HYDRAULIC EXCAVATORForeword ot Belore servicing this machine og EC regulation approved 03 Table to enter SNo znd dstrbuton ~ “04 Salety labels os Guide(Directon, SiNo, Symbol). OA SAFETY HINTS 1. Beiore operating the machine 14 2. During operating the machine. 16 3, During maintenance. 1413 4, Pasking = 1418 SPECIFICATIONS 4, Major components: 24 2. Spectcations 22 ‘8, Working range 23 4. Weight 24 5. Liting capacities 25 6. Bucket selection guide soe DT 7. Undercariage. . oo DAZ 8, Speitcaton for major components == 243 9, Recommended ols 216 CONTROL DEVICES 1.Cab devices ~- a 2, Cluster 32 8, Switches 37 4, Levers and pedals. 340 5. Air conditioner and heater: 313 6.Others 345 OPERATION 1. Suggestion for new machine 4A 2. Check before starting the engine. 42 3, Starting and stop the engine 4. Operation ofthe working device 5, Taveling of the machine CONTENTS 6. ficient working method: 41 7. Operation in the special worksites 445 8. Normal operation of excavator a7 9, Attachment lowering 418 10, Storage « aig 11, RCV lover operating pattern. 421 TRANSPOTATION 1. Preparation for transportation 2, Dimension and weight ~ 3. Loading the machine 4. Fang the machine 8. Loading and unloacing by crane MAINTENANCE 4. Instruction 2. Tightening toque 3, Fuel, coolant and lubricants 69 4, Maintenance check lst 61 5, Maintenance chart 616 6. Service instruction 18 7. Electrical system. 636 8, Aircondtioner and heater 69 ‘TROUBLESHOOTING GUIDE A 72 73 HYDRAULIC BREAKER AND QUICK CLAMP 1. Salectng hycraule breaker 84 2. Circuit configuration sone BD 3, Maintenance 83 4, Precaution while operating the breaker ~~ 6-4 $8, Quick clamp mr oo BH INDEX + vm GAFOREWORD ‘This manual contains @ number of instructions and salety recommendations regarding driving, handing, lubrication, maintenance, inspection and adjustment ofthe excavator ‘The manual is o promote safety maintenance and enhance machine performance. Keep this manual handy and have all personnel read it periodically. It you sel the machine, be sure to give this manual tothe new owners. ‘This machine complies with EC directive “98/97IEEC’. 1. Read and understand this manual before operating the machine. “This operator's manual may contain attachments and optional equipment that are not available in your area. Please consult your local Hyundai istibutor for those items you requir. Improper operation and maintenance of this machine can be hazardous and could result in serious injury or death. ‘Some actions involved in operation and maintenance of the machine can cause a serious accident, if they are not done in a manner described in this manual. “The procedures and precautions given inthis marwsl apply only to intended uses of the machine. It you use your machine for any unintended uses that are not specifically prohibited, you must be sure that itis safe for you and others. In no event should you or others engage in prohibited uses of ‘actions as described in his manual 2. Inspect the jobsite and follow the safety recommendations in the safety hints section betore operating the machine 3. Use genuine Hyundai spare parts forthe replacement of parts. We expressly point out that Hyundai will not accept any responsibilty for defects resulting from non- {genuine parts or non workmantike repair. in such cases Hyundai cannot assume liailly for any damage. ‘Continuing improvements inthe design ofthis machine can lead to changes in detail which may not be reflected in this manual. Consult Hyundai or your Hyundal distributor forthe latest available information for your machine or for questions regarting information inthis manval. otBEFORE SERVICING THIS MACHINE itis the responsibilty of the owner and all service and maintenance personnel o avoid accidents and serious injury by keeping this machine properly maintained. ttalsois the responsibilty ofthe owner and all service and maintenance personnel to avold accidents and serious injury while servicing the machine. No one should service or attempt to repair this machine without proper training and supervision. ‘All sorvice and maintenance personnel should be thoroughly familiar with the procedures and precautions contained inthis manual. ‘All personnel also must be aware of any federal, state, provincial or local aws 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 rcumstance or environment in which tis macrine may be used and serviced, ‘All personnel must remain alert to potential hazards. ‘Work within your level of training and skil ‘Ask your supervisor if you are uncertain about a particular task. Do not ty to do too much too fast. Use your common sense. o2Noise level (EN474-1 ANNEXS.10 and 2000/14/EC) areas followings. Lwa : 98d8(EU only) Lea: 7808 + The value of vibrations transmitted by the operator's seat are lower than standard value of (EN474-1 ANNEX 43.1.3)TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR: Machine Serial No, Engine Sail No. Maruitacturing year Manufacturer ‘Hyundai Heavy Industios 0, Lt Address 41 Chonha-Dong, Dong-Ku Usan “The Republic of Korea Distrbutorfor USA Hyundai Heavy Industries US.A ne Adsross 965 Estes Avonue EIK Grove wilage iL 60001 USA Distributor for Europe Fiyuncai Heavy Industies Europe NV. Asda Vossondal 11 2240 Goal Belgium | Dealer Aaress 4| SAFETY LABELS mie 1. LOCATION Always keep these labels clean. If they are lost or damage, attach them again or replace them with a nev abe 2 ES Ce — 1p 120825 CONSOLEBOXH CONSOLE BOXLH SEAT BASE-LOWER 1 Fueling 40 General cautions-cabin 19 No step-engine hood 2 Battery-accident 11 Safety front window 20. Name plate 3 Retlecting 12 Emergency exit 21 General waming frame 4 Ling point ideooram 13. Decal-airconfiter 22 Indicate-grease 5 Keepdearboonvarm —14_Decal-console ting 23 Robex 6 Keep clearrear 45 Controlideogram-LH 24° Model name 7 Keep dear-side 16 Controlideogram-RH © 25. Serviog instruction 8 Caution-engine room 17 Hydraulic oiluirication 26 Lifting chart 2 Control ideograms 18 Faling 27 Trade mark-boom 28 Boom swing lock os2, DESCRIPTION ‘There are several specific warning labels on this machine please become familiarized with all warning labels. Replace any safety label that is damaged, or missing. 1) FUELING\(tom 1) “This warning label is positioned on the right side of fuel filer neck, Stop the engine when refueling. All lights or flames shall be kept at a safe distance while refueling. 2) BATTERY ACCIDENT (tte 2) This warning label is positioned on the battery cover. ‘A Electrolyte containing suffuric acid cause severe bums. Avoid being in contact with skin, eyes or clothes. In the event of accident flush with sufficient water, call a physician immediately. = Maintain the electrolyte at the recommended level. Add distiled 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 the battery. AExtinguish all smoking materials and ‘open flames before checking the battery. ADo not use matches, lighters or torches as a light source near the battery for the probable presence of explosive gas. A.Do not allow unauthorized personnel to change the battery or to use booster cables. ‘.For safety from electric shock, do not battery terminals with a wet hand. A CAUTION| 068) KEEP CLEAR-BOOM/ARM(ten5) This waming label is positioned on both side ofthe boom. A Sorious injury or death can result from falling ofthe attachment. To prevent serious injury or death, keep clear the undemeath of attachment. 4) KEEP CLEAR-REAR(liem 6) This waming label is positioned on the rear ‘of engine hood. ‘To prevent serious personal injury or death keep clear of machine swing radius. Do not deface or remove this label from the machine. 9) SIDE KEEP CLEAR(Item 7) This waming label is positioned on the side of engine hood. To prevent serious personal injury or death keep clear of machine swing a radius, Ly Do not deface or remove this label from the machine. o76) CAUTION-ENGINE ROOM(ttem 8) This warning label is positioned on the side of radiator, ‘4.00 not open the engine hood during the engine's running, AEscaping fluid under pressure can penetrate the skin causing serious injury. » Study the service manual before service job. ANever open the filer cap while engine running or at high coolant oil temperature. ‘AStudy the operator's manual before starting and operating machine, A.Do not touch exhaust pipe or it may ‘cause severe bum. 7) CONTROL IDEOGRAM((tem 9) This warning label is positioned in right window of the cab. Check the machine control pattern for conformance to pattem on this label. If not, change label to match pattem before ‘operating machine. Failure to do so could result it death. x See page 4-7 for details. injury or 088) GENERAL CAUTIONS-CABIN(ltem 10) This warning label is positioned on the right side window of the cab. ‘A Serious injury or death can result from contact with electic lines. ‘An electric shock being received by merely coming into the vicinity of an electric lines, the minimum distance should be kept considering the supply voltage as page 1-7. ‘A Serious injury or death oan result from dropping bucket. ‘A Operating the machine with quick clamp switch unlocked or without safety pin of moving hook can cause the bucket to drop off. 9) SAFETY FRONT WINDOWi(tter 11) This warning label is positioned on the both side window of the cab, ‘4.Be careful that the front window may be promptly closed. 1QEMERGENCY EXIT (tom 12) This warning label is positioned on the right side window of the cabs ‘The right side window serves us an alternate exit. AAt case of emergency, use the hammer for braking the right side window of the cab. ¢ og‘11)DECAL-AIRCON FILTER({ter 13) This warning label is positioned on the lower seat base. x Periodic and proper inspection, cleaning and change of filter prolong air conditioner life time and maintain good performance. 12)DECAL-CONSOLE TILTING(ltem 14) ‘This warning label is positioned on the LH console box. Before you get off the machine be sure to tit the LH console box. 49 CONTROL IDEOGRAM-LH (Iter 15) This warning label is positioned on the LH console box. ‘A.Check the machine control pattern for conformance to pattem on this label. If not, change label to match pattern before ‘operating machine. ‘A Failure to do so could result in injury or death, » See page 4-7 for details. 14) CONTROL IDEOGRAM-RHiltem 16) This warning label is positioned on the RH console box. Check the machine control pattern for conformance to pattem on this label. If ‘not, change label to match pattem before ‘operating machine, 4 Failure to do so could result in injury or death, x See page 4-7 for details. 