ...ive their amendments and other applicable directives EMC 2014 30 EU Certificate number Date DD MM YYYY Notified body Noise levels 2000 14 EC Certificate number Date DD MM YYYY Conformity assessment proc Annex VIII Full Quality Assurance Notified body Measured sound power level nnn n dB A Guaranteed sound power level nnn n dB A Engine information Manufacturer Engine model name Type approval number ...

Page 6: ...2 DISCLAIMER THIS TRANSLATION IS BASED UPON THE ORIGINAL ENGLISH OPERATION AND MAINTE NANCE MANUAL THE ENGLISH VERSION SHALL PREVAIL OVER THE TRANSLATION IN CASE OF ANY LE GAL DISPUTE 0 2 ...

Page 7: ...procedures and precautions given in this manual apply only to intended uses of the machine If you use your machine for any unintended use that is not specifically prohibited you must be sure that it is safe for you and others In no event should you or others engage in prohibited uses of actions as described in this manual Some illustrations in this manual show details or attachments that can be di...

Page 8: ...e years whichever occurs first Naturally this warranty does not cover to damage arising from accident misuse or negligence use of non Hyundai parts or from alterations not authorized by Hyundai Emission related components according to the EPA regulation 1 Air induction system 2 Fuel system 3 Ignition system 4 Exhaust gas recirculation systems 5 After treatment devices 6 Crankcase ventilation valve...

Page 9: ...ll personnel also must be aware of any federal state provincial or local laws or regulations covering the use and service of construction equipment The procedures in this manual do not supersede any requirements imposed by federal state provincial or local laws Hyundai can not anticipate every possible circumstance or environment in which this machine may be used and serviced All personnel must re...

Page 10: ...uipment co Ltd Address 12th fl Hyundai Bldg 75 Yulgok ro Jongno Gu Seoul 03058 Korea Distributor for U S A Hyundai Construction Equipment U S A Inc Address 6100 Atlantic Boulevard Norcross GA 30071 U S A Distributor for Europe Hyundai Construction Equipment Europe N V Address Hyundailaan 4 3980 Tessenderlo Belgium Dealer Address 0 6 ...

Page 11: ...PROVED Noise levels EN474 1 2006 and 2000 14 EC are as follows Lwa 102 dB EU only Lpa 70 dB The value of vibrations transmitted by the operator s seat are lower than the standard value of EN474 1 2006 and 2002 44 EC 0 7 ...

Page 12: ...on 12 Control ideogram 13 Air conditioner filter 14 Electric welding 15 Lift tie 16 Air cleaner element 17 Manual lowering valve 18 Fueling 19 Battery accident 20 Hyd oil lub 21 High pressure hose 22 Bio oil 23 Engine door shearing 24 Service instruction 25 Start procedure 26 Diesel exhaust fluid 27 Specification sheet 28 Grease center 29 Keep clear Reflect 30 Name plate 31 ROPS plate 32 Accumulat...

Page 13: ...terminals or across the batteries Shorting could bypass the engine neutral start sys tem Shorting could also damage the electri cal system 2 TURBOCHARGER COVER item 2 This warning label is positioned on the turbocharger cover Do not touch turbocharger or it may cause severe burn When the engine is running or immediately after engine shut down 3 HYDRAULIC OIL LEVEL Item 3 This warning label is posi...

Page 14: ...ned on the middle of the boom When working under or around the bucket or linkage with the bucket raised proper sup port must be provided for the bucket and or the linkage 6 STEERING WARNING Item 9 10 The warning label is positioned on both sides of the front frame No clearance for persons in this area when machine turns Severe injury or death from crushing could occur 7 ENGINE START CAUTION Item 1...

Page 15: ...ditioner filter Periodic and proper inspection cleaning and change of filter prolong air conditioner life time and maintain good performance 10 ELECTRIC WELDING Item 14 This warning label is positioned on the side of the battery box Before carrying out any electric welding on this machine follow the procedure descri bed below Pull the connectors out of all electronic control units Connect the grou...

Page 16: ... to the tying points 12 AIR CLEANER ELEMENT item 16 The warning label is positioned on the air cleaner Periodic and proper inspection cleaning and change of elements prolong engine life time and maintain the good performance of en gine 13 MANUAL LOWERING VALVE Item 17 The warning label is positioned on the left side of the front frame Be sure no one is under or near the attach ment before lowering...

Page 17: ...olyte containing sulfuric acid cause severe burns Avoid being in contact with skin eyes or clothes In the event of acci dent flush with sufficient water call a physi cian immediately Maintain the electrolyte at the recommended level Add distilled water to the battery only when starting up never when shutting down With electrolyte at proper level less space may cause the gases to be accumulated in ...

Page 18: ...not open the engine door during the en gine s running Stay clear of rotating parts Do not touch exhaust pipe or it may cause severe burn 20 START PROCEDURE Item 25 This warning label is positioned on the right side win dow of the cab Start Procedure 1 Start ignition on 2 Wait up to 4 seconds for grid heater operation in summer 45 seconds in winter 3 Start cranking 4 If engine still does not start ...

Page 19: ...umulator A special air bleed valve is required for this operation so please contact your Hyundai distributor 23 CAUTION WATER SEPARATOR TURBO CHARGER Item 33 This warning label is positioned on the right side win dow of the cab In order to protect high pressure fuel sys tem please drain water in water separator before starting the engine In order to prevent a turbocharger failure please allow more...

Page 20: ...pening the inlet covers on the right and left side Firefighting can take place using the holes on the screen which provide access to the engine compartment with e g handheld fire extinguisher The extinguishing agent contains glycol which may cause injuries in case of contact Avoid contact In case of contact with the eyes rinse with water In case of skin con tact wash with soap and rinse with water...

Page 21: ... 29 QUICK COUPLER Item 41 This warning label is positioned on the middle of the boom Serious injury or death can result from drop ping bucket Operating the machine with attachment switch unlocked or without safety pin of moving hook can cause the bucket to drop off 30 STAY FIX Item 43 This warning label is positioned on the side cover of the LH and RH cowl Be sure to support the stay when the door...

Page 22: ...uring year 6 Maximum certified weight ROPS FOR EU ONLY The product identification number assigned to this particular machine and should be used when requesting information or ordering service parts for this machine from your author ized HYUNDAI dealer The product identification number is also stamped on the frame 0 18 ...

Page 23: ...following when you order parts or the machine is out of order 1 MACHINE SERIAL NUMBER The numbers are located on the left side of the rear frame 2 ENGINE SERIAL NUMBER The numbers are located on the engine name plate It is also located on the left side frame of the cab inside Backward Forward Right Left Machine serial No Engine serial No Cab inside LH GUIDE 0 19 ...

Page 24: ... work Leveling work Loading work Transporting work Please refer to Efficient working method on page 4 14 for further details 4 SYMBOLS Important safety hint It indicates matters which can cause great loss on the machine or the surroundings It indicates useful information for the operator 0 20 ...

Page 25: ...1 CALIFORNIA PROPOSITION 65 SAFETY HINTS 1 1 ...

Page 26: ...rses on the operation of the machine and fully understand how to use the tools Improper operation refueling inspection or repair of this machine may cause serious injury or death Do not attempt to operate refuel inspect or repair this machine before reading and understanding the product information on such tasks This manual describes preventive measures and warnings about the product Neglecting th...

Page 27: ...ntly deformed or damaged Machines operated in areas where there is a risk of objects falling onto the cabin are fitted with a Falling Object Protective Structure FOPS pursuant to ISO 3449 3 Fire and Explosion 1 Prevention of fire The following actions should be taken to minimize the risk of fire Do the visual inspection before operating the machine to check for any risk of fire Do not operate the ...

Page 28: ...r sparks and be sure to wear suit able PPE Personal Protective Equipment 2 Prevention of explosion The following actions should be taken to minimize the risk of explosion Preheating function is provided to certain ma chines that are used in extremely cold environ ments Never use starting aid fluid in a low temperature environment as it can have an adverse effect on the engine performance and may c...

Page 29: ...f the engine is running it may cause a persistent fire Stop the engine without delay In the event of an electric short disconnect the batteries to eliminate the main ignition source In the event of an electricity leak resulting from damage to the power wiring caused by fire discon nect the batteries to eliminate the secondary ignition source If a fire becomes too large to control assess the follow...

Page 30: ... drill ROPS to mount a fire extinguisher Contact your dealer or distributor for more information about the correct mounting of fire extinguishers 4 Health and Safety 1 Personal protective equipment The wearing of personal protective gear is mandatory for protecting the human body from hazardous chemicals and hazardous environments The wearing of personal protective gear is a means of preventing di...

Page 31: ...muffs separately or in combination depending on the level and duration of noise Safety shoes Protects the feet from falling objects impacts and sharp objects 3 Health and safety instructions in hazardous environments Comply with the following instructions during operation and maintenance of the machine 4 When handling oil Failure to wear personal protection may result in burns caused by contact wi...

Page 32: ... the skin with the refrigerant Wear protective gloves made of materials that are re sistant to chemicals such as neoprene and butyl rubber Never smoke when handing refrigerant If refrigerant comes into direct contact with the skin wash the skin with warm water immediately 7 When handling coolants After operation of the machine the coolant is of high temperature and high pressure and is retained in...

Page 33: ...bjects Earplugs or earmuffs may be necessary when working in a noisy place 9 When working in places with a high level of noise When the operator is exposed to the noise exceed ing 90 dB A for 8 hours or longer wear earplugs or earmuffs 10 Personal protection gear for various situations Situation Symbol Oil handling Battery handling Refrigerant handling Coolant handling Repair by welding 1 9 ...

Page 34: ...bration data of the machine and methods of calculating the vibration level The vibration level of the machine varies according to any of the following conditions Driving habits of the operator i e aggressive mild temperament when driving Quality of seat and suspension Type of machine attachments and conditions of machine Conditions of work site working environment ground surface conditions and wea...

Page 35: ...l All vibration values are indicated in m s2 2 Instructions on mitigating vibration Machines should be correctly adjusted and maintained to ensure smooth operation The terrain condi tions should be observed The following instructions will help reduce the whole body vibration level a Use machines and attachments of the correct types and sizes b Maintain the machines pursuant to the manufacturer s r...

Page 36: ...ther place at the worksite for safety accidents Keep contact information e g phone number to re quest help with an emergency situation or injury 6 Safety Information on the Machines and Operation 1 Before Operating the Machine 2 Checking the worksite Carefully examine the following conditions and take the necessary actions if required to prevent risk factors before operating the machine Check the ...

Page 37: ...he operator should read and fully understand the operator s manual before operating the ma chine The operator should fully understand the details and procedures of the work to be performed If a risk of a safety accident is suspected consult sufficiently with the responsible worker and only perform the work after taking the necessary preventive measures 4 Machine conditions to be checked before op ...

