Hyundai HB100 Backhoe Loader Operator's Manual 2023 - PDF DOWNLOAD

CONTENTS 1 SAFETY HINTS 1. Before operating the machine ----------------------------------------------------------------------------------------- 1-1 2. During operating the machine ----------------------------------------------------------------------------------------- 1-3 3. During maintenance --------------------------------------------------------------------------------------------------------- 1-6 4. Parking ------------------------------------------------------------------------------------------------------------------------------ 1-9

2 SPECIFICATION 1. Major components ------------------------------------------------------------------------------------------------------------ 2-1 2. Dimensions ----------------------------------------------------------------------------------------------------------------------- 2-2 3. Specification for major components ------------------------------------------------------------------------------- 2-3

3 CONTROL DEVICE 1. Cab device ------------------------------------------------------------------------------------------------------------------------ 3-1 2. Instruments ----------------------------------------------------------------------------------------------------------------------- 3-2 3. Switches ---------------------------------------------------------------------------------------------------------------------------- 3-7 4. Drive controls -------------------------------------------------------------------------------------------------------------------- 3-15 5. Operating levers --------------------------------------------------------------------------------------------------------------- 3-18 6. Safety equipment ------------------------------------------------------------------------------------------------------------- 3-24 7. Opening and closing windows ---------------------------------------------------------------------------------------- 3-26 8. Seat controls --------------------------------------------------------------------------------------------------------------------- 3-27 9. Air conditioner and heater system ---------------------------------------------------------------------------------- 3-29 10. Radio and USB / MP3 player -------------------------------------------------------------------------------------------- 3-31

4 OPERATION 1. Suggestion for new machine ------------------------------------------------------------------------------------------- 4-1 2. Check before starting the engine ------------------------------------------------------------------------------------ 4-2 3. Starting the engine ----------------------------------------------------------------------------------------------------------- 4-3 4. Stopping and parking the machine --------------------------------------------------------------------------------- 4-6 5. Traveling position -------------------------------------------------------------------------------------------------------------- 4-7 6. Efficient working method ------------------------------------------------------------------------------------------------- 4-11 7. Operating in the special work sites -------------------------------------------------------------------------------- 4-23 8. Towing the machine ---------------------------------------------------------------------------------------------------------- 4-25 9. Storage ------------------------------------------------------------------------------------------------------------------------------ 4-27

5 TRANSPORTATION 1. Road traveling ------------------------------------------------------------------------------------------------------------------- 5-1 2. Preparation for transportation ------------------------------------------------------------------------------------------ 5-2 3. Loading the machine -------------------------------------------------------------------------------------------------------- 5-3 4. Fixing the machine ----------------------------------------------------------------------------------------------------------- 5-4

6 MAINTENANCE 1. Instructions ------------------------------------------------------------------------------------------------------------------------ 6-1 2. Tightening torque -------------------------------------------------------------------------------------------------------------- 6-4 3. Fluids, lubricants and capacities ------------------------------------------------------------------------------------- 6-7 4. Maintenance check list ----------------------------------------------------------------------------------------------------- 6-9 5. Maintenance chart ------------------------------------------------------------------------------------------------------------ 6-12 6. ROPS/FOPS structure ----------------------------------------------------------------------------------------------------- 6-14 7. Loader arm safety strut ---------------------------------------------------------------------------------------------------- 6-15 8. Lubrication ------------------------------------------------------------------------------------------------------------------------- 6-16 9. Checking the foot brake fluid level ----------------------------------------------------------------------------------- 6-20 10. Electrical system --------------------------------------------------------------------------------------------------------------- 6-21 11. Engine -------------------------------------------------------------------------------------------------------------------------------- 6-26 12. Fuel system ----------------------------------------------------------------------------------------------------------------------- 6-35 13. Hydraulic system -------------------------------------------------------------------------------------------------------------- 6-38 14. Transmission --------------------------------------------------------------------------------------------------------------------- 6-41 15. Tires and wheels -------------------------------------------------------------------------------------------------------------- 6-43 16. Axles ---------------------------------------------------------------------------------------------------------------------------------- 6-45 17. Wear pads ------------------------------------------------------------------------------------------------------------------------- 6-47 18. Air conditioner and heater ------------------------------------------------------------------------------------------------ 6-50

7 TROUBLESHOOTING GUIDE 1. Engine -------------------------------------------------------------------------------------------------------------------------------- 7-1 2. Electric system ------------------------------------------------------------------------------------------------------------------ 7-2 3. Power train system ----------------------------------------------------------------------------------------------------------- 7-3 4. Hydraulic system -------------------------------------------------------------------------------------------------------------- 7-4

8 INDEX INDEX ------------------------------------------------------------------------------------------------------------------------------- 8-1

FOREWORD This manual contains a number of instructions and safety recommendations regarding driving, handling, lubrication, maintenance, inspection and adjustment of the backhoe loader.