010 Oe? O aS19) HYDRAULIC OIL LUBRICATION((tom 17) This warming label is positioned on the right side of air breather. » Do not mix with different brand oils. A Never open the filler cap while engine running or at high hydraulic oil temperature. Loosen the cap slowly and release intemal pressure completely. 16) FALLING (tem 18) This waming label is positioned on the top ‘ofthe hydraulic tank. 4 Falling is one of the major cause of personal injury. ‘A.Be careful of slippery conditions on the platforms, steps and handrails whon standing on the machine, INO STEP-ENGINE HOOD (Item 19) This warning label is positioned on the engine hood, ‘4.Do not step on the engine hood. ez ®| A _t on18) GENERAL WARNING-FRAME((em 21) This waming labe is positioned right side of ‘upper frame, ‘Study the operator's manual before transporting the machine, if provided and tie down arm and track to the earrior with lashing wire. x See page 5-6 for details. ‘A.Make sure wire rope is proper size and keep correct hoisting method. x See page 5-7 for detalls. {Place the bucket on the ground whenever servicing the hydraulic system. += Check oil level on the level gauge. x Refil the recommended hydraulic oll up to specified lavel if necessary. otaGUIDE 1. DIRECTION cf) ‘The direction of this manual indicate forward, badovard, right and lft on the stander of operator wen the travel moior is inthe rear and machine is onthe traveling direction Stet Travel motor” 2. SERIAL NUMBER, Inform following when you order parts or the machine is out of order. 1) MACHINE SERIAL NUMBER ‘The numbers are located below the front window of the operators cab. 2) ENGINE SERIAL NUMBER, The numbers are located on the engine name plate, 3. SYMBOLS A. Important safety hint. © Itindicates matters which ean cause the great loss on the machine or the surroundings. 2% Itindicates the useful information for operator. O13Think safety fit In special situation, wear protective clothing including a safety helmet, safety shoes, gloves, safety glasses and ear protecton as required by the job condition. ‘Almast every accident is caused by disregarding the simple and fundamental safety hints. Be sure to understand thoroughly all about the operator's manual before operating the machine, Proper care is your responsibilty Fully understand the details and process of the construction before starting the work, If you find anything dangerous on the job, ‘consul with the job supervisor forthe preventive measures before operating the machine, Do not operate when tired, oF after drinking alcoholic beverages or any type of drugs, oy‘Check deily according tothe operation manual, Repair the damaged parts and tighten the loosened bolts Check for leakage of engine ol, hydraulic oi, fuel and coolant. oop machine clean, clean machine regularly Operate ater complete repair. Be prepared if fire stats, Keep a fire extinguisher handy and emergency numbers for a fire department near your telephone,UNAUTHORIZED MODIFICATION Any modification made without authorization from Hyundai can create hazards. Before making a modification, consult your Hyundai distributor. Hyundai will not be responsible for any injury or damage caused by any unauthorized modification, PREPARE FOR EMERGENCY ‘Only in case of emergency, use the installed hammer for breaking the windshield of the cab, and then exit carefully, Have a fre extinguisher and frst aid kit ready for ‘emergencies such as fires or accidents Leam howto use the fie extinguisher Be sure you know the phone numbers of persons you should contact in case of an ‘emergency. ROTATING BEACON When you operate a machine on a toad or beside a road, a rotating beacon is required to avoid any traffic accident. Please contact your Hyundai distributor to install itPRECAUTIONS FOR ATTACHMENTS: When installing and using an optional attachment, read the instruction manual for the attachment and the information related to attachments in this manual, Do not use attachments that are not authorized by Hyundei or your Hyundai distributor. Use of ‘unauthorized attachments could create a safety problem and adversely affect the proper operation and useful ie ofthe machine. Any injuries, accidents, product failures resulting from the use of unauthorized attachments are Not the responsibilty of Hyundai ‘SAFETY RULES ‘Only trained and authorized personnel can operate and maintain the machine. Follow all safety rules, precautions and instructions when operating or performing ‘maintenance on the machine. When working with another operator ora person con worksite traffic duty, be sure all personnat understand all hand signals that are to be used. ‘SAFETY FEATURES Be sure all guards and cavers are in their proper position. Have guards and covers repaired if ‘damaged. Use safety features such as safety lock and seat belts propery. Never remove any safely features. Always keep them in good operating condition. Improper use of safety features could result in serious bodly injury or death. MACHINE CONTROL PATTERN Check machine contol pattem for conformance to pattern on label in cab. IF not, change label to match pattern before operating machine. Feallure to do so could result in injury.CALIFORNIA PROPOSITION 65 Diesel engine exhaust and some of its ‘constituents are known to the Slate of California to cause cancer, birth defects and other reproductive harm, ‘This product contains or emits chemicals known to the State of California to cause cancer or birth 16006 09 Overall height of cab» & 2550( 8 4") Ground clearance of counterweight FE 69 2 3") Engine over height @ 1650 5 59 ‘Minimum ground clearance H 3801" 3) Rearend distance 1 . 16405 5) ar-ond sing racius r mes) 1680 5 5) Disance been tumblers J 190 6 69 Undercariage length K 2530( 8 4°) Undrariage with L 1900 6 39 Track gauge M 1500( 4°11") Track hoe wih, sansa N 40086) Heigtottiads ° Ss 12) Ground cearance of ado uw P “2 1 5) Depth of blade down a 440 1" 5") Tavel speed Lowhigh) Frito) 224. 45al25) Shing speed =n 36 Gradeabilty Degree(s) 35(70) Ground pressure(400mm shoe) kglicr (ps)WORKING RANGE 1) 3.0m(9' 10") MONO BOOM WITH BOOM SWING POST Description {mis 3") Arm ‘Max digging reach A ‘etsomm (20" 2) = ‘Max digging reach on ground | A 60101 19" 91) Max digging depth 8 ‘6200 (126°) [Maxcigging depth (etieve |B ‘s420nn(11" 31) ‘Max vertioal wall igging depth | © ‘200mm (10" 6) ‘Max digging height. ° ‘5700 (182") Max dumping height E 406013" 3) Min sing radius F ‘360mm 7°") ‘Boom swing racus(etight) Bucket digging force Arm crowd force T 1: Power boost 23Uppersirucuro assembly Main frame wold assombly 660 Engine asserbiy 280 Main pump assembly 30 ‘Main control valve assembly 40 ‘Swing motor assembly 70 ‘Hydraulic ol tank assembly Fuel tank assombiy ‘Boom swing post 110 Counterweight| 210 ‘Cab assembly Lower chassis assembly 2160 “Tack frame weld assembly ‘Swing bearing 100 Tiavel motor assemby “Turing joint 30 “Tack reco! spring 30 lelar Carter roller 10 “Tack rll 10 Sprocket 20 “Track-chain assembly(400nm standard triple rouser shoe) 330, Dazer blade assembly 210 Front attachment assembiy(3.0m boom,1.6m arm, 0.180? SAE heaped bucket) 740 8.0m boom assembly 8 1.6marm assembly g (0.181? SAE heaped bucket Boom oyinder assembly ‘Armoyiner assembly Bucket cyinder assembly ‘Bucket contol ink assembly Dozer cyinder assemby ‘Boom swing eyindor assembly 8\/8l/s\slsiais5 LIFTING CAPACITIES 1) 3.0m( 9110") boom, 1.6m{ ' 3") arm equipped with 0.18m'(SAE heaped) bucket and 400mm( 16") tiple grouser shoe, the daze blade up wth 210kg(4600) counterweight . 6 + Rating over-ront + ED : Rating over-side or 360 degree : Toad ads ‘Aimax reach Load point 2.0m(6it) 3.0m(108) 4.0m{ 16511) 5.0m(15!) Capacity Reach eight ™ ) B® let | & lem) Bh lem] & lew mt) 3a io a8 (5) |b _ - (3) 40m fig =) = 504 ism |B 2 | (5 aan fio “ao | 00 37 ito) | Py 83) zon fig | 2680) 20 | 0 ‘on 70 Bi (Gf) || ‘6600 | “6500 | “3650. 236) 1630, 094) on" fig "20 @ 710 se Gy_|b _| sito |_ 20 1570 | (aa) [Ground kg | “20 | 20 | ero se, 20 | (580 | 580 Line | | ‘sia | *5t40 | "300 2160 1820, | (184) Lom [ig] 30) 280 | 20 “im | so} sit (st) |p| 7650 | 6670 | “5600 2120 "0 | 1500 | (168) 20n |i | ave) seo | 20 “io | 90} at wet) |b| eco! feo | 070 | 310 | 2070 | (135) “aom |g | 20 | co rom) | | 4690 | “4530 Nota 1. Liting capacity are based on SAE J1097 and ISO 10567. 2. Ling capacity of the ROBEX series does not exceed 75% of tipping load with the machine 6 firm, level ground or 87% of full hydraulic capacity. 8. The load point i a hook located onthe back of the bucket 4, indicates load limited by hydraulic capacity. 252) 3.0m( $'10") boom, 1.6m 5° 3") arm equipped with 0.18m(SAE heaped) bucket and 400mm(16") triple grouser shoe, the dozer blade down with 210kg(460Ib) counterweight. Cad os imaxceach Loaspoin | Zone San(ton | a0n(16H) | SOn(i6H) | Capeciy | Reach spa [ x y wot lem] lem] gle] & [om |G | ee | om 3.0m [ig “a6 [960 | 408, (15i)_| Ib 20e0 | 2000 | (134) 400] "wo | ra] sot (15M), 2 “2140 | 1700} (165) 0m “wo | 50) ser (108) 8 70 | 1990 | (183) Zn [ig 7] 7S] too] 50 | sa ef |e 3|_ go] 0) ao] ast, 10F [ia ao] ro] on | sm] 52 (i) _| “mem | 1570} ‘200 | 1280 | (18:1 | af ee | 1.0m | kg | “20m [ig (si)_| “300 Jia ino |'8 | 266, BUCKET SELECTION GUIDE .07a" SAE (0.180? SAE heaped buckot heaped bucket Capacity Wath " Weight ‘30m 910") boom ‘SAE | CECE | Without | wih ; heaped | heaped |side cute side cuter ‘6m (5 Sym sci | tint [ie | Sm | Jeamer | om | 024 | 1427 | 85 | sar marist sty tig 0.18m* | 0.15m | 705mm | 770mm | 137kg @ orless (0.24y0') | (0.20y0) | (27.8") | (30.3") | (3000)7. UNDERCARRIAGE 4) TRACKS, Xleg type center frame is integrally welded with reinforced box-section track frames. The design includes dry tracks, lubricated rollers, idlors, sprockets, hydraulic track adjusters with shock absorbing springs and assembled track-type tractor shoes with triple grousers. 