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Hyundai HSL1500T Track Manual Download Page 65

6.  Engine (Continued)

Problem

Cause

Remedy

Engine overheated

Deficient output

Battery quickly discharges

Engine oil insufficient
Fan belt broken or elongated
Cooling water insufficient
Radiator net and radiator fin clogged
with dust
Inside of radiator corroded
Cooling water flow route corroded
Radiator cap defective
Overload running
Head gasket defective
Incorrect injection timing
Unsuitable fuel used
Incorrect injection timing
Engine’s moving parts seem to be
seizing
Uneven fuel injection
Deficient nozzle injection
Compression leak

Battery electrolyte insufficient
Fan belt slips
Wiring disconnected
Rectifier defective
Alternator defective
Battery defective

Replenish.
Change or adjust.
Replenish.
Clean.

Clean or replace.
Clean or replace.
Replace.
Lessen the load.
Replace.
Adjust.
Use the specified fuel.
Adjust.
Repair or replace.

Repair or replace injection pump.
Repair or replace nozzle.
Replace head gasket, tighten cylinder
head bolt, glow plug and nozzle
holder.
Replenish distilled water recharge.
Adjust belt tension or charge.
Connect.
Replace.
Replace.
Change.

4.  MAINTENANCE

66

Summary of Contents for HSL1500T Track

Page 1: ...NOT ATTEMPT TO ENLARGE ITS RIGHTS UNDER THE WARRANTY BY MAKING CLAIM FOR INDEMNITY FOR BREACH OF CONTRACT FOR BREACH OF COLLATERAL WARRANTY FOR A TORT INCLUDING NEGLIGENCE MISREPRESENTATION OR STRICT...

Page 2: ...Backfilling 3 7 Auxiliary Hydraulics 3 8 Lifting 3 9 Towing 3 10 Securing and Transporting 3 11 Lowering Lift Arms 3 12 Accumulator INDEX 4 MAINTENANCE 4 1 Preventive Maintenance Service Schedule 4 2...

Page 3: ...Operator necessary operating servicing and preventative maintenance instructions on the loader Read this manual completely and know the loader before operating or servicing it Do not do any service pr...

Page 4: ...electrical line locations before you start to dig 8 Watch out for overhead and underground high voltage electrical lines when operating the loader 9 Always park the loader on level ground where possib...

Page 5: ...d and understand the Owners and Operator s Manual before operation WARNING BYSTANDERS BEWARE To avoid personal injury all bystanders should keep a safe distance from the machine during operation This...

Page 6: ...ecific service and backhoe operating procedures WARNING START SAFELY 1 Sit in the operator s seat and adjust it so you can operate all of the controls properly 2 Adjust the seat and fasten the seat be...

Page 7: ...ne position the machine at right angles to the slope Lower the attachment to the ground engage the parking brake and block the wheels C359 For track loaders follow the same procedure except place your...

Page 8: ...at Belt 2 4 Seat Bar 2 5 Parking Brake 2 6 Throttle Control 2 7 Lift Arm Supports 2 8 Steering Controls 2 9 Electrical Solenoid Auxiliary 2 10 Foot Controls 2 11 Hand Controls 2 12 Quick Tach 2 13 Ele...

Page 9: ...temperature has exceeded recommended levels Shut off the engine immediately and determine the cause 10 Brake Indicator Light The brake light will illuminate when the parking brake is engaged 11 Seat B...

Page 10: ...s switch provides alternate switching Press to activate Hi Speed function Pressing and releasing the switch a second time will return the loader to the Low Speed function See Fig 2 2A 2 Horn Switch no...

Page 11: ...g the loader adjust and fasten the seat belt Fig 2 3B around you The seat and seat belt also have integrated safety lock switches whereby the operator must be seated in the seat with the seat belt sec...

Page 12: ...hey are in the neutral position 2 5 REAR WINDOW For emergency exiting of the loader pull on the tag on the top of the rear window to remove the rubber cord Fig 2 5 Push the rear window out of the rear...