The manual is to promote safety maintenance and enhance machine performance.

Keep this manual handy and have all personnel read it periodically.

If you sell the machine, be sure to give this manual to the new owners.

This machine complies with EC directive "2006/42/EC".

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 distributor for those items you require.

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 in this manual apply only to intended uses of the machine.

If you use your machine for any unintended uses that are not specifically prohibited, you must be sure that it is safe for you and others. In no event should you or others engage in prohibited uses of actions as described in this manual.

2. Inspect the jobsite and follow the safety recommendations in the safety hints section before operating the machine.

3. Use genuine Hyundai spare parts for the replacement of parts.

We expressly point out that Hyundai will not accept any responsibility for defects resulting from nongenuine parts or non workmanlike repair.

In such cases Hyundai cannot assume liability for any damage.

Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual. Consult Hyundai or your Hyundai distributor for the latest available information for your machine or for questions regarding information in this manual.

0-1

BEFORE SERVICING THIS MACHINE It is the responsibility of the owner and all service and maintenance personnel to avoid accidents and serious injury by keeping this machine properly maintained.

It also is the responsibility of the owner and all service and maintenance personnel to avoid accidents and serious injury while servicing the machine.

No one should service or attempt to repair this machine without proper training and supervision.

All service and maintenance personnel should be thoroughly familiar with the procedures and precautions contained in this manual.

All personnel also must be aware of any federal, state, provincial or local laws or regulations covering the use and service of construction equipment.

The procedures in this manual do not supersede any requirements imposed by federal, state, provincial or local laws.

Hyundai can not anticipate every possible circumstance or environment in which this machine may be used and serviced.

All personnel must remain alert to potential hazards.

Work within your level of training and skill.

Ask your supervisor if you are uncertain about a particular task. Do not try to do too much too fast.

Use your common sense.

0-2

EC REGULATION APPROVED · Noise level (EN474-1 : 2006 and 2000/14/EC) are as followings.

LWA : 107.5 dB LPA : 85 dB

· The value of vibrations transmitted by the operator's seat are lower than standard value of (EN474-1 : 2006 and 2002/44/EC)

0-3

TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR Machine Serial No. Engine Serial No. Manufacturing year Manufacturer

Hyundai Heavy Industries co., Ltd.

Address

1, Jeonha-Dong, Dong-Ku, Ulsan 682-792, Korea

Distributor for USA

Hyundai Heavy Industries USA, Inc

Address

955 Estes Avenue EIK Grove village IL, 60001 USA

Distributor for Europe

Hyundai Heavy Industries Europe N. V.

Address

Vossendal 11 2240 Geel Belgium

Dealer Address

0-4

MACHINE DATA PLATE

1, JEONHA-DONG, DONG-GU, ULSAN 682-792, KOREA

EQUIPMENT

1, JEONHA-DONG, DONG-GU, ULSAN 682-792, KOREA

OPERATING WEIGHT

MODEL

ENGINE POWER(PS/KW/rpm)

2

OPERATING WEIGHT

MODEL

ENGINE POWER(PS/KW/rpm)

SERIAL-NUMBER

MFG. YEAR

4

1

4

1

EQUIPMENT

2

5 SERIAL-NUMBER

3

5 6

3 DO NOT DEFACE OR REMOVE THIS PLATE

DO NOT DEFACE OR REMOVE THIS PLATE

FOR EU ONLY 21090FW10

1 2

Equipment Model name

3 4

Serial number Operating weight

5 6

Engine power Manufacturing year

※ The machine serial number assigned to this particular machine and should be used when requesting information or ordering service parts for this machine from your authorized HYUNDAI dealer.

The machine serial number is also stamped on the frame.

0-5

GUIDE (direction, (direction, S/No, symbol symbol) 1. DIRECTION In this manual, the directions are indicated as shown in the right figure.