2) TYPES OF SHOES ae weet | oo ar Shoe with | nin) 400416) 400416) nes7 | OPerainawoint | ttt) ‘5700(12570) '5700(12570) Bee _ Oat oer 3) NUMBER OF ROLLERS AND SHOES ON EACH SIDE tom Quantity Carrier rllers TEA Track lars SEA Treck shoes _ EA 288. SPECIFICATIONS FOR MAJOR COMPONENTS: 4) ENGINE tem ‘Speciation Model Yanmar sTNVS4L pe “oye diesel engin, low erission Cooling method ‘Water cooing ‘Number of eyindors and arangernent 4 oyindes, imine Fring order +342 Combustion chamber type Directinjecion ype jinder bore x stoke 943 110nm(8.70" x Piston displacement ‘30646 188¢u in) - ‘Compression ratio 19:1 Rated gross horse ponerSAE J1995) ‘ati at 2200rpm(40KW at 220015) Maximum torque at 1400;pm 20. - (tab - A) Engine ollquenity 921 (2AUS. a) Dry weight 2504985730) High ding speed 2400+ 50mm | Low icing speod +1050 100% Fated fuel consumption 167. 7ghip- brat 2200rpm Stating motor 13.0 ‘Alternator - 120554 - | Battony 312 x 1008 2) MAIN PUMP tam SSpeetication cE ‘Variable iaplacement tandem axis piston pumps | Capaciy 2x Boater ‘Mavimum pressure 2atkgior (318055) Rated ol fow 2x 56 | min(14.5US. gpw 12UK, gem) Rated speed 220019 _ 299) GEAR PUMP tm Specification ype Fixed displacement gear pump single stage Capacity 162/450cK0 Maximum pressure 220,304 313014800) ated ol flow 35.899 / Inin@.426US.gpm/78722UK. gpm) 4) MAIN CONTROL VALVE, tem ‘Speciicaon Type Sectional, 10 spo0is+1 option Operating method Hiyéraul plot systems Mechanical conto system ain rit valve pressure 220319058) (Gvercad eet vive pressure 241058) 5) SWING MOTOR tem Speciation Tipe) Fed displacement al piston motor Capacity 2a.sTecioy Rojo pressure 2odkgten(240ps) Braking sysiom ‘Automate, eping plied hydraulic released Braking torque akg = mTOR Brake oleaso pressure 20- 404g (84-5708) Reduction gear ype 2. sage planetary ‘Suing speed 6190 6) TRAVEL MOTOR tem Speacation “ype ‘Variable dsplzcement ail pston motor elit pressure 2 22013098) Reduction gear typo 2staga planctay Braking system ‘Alorat, sping applied hycraule released Brake release pressure siglon (12808) Braking torque S.igl-mi6tt 1) 2407) REMOTE CONTROL VALVE thom ‘Specieation wpe Pressure reducing type ‘Operating pressure {Sante __ 2okglo(2B4ps) Single operation stoke 6.58 Smm(0.26033h0) 8) CYLINDER tem ‘Speciation Bore dia x Rodda x Stoke | 9110x 65x 715am Boom oylinder Cushion Extend only Bore da x Rod dia x Stoke | #90% 055% 650mm Arm eyinder — Gustin Ertend and retract Bore da x Rodda x Stoke | 880% 850% 660mm Bacteteyier | Discoloration of cylinder rod can occur whan tha friction reduction additve of lubrication oil spreads on the rod surface, x Digooloration does not cause any harmful effect on the cylinder performance. 9) SHOE tom Wath Ground pressure | Linkquantiy | Overall width | s6-7 4oonm(t6) | o:33Kglei(.69ps) 40 ‘g00mm( 6 9") 1QBUCKET = i Capacity “Tooth Wiath CECE heaped | @2n"tIY |Without side cutter] With side cutter sro | oxem(o2ia) | o.1m(02007 osmn(ars) | 77Onm(30.5) BST ort | oc7mioeya) | oosmoosey | 3 | stsmmiz4y | S60nm(t429) anUse only oils listed bolow or equivalent. Do not mix afferent brand cil. 6 Ambient emperatue "O("F) i pi epacty Benin pei |) WGA | si 2 10 0 0 2 % 40 (4) (14) @2)_ 6) 6) _(05) (104) Engine aoe Engrool | 9204) Swing ive 15104) Goarai Fal aie eg Tank: Hydrauietark | Hydeuioot | 701185) System 1201.7) Fucltank | Diesottuat | 120631.7) Fring (ccenatt sy | Grease | Asrequres ke Mauro of (Resenoitang | ancwaier | 1028) 50:50 SAE: Society of Automotive Engineers API: American Petroleum Institute 180 _ Intemational Organization for Standardization [NLGI_ : National Lubricating Grease Institute ‘ASTM : American Society of Testing and Material 22CONTROL DEVICES 1. CAB DEVICES. 1) The ergonomically designed console box and suspension type seat provide the operator with comfort 2) ELECTRONIC MONITOR SYSTEM (1) The centralized electronic monitor system allows the status and conditions of the machine to be ‘monitored ata glance, @ tis equipped with a safety warming system for ealy detection of machine malfunction. Switeh pane! 2— Safety hammer Cassette & radio. Dozer control lever— (Cup holder — ‘Switch panel 1 Custer Defroster Breaker operation sw —~ Storage box ~ FAH contral lever ~—— Engine speed 1 — control lever ravel lever —— Aircon & heater Boom swing pedal“ controler Travel pedal 7 Hom suiteh Foot rest LH control lever —_ Salety lever 3H-2.CLUSTER The cluster consists of gauges and lamps as shown below, to warn the operator in case of abnormal machine operation or conditions forthe appropriate operation and inspection. + Gauges _: Indicate operating status of the machine. + Waring lamp : Indicate abnormality ofthe machine(Red). + Pilotlamp Indicate operating status ofthe machine. x The monitor Installed on this machine does not entirely guarantee the condition of the ‘machine. Daily inspection should be performed according to chapter 6, Maintenance, x When the monitor provides a warning, immediately check the problem and perform the required action. Engine coolant tomp gauge ‘Overhieat warning lamp ——~ f |_—Prataat switch Engine i pressure warning tam Aireloanor waning lamp ee = Preheat pit lamp Hyd oi tmp warning lam beiciemp nesialene Travel speed contol switch ‘Waring up plat lamp —Travel speed pit ampthigh) Hour adjust switch — — Travel speed pitt lamp(Low) Cleek ~~ Minute adjust swten » The warning lamp lights ON and the buzzer sounds when the machine has a problem. In this case, press the buzzer stop switch and buzzer stop, but the waming lamp lights until the problem is cleared, 321) GAUGES AND DISPLAYS (1) Service meter ‘Red range Red ~,_| @ Engine rpm gauge (© This meter shows the total operation hours ofthe machine. @ Aways ensure the operating condition of the mater during the ‘machine operation, Inspect and service the machine based on haurs as indicated in chapter 6, maintemance. © This gauge indicates the amount of fuel n the fuel tank. © Fl the fuel when the red range or warning lamp i ON. ‘© Ifthe gauge illuminates the red range or waming lamp g) fon even though the machine is on the normal condition, ‘check the electric device as that can be caused by the poor ‘connection of electricity or sensor. © Engine coolant temperature gauge © This indicates the tomparature of coolant. +Redrange : Abowe 105°0(221"F) @ When the red range pointed or waming lamp © ON, engine do not abruptly stop but run it at medium speed to allow it to 00! gradually then stop it (Check the radiator and engine x I the engine is stopped without cooled down running, the temperature of engine parts will rise suddenly, this could cause severe engine trouble. © This gauge displays the number of engine revolutions per minute © This displays the current ime. @ Refer to the hour/minule adjust switch for adjusting time. 332) WARNING AND PILOT LAMPS (f) Fuel low level waming lamp (@ Hydraulio ol temperature waming lamp al. 6 @ Overhoat waming lamp = © Alrcleanor waming lamp @ Engine oil pressure waming lamp © This lamp blinks and the buzzer sounds when the level of fuel isbelow 13 | (34US. gal. @ Fill the fuel immediately when the lamp blinks © Tris warning lamp operates and the buzzer sounds when the temperature of hydraulic oll is over 105 °C 221 “F) @ Check the hydraulic ol evel when the lamp bins. @ Check for debris between oil cooler and radiator. © This lamp blinks and the buzzer sounds when the temperature cof coolant is over the normal temperature 110°C 230°F) @ Check the cooling systern when the lamp blinks. @© This lamp blinks and the buzzer sounds after starting the engine because ofthe low oll pressure. @ It the lamp biinks during engine operation, shut OFF engine immediately, Check oi level. © This lamp blinks and the buzzer sounds when the filter of air cleaners clogged. @ Check the fiter and clean or replace it a4(© Battery charging waming Ey @ Warming up pilot lamp oF $f @ Preheat pilot amp 00 lamp (D This lamp blinks and the buzzer sounds when the starting switch is ON, itis turned OFF alter starting the engine. ® Check the battery charging circuit when this lamp blinks during engine operation © This lamp is tuned ON when the coolant temperature is below 30°C(86 °F). © Warming up operation needed untl this lamp OFF ‘© When engine preheating snitch is turned ON, pilot lamp cames ON. © Reter to the preheating switch for details. {9) Travel speed pilot lamp(High) (© When this lamp turned ON, the machine travel high speed. @ Reler to the travel speed select switch for details. (10) Travel speed pilot lamp(Low) © When this lamp turned ON, the machine travel low speed. @ Reler'o the travel speed select switch for details. 359) SWITCHS ({) Travel speed control switch @) Buzzer stop switch (ee {@) Prohoat switch PRE, HEATER| ( Hour adjust switch © Minuto adjust switch © This switch is to control the travel speed which is changed to high speed(Rabbit mark) by pressing the switch and low ‘speed(Turlle mark) by pressing it again. © When the starting switch is turned ON first, normally the alarm buzzer sounds for 6 seconds during lamp check operation. @ The red lamp lights ON and the buzzer sounds when the ‘machine has a problem. In this case, press this awitch and buzzer stops, but the red lamp lights untl the problem is cleared, © In case of severe cold weather, this switch is used to preheat engine before starting. @ When this switch is pressed, the preheat pilot lamp is tuned (ON for 15 seconds in sequence and lamp OFF when the time is completed, @ When the start key move to ON positon, the preheat function is activated automatically under the coolant temperature is below 10°C{50"F}. © This switch is used to adjust hour. © The switch is pressed, hours increased. © This onitch is used to adjust minute. © The switch is pressed, minute is increased. 36i Di] Cigar tight ‘Quick coupler switch — Breaker selection switch Aircon switch Washer/uiper switch — Main light switch Start switch ——— Travel alarm switch —Boacon switch panel 1 Mester switch Breaker operation switch: — Horn switch 4) STARTING SWITCH (1) There are three posions, OFF, ON and START, =O (OFF): None of electrical circuits activate + [ (ON) :Allthe systems of machine operate. - & (START) : Use when starting the engine, Release key o immediately ater starting. 25 » Key must be in the ON position with engine running to maintain porszer clectrical and hydraulic function and prevent serious machine damage. 372) MAIN LIGHT SWITCH (1) This switch use to operates the head light and work light by two step. First step: Head light and cluster illumination lamp comes ON. + Second step : Work ight comes ON. Also, the below indicator lamp comes ON. (1) This switch use to operates the air conditioner. (@) Refer to the air conditioner and heater for detail operation. HER SWITCH (1) The switch use to operates the wiper and washer by two step. + Firststep : The wipor operates. + Second step : The washer liquid is sprayed and the wiper is operated only while pressing. If release the switch, etum tothe fist step poston. 