Page 38: ... foot or vice versa when getting on or off the machine Do not sit on a seat not suited or intended for sitting Three point contact means making contact with the machine with both hands and one foot or with one hand and both feet 2 During operation The operator should start the engine only after sitting on the operator s seat Make sure that all levers are shifted to the neutral position before star...

Page 39: ...d with the attachment extended forward to keep the machine balanced and with the bucket raised at least 20 30 cm from the ground Never travel down a slope in neutral Keep the bucket 20 30 cm above the ground and use the bucket as a brake in an emergency situa tion If the engine suddenly stalls immediately bring the bucket to the ground If the fuel gauge reaches the red zone while op erating the ma...

Page 40: ...ter every 40 km or on an hourly basis and take a break Check the level of fuel and coolant Never shift the gear to the neutral position when driving down a slope Changing direction when operating the machine on a slope is dangerous Do not drive on a slope of 30 or more Drive slowly when traveling the machine on rough terrain or moving over obstacles Install chains on the tires when operating the m...

Page 41: ...fic areas 1 Operating in extermely cold environments Do not attempt to start stop or turn the machine suddenly as this may cause it to slip There is potential for the machine to slip Snow covered or frozen ground may be slippery and dangerous Idle operation of the machine may be required to elevate the engine temperature during startup An impact resulting from a sudden movement of the boom or the ...

Page 42: ...ng in dusty or sandy environments Check the radiator grill for clogging by pollutant and remove them if any Check the fuel system and protect it from dust or sand when refueling Inspect the air cleaner regularly and replace it if necessary If the gauge lamp on the dashboard lights up and the buzzer sounds at the same time clean or replace the air cleaner independently of the usual inspection cycle...

Page 43: ...ear protective goggles and protective clothes when cleaning the machine using a com pressed water jet Do not spray water or steam directly onto the electronic components Use proper lighting devices when operating the machine in a dark area Use lighting devices that satisfy the explosion proof requirements when handling inflammable ma terials such as fuel and hydraulic oil Never attempt to use a di...

Page 44: ...terials so special care should be exercised when handling such materials to prevent fire and explosion Oil that leaks on to a hot surface or electronic components may cause a fire Keep all fuels and lubrication oils in adequate containers Do not smoke while refueling fuels or at the re fueling point Do not smoke in a space where battery electro lyte and other inflammable materials are han dled Kee...

Page 45: ...ing work in a well ventilated place Remove all inflammable materials from areas in the vicinity of welding work Provide fire extinguishers 7 Precautions to take when working on the ma chine There is a risk of falling when working on the machine Keep the area around the workers feet clean and tidy Do not spill oil or grease Do not leave tools lying on the floor Be careful on the floor when moving N...

Page 46: ...hard Do not install a bent or damaged line or hose Make sure that all of the clamps and protective devices are properly installed Check the pipes and hoses regularly and replace any damaged parts if necessary 9 Cautions on inspecting the tire Always keep the tires inflated to the proper pressure Overheating or rupture of the tires may result in serious injury Repairing or changing the tires requir...

Page 47: ...s injury Use a voltmeter when inspecting the battery charging Regularly inspect the battery cable and replace it if damaged A battery cable with exposed wires may cause a short if it comes into contact with the ground ing surface A short circuit of the battery cable may cause heat from the battery current and result in a fire If the wires of the ground cable are exposed be tween the battery and th...

Page 48: ...ors is unavoidable store it on a wooden pallet Keep the exposed area of the piston load of the cylinder covered Bring the attachments right down to the ground and keep the wheels and the track immobile by placing wheel chocks 3 Regular lubrication during storage Breaking the lubrication film on parts may cause abnormal abrasion during the next operation Start up the engine once a month perform all...

Page 49: ... that the DEF tank be filled completely full of DEF in order to correct any fault conditions The use of DEF AdBlue meeting ISO 22241 1 is required There is no acceptable substi tute Some locations may reference the DIN 70070 standard Diesel Exhaust Fluid specification limits of this standard are identical to ISO 22241 1 Safety Requirements for fuel The engine has been optimized for use with an exh...

Page 50: ...assification CJ 4 To determine if the lubricating oil meets CES 20081 review the label on the back of the lubricating oil bottle for the CES 20081 reference If acquiring the lubricating oil in bulk contact the supplier for the lubricating oil specifications and confirm that the oil meets CES 20081 Also located on the lubricating oil bottle is the API service symbol which is shown in the accompanyi...

Page 51: ...ght Hydraulic tank Radiator Counterweight Battery Main control valve Boom cylinder Boom Main pump Engine Air cleaner Cab Bucket cylinder Bell crank Fuel tank Front axle Transmission Rear axle Steering cylinder Bucket link SPECIFICATIONS 2 1 ...

Page 52: ... 10 Dump reach full lift H 1065 3 6 Width over tires I 2375 7 10 Dump angle J degree 48 Roll back angle carry position K 47 Cycle time Lift with load sec 5 8 Dump with load 1 5 Lower empty 3 6 Maximum travel speed km hr mph 39 5 24 5 Braking distance m ft in 13 0 42 8 Minimum turning radius center of outside tire 5 05 16 7 Gradeability degree 30 Breakout force kg lb 9150 20065 Travel speed Forward...

Page 53: ...mp reach full lift H 1035 3 5 Width over tires I 2375 7 10 Dump angle J degree 48 Roll back angle carry position K 48 Cycle time Lift with load sec 5 8 Dump with load 1 5 Lower empty 3 6 Maximum travel speed km hr mph 39 5 24 5 Braking distance m ft in 13 0 42 8 Minimum turning radius center of outside tire 5 05 16 7 Gradability degree 30 Breakout force kg lb 9070 20000 Travel speed Forward First ...

Page 54: ...full lift H 1145 3 9 Width over tires I 2375 7 10 Dump angle J degree 48 Roll back angle carry position K 47 Cycle time Lift with load sec 5 8 Dump with load 1 5 Lower empty 3 6 Maximum travel speed km hr mph 39 5 24 5 Braking distance m ft in 13 0 42 8 Minimum turning radius center of outside tire 5 05 16 7 Gradeability degree 30 Breakout force kg lb 9770 21540 Travel speed Forward First gear km ...

Page 55: ...h full lift H 1115 3 8 Width over tires I 2375 7 10 Dump angle J degree 48 Roll back angle carry position K 48 Cycle time Lift with load sec 5 8 Dump with load 1 5 Lower empty 1 5 Maximum travel speed km hr mph 39 5 24 5 Braking distance m ft in 13 0 42 8 Minimum turning radius center of outside tire 5 05 16 7 Gradeability degree 30 Breakout force kg lb 9690 21365 Travel speed Forward First gear k...

Page 56: ...ential 750 1653 Tire 17 5 R5 L3 154 340 Hydraulic tank assembly 157 347 Fuel tank assembly 198 437 Main pump assembly 36 80 Fan brake pump assembly 6 14 Main control valve 2 3 spool 42 55 93 122 Boom assembly HL930A 550 1213 HL930A XT 625 1378 Bell crank assembly 136 300 Quick coupler assembly 293 646 Bucket link 30 67 1 9 m3 bucket with bolt on cutting edge 810 1786 1 8 m3 bucket with 1 tooth 730...

Page 57: ...7 lbf ft at 1200 rpm Engine oil quantity 11 ℓ 2 9 U S gal Wet weight or Dry weight 383 kg 845 lb Stater motor 24V 4 8 kW Alternator 24V 95A 2 MAIN PUMP Item Specification Type Variable piston pump Capacity 60 cc rev Maximum operating pressure 250 bar 3626 psi Maximum operating speed 2230 rpm Rated output flow at 2200 rpm 132 ℓ min 3 FAN AND BRAKE PUMP Item Specification Fan Brake Type Gear Pump Ca...

Page 58: ...WER TRANSMISSION DEVICES Item Specification Torque converter Model ZF 4WG130 Type Single stage single phase Ratio 2 302 1 Transmission Type Full automatic power shift Gear shift Forward fourth gear reverse third gear Control Electrical single lever type kick down system Pump rated fl ow 85 ℓ min 22 5 U S gpm at 2000 rpm Axle Drive devices 4 wheel drive Front Front fixed location Rear Oscillation 1...

Page 59: ... at a glance 2 It is equipped with a safety warning system for early detection of machine malfunctions Cluster Steering wheel Gear selector lever Accelerator pedal Horn button Aircon heater switch Radio USB player Fingertip remote control lever opt Brake pedal Operator s seat Starting switch Switch Multi function switch Remote control lever std FNR remote control lever opt Kick down switch Monitor...

Page 60: ...ndicates selected the driving speed and direction The cluster installed on this machine does not entirely guarantee the condition of the ma chine Daily inspection should be performed according to Section 6 Maintenance When the cluster provides a warning immediately check the problem and perform the re quired action Fuel gauge Warning lamps 1 Speedometer Left turning pilot lamp Engine coolant temp ...

Page 61: ...re of the coolant White range 40 105 C 104 221 F Red range Above 105 C 221 F b If the indicator is in the red range or the lamp blinks in red turn the engine OFF and check the radiator and engine If the gauge indicates the red range even when the machine is in a normal condition check the electric device as this can be caused by a poor connection of electricity or a sensor 4 Transmission oil tempe...

Page 62: ... lamp T M oil temp warning lamp Engine overheat warning lamp Fuel level warning lamp Exhaust system cleaning inhibit warning lamp Fail in SCR system warning lamp 1 Emergency warning lamp a This lamp blinks when each of the below warnings occurs Warning lamps turn ON MCU input voltage abnormal Monitor communication data error Engine ECM and TCU communication data error b When this warning lamp blin...

Page 63: ...en the fuel level is low Refuel the machine as soon as possible 6 Transmission error warning lamp a This lamp lights ON and the LCD display shows the error codes when an error occurs in the transmission b Immediately pull the machine to a convenient stop Stop the en gine Investigate the cause Consult a Hyundai dealer to investigate the cause Do not operate until the cause has been corrected 7 Air ...

Page 64: ...een correc ted b Emergency This lamp indicates that the emergency steering system is active Immediately pull the machine to a convenient stop and stop the engine The emergency steering system can be manually tested Refer to the page 3 53 10 Battery charging warning lamp a This lamp is ON and the buzzer sounds when the key is turned to ON it goes OFF after starting the engine b Check the battery ch...

Page 65: ... the engine immediately and check the DEF AdBlue tank b Fill the DEF AdBlue immediately in the DEF AdBlue tank Refer to page 3 10 c This lamp lights ON when the stationary exhaust system cleaning is not performed Refer to page 3 8 Please contact your Hyundai service center or local deal er Engine shutdown cluster message up when the exhaust gas temperature reaches above 800 C 14 Engine coolant low...

Page 66: ...ngine power will be re duced automatically if ac tion is not taken The exhaust system cleaning can be accom plished by Changing to more challenging duty cycle Performing a manual exhaust system cleaning On On On These lamps will be ON when a sta tionary manual exhaust system cleaning is not performed Stop the engine immediately Please contact your Hyundai service center or local dealer 17 Exhaust ...