Right

Front

Rear Left

HB100FW11

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 right window of the operator's cab.

Machine serial no.

HB100FW02

2) ENGINE SERIAL NUMBER The numbers are located on the engine name plate.

Engine serial no.

HB100FW03A

3. SYMBOLS Important safety hint.

It indicates matters which can cause the great loss on the machine or the surroundings. ※ It indicates the useful information for operator.

0-6

SAFETY LABELS 1. LOCATION Always keep these labels clean. If they are lost or damage, attach them again or replace them with a new label.

7 9

6 17

23

14

16

23

5 24 10

20

23

8

18 22

20

12

5

17 4 15 23

16

23 10 24 11

1

2 23

21 11

1 2 3 4 5 6 7 8

19

3

5

Ref operator manual Overall width Control ideogram Machine control pattern Bucket stopper Radiator cap Caution engine hood Tie

13

5

9 10 11 12 13 14 15 16

8

HB1001SH03

Steering wheel Crush hazard Speed limit ROPS plate Name plate Model name - LH Model name - RH Hyundai logo

0-7

17 18 19 20 21 22 23 24

Hyundai logo Service instruction ROPS cab Keep clear/reflect Fueling Hydraulic oil level Reflector - side Cooling fan

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) REF OPERATOR MANUAL (item 1) This warning label is positioned on the right side window of the cab.

Study the operator's manual before starting and operating machine.

21070FW22

2) CONTROL IDEOGRAM (item 3) This warning label is positioned on the left side window of the cab.

Confirm the operation of control lever and working device before operating the machine.

(OPTION)

※ Refer to the page 3-18 for details.

WARNING BE CAREFUL ACCIDENTAL CONTACT THE CONTROL LEVERS WHILE YOU ARE STAYING INSIDE CABIN. THE WORKING EQUIPMENT CAN MOVE IF YOU TOUCH THE CONTROL LEVERS ACCIDENTALLY EVEN IF THE ENGINE DOESN'T RUN HB100FW05

0-8

3) MACHINE CONTROL PATTERN (item 4) This warning label is positioned in the right window of the cab.

Check the machine control pattern for conformance to pattern on this label. If not, change label to match pattern before operating machine.

Failure to do so could result in injury or death.

※ Refer to the page 3-20 for details.

HB100FW06

4) BUCKET STOPPER (item 5) These warning labels are positioned on the both sides of the booms.

When working under or around the bucket or linkage, with bucket raised, proper support must be provided for the bucket and/or the linkage.

7803AFW05

5) RADIATOR CAP (item 6) This warning label is positioned on the engine hood.

Never open the filler cap while engine running or at high coolant temperature.

77070FW11

0-9

6) CAUTION ENGINE HOOD (item 7) The warning label is positioned on the engine hood.

Be sure to support the stay when the door needs to be opened.

Be careful that the opened door may be closed by the external or natural force like strong wind.

HB100FW07

7) CRUSH HAZARD (item 10) Never walk or work under equipment unless it is supported by a mechanical device.

Equipment which is supported only by a hydraulic device can drop and injure you if the hydraulic system fails or if the control is operated (even with the engine stopped).

Empty the shovel and raise the loader arms fully.

Stop the engine and remove the starter key.

Release the safety bar.

Install the safety bar.

Lower the arm onto the safety bar.

HB100FW08

8) FUELING (item 21) This warning label is positioned on the right side of fuel tank.

Stop the engine when refueling. All lights or flames shall be kept at a safe distance while refueling.

21070FW04

0-10

9) HYDRAULIC OIL LEVEL (item 22) This warning label is positioned on the left side of hydraulic oil tank.

Place the bucket on the ground whenever servicing the hydraulic system.

STOP

※ Check oil level on the level gauge. ※ Refill the recommended hydraulic oil up to specified level if necessary.

91U2-01131

HB100FW09

0-11

1. SAFETY HINTS 1. BEFORE OPERATING THE MACHINE THINK-SAFETY FIRST. In special situation, wear protective clothing including a safety helmet, safety shoes, gloves, safety glasses and ear protection as required by the job condition.

Almost all accidents are caused by disregarding the simple and fundamental safety hints.

Be sure to understand thoroughly the operator's manual before operating the machine.

Fully understand the details and process of the construction before starting the work.

If you find anything dangerous on the job, consult with the job supervisor for preventive measures before operating the machine.