5) TRAVEL ALARM SWITCH(Option) (1) This switch is the signal to alarm surroundings when the machine travels to forward and backward. (2) On pressing this switch, the alarm operates only when the machine is traveling, 6) BREAKER SELECTION SWITCH(Option) (1) This switch is used to operates breaker. x The breaker operates only when this switch is pressed.7) BEACON SWITCH(Option) JOHORN SWITCH Horn ewe 3, = (1) This switch turns ON the rotary light on the cab. (2) The below indicator lamp is tumed ON when operation this suiteh. 8) QUICK CLAMP SWITCH(Option) (1) This switch is used to engage or disengage the moving hook on quick clamp, % Refer to the page 8-6 for details. (1) This evitch is used to shutoff the entre electrical system, (2) | : The battery emains connected tothe electcal systom, (0: The battery i disconnected othe electrical system » Never turn the master switch to O(OFF) with the engine running. ttcould resultin engine and electrical system damage. (1) This switch is at the top of let side control ever. (On pressing, the horn sounds, 11) BREAKER OPERATION SWITCH (1) On pressing this switch, the breeker operates only when the breaker selection switch on the switch panel is selected 39| 4. LEVERS AND PEDALS _ [eee Dozer control lever — Travel lover Boom swing pedal ‘Travel pedal Engine speed control lever LH contro! lover Saloty ovor 1) LH CONTROL LEVER | (1) This joystick is used to contral the swing and the arm, i (2) Refer to operation of working deviee in chapter 4 for details. kN 2) RH CONTROL LEVER — (1) This joystick is used to control the boom and the bucket. in (2) Retr to operation of working device in chapter 4 for details. REN9) SAFETY LEVER, (1) All control levers(except travel levers and pedals) are disabled from operation by locating the lever to lock position as shown, = Be sure to raise the lever to LOCK position when leaving from operators seat. (2) By pushing lever to UNLOCK position, machine is operational ¥« Do not use the safety lever for handle when getting on or off the Uniock resco machin, ‘A. The machine Is able to travel even when the safety lever is in the LOCK position. 4) TRAVEL LEVER (1) This lever is mounted on travel pedal and used for traveling by hand, “The operation principle is same as the travel pedal (@) Refer to traveling of the machine in chapter 4 for details. é ean? 5) TRAVEL PEDAL TS ]_(1) This pedals used to move the machine forward or backward Ife side pedals pressed, ft rack will move. { right side pedal is pressed, right track will move, 4 e (@) Refer to traveling of machine in chapter 4 for detail. 6) SEAT AND CONSOLE BOX ADJUST LEVER, x (1) This lever is used to move the seat and console bax to fit the contours of the operators bod, (2) Pullthe lever to adjust forward or backward over 90mm(3.5") Adjust lover 7) ENGINE SPEED CONTROL LEVER eam (This lever is used fo increase or decrease the rotation speed of Scagiber nga. Less (2) Move the lever backward to increase engine RPM. Move the lever forward to decrease engine RPM, Ve | @When stopping the engine, move the engine speed control lever O sare forward completely and turn key OFF ant8) DOZER CONTROL LEVER: Dozer ental ver (1) This leveris used to operate the dozer blade, a (2)Ifthe levers pushed forward, the dozer blade willbe going down, z. It the leveris pulled back, the dozer blade willbe going up. dt W\eeos 9) BOOM SWING PEDAL (1) This pedals used to swing the boom tothe right and left rection. {2) Move the lok lever to unlock poston by foot. ‘Boom swing pedal Unto 4 (0) The pedals pressed to front side, boom will move othe let rection, ie The pedal is pressed to rear side, boom will move to the right ‘Lock lever Girection. 342.Its possibie to contol he fan to four stops. + | slow +L :Medium-Low + TIL :Nedium-High » H:High2) OUTLET CHANGE OVER SWITCH ‘Switch postion 9) TEMPERATURE CONTROL SWITCH — (Q) Cooling Air conditioner switch : ON) ‘@ Turned ON the air conditioner switch on the switch panel. © Turn the control switch into blue range to decrease output alt ‘temperature. {@) Heating(Air conditioner switch : OFF) ‘@ Turned OFF the air conditioner switch on the switch pane! @ Turn the control switch into red range to increase temperature. 4) OUTLET CONTROL LOUVER ‘The direction of air can be controlled. can be closed or opened. 344(BlOTHERS Cossti & radio 12V socket 1) CASSETTE AND RADIO(~#1450) Teter nem roe nie yieeceeae agro ‘Tone controller Band button "Cassette tape insertar a * (0.0 Ee Seok Tune Pre-set buttons Displayer button button HYUNDAI [orcas 315() Power and volume switch []__ © Tis ewitch is turned to right, power willbe tuned ON and the sound 's increased. © Mit is tured to left, volume will be decreased and power will be turned OFF, The volume controller of the cassette radio does not operate when turning ON the remote controller power. © I this seek button is pressed, the radio automatically stops at the next frequency of broadcasting for your Istening. © Whenever you press "+" button, higher channels are selected, ® Whenever you press " -* button, lower channels are selected. ® General ‘AM band : Frequency changes in 9kHz between 531 to 1602kt FM band : Frequency changes in 0.1MHz between 87.5 to 108.0ME2, @ America ‘AM band : Frequency changes in 10kHz between $30 to 1710kH2, FM band : Frequency changes in 0:2MHz between 87.9to 107.9MHz, © Europe LW band : Frequency changes in kHz between 153 to 279KH2, IMW band: Frequency changes in SkHz between 522 to 162042, FM band : Frequency changes in 0.05vHz between 87.5 to 108,0MH, (4) Pro setbutton [© You can immediatly isten to the station by pressing pre-set bution OOM forwhich broadcasting station is pre-set. © How to sot broadcasting in memory. (eee) + You can pre-set 6 stations each AMIFM band, pa + When you want the staion tobe set in memory, press selected pre-set button for more than 2 seconds. 316©) Displayer CGenaral& America © General and America When radio is turned ON, stereo, AM, FM, FM2, MTL and reception frequency are displayed, ® Europe = When rack is turned ON, stereo, LW, MW, FM, FM2, MTL and reception frequency are displayed. @ When cassette tape is played, indicator aro + , +) are displayed. {© LefvRight speaker volume button BAL @ Tone button [ saseTne © Ifbelance buton is pressed, wil spring out Volume of right and left speakers wil be adjusted by turning the button to right or et. ® twill be fixed by pressing again after adjustment © BASS tone If tone bution is pressed, it will spring out If tis tumed to right, BASS tone is increased, and if itis turned to loft, BASS tone is decreased. © TREBLE tone @ Band button You can adjust the TREBLE tone by pullout the button. Iftis tuned to right, TREBLE tone is increased, and its turned to lof, TREBLE tone is decreased. @ Itwillbe fixed by pressing again ator adjustment. © You can listen to broadcasting on AM or FM band by pressing this band selection button, (@) Tape winding/Rewinding button Gl) © If you press this button once while the tape is playing the direction willbe reversed. @ If you press one of these buttons the tape will be winding fast or rewinding, and if you press another button on a certain point, the tape willbe played 3472) SEAT ‘The seat is adjustable to fit the contours ofthe operator's body. It wil educe operator fatigue dus to long work hours and enhance work efficiency. (1) Forward/Backward adjustment(A) © Pullever Ato adjust seat forward or backward @ The seat can be moved forward and backward — cover 170mm(6.7") in 9 steps. 2) Upward/Downward adjustment(B) ‘© Pull or push lever B to adjust seat upward or downward. @ Forward or backward side adjustment only can be made, tilting to one side, by moving lever B 8 respectively. @ Rectining adjustment(C) Pilllover C to adust seat back res. ( Arm rest adjustment(E) This can be adjusted by rotating the dial or knob E torightand left. {@) Head rest adjustment (D) This is adjustable vertically and inclinedly to fit ‘operator's requirements, {© Cushion adjustment (F) ‘Agjust the handle to the operators weight ‘A Always check the condition of the seat belt and mounting hardware before operating the machine. ‘A. Replace tho seat belt at least once every three years, regardless of appearance. 3) CIGAR LIGHTER [=] _(1) Tris can be used when the engine starting switch is ON. (2) The lighter can be used when it springs out in a short while ator being pressed down Service socket co Use cigar lighter socket when you need emergency power. Do not use the lighter exceeding 12V, 1200. 4) 12V SOCKET (Option) —_— (1) Utlize the power of 12V as your need and do not exceed power of 12V, 120. 3185) FUSE BOX (1) The fuses protect the electrical parts and wiring from buming out. (2) The fuse box cover indicates the capacity of each {use and circuit it protects. ® Replace a fuse with another of the same capacity. ‘A. Bofore replacing a fuse, be sure to tum OFF the starting switch. 6) UPPER WINDSHIELD Grip (1) Perform the folowing procedure in order o open the upper windshield, © Release both latches in order to release the upper windshield. @ Hold both grips that are located at both side the windshield frame push the windshield upward @ Hold both grips that are provided on the windshield frame and back into the storage position until auto lock latch is engaged. (2) Perform the folowing procedure in oder to cose the upper windshielt. Reverse step @ through step @ in order to close the upper windshield. 349)7) RADIO AND CASSETTE (Standard, #1451~) 88 7 15 16 418 to 10 321 8 45 612 1112 11 erases RADIO AND CD PLAYER(Option) ae T 16 15 to 10 321 8 4562 12 "FRONT PANEL PRESENTATION 4 C4) Preset button 4 41 SOURCE -- Shor press: Change source(Radio/CD) AND ----~-GD random playback on/off DS ~--»-» Long press : RDS ondoft 2g) ~~-Presetbutton 2 BAND ~~» Short press :To select band RPT ~~ CD repeat track on/off Long press: Autostoro(CD) 3(CS_) ~--Preset button 3 Short press: Autostore(Cassette) SCN CD's track sean Thier indi 44) Preset button 4 SCE) a pestbutens ‘Short press : Auto search upldown Long press : Manual search upidowin 6 (Taw) Shi :TAonoft Ce AE ‘Cassette mode : No function Long press : AF on/ott 7 SOUND ~~ Select sound/audio styles CD mode BO enn Short press : power on ‘Short press : Nextiprevious track Long press : power off Long press : Fast forward or fast rewind MUTE «Short press :To mute orcancelmute. 