Page 67: ...ight ON during the exhaust system cleaning is operating d The exhaust system cleaning and or HEST warn ing lamp will light OFF when the exhaust system cleaning is completed 18 HEST High exhaust system temperature warning lamp a This warning lamp indicates when illuminated that exhaust tem peratures are high due to exhaust system cleaning b The lamp will also illuminate during a manual exhaust syst...

Page 68: ...automati cally On Blink On On This is happened when 30 minutes elapsed with empty conditions 0 of the DEF AdBlue tank The engine will enter the final derate level which may include low idle lock or en gine shutdown with restart limitations In order to remove the final derate the DEF AdBlue tank must be filled to above 10 persent gauge read ing 20 Fail in SCR system warning lamp a This warning lamp...

Page 69: ...inating direction is upward b This lamp comes ON when the dimmer switch is operated e g when passing another vehicle 2 Parking brake pilot lamp a When the parking brake is actuated the lamp lights ON Check the lamp is OFF before driving 3 FNR select pilot lamp Option a The lamp comes ON when the FNR select button on the optional FNR remote control lever is pressed Refer to page 3 56 77073CD12 7707...

Page 70: ...LCD can be used with the gear selector It indicates speed driving direction DEF AdBlue level and trans mission warning No Symbol Meaning Remark 1 N Actual gear display Forward reverse neutral 1 2 3 4 5 Actual gear Parking brake mode active 2 Forward reverse 3 Gear range display 4 DEF AdBlue level Display the amount of liquid in the DEF Ad Blue tank 5 DEF AdBlue level warning lamp Fill the DEF AdBl...

Page 71: ... tem perature Alternate between WS and actual gear direc tion while driving in neutral only displayed WS if no fault is detected Cool down transmission WT Warning torque con verter temperature Alternate between WS and actual gear direc tion while driving in neutral only displayed WS if no fault is detected Cool down transmission 3 13 ...

Page 72: ... Switchs 2 Lamps 1 Menu bar 1 Refer to page 3 42 2 Refer to page 3 45 1 MAIN DISPLAY You can select or set the menu by the switches or touch screen Please refer to switch page 3 45 for selection and change of menu and input value Display type can be changed by operator See page 3 39 for details 3 14 ...

Page 73: ...ain menu Press Sub menu TYPE B Tap 1 Clock 2 Buzzer 3 Wiper speed 4 Camera screen 5 Menu 6 Machine monitoring 7 Fuel rate 8 Engine mode Operation history 9 Transmission mode 10 ECO gauge 11 Engine rpm 12 Quick menu 13 10 lamps 3 15 ...

Page 74: ...Wiper speed Set the wiper speed slow normal fast and very fast c Menu Move to the main menu d Buzzer stop If you want to stop the buzzer sound touch the icon a Clock setting b Wiper speed c Menu d Buzzer stop 2 Change display information In main display you can check the data and set up what you want by touching each window area or icon 3 16 ...

Page 75: ...the other items are not available To display the other items the weighing system should not be selected Weighing system see page 3 24 a Machine monitoring b Fuel rate Set average fuel rate or a days fuel used on main display screen Refer to page 3 33 a Fuel rate 760F3CD08B 1 c Engine mode and operation history Set the engine mode A Refer to page 3 22 Set Hour meter ODO meter B Refer to page 3 32 a...

Page 76: ...d Transmission mode Set the clutch cut off A shift B and torque converter lock up mode C Refer to page 3 23 a Transmission mode 3 18 ...

Page 77: ...cycle can be changed Refer to page 3 36 d Help Read the monitor manual as a PDF file on the monitor Smart terminal The menu features a smartphone and operates the mir acast Operation of screen mirroring can be dangerous while driving Driver is responsible for accident or other dam ages Operate the screen mirroring while stopping for safety a User switching b Active fault c Maintenance d Help a Vir...

Page 78: ...ature of hydraulic oil cooling water transmission oil or battery voltage is not in nor mal state b Case of warning sign Icon Description Above 106 C of hydraulic oil tem perature Above 105 C of cooling water temperature Above 107 C of transmission oil temperature Below 24 5 voltage of battery for 3 minutes Above 100 C of axle oil tempera ture option 5 Communication error a MCU could not communicat...

Page 79: ... Auxiliary attach max flow level Max oil flow level setting Soft end stop Boom up down Bucket in dump ON OFF Speedometer frequency setting Speedometer setting Cooling fan reverse mode Off Manual Automatic Wiper level setting Slow Normal Fast Very fast Calibration Boom bucket angle Boom pressure Brake ped al sensor AEB Engine auto shutdown Once On Always Disable ESL system setting 2 Monitoring Mach...

Page 80: ...play order Reverse mode AAVM setting AAVM camera reverse mode 5 Multimedia Media player Smart terminal Play video and audio files in USB Operation of screen mirroring 2 Mode a Engine setting mode Engine mode The operator can adjust the machine s performance Econo Maximum fuel efficiency for general loading Power Maximum power output for hard digging operation or hill climb Smart power Fuel efficie...

Page 81: ...mal autoshift function continues after the kick down switch is released c Clutch cut off C C O mode L mode M mode H mode Left brake pedal Four modes are available for operator s preference and job condition OFF The clutch cut off function is disabled L Low The clutch is disengaged early for short distance and rapid loading M Medium The clutch is disengaged normally for general digging and loading ...

Page 82: ...n to 1st gear for general digging and loading operation AH Auto Heavy Automatic shifting point is normal with automatic kick down to 1st gear for more powerful operation e Torque converter T C lock up mode 5 speed transmission If you select ON the lock up clutch on the torque converter will automatically activate according to load Lock up clutch function option To prevent power loss in the torque ...

Page 83: ...uck Refer to page for 3 48 details Error detection Set error detection ON OFF OFF Errors are not displayed ON ⓐ ⓑ and ⓒ are displayed on main display screen ⓐ The boom lift was performed too fast ⓑ The bucket was not in the fully tilted back position while bucket was in the weigh range ⓒ The hydraulic temperature is low below 40 C Boom pressure calibration See the page 3 28 for details Weighing sy...

Page 84: ...r dumping operation In order to recheck weight go to the ⓑ after changing boom posi tion below 15 Dump operation It is checked by buck et cylinder s stroke change below 250 mm The temperature for the hydraulic oil must be raised to at least 40 C 104 F before opera tion g Boom bucket detent mode OFF Detent functions are not operated ON Boom or bucket detent functions are operated Save position Refe...

Page 85: ...ent flow can be easily adjus ted and controlled Set the oil flow level from 0 to 15 level by using button j Soft end stop mode option This function gives shock free operation by reducing the speed of attachment near the end stroke Set the soft end stop function ON OFF k Speedometer frequency setting mode Press the speedometer setting bar or for 3 seconds Only for the service person Do not adjust a...

Page 86: ...e Setting wiper speed in J position of multi fumction switch slow normal fast and very fast Refer to the page 3 57 n Calibration You should turn OFF Soft end stop before start calibration Press NEXT button after following the instruction at each step If correction is right NEXT button will be activated then go to next stage After following each step correctly the message Calibration completed will...

Page 87: ...cket must be max tilting position b Raise boom at maximum high position and press NEXT button or c Position boom at 5 and press NEXT button or d Retract bucket cylinder length to minimum position at 5 boom position and press NEXT button or e Extend bucket cylinder length to maximum position at 5 boom position and press NEXT button or f In case above steps are carried normally Calibration is done m...

Page 88: ... 40 60 C Check if pressure sensor or angle sensor is in normal condition for accurate work load al gorism or pressure sensor calibration pressure sensors at boom cylinder head area and rod area boom angle sensor CD 80 bell crank angle sensor CD 81 Sensor error message during pressure sensor calibration sensor need to be checked Brake pedal sensor calibration Turn the engine OFF and turn the starti...

Page 89: ... Kx Kx couldn t be calibrated AEB finished E Engine speed too low Raise engine speed E Engine speed too high Lower engine speed T Transmission oil temperature too low Heat up transmission T Transmission oil temperature too high Cool down transmission FO Output speed not zero FN Shift lever not in neutral position FP Parking brake not applied Transmission stays in neutral you have to restart the TC...

Page 90: ... Total distance this item cannot be initialized Total working hour can check on service meter See page 3 72 Latest Working hour distance after reset If you select Initialization working hour distance start zero To display the item in main display select the item in main display See the page 3 14 c Fault history 3 32 ...

Page 91: ...nit AAVM All Around View Monitoring d Fuel consumption history Display the fuel consumption history General record average fuel rate and a days fuel used Hourly record Daily record Mode record P P smart E mode Operation efficiency record Shuttle shift Idle Relief e Machine information Software versions of MCU ECM TCU EHCU RMCU Cluster and monitor can be checked 3 33 ...

Page 92: ...he operator starts the engine first But the operator can restart the engine within the specific time without inputting the password The specific time can be set maximum to 2 days Smart key authentication function Enable Set the using or not of smart key If you using smart key ESL function always be activated Disable Register or delete user tag and display registered user tag When delete user tag a...

Page 93: ...standstill for a period that exceeds the period in days set by the operator without any activity then to prevent the machine batteries from draining the Remote Door Functionality will be disabled When this happens the operator will be able to only use the machine Key to open the cab door after which the Remote Door functionality can be enabled again during first start up During the first start up ...

Page 94: ...f 50 hours Show the maintenance history below 10 When history have more than 10 delete the old item Change or replace interval Refer to page 6 8 c Service menu Sensor monitoring Display information of each sensors Speed limit setting 20 40 km h 5 km h intervals EHCU I O information Real time monitoring joystick stroke EPPR current 3 36 ...

Page 95: ...date Update file in USB memory e Owner menu editing Owner menu editing Owner can set the status of the function Enable Disable Menu list In the menu owner can set the list of the function to lock or unlock it Owner passward change Default password 11111 Owner can manage and change the password 3 37 ...

Page 96: ...tic control of LCD brightness as set level of day night Setting day time Set the time for daylight If you set the time for daylight the rest time will be night b Clock setting Set the time hour minute and AM or PM c Unit setting Volume ℓ gal Temperature C F Distance km mile Weight ton lb Pressure bar Mpa kgf m2 psi Using button Move to other item by 3 38 ...

Page 97: ...n engages the reverse gear R1 R3 the camera mode is displayed automati cally in the main display If the camera is not equipped this menu is not useful If the camera monitor is equipped camera will showing on camera monitor only This menu is not useful See the page 3 89 In the main display if the is touched or switch is pushed the first ordered display camera will be viewed If AAVM is equipped this...

Page 98: ...e it detects surrounding pedestrians or objects and the warning buzzer sounds User can turn OFF the warning sound by pressing buzzer stop switch When the worker or pedestrian go near the danger area line green radius 3 m an external danger area of equipping on the main display the warning buzzer sounds and it displays the green rectangular box for the recognition of the worker and pedestrian At th...