Page 13: ...ff the engine return the throttle control to idle position and allow the engine to cool at least 2 minutes Pulling upward out will increase engine speed Turn the handle to lock Turn the handle to rele...

Page 14: ...or attachment from the quick tach raise the lift arms to full height and shut OFF the engine Push the two lift arm support pin handles located directly in front of the operator at the top of the oper...

Page 15: ...turned by moving one lever further forward than the other To turn right move the left lever further than the right lever To turn left move the right lever further than the left lever Fig 2 8B For the...

Page 16: ...cuit a toggle switch is located on the L H instrument panel Fig 2 9B Placing the switch in the ON position provides continuous hydraulic flow to the female quick connect coupling located at the front...

Page 17: ...ion Moving the left hand control lever Fig 2 11A to the left will cause the lift cylinders to extend raising the loader s lift arms Moving the control lever to the right causes the lift cylinders to r...

Page 18: ...t tilt cylinders Fig 2 12C which will line up the bottom of the attachment with the quick tach lock pins Shut off the engine Push the locking lever 1 fully down Fig 2 12D extending the lock pins Fig 2...

Page 19: ...on the engine cover The panel consists of the following 1 Engine Pre Heater Relay 2 Starter Relay 3 Fuse Panel FUSE PANEL 3 4 Electric Fuel Solenoid Shutoff 15A 5 Alternator 10A 6 Electric Auxiliary 1...

Page 20: ...Two Speed control returns to the Low speed function An indicator panel is mounted on the LH ROPS post Fig 2 14B to show the operator which function is activated at any given time For proper loader op...

Page 21: ...22...

Page 22: ...Shut Off Procedure 3 2 Operating Procedures 3 3 Operating Track Loader 3 4 Filling From a Pile 3 5 Digging With a Bucket 3 6 Leveling and Backfilling 3 7 Auxiliary Hydraulics 3 8 Lifting 3 9 Towing 3...

Page 23: ...engine immediately and determine cause 7 Allow the engine to warm up for five minutes before operating When ready to operate lower the seat bar and advance the throttle to full on position 3 Shut Off...

Page 24: ...a slope with the heavy end of the loader pointing towards the top of the slope 3 3 OPERATING TRACK LOADER 1 Tracks are designed to provide you superior floatation and traction as compared to wheel lo...

Page 25: ...turned up against a curb or mound Fig 3 3D and Fig 3 3E This can cause the tracks to derail or form cracks in the edge of the track 6 Avoid operating or turning on sharp objects such as jagged rocks o...

Page 26: ...the front of the bucket and move the L H control lever away from you to raise the lift arms Fig 3 3B When the bucket is full back away from the pile To dump the bucket Fig 3 3C push down on the heel o...

Page 27: ...lower the lift arms completely down Move the R H control lever away from you and place the cutting edge of the bucket on the ground Fig 3 4D Drive the loader forward at a slow rate and continue to ti...

Page 28: ...terial To level the ground with a hand control unit raise the lift arms and tilt the bucket down by moving the R H lever away from you Move the L H control lever all of the way towards you Fig 3 5H to...

Page 29: ...ment panel Fig 3 6L should be placed in the ON position When the auxiliary circuit is not in use switch to the OFF position otherwise starting the loader may be difficult or impossible and damage to t...

Page 30: ...d Loaders Track equiped loaders must not be lifted using cab mounted lifting points If it is necessary to lift loader it must be done with a lifting frame that supports the entire loader under the tra...

Page 31: ...alve nut Fig 3 8B counter clockwise two 2 revolutions DO NOT open the valve past two 2 turns When open the valve connects both sides of the pump motor circuit and allows the motor to turn for towing s...