Do not operate when tired, or after drinking.

Alcoholic beverages, or any type of drugs.

Check daily according to the operator's manual.

Repair the damaged parts and tighten the loosened bolts.

Check for leakage of engine oil, hydraulic oil, fuel and coolant.

Do not operate the machine if it requires repairs.

Operate after complete repair.

Make sure safety lock pin is removed before operating the machine.

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 authorize by or your distributor. Use of unauthorized attachments could create a safety problem and adversely affect the proper operation and useful life of the machine.

Any injuries, accidents, product failures resulting from the use of unauthorized attachments will not be the responsibility 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 or a person on worksite traffic duty, be sure all personnel understand all hand signals that are to be used.

SAFETY FEATURES Be sure all guards and covers are in their proper position. Have guards and covers repaired if damaged.

Use safety features such as the safety lock lever and seat belts properly.

Never remove any safety features. Always keep them in good operating condition.

Improper use of safety features could result in serious bodily injury or death.

1-1

SECONDARY CAB EXIT The door on the right side of the cab, also serves as a secondary exit.

Only in case of emergency, use installed the hammer for breaking the windshield of cab, and then exit carefully.

7707FW12

FIRE EXTINGUISHER AND FIRST AID KIT Be sure fire extinguishers have been provided and know how to use them.

Provide a first aid kit at the storage point.

Know what to do in the event of a fire.

Be sure you know the phone numbers of persons you should contact in case of an emergency.

73031SH10

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.

SEAT BELT Check the condition of the seat belt and mounting hardware before operating the machine. If the seat belt mounting hardware is worn or damage, replace the seat belt mounting hardware. Make sure that the mounting bolts are tight.

Replace the seat belt at least once every three years regardless of appearance.

73031SH11

Always use seat belts when operating your machine.

1-2

2. DURING OPERATING THE MACHINE Use the handle and footstep when getting on or off the machine.

Do not jump on or off the machine.

Sound the horn to warn nearby personnel before operating the machine.

Operate carefully to make sure all personnel or obstacles are clear within the working range of the machine.

Place safety guards if necessary.

When using the work equipment, pay attention to jobsite.

Provide proper ventilation when operating engine in a closed area to avoid the danger of exhaust gases.

Check the locations of underground gas pipes or water line and secure the safety before operation.

The operating near the electrical lines is very dangerous. Operate within safe working range permitted as below.

Supply voltage

Min safe separation

6.6 kV

3 m (10 ft)

33.0 kV

4 m (13 ft)

66.0 kV

5 m (16 ft)

154.0 kV

8 m (26 ft)

275.0 kV

10 m (33 ft)

If the machine touches the electric power lines, keep sitting on the operator's seat and make sure the personnel on the ground not to touch the machine until turning off the electric current. Jump off the machine, do not contact the machine when you need to get off.

While traveling on public roads, lift the bucket 40~50 cm above the ground. Do not drive with the bucket loaded.

When the bucket is loaded, avoid sudden swinging or starting. Overloading is dangerous. sure the load does not exceed the permissible level.

Make

The operation on a slope is dangerous.

Avoid operating the machine on a slope of over 10 degree.

Operate the machine after making ground flat when operation is required on a slope.

Avoid parking and stopping on a slope.

Lower the bucket to the ground and block the tire when parking.

Avoid traveling in a cross direction on a slope as it can cause the danger of rolling over and sliding.

Traveling on the slope is dangerous.

Be sure to operate slowly when driving down a slope and maintain the bucket at a height of 20~30 cm (1 ft) above the ground so that it can be used as brake in an emergency.

Steering of the machine while traveling on a slope is dangerous.

When an inevitable turning of direction is required, turn on the flat and solid ground.

The engine angularity limits are 30˚.

Do not operate by more than the engine limits in any case.

1-3

Watch out for obstacles. Be particularly careful to check the machine clearance during steering.

Always operate machine with proper ROPS/ FOPS installed.

Do not attempt to repair a rollover protective structure (ROPS) after an accident.

Repaired structures do not provide the original structure and protection.

Test and approved as a protective CAB according to ROPS and FOPS standard.

Meets : ISO 3471 / 3449 / 3164, SAE J1040 / J231 / J397 Avoid operating on a cliff, or soft ground as there is danger of rolling over.

Take necessary precautions when working after rain, or blasting because the ground may not be firm enough.