Page 99: ...buzzer by pressing the buzzer stop switch And then please work after you check whether the danger factors are solved g Multimedia Media player Play video files from USB mp4 mkv avi 3gp divx f4v flv mpeg mov vob wmv webm xvid Play audio files from USB mp3 mp4 ogg wma wav flac aac Smart terminal The menu features a smartphone and operates the miracast Operation of screen mirroring can be dangerous w...

Page 100: ...matic warming up is cancelled when the engine coolant temperature is above 30 C or when 10 minutes have passed since starting the engine 2 Seat belt pilot lamp a This lamp lights ON for the first five seconds after starting the en gine 3 Preheat pilot lamp a This lamp lights ON when start switch is turned clockwise to the ON position Light will turn off after approximately 5 45 seconds depending o...

Page 101: ...er to page 3 23 6 Float mode pilot lamp a This lamp lights ON when the boom float is activated Refer to page 4 8 7 Ride control pilot lamp option a Auto ride control a This lamp lights ON when the automatic ride control function is acti vated ON Conditional speed setting Refer to page 3 47 b Manual ride control a This lamp lights ON when the manual ride control function is activa ted ON Always set...

Page 102: ...orque converter lock up function is operating Refer to page 3 24 10 Fuel warmer pilot lamp a This lamp is turned ON when the coolant temperature is below 10 C 50 F or the hydraulic oil temperature 20 C 68 F b The automatic fuel warming is cancelled when the engine coolant temperature is above 60 C and the hydraulic oil temperature is above 45 C since the start switch was in ON position 3 44 ...

Page 103: ...n keypad is not pressed for 3 seconds convert screen to main display If you push the left and right switch at the same time you move to the language set tings 1 Menu Home switch a Main display to main menu main menu to main display Menu Home switch ESC switch Left Right switch Enter switch Camera switch Main light switch Beacon lamp switch Work light switch Central grease lubrication switch Rear w...

Page 104: ...s switch is not useful See the page 3 89 6 Main light switch a This switch operates the clearance lamp and head light Position lamp Clearance lamp and cluster illumination lamp come ON The green pilot lamp is turned ON Head lamp Position lamp Clearance lamp cluster illumination lamp and head light come ON The green pilot lamp is turned ON 7 Work lamp switch a This switch operates the front and rea...

Page 105: ...ever use an attachment before you have checked its mounting b Engage quick coupler The quick coupler pins move in the engaged position and buzzer sounds The green pilot lamp is turned ON Check for engagement as followings 1 Put down pressure on the attachment 2 Back up the machine and make sure that there is no movement between the quick coupler and attachment 10 Ride control switch option a Forwa...

Page 106: ...k status 3 Target weight 4 Loaded weight 5 Remaining weight to com plete job Over weight to complete job 6 Progress bar Total weight 7 Select button for mode Standby mode Weigh mode 8 Project name 9 Truck name 10 Operator 11 Materials 12 Go to Work load setting menu 13 Save Work log to USB 14 Delete Work log 15 Go to Main menu Work mode switch Short press Press and hold 3 48 ...

Page 107: ...ilot lamp is turned ON 13 Beacon lamp switch option a This switch turns ON the rotary light on the cab b The green pilot lamp is turned ON 14 Mirror defrost switch option a ON In ON condition it operates for 15 minutes After 15 minutes the defrost function stops automatically The green pilot lamp is turned ON b OFF Stops defrost function 15 Detent setting switch a Boom and bucket Set the boom and ...

Page 108: ...n switch a ON Remote control lever provides the operator with precise control of the work equipment bucket and boom cylinders can be controlled precisely The green pilot lamp is turned ON b OFF Turn off the function 3 50 ...

Page 109: ...cy test switch Horn button Kick down switch Workload button Starting button opt Starting switch Exhaust system cleaning switch Hazard switch Horn button FNR switch Workload button Kick down button FNR select button Fingertip opt Differential lock switch Air compressor switch opt 3 51 ...

Page 110: ...to unlock the hydraulic pilot line This switch can be set to the ON or OFF position only when the safety button is pulled to the unlock position 3 PARKING BRAKE SWITCH 1 When the switch is pressed to the ON position the parking brake will start to operate and the cluster warning lamp will come ON 2 Press the release position in order to disengage the parking brake When operating the gear selector ...

Page 111: ...witch When the switch is re leased the differential lock function is disengaged and the switch returns to the OFF position 3 Auto mode Press the A of the switch for the auto mode of the differential lock function If you press the switch the axle differential lock will automatically engage when the differential function is used While the axle differential lock function is operating the differential...

Page 112: ...Refer to page 3 8 for details This switch can be move to the manual position b only when the safety button is pulled to backward Also this switch return to the auto position when released the manual position b 7 HORN BUTTON 1 If you press the button the horn will sound 8 CAB LAMP SWITCH 1 This switch turns ON the cab room lamp a DOOR The lamp comes ON when the door is opened When the door is close...

Page 113: ...hing the switch and recovering to current speed quickly when push the switch one more time b Mode 2 down It shifts down from current gear to one step lower speed when push the switch every time The kick down function is released in only 1st speed Refer to page 3 23 for the kick down mode The normal autoshift function continues after the kick down switch is released Kick down switch Joystick steeri...

Page 114: ...d the machine moves forward b If the down side R REV of this switch is pushed the machine moves backward c This function is automatically released when the engine is stop ped parking brake is ON or gear selector lever is out of neutral 4 Auxiliary roller If the machine is equipped with auxiliary hydraul ics this roller is used for the attachments 11 WORKLOAD BUTTON 1 This button is used to calcula...

Page 115: ...id is LOW add the washer liquid in cold win ter days or water The capacity of the tank is 1 liter If the wiper does not operate with the switch in ON J When placed in Ɇ or ɇ position turn the switch OFF O immediately and check the cause If the switch remains ON motor failure can result 2 Dimmer switch a This switch is used to adjust the head light direction b Switch positions Up to flash for passi...

Page 116: ...ntrol lever Joystick type Steering wheel lever Steering wheel Gear selector lever Accelerator pedal Joystick steering control lever opt Differential lock foot switch Remote control lever FNR type Remote control lever EH type 3 58 ...

Page 117: ...you pull the gear selector lever the machine moves backward 3 If you turn the gear selector lever forward the machine increases the speed If you turn the gear selector lever backward the machine reduces the speed 3 ACCELERATOR PEDAL 1 This pedal controls the engine speed The engine speed will in crease in proportion to the degree of force applied to this pedal 2 Unless this pedal is pressed the ma...

Page 118: ... not cut off Do not operate the machine with foot the brake pedal unnecessarily or bring premature wear of brake disc c Clutch cut off function Refer to page 3 23 2 Right brake pedal service brake function only This pedal functions as service brake only 5 STEERING WHEEL 1 Two multi motion cylinders in the center of the machine will operate the steering function 2 If the steering wheel is turned to...

Page 119: ...conditions are met press the select button B The joystick steering pilot lamp on the cluster will be ON and joystick steering can be activated c Steering will remain enabled until machine speed is zero and one of the following conditions is met LH armrest is raised Parking brake is engaged Gear selector lever is in forward or backward position Operator is not seated on the seat Press the select bu...

Page 120: ...el is adjustable to tilt Tilting 40 2 By pulling up the lever the wheel is adjustable to telescope Telescoping 80 mm 8 DIFFERENTIAL LOCK FOOT SWITCH 1 Press the foot switch for the differential lock function When you press the foot switch the differential lock will engage im mediately and the differential lock pilot lamp turns ON the buzzer sounds 2 The differential lock function is temporarily en...

Page 121: ...matically keep the optimum condition in accordance with the operator s temperature configuration sensing the ambient and cabin inside temperature Location of air outlet Power switch Fresh air air recirculation switch Temperature control switch Auto switch Defroster switch Fan speed switch Air conditioner switch 3 63 ...

Page 122: ...ned ON 3 AIR CONDITIONER SWITCH Compressor switch a This switch turns the compressor for the air conditioning b In accordance with the temperature sensed by the duct evapora tor sensor the compressor turns ON or OFF automatically The air conditioner operates to remove vapor and drains water through a drain hose Water can be sprayed into the cab in case there is a problem with the drain cock at the...

Page 123: ...sing recirculation for a long time Check the recirculation filter periodically to keep a good efficiency 6 FAN SPEED KNOB a This knob controls the fan speed manually There are 9 steps to control the fan speed 7 TEMPERATURE CONTROL KNOB a This knob controls the position of the water valve when the air con ditioner switch is ON or OFF b When the AUTO switch is ON the temperature control knob deter m...

Page 124: ...ator fatigue due to long work hours and enhance work efficiency Always check the condition of the seat belt and mounting hardware before operating the machine Not wearing the seat belt during the machine operation may result in serious injury or death in the event of an accident or machine overturn 12V socket Seat Fuse relay box Transmission control unit Machine control unit 12V socket Cigar light...

Page 125: ...matic weight and height ad juster arrow with the machine at a standstill and the operator s sitting on the seat The operator must sit absolutely still during adjustment Before adjusting the weight adjust shock absorbers to the position soft To prevent damage to the health the setting for the operator s weight must be checked and adjusted be fore the machine is operated Height adjustment AIR SUSPEN...

Page 126: ...wards By moving the seat pan backwards or forwards the desired seating position can be reached 4 Seat pan angle adjustment a The angle of the seat pan can be individually adjusted b To adjust the angle of the seat pan pull the left handle upwards By exerting pressure on or off the front or rear part of the seat pan it can be moved to the desired angle position 5 Armrest LH a The armrests can be fo...

Page 127: ...b to the inside it will be lowered 7 Headrest a The headrest can be individually adjusted for height by pulling it upward over the vari ous increments up the end stop b By pushing forwards or rearwards the angle of the headrest can be adjusted individually c To remove the headrest pull it over the end stop 8 Document box a The document box is placed on the rear side of the backrest b To open the d...

Page 128: ...red position and re lease a Soft b Hard 11 Fore aft isolator a It is useful to activate the fore aft isolator This means that shock impacts in the driving direction can be bet ter absorbed by the seat a Fore aft isolator off b Fore aft isolator on 12 Lumbar support a By turning the adjustment knob to the left 2 or right 1 both the height and curvature of the backrest cushion can be individually ad...

Page 129: ... function of the seat so make sure you keep your seat clean Upholstery does not need to be removed from the seat frame for cleaning Take care with the backrest it may jerk forward and cause injury When clean ing the backrest cushion the backrest must be held in place when operating the backrest lever Do not clean the seat with a pressure washer During cleaning the upholstery must not be soaked thr...

Page 130: ...ation hours of the machine 2 Always ensure the operating condition of the meter during the ma chine operation Inspect and service the machine based on hours as indicated in chapter 6 maintenance 6 MCU ECM TCU CONNECTOR 1 MCU communicates the machine data with laptop computers through RS232 service socket 2 ECM communicates the engine data with cummins INSITE adapter through J1939 service socket a ...