13 Fe Fast forward(cassette deck) 9 won Display “wa Fast rewind{cassette deck) 10 Volume knob : Press upidown to 18 Ak ~~~ Disc efec(CD) ‘adjust the volume ; adjust selected Eject cassette audio mode 16 -- ~- CD opening / Cassette opening"AUDIO (1) Power and mute button @ Volume button i YE een (@)Sound button UND) = ( POWER ONIOFF Press © to switch on the set. Press © for more than 2 seconds to switch ofthe set @MUTE(Silence) ‘Short press © key to mute or cancel the mule(silence).. 1 The silence petiod may be interrupted by ALARM announcement ot ‘ralfic announcement messages(I Ais switched or). © Press the volume button uptown to adjust the volume. Pease make sure you can still hear the trafic(homs, sirens... SOUND Whether you listen to Jazz, Vocal, Pop, Classic or Rook music, the ‘SOUND button isthe perfect sating for your choice Press SOUND then the sound button to select BASS-Treb for your own sound style, or adjust the settings with the volume Upidown buttons to select one ofthe pre define sound styles: “BASE -TRE_ : Yourown settings of bass and treble. =FLAT Original “JAZZ Jazz music -VOCAL Speech POP Pop music -CLASSIC —_: Classical music - ROCK lock music @AUDIO SETTING + Press SOUND to select desired audio mode, + Adjust the settings with the volume upidown buttons - Sound siyle : BASS-TRE, FLAT, JAZZ, VOCAL, POP, CLASSIC, ROCK -BASS Low notes “TREBLE —: High notes -BALANGE — : Leftright -FADER ——: Rearfront -LouD ‘OFF, LOW, MID, HIGH Press the volume button to adjust the solected audio mode. Alter § seconds the display goes back to the last mode of ‘operation. Adjustment of Bass and Treble settings is only possible when BASS-TRE is selected as the sound styl. 321( Source button © Press SOURCE to select the desired source : ~ TUNER -cO x Products with cassette mechanism will change source to cassette only when a tape is inserted, RADIO !) Wave band / Automatic search button ~~ WAVEBAND. @ "Pes BAND xr he dss 0-0) ti ea fast — ~ LW +—MWAST(AMAST) -— Mw s @ AUTOMATIC SEARCH Use search tuning to automaticaly search fora station. + Press to tune a station of a lower frequency or ® to a higher frequency, * Tosearch for another station, press the key again @MANUAL TUNING(If you know the frequency of the required station) + To switch to manual tuning : Long press the search button 1 or ® for more than 2 seconds ill switch the tuning to manual tuning. * Then press 4 fo tune to a station of a lower frequency or ® to a higher requency, * When keys are released, a time-out start to count. Aller § seconds time-out, display ‘Auto’ for one second and return to automatic search,(2) Proselected button Preselected stations © Manually storing stations in a preset Five stations per band can be stored and recalled using the preset keys(t 108). Tune into the desired station. + Press the desired preset key(1 o 5) for more than 2 seconds to + store the curent tuned station. ‘When storing an FM station, the current program station name and the AF mode are stored on the preset(Some stations use altemating program service nama). @ Recaling a preset Press the desired preset key(1 105) to recall he stored station. @ Automatically storing stations(AUTO-STORE) You can automatically store 5 strongost FM stations on the FM AST. band of 5 sttongest NW(AM) stations on the MWW(AM) AST band, ‘When you use Auto store, the new stations replace any stations previously stored in the FM AST band or tho MWV(AM) AST band. + Press AST to activate autostore. + The set gives a beep and then mutes, + When it has finished, you hear a beep followed by the station stored on preset 1 + Sometimes it may not be possible to find 5 stations. 323= RADIO DATA SYSTEM(RDS) ON FM ——J More and more stations broadcasts RDS informations in order to ‘offer you many advantages including: (1) Program service name(PS) Allows the radio to display the name of the station instead ofits frequency. (@) Automatic returning(AF) “The cot remains tuned tothe current sition by continualy searching the bestalernative frequency for best reception. You can switch AF oft - Actvate/Deactivate AF “This set continuously search for other elteratve frequencies forthe ‘tuned rac station and automatically selects the best frequency for reception, Long press (FA) for more than 2 second to activate! deactivate AF, (@ Alarm messages(PTY ALARM) This set automatically receives emergency messages made by the broadcaster. + During the messages the display shows ALARM" and the station- name allemately. (@ Traffic announcements(TA) ‘You can activate the TA modes to give prioty so as to hear traffic announcements related to these subjects(even if you play a cassettes/CD or mute the set) ~ Actvate/Deactivate TA + Shor press BAND to select an FM band. + Press (Faw) to acivateldeactvate TA. - Ifyou activate TA mode + You will hear the trafic announcements when broadcast by station(evon if you play a cassette!CD or mute the set). If the tuned station does not enable the reception of traffic announcements, the display shows 'NO TA’. The radio ‘automatically searches and appropriate station. - Interrupting traffic announcoment mode If you do not wish to continue listening to a particular tratfic ‘announcement "Short press CFA) key to interrupt trafic announcement without ‘switching off the mode + The set wll return tothe previous operating mode. x You can switch off RDS features if not required. Long press RDS key to switch off RDS, + ADS related features e.g, TA, ol..will be deactivated when RDS is switch of. 324"CASSETTE PLAYER (1) Winding/Rewinding button ~~) Only use good quality cassettes » To avoid possible tape damage always take out the cassette after Z | > ) use. Protect your cassettes. Put them back in their boxes immediately ater use. 1 Never expose cassettes to heat or direct sunlight. © Play back Side the cassette, with the open side to the right into the cassette opening. Playback stars. ‘The direction of playback s shown by indicator » . @ Stopping playback( ) + To stop playback, Press the & button fully home. + The unit will switch over to radio reception. + The cassette is partially ejected, ‘@ Reverse(before the end of the tape) Press the +4 and» buttons atthe same time halla in @ Fast rewind / Fast forward( + or » ) The direction of fast winding depends on the direction of play indicated on the display Distlay curing pleyback | ‘Action Key to press » Fast forward » > Fast rewind « < Fastforward “ < Fast rewind » During fast forward or rewind the radio resumes. if you continue fast ‘winging until the end of the tape, play back restarts automatically © To stop fast winding ‘To stop fast winding before the end ofthe tape, press the key which isnot pressed(-+ or ».). Playback is then resumed, @End of the tape ‘Atte end ofthe tape, playback continues in the revers direction ‘© Maintenance Alter extended use of the cassotte player, cust, contamination or {gfe can accumulate on the playback head. This results in diminishing high-note reproduction. This can be remedied using a cleaning cassette(one or twice a month) and playing it through ike an orcinary cassette 3.25=CD PLAYER (1) Winding / Rewinding button © CD playback This CD player is suitable only for 12em disc, do not use iegular shaped CD. + Slide the dise into the slot with label facing upwards. Playback starts, + Ifaciscis already inserted : Press SOURCE to select CD as the source. Playback stars. @ Previous / Next track( < or ») + Short press the - or » button to select the desired track. + Playback resume withthe chosen track, @ Fast rewind / Fast forward( ) + Long press the or ® button for more than 2 seconds to quickly move rewind or forward through the disc. + Normal play back resumes when you release the button, @ Random track playback + Press RND to activate / deactivate random track playback. © Repeat track + Press RPT to activate / deactivate repeat current rack © Scan track ‘The scan function enables you to listen to the fist few seconds of each track, + Press SCN to activate / deactivate scan track. @Dise eject + Press a to eject the disc‘RADIO SETTING | (AMERICA Press © , No. 1 and No. 4 buttons at the same time. Set up ii ‘completes displaying * AMERICA’. ‘ain @ SOUTH AMERICA saci Press ©, No, 2 and No. 5 buttons at the same time. Set up —e completes displaying * SOUTH’ @ASIA Press © , No. 1 and No. § buttons at the same time. Set up ‘completes displaying * ASIA’, (@) EUROPE Press power, No. 2 and No, 4 buttons at the same time. Set up ‘completes displaying * EUROP". 8) REMOTE CONTROLLER (1) Power ON/OFF button ® Press © to switch ON the set. Press © for more than 2seconds to POWER ‘switch OFF the set. @) Volume button(up) + Short press : Volume up one step + Long press : Volume up continuous VOLUME gar{@) Volume button(down) [] Short press: Volume down one step waa Long press : Volume down continuous. EV @ Source & mute button + Short press : Change soutce(Radio/CD) + Long press : To mute or cancel mute. (@) Next button O Tuner mode + Short press : Preset up (=/ + Long press : Band up ® Cassette mode + Short press : Reversa(before the end ofthe tape) sono + Long press : No function cD mode + Short press : Tack 1 + Long press : Scan track {© Search button(up) © Tuner mode + Short press : Search up one step ~ Long press : Search up continuous © Cassette & CD mode SEARCH + Short press ; Next track conc + Long press : Fastforward () Search button{down) © Tuner mode ‘SEARCH + Short press : Search down one step + Long press : Search down continuous + Short press : Previous track sons + Long press : Fast rewind 328{/ SUGGESTION FORNEW MACHINE OPERATION 1) takes about 100 operation hours to enhance its designed performance. 2) Operate according to below three steps and avoid ‘excessive operation forthe intial 100 hours. Servo motor Load Until 10hous | ‘About 60% Until 100 hours | ‘bout 80% ~ Ate 100 hou | 100% vs Excessive operation may deteriorate the potential performance of machine and shorten lifetime of the machine. 3) Bo careful during the initial 100 hours operation (1) Check daily forthe level and leakage of coolant, engine ol, hydraulic oil and fuel. (@ Check regulaty the lubrication and fil grease daly al ibrication points. ) Tighten bolts. (4) Warm up the machine fully before operation. © Check the gauges occasionally during the operation. (@) Check if the machine is operating normally during operation. 