This machine is intended to be used only for excavation and loading. Do not use this for pulling up materials. Unlike a crane, this machine is not equipped with devices needed to pull up things.

Slow down when traveling through obstacles or uneven ground.

When operating in water or when crossing shallows, check the bed soil condition and depth and flow speed of water, then proceed taking care that water is not above axle housing.

73031SH34

Never allow anyone near the center articulation pivot.

If the machine turned, they could be crushed.

7707FW07

Use lights at night or in dark areas.

Be careful in the condition of bad clearance of sight caused by cloud, snow or rain.

Put the chains on the tires when moving or working on the snowed and frozen road, and avoid doing sudden start, stop and swing.

When machine is used for snow removal, be alert for hidden objects.

Be careful when traveling on icy surface.

Keep bucket low to ground.

Be careful when driving under a height limited place, for instance, a tunnel, an overpass, and an overhead cable.

1-4

MOUNTING AND DISMOUNTING Never jump on or off the machine. Never get on or off a moving machine.

When getting on or off the machine, face the machine and use the handhold and steps.

Never hold any control levers when getting on or off the machine.

Always maintain three-point contact with the handholds and steps to ensure that your support yourself.

If there is any oil, grease, or mud on the handholds, steps or nonslip tapes, wipe it off immediately.

Inspect, and as necessary, repair or replace the damaged parts and tighten any loose bolts.

When carrying out inspection and maintenance with the mud guarder opened, pay attention to avoid the injury or damage by the mud guarder.

ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT When standing up from the operator's seat, always place the safety switch securely in the Lock position. If you accidentally touch the RCV lever when they are not locked, the work equipment may suddenly move and cause serious injury or damage.

When leaving the machine, lower the work equipment to the ground, set the pilot cut off switch to the Lock position, then stop the engine and use the key to lock all the equipment. Always take the key with you.

1-5

3. DURING MAINTENANCE During maintenance do not allow any unauthorized person to stand near the machine. Also, be careful of people in the vicinity.

Stop the engine immediately when the trouble of the machine is found.

Inspect immediately the cause of trouble such as vibration, overheating and trouble in the cluster then repair.

Park on a flat place for inspecting and repairing and properly TAG machine is not operational. (remove start key) Extreme care shall be taken during maintenance work.

Parts may require additional safe guarding.

Do not remove the radiator cap from hot engine.

Open the cap after the engine is cool, below 50˚C (112˚F) to prevent personal injury from heated coolant spray or steam.

73031SH46

Do not work below the machine.

When working under of around the bucket or linkage, with the bucket raised, proper support must be provided for the bucket and / or the linkage.

There is the danger of fire in fuel and oil.

Store in cool dry area, away from any open flames.

Do not refuel the machine while smoking or when near open flame or sparks.

Always stop engine before refueling machine.

Spilled grease and oil are dangerous to safety.

Keep your machine always clean and dry.

Disassembly, reassembly and repair of tire requires special skills and equipment.

Contact a tire repair shop.

Be prepared if a fire starts.

Keep a fire extinguisher handy and emergency numbers for a fire department near your telephone.

1-6

When servicing and checking engine compartment at the engine hood opened, be careful head against door.

Do not open the engine hood while engine is running.

73031SH52

Do not touch exhaust pipe, or it may cause severe burn.

73031SH53

Be sure to support stay, when the engine hood needs to be opened.

Be careful the external or natural force like strong wind.

73031SH54

The anti-slip protection should be replaced if they have become worn or have been printed over.

1-7

KEEP THE MACHINE CLEAN Spilled oil or grease, or scattered tools or broken pieces are dangerous because they may cause you to slip or trip.

Always keep your machine clean and tidy.

If water gets into the electrical system, there is danger that the machine may not move or may move unexpectedly.

Do not use water or steam to clean the sensors, connectors, or the inside of the operator's compartment.

73031SH56

HANDLING TIRES If tires are not used under the specified condition, they may overheat and burst or be cut and burst by sharp stones on rough road surfaces.

This may lead to serious injury or damage.

To maintain safety, always keep to the suitable conditions.

Disassembly, reassembly, replacement and repair of tire requires special skills and equipment. Contact a tire repair shop.

73031SH57

1-8

4. PARKING When leaving the machine lower the bucket to the ground completely and put the safety lever at parking position then remove the key.

Lock the cab door.