Page 32: ...rear tie down locations and securely attach to the transport vehicle NOTE Minimum 3 8 in grade 40 chain is required C3408 Fig 3 9 C362 SAFE SHUTDOWN PROCEDURES Stop machine Lower the bucket and other...

Page 33: ...they are locked If help is readily available have someone place a suitable support under the lift arms e g 4 x 4 Lumber or a piece of angle iron between lift cylinder end cap and lift cylinder rod mo...

Page 34: ...switch on the LH control a couple of times see Fig 3 11B Once this pressure is released the operator can disconnect the couplers to the attachment from the loader Accumulator C3896 Fig 3 11A 35 Fig 3...

Page 35: ...placement 4 Draining System Fluid 5 Oil Cooler and Cooling Fan 6 Brake Service Override 4 8 Engine Maintenance 1 Engine Specifications 2 Oil Level Check 3 Engine Oil and Filter Replacement 4 V Belt Te...

Page 36: ...riate torque Remove all debris from track area Check all safety equipment for proper operation and condition Seat belt seat bar control locks lift arm supports quick tach locks parking brake safety tr...

Page 37: ...10W30 API Classification SJ oil Drain flush and refill Use 50 mixture of ethylene glycol and water To avoid personal injury service repairs must be performed by an authorized Hyundai dealer 4 MAINTEN...

Page 38: ...sembly can be removed to provide access to the controls hydraulic and hydrostatic components To remove the seat assembly remove the fasteners located at the front of the seat DISCONNECT ELECTRICAL PLU...

Page 39: ...cessary to add oil remove the reservoir cap located at the top of the oil reservoir and add oil until oil appears in the oil level sight glass Use a good quality 10W30 oil which meets the API classifi...

Page 40: ...g brake quick tach lock shields safety treads and control locks Lubricate all linkages springs and pivot points with a silicone based lubricant Repair or replace if necessary 6 Decals Check the condit...

Page 41: ...let it cool for at least 5 minutes to allow the oil to drain back to the oil pan To check the oil level check with the loader on level ground open the rear door and remove the dipstick Fig 4 3E Keep t...

Page 42: ...t manifold flywheel etc Replace fuel filter every 300 hours 1 5 Air Intake and Cleaner System Visually inspect the air cleaner system and be sure all hose clamps are secure and no hoses are damaged 1...

Page 43: ...o end play 3 6 Axle Seal Inspect axle seal area Clean area of debris build up and visually check for seal damage replace as required NOTE For track loaders this will be done at 300 hours 4 Controls an...

Page 44: ...y two 22 lubrication points are Rear Lift Arm Pivots 2 Lift Cylinder Bushings 4 Bucket Cylinder Bushings 4 Lift Arm Supports 2 Quick Tach Pivot and Lock Pins 4 Tandem Pivots 2 Support Arm Bearings 4 7...

Page 45: ...he drive chains should be checked after the first 50 hours for wheel loaders and after the first 300 hours for track loaders of operation and every 150 hours thereafter To inspect block the loader sec...

Page 46: ...f oil is apparent the level is satisfactory WARNING WARNING Escaping hydraulic fluid under pressure can penetrate the skin causing serious injury DO NOT use your hand to check for leaks Use a piece of...

Page 47: ...Change the hydraulic oil 1 After 1000 operating hours 2 If the oil has become contaminated 3 After any major hydrostatic repair To drain the oil remove the drain plug located at the bottom of the res...

Page 48: ...y dirt buildup with compressed air Figure 4 7E shows the radiator setup for the loader 6 Brake Service Override A service Override has been incorporated for use by authorized dealers The normal positi...

Page 49: ...the full mark 3 Engine Oil and Filter Replacement Operate the engine until warm approximately 5 minutes Stop the engine Remove the oil drain plug located at the bottom of the oil pan Remove the oil fi...

Page 50: ...t on the left hand side Fig 4 8E The fuel filter should be removed every 100 hours and any water or dirt found in the element drained off Change the filter every 300 hours To replace the filter close...