4) Replace followings after initial 50 hours of operation Checking items Service ‘Engineot Engine ol fit element Hysiaulc ol return iter element Replace Line fiter element | Fuet ter a4 ‘Avoid excessive ‘operation for inal 100 hoursCHECK BEFORE STARTING THE ENGINE 41) Look around the machine and under the machine {0 check for loosen nut or bolts, collection of cir, or leakage of ol, fuel or coolant and check the Check before condition of the work equipment and hydraulic starting system. Check also loosen wiring, and collection cof dust at places which reach high temperature, x Refer to the daily check on the chapter 6, maintenance. 2) Adjust seat to fit the contours of the operator's body forthe pleasant operation, 3) Adjust the rear view miror, Lr 428. STARTING AND STOP THE ENGINE 41) CHECK INDICATOR LIGHTS (1) Check if all the operating lever is on the neutral postion, @ Tum the starting switch to the ON position, and check folowing. © tal the lamps light ON and buzzer sounding {or6 seconds. Only below lamps wl ight ON znd all the other lights wil tun OFF after2 seconds. + Battery charging warring lamp(2) «Engine oll presaure warning lamp(1) © The preheat pilot lamp(3) wil ight ON when the coolant temperature is below 10°C. © The warming up warning famp(4) wil ight ON ‘when the coolant temperature is below 80°C. 432) STARTING ENGINE % Sound horn to warn surroundings after checking if there are abstacles in the area, x Replace the engine oil and fuel referring to recommended oils at page 2-12. » Fill anti-freeze solution to the coolant as required. (1) Check if all evers are on the neuiral position. (2) Tum the starting suitch to ON positon, (8) Check ithe preheat pilot amp(t) is turned ON. » When the preheat plot lamp is tumed ON, the preheating funtion is actuated within 15 seconds. % Alter the preheat pilot lamp is turned OFF, engine start within 10 seconds. (4) Siart engine by turning the starting switch to the ‘START position. ©) Release the starting switch immediately after slarting engine to avoid possible damage to the starting motor » Ifthe engine is started before the preheat pilot lamp goes OFF, it keeps the lamp ON within 18 seconds even after the engine is started. If the engine does not star, the start switch {tum ON position and press the preheat switch (1) for preheating. After the preheating, start the engine again, ¥ If the engine does not start, allow the starter to cool for 10-20 seconds before attempting to stat the engine again, At the cold, allow 2 minute before attempting to start the engine again. START ' ony O OFF Sra “So on oF3) INSPECTION AFTER ENGINE START Inspect and confirm the following after engine starts. (1) Is the level gauge of hydraulic ol tank in the rrormal lever? (2) Are there leakages of cil orwater? (8) Are allthe warring lamps OFF(2~10)? Is the indicator of engine coolant temperature 0 molez\na> amo zi aa>|a mo elee\s >| a]m ol<|=| ‘Same as 180 ypei 1) When transporting the machine, observe the various road rules, road transportation vehicle laws and vehicle limit ordinances, etc 2) Select proper trailer after confirming the weight and dimension from the chapter 2, specification, 3) Check the whole route such as the road with, the height of bridge and init of weight and ete, which willbe passed. 4) Get the permission from the related authority if necessary. 8) Prepare suitable capacity of trailer to support the machine. 6) Prepare gangplank for safe loading referring to the below table and ilustration. A 8 10 365 ~ 385 [a [400-425 12 4.85 ~ 460 13. 475-500 1 510-540 18 550-575 REPARATION FOR TRANSPORTATION TRANSPORTATION T ae =e — Overalllenatn2/DIMENSION/AND WEIGHT 1) ROBEX 55-7 (1) Base machine ark | Deserpfon | Unt u Leng [mtn 7a H Height | min) = wd Width mmiftin) | 1920( 6 4°) we | weight | tait)_| aarocr0540) -| 2 With 400nm(16°) tiple gouser shoes and 210kg (4601) counterweight. rd 2) Boom assembly Mark | Deserptn | Unt | Speciicaton u Length | mit | si20ci0" 3) H Height mmittn) | 1140( 3° 9) w. vwratn —_| my) | 280( 010") wt Weight ‘kg(b) 310(680) © 3.0m(9'T0") Boom with arm cylinder(Included Piping and pins). res (3) Arm assembly tak | Deseriton | Unt | Specicaton L Length | mmr) | 2190( 612°) | H Height mmitin) | 450{ 1° 6") w with | mtn) | 170( 07") wt Weight, ‘g(t 210(460) % 1.6m(6' 5) arm with bucket oyinder(included linkage and pins). vesmva (@) Bucket assembly Mark | Deseripton | Unit | Specication L Longin | min) | s0204 3°" 4 Height | moti) | 570 140") w Width rmnftin) | 740{ 2 5") wt [Wein [katy | 1701380) 0.18mi0.24y6%) SAE heaped bucketincluded ‘tooth and side cutters). sss 52© Boom cylinder ark | Desaiton | unt | Specifeaion eS) H [Height | mi | 1501 0° 6) Wo | With | mm | 2a 47) | we | Weg | tt) | 581120) > Tnclided piping (6 Cab assembly ark | Doseipion | Unt | Specicatin | torah [mein | 15100 4429 # Height | mmitvin) [15600 529 ~ | we Width mmifein} | 1060( 3' 6") wt Weight i) 280(620) @ Counterweight Wark | Desereion | Unt | Specienton [tena | retin) | 12001 607 Ho | Height | mnt | 5000769 we [wan | erin | 0007792 im 2101460)[B/LOADING THE MACHINE | | 1) Load and unload the machine on a flat ground, 2) Use the gangplank with sufficient length, width, thane ede 8) Place the swing lock lever fo the LOCK position | before fixing the machine at the bed of tral and ‘confirmif the machine parales the bed of tale. Keep the travel motor in the rear when leading and in the front when unloading, 4) Do the following after loading the machine to the trailer, (1) Stop loading when the machine is located horizontally withthe rear whee! of tale, (@) Swing the machine 180 degree, ba(8) Lower the working equipment gently after the location is determined. it Place rectangular timber under the bucket ‘oytinder to prevent the damage of it during transportation. ‘A.Be sure to keep the travel speed switch on the LOW(turtle mark) while loading and Unloading the machine. ‘Avoid using the working equipment for loading and unloading since it will be very dangerous. ‘A.Do not operate any other device when loading. ‘A Be careful on the boundary place of loading Plats or traller as the balance of machine will abruptly be changed on the point. 56(A.FIXING THE MACHINE 1) Lower down the working device on the loading plate of trailer 2) Keep the safaty lever on the LOCK postion. 3) Turn OFF all the switches and remove the key. 8) Secure all locks. Cabin— ti Engine hood Tool box 6) Place timber undemeath of the track and fix firmly with wire rope to prevent the machine from ‘moving forward, backward, right or left.5/LOADING AND UNLOADING BY CRANE 4) Check the weight, length, width and height of the ‘machine referring to the chapter 2, specification when you are going to hoist the machine, 2) Use long wire rope and stay to keep the distance with the machine as it should avoid touching with the machine. 3) Put a rubber plate contact with wire rope and ‘machine to prevent damage. 4) Place crane on the proper place. 5) Install the wire rope and stay like the ilustration, ‘4 Make sure wire rope is proper size, ‘Place the safety lever to LOCK position to prevent the machine moving when hoisting the machine. ‘The wrong hoisting method or installation of ‘wire rope can cause damage to the machine. ‘A.Do notload abruptly. ‘A Koop area clear of personnel. ite rope Wire rope _Siay _4. INSTRUCTION 4) INTERVAL OF MAINTENANCE. (1) You may inspect and service the machine by the period as described at page 6-11 based on hour ‘meter at cluster. @) Shorten the interval of inspect and service depending onsite condition (Such as dusty area, quay, sea shore and etc) @ Practice the entire related details at the same. time when the service interval is doubled. For example, in case of 1COhours, carry out all the maintenance "Each 100hours, each 50 hours and daily service, at the sama timo, 2) PRECAUTION (1) Start to maintenance after you have the full knowledge of machin. (2) The monitor installed on this machine does not entirely guarantee the condition of the machine. Daily inspection should be performed according toclause 4, maintenance check list. (9) Engine and hydraulic components have been preset in the factory. Do not allow unauthorized personnel to reset them, ) Ask to your local dealer or Hyundai for the ‘maintenance adviee if unknown, (6) Drain the used oil and coolant ina container and hhandle according to the method of handing for industrial waste to meet with regulations of each Province or country. MAINTENANCE Service meter9) PROPER MAINTENANCE (1) Replace and repair of parts It is required to replace the wearable and ‘consumable parts such as bucket tooth, side cuter, fiter and ete., regularly. Replace damaged or wor parts at proper time to keep the performance of machine. (2) Use genuine parts. (8) Use the recommended oil (4) Remove the dust or water around the inet of ol tank before supplying ol. {6) Drain oll when the temperature of oll is warm. © Do not repair anything while operating the engine. Stop the engine when you il he ol. (7) Relieve hydraulic system of the pressure before repairing the hydraulic system. {@) Confirm i the cluster i in the normal condition alter completion of service. {@) For more detail information of maintenance, please contact local Hyundai dealer. x Be sure to start the maintenance ater fully understand the chapter 1, safety hints. 624) RELIEVING THE PRESSURE IN THE HYDRAULIC SYSTEM Spouting of oll can cause the accident when loosening the cap or hose right after the ‘operating of machine as the machine or oll is ‘on the high pressure on the condition, Be sure to relieve the pressure in the system bofore repairing hydraulic system. (1) Place machine in parking positon, and stop the engine (@) Set the safety lever completely in the release position, operate the control levers and pedals fully to the front, rear, left and right, to release the pressure in the hydraulic circu. % This does not completely release the pressure, so when serving hydraulic ‘component, loosen the connections slowly and do not stand in the direction where the oil ‘spurt out. (8) Loosen the cap and relieve the pressure inthe ‘tank by pushing the top of the air breather. 