Park the machine in the flat and safe place.

Hope you can work easily and safely observing safety rules.

For safe operation, observe all safety rules.

1-9

2. SPECIFICATIONS 1. MAJOR COMPONENTS

Tire

Engine assy

Bucket

Radiator

Tilt cylinder

Engine hood

Fuel tank

ROPS/FOPS Cabin

Transmission Hydraulic oil tank

Stabilizer

Exhaust tail pipe

Attachment Front axle

Tool box

Rear axle

Boom

Extendable dipper

Bucket Swing post carriage Control linkage

Lift cylinder

HB1002SP01

2-1

2. DIMENSIONS

K M

E

45

H H'

1) HB100/HB90

L

L'

B

C

D

F

J N

J'

P

G G'

A

HB1002SP02

Operating weight Transport length Transport height Transport width

Description

Unit

Standard dipper and GP bucket Extendible dipper and MP bucket

Specification HB100

HB 90

kg (lb)

7900 (17420)

7830 (17260)

kg (lb)

8500 (18740)

8440 (18610)

GP bucket

5800 (19' 0")

5800 (19' 0")

MP bucket

5850 (19' 2")

5850 (19' 2")

Standard dipper

3650 (12' 0")

3450 (11' 4")

Extendible dipper

3700 (12' 2")

3500 (11' 6")

2350 (7' 9")

2350 (7' 9")

GP bucket MP bucket

Overall length

A

7350 (24' 1")

7350 (24' 1")

Dump clearance

B

2735 (9' 0")

2735 (9' 0")

Hinge pin height

C

3530 (11' 7")

3530 (11' 7")

Dump reach

D

785 (2' 7")

785 (2' 7")

Max loading height

E

4380 (14' 4")

4380 (14' 4")

Depth of bucket down

F

105 (0' 4")

105 (0' 4")

Max digging depth (STD)

G

4455 (14' 7")

4250 (13' 11")

Max digging depth (EXT)

G'

5665 (18' 7")

5470 (17' 11")

Max digging height (STD)

H

5570 (18' 3")

5370 (17' 7")

Max digging height (EXT)

H'

6390 (20' 12")

6190 (20' 4")

Backhoe Max digging reach (STD) data Max digging reach (EXT)

J

5550 (18' 3")

5350 (17' 7")

J'

6665 (21' 10")

6480 (21' 3")

Max loading height

K

3720 (12' 2")

3520 (11' 6")

Minimum ground clearance

L

350 (1' 2")

350 (1' 2")

Height of outrigger

L'

363 (1' 3")

363 (1' 3")

Dumping height

M

3860 (12' 8")

3660 (12' 0")

Loader data

mm (ft-in)

2-2

3. SPECIFICATION FOR MAJOR COMPONENTS 1) ENGINE Specification

Item

HB100

HB90

Manufacture

FPT (IVECO)

Model

F4GE9484F*J

F4GE9454J*J

Type

4-stroke, turbocharged and charge air-cooled

4-stroke, turbocharged

Non-road emission standards

Certified to EPA Tier 3 / EU stage III-A 4.5 ℓ (1.2 U.S.gal)

Piston displacement Fuel

Diesel

Rated horse power (Gross)

99 hp (74 kW) at 2200 rpm 89 hp (66 kW) at 2200 rpm

Maximum torque at 1250 rpm (Net)

44 kgf·m (318 lbf·ft)

41 kgf·m (297 lbf·ft)

Alternator

90 amp

Battery

12V

2) MAIN PUMP Specification

Item

HB100

Type

HB90

Fixed displacement double gear pump

Capacity

Steering

40 cc/rev

35 cc/rev

Attachment

35 cc/rev

35 cc/rev

Maximum operating pressure Rated oil quantity

250 kgf/cm2 (3560 psi) Steering

88ℓ/min (23.3 U.S.gpm)

77ℓ/min (20.3 U.S.gpm)

Attachment

77ℓ/min (20.3 U.S.gpm)

77ℓ/min (20.3 U.S.gpm)

2200 rpm

Rated speed

3) MAIN CONTROL VALVE FOR LOADER Item

Specification

Type

2 spool (OPT : 3 spool)

Operating method

Manual control

Main relief valve pressure

250 kgf/cm2 (3560 psi)

Unloading relief valve pressure

220 kgf/cm2 (3130 psi)