Page 51: ...ff located on the side of the fuel tank is open Fig 4 8F Open the bleed valve by turning it counter clockwise Fig 4 8G on top of the injector pump Place the throttle at idle then turn the engine over...

Page 52: ...e new filter for seal or pleat damage 2 8 Insert the new filter properly The seal area is on the inside of the open end of the primary filter A new filter has a dry lubricant to aid installation The c...

Page 53: ...radiator petcock Fig 4 10B in to open Release the radiator cap Remove the lower coolant hose from the engine to drain the coolant from the engine block Drain flush and replenish the cooling system fl...

Page 54: ...ve terminal of the booster battery Connect the other end of the same cable to a ground Keep cables away from moving parts Start the engine After the engine has started disconnect the end of the second...

Page 55: ...20 PPLE 20 PPLE WHT 20 GREY WHT 20 BRN WHT 18 WHT RED 20 BLUE WHT 20 RED 14 GREY 20 RED OR 18 RED OR 16 RED OR 16 LT GREEN 14 LOW CHARGE PRESSURE C B A BRN YL 18 YL18 YL WHT 18 YL WHT 18 YELLOW 18 LT...

Page 56: ...WHT 20 OR BLUE 20 PPLE WHT 20 WHT 10 TAN 20 LT GRN 18 PINK 20 BLUE WHT 20 PINK 20 RD WHT 20 BLUE 18 87a 87 85 86 30 87a 87 85 86 30 CIRCUIT BREAKER W H T 1 0 WHT RED 18 SHUT OFF A B A B RED 18 RED 16...

Page 57: ...other suitable blocking to support the loader while repairing tires 1 15 Insure jack has adequate capacity to lift your loader 1 16 Insure jack is placed on a firm level surface 1 17 Do not put any p...

Page 58: ...have tears chunks or cuts Operation in an area where there is more debris will place more inside the track and accelerate the wear Rollers should be replaced when rubber tire is completely worn off on...

Page 59: ...AINTENANCE 5 Scraper Inspection Inspect scrappers for damage and wear and replace if needed Fig 4 13D C4414 Fig 4 13D Scrapers WARNING To avoid personal injury do not operate the loader without the re...

Page 60: ...ion check valve spring broken Main relief or port relief valve in control valve faulty Internal leakage in pump due to wear Oil bypassing one or both lift cylinder piston seals External leak between o...

Page 61: ...e to low oil level in reservoir Air in system due to leak at suction fitting Internal pump or motor wear caused by overspeeding Excessive play in linkage or pintle lever Control levers binding Repleni...

Page 62: ...ings binding in lever assembly Inspect replace or clean as required Inspect linkage for wear at rod ends loose counter nuts Replace bolt Inspect pintle lever for wear at bolt hole Ensure bolt clamping...

Page 63: ...e solenoid or binding solenoid locks Loosen screws and re adjust Check continuity of connectors seat bar switch seat switch seat belt switch and wires 4 MAINTENANCE 6 Engine Problem Cause Remedy Engin...

Page 64: ...l ring worn or stuck Piston ring groove worn Valve stem and guide worn Crankshaft bearing and crank pin bearing worn Injection pump s plunger worn Injection pump broken Head gasket defective Cylinder...

Page 65: ...s moving parts seem to be seizing Uneven fuel injection Deficient nozzle injection Compression leak Battery electrolyte insufficient Fan belt slips Wiring disconnected Rectifier defective Alternator d...

Page 66: ...R PUMP PUMP 250 255 LOADER HYDRAULIC LAYOUT 250 255 LOADER HYDRAULIC LAYOUT WITH WITH BRAKES BRAKES WITH WITH BRAKES BRAKES 2 2 4 4 3 3 1 1 A B D C SELF LEVEL SELF LEVEL VALVE VALVE LIFT LIFT CYLS CYL...