Page 131: ...ity Before replacing a fuse be sure to turn OFF the starting switch 8 TILT HANDLE FOR RIGHT SIDE WINDOW 1 Pull the handle backward and push the handle outward in order to open the window to the partial open position Remove the pin from the handle Push the window to the fully open position Open the window periodically in order to ensure proper operation Lubricate or repair the window as necessary P...

Page 132: ... controller and the cluster are disconnected Three LED are turned OFF Trouble on MCU power Check if the input power wire 24 V GND of control ler is disconnected Check the fuse 1 Green 2 Red 3 Yellow 10 TRANSMISSION CONTROL UNIT TCU 1 The control unit is shifting to the required gears fully automatically giving consideration to the following criteria Gear selector lever position Driving speed Load ...

Page 133: ...13 REAR CAMERA option 1 The rear camera is available as a option Refer to page 3 39 3 75 ...

Page 134: ...5 3 Mode button audio mute button DIR Directory down button 4 Call pair button 11 Station preset 6 DIR Directory up button 5 Call end button 12 Scan play button SCAN Best station memory BSM button 13 Auto tune up seek up button 6 Station preset 1 14 Auto tune down track down button DIS Display button 15 USB connector 7 Station preset 2 16 AUX IN jack 8 Station preset 3 17 MIC hole RPT Repeat play ...

Page 135: ...ay the hour will blink turn VOL knob right or left to adjust hour Simply press VOL again the minute will blink turn VOL knob to adjust minute Then press VOL again to confirm the clock once finished b Menu selection a This button can adjust the sound effect and other things Each time you press this button 2 LCD displays as follows BAS TREB BAL L R FAD F R EQ LOUD ON BEEP 2ND On each setting the lev...

Page 136: ...ASS and TREBLE modes are not displayed g Loud control When listening to music at low volume levels this feature will boost the bass and treble response This action will compensate for the reduction in bass and treble performance experienced at low volume To select the loudness feature press button 2 until LOUD is displayed then turn knob 2 right or left to activate or deactivate loudness h Beep co...

Page 137: ...or AM b Manual tuning button a To manually tune to a radio station simply turn encoder TUNE 2 left or right to increase or decrease the radio frequency c Auto tuning button a To automatically select a radio station simply press the seek up or seek track down button 3 79 ...

Page 138: ...e Preset scan PS Best station memory BSM button a Press BSM button 12 momentarily to scan the 6 preset stations stored in the selected band When you hear your desired station press it again to listen to it Press BSM button 12 for longer than 2 seconds to activate the Best Station Memory feature which will automatically scan and en ter each station into memory If you have already set the preset mem...

Page 139: ...isplay NO FILE b Track Seek up Track down button a Press TRACK SEEK up 13 or TRACK down 14 to select the previous or next track Press and hold one of the buttons to ad vance the current track rapidly backward or forward c MP3 directory File searching a The SEL button 2 is used to select a particular directory or file in the device Turn the TUNE knob 2 to the right or to the left to dis play the av...

Page 140: ...folder Press and hold the SCAN button for longer than 2 seconds to scan through and play the tracks in the current folder SCAN off Simply press the SCAN button again to cancel the SCAN feature f Repeat track play button RPT REPEAT playback Simply press RPT 8 button to play the current track repeatedly REPEAT folder Press and hold RPT for button longer than 2 sec onds to repeat play the tracks in c...

Page 141: ...media player headphone socket at each end as follows Adjust the portable media player to approximately 3 4 volume and start playback Press the MODE button 3 on the audio unit to change into AUX mode The volume and tone can now be adjusted on the audio unit to the desired level The audio quality of your media player and the audio tracks on it may not be of the same sound quality as the audio system...

Page 142: ...will light after a bluetooth device connected b Battery icon It indicates the battery status of the connected bluetooth device c Signal strength icon This indicates the signal strength of the connected Bluetooth device b Pairing in hands free modes a Press and hold CALL button 4 for 2 seconds until you hear beep sound then appears PAIR STR on the display b For the next procedure go to cellular pho...

Page 143: ...deleted The connecting priority will be given to the last connected cellular phone If you want to change the connecting priority try to connect this audio unit from the cellu lar phone d Bluetooth connection and disconnection a When established bluetooth connection between this audio unit and the cellular phone bluetooth icon on the display appears and then the display shows HF AV CONN when handsf...

Page 144: ...audio unit is better than calling between one audio unit and another one g Last call number dialing a Press CALL button 4 briefly it appears CALL TO then simply press CALL button once again it would make the last call with phone number display on LCD If Reject call is activated in your phone then your cellular phone does not support Reject Call function If you are using SAMSUNG phone then you may ...

Page 145: ...o reset unit by any of following two methods a Press and hold simultaneously for about 5 seconds without Bluetooth Press and hold simultaneously for about 5 seconds with Bluetooth b Take out the fuse for the audio system in the vehicle once and then plug again It will be necessary to re enter the radio preset memories as these will have been erased when the microprocessor was reset After resetting...

Page 146: ...old mode 3RPT buttons for 3 seconds LATIN area Press and hold mode 4RDM buttons for 3 seconds d USB version USB 1 1 e Bluetooth version V2 1 f Bluetooth supported profile A2DP Advanced audio distribution profile AVRCP Audio Video remote control profile HFP Hands free profile 3 88 ...

Page 147: ...15 CAMERA MONITOR OPTION 3 89 ...

Page 148: ...ing guide line On Off Menu select Adjust menu escape Favorite view menu preset Menu select Adjust menu escape MENU Menu enter Parking guide line adjust long key 2 sec Menu next page Menu enter Menu next page UP Previous view short key Adjust to the volumn set in the menu long key Menu Up Menu Adjust Up Previous view short key Adjust to the volumn set in the menu long key Menu up Menu adjust up DOW...

Page 149: ... 2 Interlocked with other devices 3 91 ...

Page 150: ... 3 Operation scenario Single camera mode 3 92 ...

Page 151: ... 4 Operation scenario AAVM mode 3 93 ...

Page 152: ... 5 AAVM view mode type 3 94 ...

Page 153: ... 6 Function menu tree Single cam mode 3 95 ...

Page 154: ... 7 Function menu tree AAVM mode 3 96 ...

Page 155: ... 8 Parking guide line adjust 3 97 ...

Page 156: ... 9 How to set function menu 3 98 ...

Page 157: ... 10 Composition of menu screen 3 99 ...

Page 158: ... 11 Value adjustment 3 100 ...

Page 159: ... 12 When radar mounted monitor display 3 101 ...

Page 160: ......

Page 161: ...hours operation 1 Check daily for the level and leakage of coolant engine oil hydraulic oil and fuel 2 Check and fill the lubrication regularly Grease all lubrication points daily 3 Tighten bolts 4 Warm up the machine fully before operation 5 Check the gauges during operation 6 Check if the machine is operating normally during operation 4 Replace the following after the initial operation hours Che...

Page 162: ...ontours of the opera tor s body for pleasant operation 4 Make sure that the machine is equipped with a lighting system that is adequate for the job con ditions Ensure that all lights are in proper work ing condition 5 Adjust the rear view mirror 6 Make sure that there is no personnel in the area before you start the engine Make sure that there is no personnel in the area before you move the machin...

Page 163: ...l pressure warn ing lamp 2 Brake fail warning lamp 3 Monitor a The buzzer sounds for 3 sec onds with the Hyundai logo on the monitor b If the ESL mode is set to the en abled enter the password to start engine c If the password has failed 5 times please wait 30 minutes before re attempting to enter the password Refer to the page 3 34 for ESL system setting 2 STARTING THE ENGINE IN NORMAL TEM PERATU...

Page 164: ...re 1 Check if the parking brake is locked with the parking switch ON 2 Check if the gear selector lever is in the neutral position 3 Check if the pilot cut off switch is locked with the switch OFF 4 Turn the starting switch to the ON position and wait 1 2 minutes More time may take accord ing to ambient temperature 5 Start the engine by turning the starting switch to the START position after the p...

Page 165: ...d Are the sound and vibration normal Do not increase engine speed quickly after starting It can make damage to the engine or turbocharger If there are problems in the control panel stop the engine immediately and correct problem as required 5 TRANSMISSION COLD STARTING 1 At an oil temperature in the shifting circuit 12 C the transmission must be warmed up for some minutes 2 This must be carried ou...

Page 166: ...ngine is abruptly stopped before it has cooled down engine life may be greatly shortened Consequently do not abruptly stop the engine apart from in an emergency In particularly if the engine has over heated do not abruptly stop it but run it at medium speed to allow it to cool gradually Then stop it 1 Place the gear selector lever in neutral 2 Push the parking brake switch to the ON position 3 Run...

Page 167: ...un the engine at mid range speed 3 Push the pilot cut off switch to the ON position 4 Lift the boom slightly and extend the bucket cyl inder to the stroke end to relieve hydraulic pres sure Do not leave hydraulic pressure re lieved for more than 30 seconds 5 Shorten the bucket cylinder to the stroke end to relieve hydraulic pressure Do not leave hydraulic pressure re lieved for more than 30 second...

Page 168: ... returns to the neutral position Control lever Boom lower 1 Push the control lever forward in order to lower the boom Boom raise 2 Pull the control lever backward in order to raise the boom Bucket roll back 3 Move the control lever toward the left in order to tilt the bucket backward Bucket dump 4 Move the control lever toward the right in order to dump a load from the bucket Boom float 5 Push the...

Page 169: ...edal gently to move the machine 3 Changing the direction and speed a The gear selector is designed for the mounting on the left side of the steering column b The positions speeds 1 to 4 are selected by a rotary motion the driving direction Forward F Neutral N Reverse R by tilting the gear selector lever c A neutral lock is installed as protection against inadvertent drive off Position N Gear selec...

Page 170: ...e en gine OFF 5 Precautions when driving a If the monitor warning lamp lights up put the gear selector lever in the neutral position and stop the machine Stop the engine after run ning it at low idling Then resolve any problems regarding operation of the machine b When the load gets lighter while operating the machine the speed of the machine will in crease Please be careful c When the machine tra...

Page 171: ...d Lower the bucket to the ground e Push the pilot cut off switch to the OFF po sition When parking on a slope block the tires Pilot cut off switch OFF 4 11 ...

Page 172: ...gear selector lever is in the neutral position c Check if the pilot cut off switch is OFF d Run the engine at low speed without oper ating the equipment for about 5 minutes Turn the starting key to the OFF position and remove the key 8 Checks after the engine is stopped a Check the leakage of oil and water the work equipment and the exterior of the machine b Refill the fuel tank c Remove any debri...

Page 173: ...y lower the bucket immediately and brake the ma chine 4 When parking on a slope use the bucket as a brake and place blocks behind the tires to pre vent sliding The machine cannot travel effectively on a slope when the oil temperature is low Per form the warming up procedure when you are going to travel on a slope Be careful when working on slopes It may cause the machine to lose its balance and tu...