8 ‘Cap ¥ Pushing 638) PRECAUTION WHEN INSTALLING HYDRAULIC HOSES OR PIPES (1) Be particularly careful thatthe joint of hose, pipe a and functioning item are not damaged. ‘Avoid contarrination. {@) Assemble after cleaning the hose, pipe and joint ‘of functioning item, {@) Use genuine parts. (4) Do not assemble the hose in the condition of twisted or sharp radius. | (6) Keep the specified tighten torque. z6) PERIODICAL REPLACEMENT OF SAFETY PARTS. (1) Itis desirable to do periodic maintenance the machine for using the machine safely for along time. However, recommend to replace regularly the parts related safety not only safety but maintain satisfied performance. (2) These parts can cause the disaster of life and material as the qualty changes by passing time and itis worn, diluted, and gots fatigued by using repeatedly. These are the parts which the operator can not judge the remained lifetime of them by visual inspection. @ Repair or replace if an abnormality of these parts is found even before the recommended replacement interval Poriodica eplacementot safety parts | iteral Fuol heso(ank-ongine) | ry Engine | Heater hose 2 years (heater-engine) Pump suation hase Mein | Pump dalveryhose | SY coat eas tiriaute| | Swing hose system ‘Boom eylinder line hose |W o em eyindernehose | SY wotial ameyinrino hese | PY, Bucket oyinderiine hose 1, Replace O-ring and gasket at the same time when replacing the hose. 2 Replace clamp at the same time if the hose clamp is cracked when checking and replacing the hose. 65_2. TIGHTENING TORQUE _ Use folowing table for unspecified torque. 4) BOLT AND NUT (1) Coarse thread meee ar 10 ign wt wk M 6x10 09-13 65-94 80-123 M Ox 125 20-30 145-217 27-41 195-297 Mi0x15 40-80 239-434 55-83 398-600 Mia x 175 74-112 535-810 98-158 709-114 M14 x20 122-166 882-120 167-25 121 ~ 163 ie x20 186-252 135-102 252-942 162-207 MiB x20 258-350 187-253 351-475 | 254-348 a0 %25 362-480 262-354 492-668 356 - 482 Mee x25 483-839 349-458 658-980 476-708 M2830 25-845 482-611 50-115 15-832 M0 x80 124-168 898 1214 168-200 1223 - 1658 M95 x40 174 ~ 236 1261 - 1704 250 ~ 310, 1908 - 2242, @ Fine thread Bott 0 s a gem wet ifm wt Mexto 22-34 159-246 30-46 217-318 Mioxt2 45-67 25-485 59-89 427-644 Miaxt2s | 78-118 564-839 108-160 767-116 | Miaxts 133-181 962-131 179-244 130-174 Mex 15 198-259 144195 266-360 182-280 Migx 18 286-438 207-315 384-520 28-378 M20 x15 40.0 - 54.0 289 - 391, 584-722 386 ~ 522, 22x15 27-718 381-516 707-957 51-692 Merx20 | 679-919 481-65 909 128 658-890 a0 x20 137-185 980~ 1559 182-248 1314-1796 Mg6 x 30 192-280 1390 1680 282-354 1804 ~ 2550 662) PIPE AND HOSE ‘Thread sie Width across fat) ‘-m tot a 19 3 27 3" i E} 4 239 2 27 5 962 3a 36 12 868 r at 14 101, 9) FITTING Thvead size Wath across fate) kg-m et ie" 8 4 208 ae 22 8 362 Ve a7 6 434 ae 38 13 940 r a 16 108 674) TIGHTENING TORQUE OF MAJOR COMPONENT Tae ve Dessipions ents [oy ae | ‘Erorermavangbateapontncey | uot | resto | s05are_ [EngremouingbottacotFae) | rex20 | B0xto | 78872 _ Fantrmaningtana | Mioxts | sexta | sost00 | ‘Coupling mounting bolt Mio x 15 6.0410 [ag4e72 anu outing bok wiaxi7e | iasx00 | s28220 | acolo outing Bt wexias | 25s05 | 16235 [ort [Retake | We 20 | —abaas | ersiBt be. [vdadooranvnourimoot | wiex20 | ass2s | verares | 8 Tuning int mung bl ra wiaxi7s | iaesa0 | seaz20 10 Sung notrnouningbat | Mex 20 | Zora | 216800 Tl py Sabena upperauingtar [a x20 | zo7as | 2isas80 2] PRT [surgbemrniovermerigdat | wns 20 | ae7sas | areaso0 | [1s| ss” [Trawinowrmuningoat | éxzo | anaeo | _wssi80 n spreetnoning bot wiax20 | ta6t20 | _Meeero is Cari tr euning bal it Pex 20 [asso | 2073380 6 Tctrerramingtt | mex 20 | étsso | zrasno 1) ner fecmmotmrmsugia | wax 75 | Tassso | sso [18 xk soo mung bl, rt Pveaowne | war | 1sre72 | nm “ak guard maui bat wiex20 | eestae | 28290 20 Courter weht mousing bal Puan x25 | sraxea | ses5s [21| hers | Copmaningtona | Bx 175 | i2st8o | 94220 | Zz Operate set rouning ok wexias | 17so1 | 05207 683. FUEL, COOLANT AND LUBRICANTS 1) NEW MACHINE New machine used and filed wih folowing lubricants, Deseripion| Specification Engine of SAE 15W-40(API CH-4) Hydraulic ol 180 VG 46(SAE 100) Grease ‘Swing and travel reduction gear SAE 85W-140(API GL-5) Lithium base grease NLGI No 2 Ful ASTM D975No.2 Coolant ‘Mixture of 50% ethylene glycol base antitoeze and 50% water. SAE API Iso NI ASTM : Society of Automotive Engineers + American Petroleum Institute + International Organization for Standardization + National Lubricating Grease Insitute ‘American Society of Testing and Material 692) RECOMMENDED OILS. Use oniy ols listed below or equivalent. ‘Do not mix different brand oil. Ambient temperature “C(*F) Service pont | Kindottua | pee, 2 1 o 0 2 % 40 (4) (14) (22) (60)_(68)_(26) (104) Engine ci com | Endect | 92724) ‘Swing drive 1.5(0.4) Gearot 1252 Fal ive 633, Tanke | Hydaulctank | Hygkaute ot | 701188) } ‘System: | 200817) Fuel tank: Diesel fuel 120(31.7), Fig wi Oe) | Grose | Aaroquted Nox of (Rosonoitank) | andwater | 1025) 30:504, MAINTENANCE CHECK LIST 4) DAILY SERVICE BEFORE STARTING Check items Visual chock Ful tank Hysrauic ol lave Engine ol level CCootat evel ‘Control pane! & pit lamp Water separator Fan bolt tension 2) EVERY 50 HOURS SERVICE ‘Checkitems | ‘Service Fuel tank Drain “Tack tension Check, Adjust ‘Suing beating Lubricate ‘Suing reduction gear oil Check, Add ‘Swing reduction gear grease Lubricate Lubricate pin and bushing Lubricate Boom oylinder head and rod Boom connecting ‘Aum oylinder head and rod Boom + Arm connesting + Bucket oyinder head and rod ‘Arm + Bucket connecting ‘Aum + Link, Buckot control ‘Bucket cont ros ‘Boom swing post + Upper fame connecting + Boom swing ylinder head and rod «Dozer blade + Lower frame connecting Dozer bade cylinder head and rod3) INITIAL 50 HOURS SERVICE Check terns Service Page Engino ol Change 618,19 Engine oi fier Replace 618,19 Pilot ine fier Replace 620 Hydraulic retum iter Replace 629 Fuel filer Replace 6.26 Botts & Nuts Check, Tight 68 + Sprocket mounting bots ‘Tiavel motor mounting bots + Sing motor mounting bots + Swing boating mounting bots + Engine mounting bots + Courtenweight mounting bolts + Turning joint locating bots + Tack shoe mounting bots and nuts Hydraulic pump mounting bots Service the above items only for the new machine, and thereafter keep the normal service interval. 4) EVERY 100 HOURS SERVICE heck items Senico Page + Returner Replace 628 1 Piotiine iter Replace 629 + Eloment in hycrauic tank breather Replace 6-29 + Replace 3 filters for continuous hydraulic breaker operation only.5) EVERY 250 HOURS SERVICE Check its Service Page kEngine ol Change 618, 19 Engin ol fer Replace 618, 19 Batory electrolyte Check 636 Hyckaulle ol tur itor Replace 628 + Swing reduction gear of Change 629,90 Piotline iter Replace 629 lementin hydraulic tar breather Replace 629 Potts & Nuts (Check, Tight 68 + Sprocket mounting bots “Travel motor mounting bots + Swing motor mounting bolts ‘Swing bearing mounting bots + Engine mounting bolts + Countenwsight mounting bots + Turning joint locating bots + Track shoe mounting bots and ruts + Hydraule pump mounting bots if you use high Sulfur containing fuel above than 0.5% or use low grade of engine oll reduce change interval +4 Change ol after initial 250 hours of operation. 6) EVERY 500 HOURS SERVICE Check items, Service Page Fadator and cooter fin Check, Clean 623 ‘ieAircleaner element Inspect, Clean 24 Fuel itor Replace 628 Change 6st @ Travel reduction gear cil + Clean the primary lemant only aller 800 hours operation or when he ar cleaner warning lamp blinks. RRplace primary element and safety element ator 4 times cleanings of primary element. @ Change oil ater inital 500 hours of operation. 6137) EVERY 1000 HOURS SERVICE Check items Senice Page Tiavel motor reduction gear ol Chango eat ‘Swing reduction gear oil Change 629,20 8) EVERY 2000 HOURS SERVICE (Chock toms Sorvico Page Hydraulic tank * Ol Change ear + Sucton stainer ‘Check, Clean 628 Coolant Change 6.20, 21, 22, 23 ‘Change oil every 600 hours of continuous hydraulic breaker operation. ota9) WHEN REQUIRED ‘Whenever you have trouble in the machine, you must perform the service of related items, system bysystem. Chock tems Seniee Page Ful aystem | + Fueltank Drain or ean 625 + Water separator Diner Replace 62 Fuel tor Feplace 626 Engine lbication system + Engine a Change 618,19 + Engine oer Replace 518,19 Engine cooling system + Coolant ‘dor Change 620,21,22,28 + Radiator Clean or Fish 620,21, 22,23 Engine a system + Nircleaner Replace 628 Hydra system = Hyco ‘Addr Chango ear + Return fier Replace 628 + Potine iter Replace 629 + Element of breather Replace 620 + Sveton stainer loan 628 Under cariage Tra tonson Check, Ast ox Bucket Tooth Replace eat + Side cutar Replace 633 Linkage Acjust oa Bucket assy Replace 63 ‘ircondione and heater Circulation iter Clean os 615,Caution 1. Service intervals are based on the hour meter reading. 2. The number of each item shows the lubrication point on the machine. 3. Stop engine wii filing ol, and use no open flames. 4, For other deta, refer to the service manual 616617 ‘onal | Description en _|mbol| Hose) 7 | Hera ot ve Check, Add 701185) 2 | Engine ave Check, Ad 92(24) ‘ots 5 [ saree Lowacaar | 6 roan, [4 | witrseparior Crea Onin | =f 5 | Fanbelttension and damage Check, Adust | = ~ 6 | Atactment pins raf - | 7 _| Fuel tank strainer and drain - 1 8 | Swing bearing = 1 50 Hours | 9 | Swing drive gear case(Gear oil) 1.5(0.4) 1 alent AE) ‘Swing drive gear case(Grease) 0.2(0.05) 1 1 | Tack tion - 2 20 | Sing gear andirion 1 28 | Boom sing yindr - 1 2 | Engine of evel 1 12 | Battery(Electrolyte) 1 ip [8 imate 5 Hous || ine or element z 1 15 | Arbrator lemont 1 16 | Engro cl fior 1 17 | Arceaner coment Ouse) : 1 3, fel mananoarn =a 18 | Ful iter let - 1 ‘000 | & | Swing dive gear case 1504) | 1 Hours [21 | Final eve gear case 1209 | 2 + [ Rau oto ries) | 1 0 fa radtincoaet woes) | 1 | 22 | Hycaule ol sucionstaner Z 1 he _ [17 | Aceon comentnsiotuisi) : 2 required | 23 | Ai consdtioner filters Check, Clean : : 1 Oil symbol Please referto the recommenced kiricans for specication. DF: Diesel tel GO: Gear ci HO :Hycraui o Coolant PGL: Grease EO : Engin o[6 SERVICE INSTRUCTION’ 1) CHECK ENGINE OIL LEVEL Check the oil fovel with the machine on a flat ‘ground before starting engine. (1) Pullout the dipstick and wipe with a clean cloth, {@) Check the oil level by inserting the dipstick Completely into the hole and pling out again. {@ fol level fs LOW, acd ol and then check again, v Ifthe oil is contaminated or diluted, change tho oll regardless of the regular change interval. % Chack oll level after engine has been stopped for 15 minutes. A Do not operate unless the oil level is in the normal range. 