Overload relief valve pressure

Bucket out

175 kgf/cm2 (2490 psi)

Bucket in

300 kgf/cm2 (4270 psi)

2-3

4) MAIN CONTROL VALVE FOR BACKHOE Item

Specification

Type

6 spool (OPT : 7 spool)

Operating method

Hydraulic pilot control

Main relief valve pressure

250 kgf/cm2 (3560 psi)

Overload relief valve pressure

Boom up

300 kgf/cm2 (4270 psi)

Boom down

300 kgf/cm2 (3980 psi)

Swing LH, RH

240 kgf/cm2 (3410 psi)

Bucket in

300 kgf/cm2 (4270 psi)

Bucket out

300 kgf/cm2 (4270 psi)

Dipper in

300 kgf/cm2 (4270 psi)

Dipper out

300 kgf/cm2 (4270 psi)

5) STEERING UNIT Item

Specification

Type

Dual displacement load sensing, dynamic signal, non reaction

Displacement

156 cc/rev + 59 cc/rev

Relief valve pressure

248 kgf/cm2 (3530 psi)

Overload relief valve pressure

303 kgf/cm2 (4310 psi)

6) PILOT SUPPLY UNIT Item

Specification

Reducing & relief valve pressure Safety solenoid valve

30 kgf/cm2 (430 psi) Voltage

DC 12V

Ampere

1.8 A

7) ACCUMULATOR Specification

Item

Ride control (OPT)

Type

Pilot supply Nitrogen

Capacity

1.5ℓ

0.35ℓ

Precharge pressure

30 kgf/cm2 (430 psi)

15 kgf/cm2 (215 psi)

Max working pressure

350 kgf/cm2 (4980 psi)

170 kgf/cm2 (2420 psi)

2-4

8) REMOTE CONTROL VALVE Specification

Item

For backhoe

Type

For stabilizer

Pressure reducing type

Operating

Minimum

6.5 kgf/cm2 (93 psi)

5.5 kgf/cm2 (78 psi)

Maximum

25 kgf/cm2 (356 psi)

26 kgf/cm2 (370 psi)

19 degree

23.5 degree

Single operation angle

9) LINE FILTER Item

Specification

Filtration rating

10 μm

Max working pressure

280 kgf/cm2 (3980 psi)

Bypass cracking pressure

7 kgf/cm2 (100 psi)

10) DOUBLE PILOT CHECK VALVE FOR STABILZER Item

Specification

Max working pressure

350 kgf/cm2 (4980 psi)

Cracking pressure

4.5 kgf/cm2 (64 psi)

Pilot ratio

1 : 5.5

11) TIRES Item Front

Specification 4WD-12.5/80-18 4WD-18.4-26 (STD)

Rear

4WD-16.9-28 (OPT) 4WD-21L-24 (OPT)

2-5

12) POWERTRAIN Item

Specification 4-Speed helical-cut gears, full powershift with hydraulic control standard, electric clutch cutoff on loader lever

Transmission

Maximum travel speed with standard (18.4-26 tire) Gear

1st

2nd

3rd

4th

Forward (km/hr)

5.9

10.9

22.0

37.5

Reverse (km/hr)

7.5

13.7

21.7

N/A

Torque converter (ratio) 1 : 2.526 Differential lock

Front : Conventional Rear : Hydraulic lock (push-button activation)

Steering

Hydrostatic power and emergency steering

Brake

Service

Hydraulic wet disc, mounted inboard, self-adjusting and self-equalizing

Parking

Spring applied, hydraulically releases, wet, multi disc independent of service brakes with electric switch control

13) BUCKET Item

Capacity (liters)

Width (mm)

Weight (kg)

Loader GP

1000

2350

425

Loader MP

1000

2350

790

Trenching

170

630

140

Trenching

200

720

150

2-6

3. CONTROL DEVICE 1. CAB DEVICE 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 at a glance.

(2) It is equipped with a safety warning system for early detection of machine malfunction.

9

19

3 2 7

11

6

5 16 1 8 4 15 10 17 12

14

18

13 HB1003CD18

1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19

Start switch Gear selector switch Steering wheel Aircon and heater switch Accelerator pedal Brake pedal FNR lever Hand throttle lever Front console Side console

3-1

Multi-function switch and horn Rear console switch Boom lock Seat Radio/USB player Loader controls Backhoe controls Stabilizer controls Speed meter

2. INSTRUMENTS The indicators are located on the front console and additional instruments and gauges are located at the side of the driver's seat.