Page 174: ... get into the engine 7 Check if the proper bucket is used for the work If the capacity of the bucket exceeds that of the machine the machine s service life may be shortened 2 EXCAVATION WORK 1 Shovel work As the machine loads on the bucket with traveling tires may start to slip because of heavy load Then lift the bucket slightly to reduce load a Keep the bucket shovel parallel to the ground if the...

Page 175: ...es with its front tires lifted its driving force will deteriorate and excessive force will be applied to the rear tires Avoid operating in that posture 2 Excavation on level ground Advance the machine with the bucket low ered slightly and make sure that the buck et is evenly loaded on both sides a Lower the bucket edge slightly 73034OP06 73034OP07 4 15 ...

Page 176: ...ing prevent the excavation force from apply ing to only one side of the bucket 3 LEVELING 1 Load the bucket with soil and dump the soil gradually while driving backward 2 After dumping the soil move backward with the bucket lowered to the ground to level the ground 3 Load the bucket with soil and place the bucket in the horizontal position Then put the control lever in the BOOM FLOAT position and ...

Page 177: ...y carrying out work in such a way that the swinging angle and the traveling distance are kept as small and short as possible in accordance with the terrain 1 I method a After digging out the soil move back ward and position the dump truck be tween the heap of soil and the ma chine to load the soil into the truck b This is the fastest and most efficient way to load material The ground of the job si...

Page 178: ...bucket d Shake the bucket to throw off the soil stuck inside Move the bucket control lever to the left and right and attach the bucket to the stopper e Shake the bucket before setting it to the DUMP position so that loaded materials are evenly distributed in side the bucket This will prevent ma terials from slipping back when the bucket is placed in the DUMP posi tion 7 PRECAUTIONS DURING OPERATIO...

Page 179: ...e at the 1st speed stop the ma chine and put it in neutral Run the engine at a mid range speed until the gauge moves into the green range c When the engine stops If the engine stops on a slope press the parking brake switch immediately and lower the work equipment to stop the machine 4 Precautions when traveling Do not travel a long distance at high speed It may overheat tires and cause premature ...

Page 180: ...rn to the pro grammed position when the raise detent is activated and the boom is below the kick out position 2 Lower kickout position To set the lower kickout lower the bucket to the desired position below the midway point Then push icon A for 2 3 seconds The boom will return to the pro grammed position when the float detent is activated and the boom is at least a foot above the kickout position ...

Page 181: ...equently and keep cooling fins clean 3 Prevent sand or dust from getting into the fuel tank and the hydraulic tank during refilling 4 Prevent sand or dust from penetrating into the hydraulic circuit by tightly closing the breather cap of the hydraulic oil tank Replace the hydraulic oil filter frequently 5 Keep all lubricated parts such as pins and bushings clean at all times 6 If the air condition...

Page 182: ...places where the machine rusts easily 3 MASTER SWITCH Turn OFF the master switch and store the ma chine 4 Be sure to mix anticorrosive antifreeze solution in the radiator 5 PREVENTION OF DUST AND MOISTURE Keep machine dry Store the machine setting wood on the ground Cover exposed part of piston rod of cyl inder Lower the bucket to the ground and set a support under the tires Lubricating manifold l...

Page 183: ...rod of cylinder Operate the machine such as travelling turning and work equipment operation to make sure enough lubrication of all functional components BATTERY 1 Once a month start the engine for 15 minutes or use a charger to charge the battery 2 Every 2 months check the battery voltage and keep battery voltage over 25 08V 3 If the machine stock period is over 6 months disconnect the battery neg...

Page 184: ...The HEST Lamp will be illuminated during the entire exhaust system cleaning Tampering modifying or removing any component of the exhaust system is strictly pro hibited in law Exhaust system cleaning generates hot exhaust and causes hot exhaust system compo nents Exhaust system components get very hot and can cause severe burns Risk for fire Do not perform exhaust system cleaning in a flammable env...

Page 185: ...en the exhaust temperatures are high due to exhaust system cleaning Refer to page 3 9 for details 4 Exhaust system cleaning switch This switch is used to select the exhaust system cleaning Refer to page 3 53 for details Manual exhaust system cleaning refer to page 4 25 for de tails 4 25 ...

Page 186: ...lve lever to the OPEN position in order to lower the attach ment to the ground 3 After the attachment is resting on the ground rotate the lowering valve lever to the CLOSE position Keep all personnel away from the boom drop area when lowering the boom with the en gine stopped Keep all personnel away from the front link age when lowering the boom CLOSE OPEN Manual lowering valve MCV Front frame 4 2...

Page 187: ...imitations Air pressure 17 5 25 12PR L3 4 9 kgf cm2 70 psi 17 5 R25 L3 5 3 kgf cm2 75 psi 17 5 R25 XHA 5 1 kgf cm2 73 psi Maximum speed 39 5 km hr 24 5 mph 4 When travelling for a long distance stop every hour or every 40 km 25 miles to allow tires and other components to cool down and to check any abnormality 5 Drive with the bucket empty 6 Travel at a mid range speed and be careful to drive with...

Page 188: ...e weight and dimensions from the page Section 2 Specifications 4 Check the whole route such as the road width the height of bridge the limit of weight etc which will be passed 5 Get the permission from the related authority if necessary 6 Prepare gangplank for safe loading referring to the below table and illustration A B 1 0 3 65 3 85 1 1 4 00 4 25 1 2 4 35 4 60 1 3 4 75 5 00 1 4 5 10 5 40 1 5 5 ...

Page 189: ...n the gangplank Do not change the direction of the machine while it is on the gangplank 4 Do the following after loading the machine to the trailer 1 Lower the working equipment gently after the location is determined Place a rectangular timber under the bucket cylinder to prevent it from being damaged during transportation Do not operate any other device when loading Balance the load 5 3 ...

Page 190: ...ar 2 Push the parking brake switch 3 Push the pilot cut off switch to the OFF position to prevent the hydraulic system from operating 4 Stop the engine turn the starting switch off and remove the key 5 Secure all locks Safety lock bar Pilot cut off switch OFF Cab Tool box Cowl 5 4 ...

Page 191: ...6 Block the tires and fix firmly with wire rope or chain to prevent the machine from moving dur ing transportation 5 5 ...

Page 192: ... the proper place 5 Install the wire rope and stay like shown on the illustration Make sure that the wire rope is of the proper size Place the safety lock bar and pilot cut off switch to the OFF position to prevent the machine moving when hoisting the machine The wrong hoisting method or installation of the wire rope can cause damage to the ma chine Do not load abruptly Keep the area clear of pers...

Page 193: ... the tow eyes on the front frame 1 When you tow the machine from the rear use the tow rear eyes provided for lift tie 2 5 Do not use a chain for pulling a disabled machine A chain link can break This may cause personal injury Use a wire rope cable with ends that have loops or rings Place an observer in a safe position in order to watch the pulling procedure The observer can stop the procedure if n...

Page 194: ...n which the machine is towed 3 WHEN THE ENGINE DOES NOT WORK When towing the machine with the engine stopped do it in the following order 1 The transmission oil does not lubricate the system so remove the front and rear drive shafts 2 Loosen the steering cylinder as the steering operation is not workable Even if the brake is in good condition the brakes can only be used a limited number of times T...

Page 195: ...ponents have been preset in the factory Do not allow unauthorized personnel to reset them 4 Drain the used oil and coolant into a container and handle according to the method of han dling for industrial waste to meet with regulations of each province or country Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact skin Accumulated grease and oil on ...

Page 196: ...pletion of service 9 For more detail information of maintenance please contact your local Hyundai dealer Be sure to start the maintenance after fully understand the Section 1 Safety hints 4 RELIEVING THE PRESSURE IN THE HYDRAULIC SYSTEM Spouting of oil can cause the accident when loosening the cap or hose immediately after the operating of the machine as the machine or oil is on the high pressure ...

Page 197: ...LACEMENT OF SAFETY PARTS 1 These are the parts of which the operator can not judge the remaining lifetime of by visual inspection 2 Repair or replace if an abnormality of these parts is found even before the recommended re placement interval Periodical replacement of safety parts Interval Fuel hose engine tank Every 2 years Hose of steering system Packing seal and O ring of steering cylinder Hose ...

Page 198: ... 1461 1967 2 Fine thread Bolt size 8 8T 10 9T 12 9T kgf m lbf ft kgf m lbf ft kgf m lbf ft M 8 1 0 2 1 3 1 15 2 22 4 3 0 4 4 21 7 31 8 3 6 5 4 26 1 39 0 M10 1 25 4 2 6 2 30 4 44 9 5 9 8 7 42 7 62 9 7 0 10 4 50 1 75 2 M12 1 25 7 3 10 9 52 8 78 8 10 3 15 3 74 5 110 13 1 17 7 94 8 128 M14 1 5 12 4 16 6 89 7 120 17 4 23 4 126 169 20 8 28 0 151 202 M16 1 5 18 7 25 3 136 182 26 3 35 5 191 256 31 6 42 6 ...

Page 199: ... Fan brake pump housing mounting bolt M10 1 5 6 9 1 4 50 10 1 11 Main control valve mounting bolt M10 1 5 6 9 1 4 50 10 1 12 Steering unit mounting bolt M10 1 5 6 9 1 4 50 10 1 13 Brake valve mounting bolt M8 1 25 2 5 0 5 18 1 3 6 14 Cut off valve mounting bolt M12 1 75 12 8 3 0 92 6 21 7 15 Remote control lever mounting bolt M6 1 0 1 1 0 2 8 0 1 4 16 Safety valve M10 1 5 6 9 1 4 50 10 1 17 Hydrau...

Page 200: ...BILFLUID 426 ASTM American Society of Testing and Material SHELL DONAX TD 10W 30 DEF Diesel Exhaust Fluid DEF compatible with AdBlue TOTAL DYNATRANS MPV Ultra low sulfur diesel sulfur content 15 ppm Cold region Russia CIS Mongolia 2 RECOMMENDED LUBRICANTS HYUNDAI genuine lubricating oils have been developed to offer the best performance and service life for your equipment These oils have been test...

Page 201: ... Ethylene glycol base permanent type 60 40 ISO 22241 High purity urea deionized water 32 5 67 5 SAE Society of Automotive Engineers Recommended oil list API American Petroleum Institute BP TERRAC SUPER TRANSMISSION 10W 30 ISO International Organization for Standardization CASTROL AGRI TRANS PLUS 10W 30 NLGI National Lubricating Grease Institute MOBILFLUID 426 ASTM American Society of Testing and M...

Page 202: ...ck items Service Page Attachment pins Lubricate 6 51 Tire Air Check Add 6 41 Steering cylinder pins Lubricate 6 48 Rear axle pivot Lubricate 6 48 Fuel tank water sediment Drain 6 24 3 INITIAL 250 HOURS SERVICE Check items Service Page Engine oil and filter Change 6 14 Fuel filter element Replace 6 25 Fuel pre filter element Replace 6 24 Transmission oil and filter Change 6 45 Front and rear axle o...