2) REPLACEMENT OF ENGINE OIL AND OIL. FILTER (1) Warm up the engine. (2) Remove the cover of drain plug and connect the uick coupler hose. x A drain pan with a capacity of 20 iters(6 U. gallons) will be adequate. (@) Clean around the fiter head, remove the filter witha fiter wrench and clean the gasket surface. Engine ol fitor(@) Apply aight fim of lubricating ol to the gasket sealing surface before instaling the fits. {6 Install the fiter tothe fiter head. Remove the quick coupler hose. Mechanical over-tightening may distort the threads or damage the filter element seal. + Install the filter as specified by the filter manufacturer. Engine oi itor (© Fillthe engine with clean ol to the proper level Quanity 9.2 1 @AU.S gallons) ) Operate the engine at low idle and inspect for leaks at the fiters and the drain plug ‘Shut the engine off and check the cil level with the dipstick. Allow 15minutes for oil to drain down before checking e193) CHECK COOLANT (1) Check ifthe Jovel of coolant in reservoir tank is between FULL and LOW. {@) Add the mixture of antifreeze and water after removing the cap of the reservoir tank if coolant is not sufficient. (8) Be sure to add the coolant by opening the cap of radiator when coolant level is below LOW. (4) Replace gasket of radiator cap when it is damaged, ‘A Hot coolant can spray out if radiator cap is removed while engine is hot. Remove the cap after the engine has cooled down. 4) FLUSHING AND REFILLING OF RADIATOR (1) Change coolant ‘A Avoid prolonged and repeated skin contact with used antifreeze. Such prolonged repeated contact can cause skin disorders or other bodily injury. Avoid excessive contact-wash thoroughly after contact. Keep out of reach of children. x Protect the environment : Handling and disposal of used antifreeze can be subject to federal, state, and local law regulation. Use authorized waste disposal facilities, including civic amenity sites and garages providing authorized facilities for the receipt of used antifreeze. If in doubt, contact your local authorities for guidance as to proper handling of used antifreeze. a‘A Walt until the temperature is below 50°C (122°F) before removing the coolant system pressure cap. Failure to do so can cause personal injury from heated coolant spray, Drain the cooling systam by opening the drain valve on the radiator and removing the plug in the bottom of the water inlet. A drain pan with a capacity of 20 liters(5U.S.gallons) will be ‘adequate in most applications. (2) Flushing of cooling system O Fill the system with a mixture of sodium carbonate and water(or a commercially available equivalent). Use 0.5kg(1.0pound) of sodium carbonate for every 23 lters(6.0U.S. gallons) of water. Do not install the radiator cap. The engine is to be operated without the cap for this process. ® Operate the engine for § minutes with the ‘coolant temperature above 80°C(176°F) . Shut the engine off, and drain the cooling system. Fill the cooling system with clean water. % Be sure to vent the engine and aftercooler for complete filing. ® Do not install the radiator cap or the new coolant fit.© Operate the engine for § minutes with the ‘coolant temperature above 60°C(176"F) Shut the engine off, and drain the cooling system, If the water being drained is stil dirty, the system must be flushod again until the wator is clean. © Cooling system filling © Use a mixture of 50 percent water and 50 Percent ethylene glycol antifreeze to fill the cooling system, Coolant capacity(engine only) : 10 1 (2.6U: gallons) Use the correct amount of DCA4 corrosion Inhibitor to protect the cooling system. ® The system has a maximum fil rate of 14 liters(8.5US. gallons) per minute. Do not exceed this fl rate, ® The system must be filled slowly to prevent air locks. During filing, air must be vented from the engine coolant passage. ® Install the pressure cap. Operate the engine Until it reaches a temperature 80°C(176°F), and ‘check for coolant leaks. ‘Check the coolant level again to make sure the systemis full of coolant 6225) CLEAN RADIATOR AND OIL COOLER Check, and if necessary, clean and dry outside of radiator and oil cooler. After working in a dusty place, clean radiator more frequently. (1) Visually inspect the radiator for clogged radiator fins. (@) Use 550%Pa(80ps) air pressure to blow the dirt and debris from the fins. Blow the air in the opposite direction of the fan air flow. (©) Visually inspect the radiator for bent or broken fins. ¥ Ifthe radiator must be replaced due to bent or broken fins which can cause the engine to overheat, refer to the manufacturer's replacement procedures. () Visually inspect the radiator for core and gasket leaks. 6) FAN BELT TENSION (1) Measure the belt deflecton at the longest span of the bet + Deflection sada Newb aa (2) Inspect the drive for damage. 623 Pree with thumb Crarkshat pulley ae OK \ NOT OK7) INSPECTION OF COOLING FAN ‘A Personal injury can result from a fan blade failure. Never pull or pry on the fan. This can ‘damage the fan blade and cause fan failure. x Rotate the crankshaft by using the engine barring gear. x A visual inspection of the cooling fan is required daily. Check for cracks, loose rivets, and bent or loose blades. Check the fan to make sure it is securely mounted. Tighten the capscrews if necessary. Replace any fan that is demaged. 8) CLEANING OF AIR CLEANER (1) Primary element © Open cover and remove the element. Clean the inside of the body. © Clean the element with pressurized ai - Remove the dust inside ofthe element by the pressurized ar(Below Skgien?, 40ps) forward and backward equally. @ Inspect for eracks or damage of element by putting alight bub inside ofthe element © Insert element and close cover, x Replace the primary element after 4 times cleanings. @ Safety element + Replace the safety element only when the primary element is cleaned for the 4 times. ‘x Always replace the safety element. Never attempt to reuse the safety element by leaning the element. 624 ‘kgHlen below9) FUEL TANK (1) Fill {uel fully when system the operation to minimize water condensation, and check it with fuel gauge before starting the machine. (2) Drain the water and sediment in the fuel tank by ‘pening the drain cock. % Bo sure to LOCK the cap of fuel tank, x Remove the strainer of the fuel tank and lean itif contaminated. 4 Stop the engine when refueling. All lights and flames shall be kept at a safe distance while refueling ‘10)WATER SEPARATOR (1) Prepare a waste ol container. (@) Close the fuel cock {@) Loosen the drain cock at bottom of the water seperator and drain off any water collected inside. (@) Be sure to bleed air in the fuel system. 3 Wash the element and inside cup with clean fuel oil. % Replace the element with a new one if any damaged. 6-25 Fuel gauge Z Element Fuel cock A Floating ring Drain cock‘11)REPLACEMENT OF FUEL FILTER, (1) Clean around the fter head, remove the filter with a filter wrench and clean the gasket surface. (2) Apply a small amount of fuel to the Ong of new carte. (3) Install new cartridge by hand. = Do not add fuel to the new cartridge. Invisible Particles of dirt which might get inside the injection pump can damage its finely fnished parts. (4) Relieve the air ater mounting. »# Check for fuel leakage after the engine starts. a If air is in the fuel system, the engine will not start. Start engine after bleeding the air according to the method of bleeding air. ‘12BLEEDING THE FUEL SYSTEM (1) Turn the start switch to the ON positon and hold it in the position for 10-15 seconds to operate the fuelfeed pump. 19) LEAKAGE OF FUEL ‘A Be careful and clean the fual hose, injection pump, fuel filter and other connections as the leakage from these part can cause fire, 6-26‘44)HYDRAULIC OIL CHECK (1) Stop the engine after retract the arm and buoket cylinders, then lower the boom and set the bbuoket on the ground at a flat location as in the itustration, (2) Check the oi evel atthe level gauge of hydraulic oiltank. (9) The cil level is normal f between the red ines. 49) FILLING HYDRAULIC OIL, (1) Stop the engine tothe position of level check. 2) Loosen the cap and relieve the pressure in the tank by pushing the top ofthe air breather. (@) Remove the breather on the top of ol tank and filth oilto the specified level. + Tightening torque :1.44:L0.9k «mm (10.42.1018) (4) Start engine after fling and operate the work equipment several mes. (©) Check the oil level at the level check position attr engine stops. 16) CHANGE HYDRAULIC OIL (1) Lower the bucket on the ground paling the arm and bucket cylinder to the maximum, (2) Loosen the cap and relieve the pressure in the tank by pushing the top ofthe air breather. (8) Remove the cover. Tightening torque :6.9:+1.4kgf -m (601004) (4) Prepare a suitable container. (6) To drain the oil loosen the drain plug at the bottom of the oil tank, {6) Fill proper amount of recommended oll (7) Putte breather in the right position. {®) Bleed air hydraulic pump loosen the air breather at top of hydraulic pump assembly. {9) Start engine and run continually. Release the air by full stroke of each control lever. ear Redline Sj Level gauge Ew 4% Pushing{17)CLEAN SUCTION STRAINER Clean suction strainer as follows paying attention to the cause to be kept during oiling (1) Remove the cover on the top ofthe cil tank. + Tightening torque : 6.941 Akg! -m (60-1084 f) (@) Pullout the stainerin the tank. (@) Wesh the foreign materia on the suction strainer with gasoline or cleaning oi, (4) Replace the suction strainer if itis damaged. (6) Assemble wit reverse order of disassembly. Be sure to installa new O-ing and reinsertin the ciltank, » Loosen the bolt slowly at the cover can be spring out by the spring when removing it 18)REPLACEMENT OF RETURN FILTER Replace as follows paying attention to the cause to be kept during the replacement. (1) Remove the cover. + Tightening torque :6.9:41 akg! -m (60:410bt -) (@) Remove the spring, by-pass valve, and return fier the tank, (9) Replace the element with new one, 628 t Air breather Cover ‘O-ing i Cover— Oring Spring Bypass vatve——@