Page 67: ...T 960986 SEAL INSTALLATION TOOL To install axle seal in final drive housing Qty 1 955287 SEAL INSTALLATION TOOL To install axle seal in final drive housing Qty 1 957189 SEAL INSTALLATION TOOL To insta...

Page 68: ...745 76mm 304746 82mm 304747 105mm Removing Plates 304748 Installing Plate DIESEL ENGINE COMPRESSION TESTER Used to measure diesel engine compression and diagnosis of need for major overhaul CRANKSHAFT...

Page 69: ...or Measuring Restraint Bar Brake Cable Adjustment Special Order Only HSL1200T HSL1500T C1839 C1837 43979 43980 43981 4 15 SPECIAL TOOLS Cont d Part ILLUSTRATION DESCRIPTION MODEL MULTI METER For measu...

Page 70: ...71 5 SPECIFICATIONS 5 1 Loader Specifications 5 2 Torque Specifications 5 3 Decals 5 SPECIFICATIONS...

Page 71: ...38 mm 48 75 1238mm N Overall length less bucket 117 5 2985 mm 117 5 2985mm O Ground clearance 9 229 mm 9 229mm P Maximum grading angle bucket 88 88 Q Angle of departure 27 27 R Bucket width 73 1854 mm...

Page 72: ...PM 21 0 GPM 79 5 L min Pump Capacity theoretical 2500 RPM 19 2 GPM 72 7 L min System Relief Setting 3000 PSI 206 8 bar Control Valve Series type with float on lift and electrical auxiliary Filtration...

Page 73: ...14 qt 13 2 L 5W40 API CF Engine cooling system 4 2 gal 16 L 50 50 water ethylene glycol 5 2 TORQUE SPECIFICATIONS Loader Wheel nuts 24 100 110 ft lbs 136 149 Nm FOR NON CRITICAL AND NOT OTHERWISE MENT...

Page 74: ...600T HSL680T HSL800T HSL960T HSL1200T HSL1500T 386KG 454KG 590KG 580KG 794KG 953KG 1134KG 1134KG WARNNG RATED OPERATING CAPACITY 2 17 5 12 WARNING CARRY LOAD LOW FASTEN SEAT BELTTH23326 11 10 8 9 TH23...

Page 75: ...76 DIESEL TH23310 20 TH23308 CAUTION TH23312 22 25 24 23 HYDRAULIC HYDRAULISCH HYRAULICO HYDRAULIQUE TH23307 26 19 18 27 15 21 30 5 SPECIFICATIONS 5 3 DECALS HSL1500T 33 33 3 12 Wheel Loader Only...

Page 76: ...12 39192 21 23325 30 49019 4 36841 13 32275 22 46301 31 49021 5 25460 14 23324 23 23308 32 49022 6 41045 15 39191 24 23312 33 49020 7 43791 16 39196 25 38043 34 49733 8 37059 17 36598 26 23307 35 523...

Page 77: ...78 6 ATTACHMENTS AND BUCKETS 6 1 Hyundai Approved Buckets and Attachments 6 ATTACHMENTS AND BUCKETS...

Page 78: ...escription Approx Weight 2569 Model PA40Auger Drive Requires Mount Bit 160 lb 1891 Auger Mount 126 lb 941 9 x 48 Auger Bit w Serrated Edges 75 lb 943 12 x 48 Auger Bit w Serrated Edges 100 lb 119 14 x...

Page 79: ...lb 3189 84 Angel Broom With ManualAngle direct shipped from manufacturer 915lb 3192 84 Angle Broom With HydraulicAngle shipped from Hyundai 930 lb 3193 84 Angle Broom With hydraulicAngle direct shipp...

Page 80: ...Rake w Hydraulic Angle and Floating Linkage shipped from Hyundai 1075 lb 3253 90 Power Rake w Hydraulic Angle and Floating Linkage direct shipped from manufacturer 1075 lb LANDSCAPE RAKE Cat Descripti...

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