Page 203: ...Page Front axle oil Change 6 48 Rear axle oil Change 6 48 9 EVERY 2000 HOURS SERVICE Check items Service Page Engine cleaning Clean 6 29 Vibration damper rubber viscous Check 6 30 Hydraulic oil 1 Change 6 38 HBHO Hyundai Bio Hydarulic Oil ISO VG 46 2 Change 6 38 Coolant cooling system and antifreeze Change Flush 6 16 6 17 Hydraulic oil suction strainer Check Clean 6 38 Air conditioner and heater i...

Page 204: ...ic oil 3 Change 6 38 3 Hyundai genuine long life hydraulic oil 13 WHEN REQUIRED Check items Service Page Air cleaner element Safety Replace 6 23 Primary Clean Replace 6 23 Air conditioner and heater Outer filter Replace 6 57 Inner filter Clean Replace 6 57 DPF diesel particulate filter Clean 6 30 6 10 ...

Page 205: ...er details refer to the service manual Service in terval Item no Description Service action Oil symbol Capacity ℓ U S gal Number of service points 10 Hours or daily 1 Hydraulic oil level Check Add HO 90 23 8 1 2 Engine oil level Check Add EO 11 2 9 1 4 Radiator coolant level Check Add C 31 5 8 3 1 5 Fan belt tension damage Check Adjust 1 17 Fuel pre filter water Drain 1 29 DEF AdBlue tank Check Ad...

Page 206: ...1 500 Hours 18 Radiator oil cooler CAC condenser Clean 5 25 Air cleaner element primary Clean 1 800 Hours 2 Engine oil Change EO 11 2 9 1 3 Engine oil filter Replace 1 1000 Hours 13 Hydraulic oil return filter Replace 2 14 Hydraulic tank air breather element Replace 1 16 Fuel filter element Replace 1 17 Fuel pre filter element Replace 1 19 Center pivot pin Lubricate PGL 2 20 Transmission oil Chang...

Page 207: ...ater outer filter Replace 1 Air conditioner and heater inner filter Clean Replace 1 25 Air cleaner element safety Replace 1 Air cleaner element primary Clean Replace 1 1 Conventional hydraulic oil 2 Hyundai Bio Hydraulic Oil 3 Hyundai genuine long life hydraulic oil Oil symbol Refer the recommended lubricants for specification EO Engine oil GO Gear oil C Coolant HO Hydraulic oil PGL Grease DEF DEF...

Page 208: ...s been stop ped for 15 minutes Do not operate unless the oil level is in the normal range 2 REPLACEMENT OF ENGINE OIL AND OIL FIL TER 1 Operate the engine until the coolant tempera ture reaches 60 C 140 F Shut off the engine 2 Turn the stopper to the open position and allow the oil to drain Wrench size 10 mm A drain pan with a capacity of 30 litres 6 6 U S gallons will be adequate 3 Clean the area...

Page 209: ...l the filter to the filter head Tighten the filter until the gasket contacts the fil ter head surface Tighten 3 4 to 1 turn after gasket makes contact with the filter head Mechanical over tightening may distort the threads or damage the filter element seal 8 Turn the stopper to the close position 7807AMI07 Oil Fuel tank Open Close Stopper View A 6 15 ...

Page 210: ...e oil to drain down before checking Do not overfill the engine with oil 3 CHECK COOLANT LEVEL 1 Check the engine fault code on the monitor 2 If the following fault codes exist check the cool ant level SPN 111 FMI 18 Coolant level is low SPN 111 FMI 1 Coolant level is the most severely low 3 Add the mixture of antifreeze and water after re moving the cap of the surge tank if coolant is not sufficie...

Page 211: ... contact wash thor oughly after contact Keep out of reach of children Protect the environment Handling and disposal of used antifreeze can be sub ject to federal state and local law regu lation Use authorized waste disposal facilities including civic amenity sites and garag es providing authorized facilities for the receipt of used antifreeze If in doubt contact your local authori ties for guidanc...

Page 212: ...The engine is to be operated without the cap for this process During filling air must be vented from the engine coolant passages The system must be filled slowly to prevent air locks Wait 2 to 3 mi nutes to allow air to be vented then add mixture to bring the level to the top b Operate the engine for 5 minutes with the coolant temperature above 80 C 176 F Shut the engine off and drain the cooling ...

Page 213: ...ooling system filling a Use a mixture of 50 percent soft water and 50 percent ethylene glycol antifreeze to fill the cooling system Refer to the page 6 6 Never use water alone for coolant This can result in damage from corrosion Do not use hard water such as riv er water or well water b The system has a maximum fill rate of 19 liters 5 0 U S gallons per minute Do not exceed this fill rate The syst...

Page 214: ...tor more frequently 1 Visually inspect the radiator for clogged radiator fins 2 Use 550 kPa 80 psi air pressure to blow the dirt and debris from the fins Blow the air in the opposite direction from the fan air flow 3 Visually inspect the radiator for bent or broken fins If the radiator must be replaced due to bent or broken fins which can cause the engine to overheat refer to the manu facturer s r...

Page 215: ...he belt tension gage to measure the belt tension Fan belt tension 11 3 kg 25 lb 2 Inspect the fan belt for damage a Transverse across the belt cracks are ac ceptable b Longitudinal direction of belt ribs cracks that intersect with transverse cracks are not acceptable c Replace the belt if it is frayed or has pieces of material missing 3 Inspect the idle and drive pulleys for wear or cracks OK NOT ...

Page 216: ...1 With the engine stopped check the tensioner arm pulley and stops for cracks If any cracks are found the tensioner must be replaced 2 With the belt installed verify that neither ten sioner arm stop is in contact with the spring case stop After replacing the belt if the tensioner arm stops are still in contact with the spring case stop replace the tensioner 3 With the belt removed verify that the ...

Page 217: ...he air filter element b Use 3 kg cm2 40 psi maximum air pressure and hold the compressed air nozzle at least 2 5 cm 1 away from the pleats while cleaning Make sure to keep the clean side of air filter free of debris e Visually inspect for damage to the filter el ements and components Use a light source to help identify any defects in the media If any defects are observed discard the filter element...

Page 218: ...ing the drain cock Be sure to LOCK the cap of the fuel tank Remove the strainer from the fuel tank and clean it if it is contaminated Stop the engine when refuelling All lights and flames should be kept at a safe distance while refuelling 12 FUEL PRE FILTER Inspect or drain the collected water daily and replace the element every 1000hours 1 Drain water a Open the drain valve to evacuate water for ...

Page 219: ...to fuel filter head Remove O ring with screwdriver if nec essary 2 Lubricate the fuel filter O ring with clean lubri cating oil 3 Install the filter on the filter head Tighten the fil ter until the gasket contacts the filter head sur face Tighten the fuel filter an additional 3 4 turn after contact Mechanical overtightening can distort the threads or damage the filter element seal 4 Relieve the ai...

Page 220: ...DEF AdBlue must be added 3 When fill the tank with DEF AdBlue check the sight gauge and don t fill up F level line to pre vent overflow It is unlawful to tamper with or remove any component of the aftertreatment system It is also unlawful to use a cata lyst solution that does not meet the specifications provided or the operate the machine with no catalytic solution Be careful to entering dust sand...

Page 221: ...nt come out from the return line TCO Nearly comes out the coolant or DEF from other lines 3 Rotate the DEF AdBlue level sender counter clockwise about 20 degree with the Jig P no HDB030 0001 4 Remove the DEF AdBlue level sender without removal of the plunger ring Coolant return line DEF suction return hose Coolant suction hose DEF level sender DEF tank Air breather hose Coolant return line DEF tan...

Page 222: ...30 mm wrench can be used on the cap to aid in removal 3 Remove the filter equalizing element 4 Remove the old filter element A disposable service tool is included with the fil ter to aid in filter removal Use the appropriate end of the tool depending on the color of the plastic on the filter When inserting the tool a click sound can be heard which indicates proper engagement with the filter If the...

Page 223: ... steam cleaner wear safety glasses or a face shield as well as protec tive clothing Hot steam can cause serious personal in jury Turn OFF the master switch mounted electric box 1 Steam is the recommended method of cleaning a dirty engine or a piece of equipment 2 Protect all electrical components openings and wiring from the full force of the cleaner spray nozzle 3 Components to protect include bu...

Page 224: ... a authorized service center Please contact your Hyundai service center or local dealer 20 VIBRATION DAMPER 1 Rubber a Check the index lines A in the vibration damper hub B and the inertia member C If the lines are more than 1 59 mm 1 16 in out of alignment replace the vi bration damper b Inspect the rubber member for deteriora tion If pieces of rubber are missing or if the elastic member is more ...

Page 225: ... perform the repair shop Service tools Cummins barring tool p no 3824591 Feeler gauge 1 Prior to removing any components use com pressed air to remove any loose debris from around the mounting fasteners and sealing joints 2 Disconnect the breather tube connection at the back of the rocker lever cover In general two types of breather tube connec tions are used at the rocker lever cover A clamping p...

Page 226: ...ble Once the gasket is re moved from the rocker lever cover it must be replaced 4 Remove the mounting nuts and isolators from the rocker lever cover If equipped it may be necessary to gen tly pry the breather tube connection from the back of the rocker lever cover while removing 5 Remove the rocker lever cover Check the gasket while it is installed in the valve cover Once the gasket is re moved fr...

Page 227: ...ess in rocker lever gasket the following installation procedure must be used Press the molded gasket into the corners of the rocker lever cover Press the rest of the gasket into the rocker lever cover Engine coolant temperature must be less than 60 140 9 Use the barring tool to rotate the crankshaft un til the number is at TDC TDC can be determined by the following meth od 6 33 ...

Page 228: ...th number 1 cylinder rocker levers are loose If they are not loose rotate the crankshaft 360 de grees and check again 11 With the engine in this position lash can be checked on the following rocker arms E exhaust I Intake Four cylinder 1I 1E 2I and 3E Six cylinder 1I 1E 2I 3E 4I and 5E Lash check limits Item mm inch Intake Min 0 152 0 006 Max 0 381 0 015 Exhaust Min 0 381 0 015 Max 0 762 0 030 Che...

Page 229: ...h specifications Item mm inch Intake 0 254 0 010 Exhaust 0 508 0 020 13 Tighten the locknut Tightening torque 2 4 kgf m 17 4 lbf ft 14 Use the barring tool to rotate the crankshaft 360 degrees Following the same steps and specifications as previously stated measure lash for the follow ing rockers E exhaust I Intake Four cylinder 2E 3I 4E and 4I Six cylinder 2E 3I 4E 5I 6I and 6E Reset if out of sp...

Page 230: ...tors c Tighten the mounting capscrews Tightening torque 2 4 kgf m 17 4 lbf ft 17 If equipped at the rear of the rocker lever cover install the banjo bolt and sealing washers con necting the breather oil drain line to the rocker lever cover Tightening torque 1 2 kgf m 8 7 lbf ft Some engine the breather oil drain line is internal to the breathe connection tube 1 18 Prior to connecting the breather ...

Page 231: ...nt the breather tube connection to the rocker lev er cover Remove the capscrew s to dis connect the breather tube connection from the rocker lever cover 20 Tighten the capscrew s Tightening torque 1 0 kgf m 7 2 lbf ft 22 HYDRAULIC OIL LEVEL CHECK 1 Lower the bucket to the ground at a flat location as in the illustration Stop the engine and then leave for about 5 mi nutes 2 Check the oil level usin...

Page 232: ...op of the air breather 3 Prepare a suitable container 4 To drain the oil loosen the drain plug at the fuel tank block 5 Tighten the drain plug 6 Fill proper amount of recommended oil 7 Put the breather in the right position 8 Start the engine and run continuously Release the air by full stroke of control lever The oil must be free of bubbles If bub bles are present in the oil air is enter ing in t...

Page 233: ...nstall the cover on the tank Tightening torque 6 9 1 4 kgf m 50 10 lbf ft 26 REPLACEMENT OF ELEMENT IN HYDRAUL IC TANK BREATHER 1 Loosen the cap and relieve the pressure in the tank by pushing the top of the air breather 2 Loosen the lock nut and remove the cover 3 Pull out the filter element 4 Replace the filter element new one 5 Reassemble by reverse order of disassembly Tightening torque 1 05 0...

Page 234: ...he safety valve 2 Pull out the filter element and clean the bowl 3 Install the new element and tighten the bowl us ing spanner Spanner size 27 mm 28 LUBRICATE RCV LEVER Remove bellows and grease the joint A and the sliding parts B Bowl Safety valve A B 78036MI29 6 40 ...

Page 235: ... sive load and overspeed Avoid excessive load and overspeed in order to keep tires in good shape Do not inflate tires using flammable gases or alcohol injectors This cause explosion or personal injury Inflate tires at the pressure level recommen ded by the manufacturer and check periodi cally the pressure and wear of tires When replacing the inflated tire do not stand near the tire Check the tire ...

Page 236: ...en or bent bead wires b Tires exposing more than a 1 4 of carcass fly c Tires whose carcass is damaged over more than 1 3 of the tire width d Tires which show fly separation e Tires which has a radial crack near the carcass f Tires which are judged to be unsuitable for use because of deformation or damage 2 Separation of tire a After moving the machine to flat ground lower the bucket to the ground...

Page 237: ...ace the tire 3 Direction of tire to be installed a Be careful that the valve is facing the out side 4 Mounting of tire a Lightly tighten nuts as shown in the illus tration b Lower the jack after tire is replaced c Tighten nuts according to the specified tighten torque Tightening torque 79 2 5 kgf m 571 18 1 lbf ft 73036MI12 Torque wrench 73036MI13 Valve 6 43 ...

Page 238: ...HECK TRANSMISSION OIL LEVEL 1 The oil level check must be carried out as fol lows oil level check weekly 2 Before the oil level check the transmission must have been running to warm up enough 3 When the oil level is checked the machine must be on flat ground and the engine must be at idling speed Transmission must be in neutral position 4 Check the oil level on level sight gauge 5 Oil level Operat...

Page 239: ... transmission oil to drain into a suitable contain er 6 Remove the transmission oil filter cartridge Dispose of the used transmission oil filter car tridge properly 7 Clean the filter cartridge mounting base Re move any part of the filter cartridge gasket that remains on the filter cartridge mounting base 8 Apply a light coat of oil to the gasket of a new transmission oil filter cartridge 9 Instal...

Page 240: ... dropped It is imperative to pay attention to absolute cleanliness of oil and filter Binding is in any case the marking on the oil level gauge Prohibition to inject water to filler cap direct ly when you wash the machine 34 CLEANING TRANSMISSION AIR BREATHER 1 Remove dust or debris around the air breather 2 Remove the air breather and wash it with clean ing oil Level gauge Zone HOT Blue Red Air br...

Page 241: ...hole of the plug Provide fill level plug with O ring and install it When checking the oil level press the park ing brake switch and fix front and rear frames using the safety lock bar As the machine is hot after operation wait until the oil temperature has dropped Set the plug of planetary gear in parallel to the ground Fill oil level plug Air breather Air breather Fill oil level plug FRONT AXLE R...

Page 242: ...1 U S gal Rear axle 23 ℓ 6 1 U S gal As the machine is hot after operation wait until the temperature has dropped If a work requires frequent use of brake re place it earlier than normal change interval 37 CLEANING AXLE BREATHER 1 Remove dust or debris around the breather 2 Remove the breather and wash it with cleaning oil 38 LUBRICATION 1 Supply grease through the grease nipple using a grease gun...

Page 243: ...on 3 Rear axle pivot 2EA 4 Steering cylinder pin 4EA 5 Center pivot pin 2EA 6 Drive shaft Front flange bearing journal bearing 2EA Center sleeve yoke journal bearing 4EA Rear sleeve yoke journal bearing 3EA 1 LH RH 1 Rear axle pivot 2 Steering cilinder pivot Center pivot pin Center pivot pin 6 49 ...

Page 244: ...e place it with new ones If the contacted face of the cutting edge has worn out repair the con tacted face of it e Tighten bolts and nuts evenly to remove the clearance between bucket and cutting edge Tightening torque 62 8 9 4 kgf m 454 68 lbf ft f After a few hours of operation retighten bolts 40 REPLACEMENT OF BUCKET TOOTH 1 Replacement time Replace the bucket tooth before it has worn out to th...

Page 245: ...cription Qty A Bucket cylinder Front frame side pin 1 B Boom cylinder Front frame side right pin 1 C Boom front frame right connection pin 1 D Boom front frame left connection pin 1 E Boom cylinder Front frame side left pin 1 F Boom cylinder boom connection pin 2 G Bucket cylinder bell crank connection pin 1 H Boom bell crank connection pin 1 I Bell crank bucket link connection pin 1 J Bucket Buck...

Page 246: ...shing and create noise and vibration during operation Make sure the seals are not damaged or deformed 42 WORKING EQUIPMENT SUPPORT When carrying out inspection and maintenance with the equipment raised fit a stand under the lift arm securely to prevent the work equipment from coming down In addition set the work equipment control levers to the Hold position and put the pilot cut off switch to the ...

Page 247: ...om its stowage position d Place the safety lock bar onto the boom cylinder and secure the safety lock bar by tying the string shown as figure e Slowly lower the boom to fix the safety lock bar When lowering the boom operate the control lever very slowly 2 Lowering a Raise the boom to take the weight off the safety lock bar b Stop the engine and remove the starter key c Loosen the string and remove...

Page 248: ...n eyes Wash with clean water and go to the doctor if it enters the eyes Avoid short circuiting the battery terminals through accidental con tact with metallic objects such as tools across the terminals Do not store tools bucket tooth and other flammable things in bat tery box They could cause a fire Tighten the battery terminals securely Loosened terminals can generate sparks and lead to explosion...

Page 249: ...red terminal of the boos ter cable to the battery terminal between exhausted and new battery b Connect the black terminal of the booster cable to the battery termi nal between exhausted and new bat tery Keep firmly all connection the spark will be caused when con necting finally 2 Starting the engine a Start engine with starting key b If you can not start it by one time re start the engine after 2...

Page 250: ...rting switch b Disconnect ground cable from bat tery by master switch c Before carrying out any electric weld ing on the machine the battery ca bles should be disconnected and the connectors pulled out of the electron ic control units MCU TCU ECU cluster monitor etc d Connect the earth ground lead of the welding equipment as close to the welding point as possible Do not weld or flame cut on pipes ...

Page 251: ...ow once every one hour 2 Be careful not to overcool the cab 3 The cab is properly cooled if the operator feels cool when entering there from out side about 5 C lower than the outside temperature 4 When cooling change air occasionally 3 CHECK DURING SEASON Ask the service center for replenishment of re frigerant or other maintenance services so that the cooling performance is not damaged 4 CHECK DU...

Page 252: ...y precautions Work on the air conditioning system must only be performed by a qualified service technician Do not attempt to perform work on the air conditioning system Wear safety goggles chemical resistant gloves and appropriate personal protective equip ment to protect bare skin when there is a risk of contact with refrigerant 4 Action in case of exposure a Eye contact Limited skin contact Rins...

Page 253: ...e gauge Tighten the radiator cap firmly or replace the gasket of it Engine does not start when the starting motor is turned over Add fuel Repair where air is inhaled into fuel sys tem Check the injection pump or the nozzle In cold weather check if fuel warmer sys tem is working normal Refer to the pages 4 3 Check the valve clearance Exhaust gas is white or blue Adjust to specified oil quantity Rep...

Page 254: ...itch is turned on Inspect and repair the wiring Charge the battery Check the starting switch Check the battery relay switch Place the gear selector lever in the neu tral Starting motor turns the engine sluggish ly Charge the battery Check the starting motor The starting motor disengages before the engine starts up Check and repair the wiring Charge the battery The engine oil pressure lamp does not...

Page 255: ... axle case to the specified level Brake does not work when the pedal is de pressed Raise hydraulic oil pressure to specified level Add brake oil Bleed hydraulic oil from brake system Brake drags or stays when applied Clean breather and bleed air from brake system Brake slips Raise hydraulic oil pressure to the specified level Brake does not work properly Adjust linkage Clean brake pad Replace spri...

Page 256: ...ifting speed is slow Check the hydraulic oil level and add if necessary Replace filter in hydraulic tank Bubbles in oil Replace with specified oil Add oil if needed Oil pressure is too low Bleed air from oil line Add oil and bleed air Cylinder vibrates when operating Add oil 7 4 ...

Page 257: ...ion and buzzer sounds The green pilot lamp is turned ON Check for engagement as follows a Put down pressure on the attachment b Back up the machine and make sure that there is no movement between the quick coupler and attachment Check that the indicator is in the lock position Always check that the attachment is properly secured to the quick coupler by pressing the front part of the attach ment ag...

Page 258: ...e attachment d Reverse away from the attachment 3 PRECAUTION OF USING QUICK COUPLER When operating the machine with quick coupler confirm that the quick coupler switch is in the lock position Operating the machine with the quick clamp switch in the unlock position can cause the bucket to drop off and bring about accidents Serious injury or death can result from this accident Quick coupler switch 8...

Page 259: ...Hydraulic oil filling 6 38 Hydraulic oil level 6 37 L LCD 3 12 Loading and unloading 5 6 Lubrication 6 48 M Machine control unit MCU 3 72 Maintenance chart 6 11 Maintenance checklist 6 8 Major components 2 1 Master switch 3 72 Monitor 3 14 P Pilot cut off switch 3 52 Pilot line filter 6 40 R Radiator and oil cooler 6 20 Radio and USB player 3 76 Recommended lubricants 6 6 Return filter 6 39 S Safe...

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Page 262: ...EN English E1 September 2020 PART NO 91WA 32040 ...

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Hyundai HL930A, Operation & Maintenance Manual

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