1) FRONT CONSOLE The master warning light and indicator lamps are located in the front console.

Direction indicator(Left) Main beam indicator Direction indicator(Right) Speed meter

Indicator lamp

Differential lock indicator Parking indicator Master warning indicator

Front console switch (Refer to page 3-7)

HB1003CD66

(1) Master warning light (1 ① On the front console, the master warning light will illuminate when any of the below warning lights on the side console are illuminated.

Air cleaner blocked ; Glow ; Transmission oil temperature ; Engine oil pressure ; Charge.

77073CD09

※ When this warning lamp lights ON, machine must be checked or serviced as soon as possible.

3-2

(2) Indicator lamps (2 ① Main beam - This lamp works when the illuminating direction is upward.

- This lamp comes ON when the dimmer switch is operated, e.g., when passing another vehicle.

77073CD12

② Direction indicators - This lamp flashes when the signal indicator lever is moved.

77073CD10

③ Parking - When the parking brake is actuated, the lamp lights ON. ※ Check the lamp is OFF before driving.

77073CD13

④ Differential lock - When the differential lock is actuated, the lamp lights ON.

HB1003CD49

(3) Speedometer (3 ① Indicates the road speed in miles per hour (MPH) and/or kilometers per hours (km/h). ② Also, shows total traveling mileage of the machine.

HB1003CD44

3-3

2) SIDE CONSOLE Air conditioner & heater switch Radio & MP3 player

Cigar lighter

Fuel level gauge Coolant temp gauge

RPM gauge Rear console switch (Refer to page 3-11) Side console switch (Refer to page 3-9) Air cleaner Engine oil pressure

Warning lamp Charge Air heater Transmission oil temperature HB1003CD59

(1) RPM gauge (1 ① Indicates the engine speed in revolutions per minute (rpm). The rpm is shown on the outer ring. Each division is 100 rpm. ② Records the total running time of the engine. Use it to keep a check of running hours during maintenance intervals.

HB1003CD45

(2) Coolant temperature gauge (2 ① Indicates the temperature of the engine coolant. The gauge pointer will gradually swing upwards as the coolant temperature rises.

HB1003CD47

(3) Fuel gauge (3 ① Indicates the level of diesel fuel in the fuel tank. Do not let the fuel tank run dry, or air will enter the fuel system.

HB1003CD48

3-4

(4) Cigar lighter (4 ① This can be used when the engine starting switch is ON. ② The lighter can be used when it springs out in a short while after being pressed down.

13033CD69

※ Service socket Use cigar lighter socket when you need emergency power.

Do not use the lighter exceeding 12V, 120W.

(5) Warning lamps with audible alarm ※ If below lamps come on while the engine is running, stop the engine as soon as it is safe to do so.

Do not use the machine until the fault is put right. ① No charge - This lamp is ON when key ON, it is turned OFF after starting the engine.

- Check the battery charging circuit when this lamp comes ON, during engine operation.

77073CD22

② Air heater - This lamp lights ON when start switch is turned clockwise to the ON position. Light will turn off after approximately 10~20 seconds, depending on engine coolant temperature, indicating that preheating is completed.

77073CD14

- When the lamp goes out, the operator should start cranking the engine.

③ Engine oil pressure - This lamp is comes ON after starting the engine because of the low oil pressure.

- If the lamp comes ON during engine operation, shut OFF engine immediately. Check oil level.

77073CD18

④ Transmission oil temperature - This lamp informs the operator that transmission oil is above the specified temperature. ·ON ON : Abnormal ·OFF OFF : Normal HB1003CD09

※ When this lamp lights up during operation, stop the engine and check the machine.

3-5

⑤ Air cleaner - This lamp lights ON when the filter of air cleaner is clogged. ※ Check the filter and clean or replace it when the lamp is ON.

77073CD20

3-6

3. SWITCHES 1) START SWITCH

77073CD41

① There are three positions, OFF, ON and START. · (OFF) : None of electrical circuits activate. · (ON) : All the systems of machine operate. · (START) : Use when starting the engine. Release key immediately after starting.

Key must be in the ON position with engine running to maintain electrical and hydraulic function and prevent serious machine damage.

2) FRONT CONSOLE SWITCHES Each switch has an insert with a graphic symbol, this symbol and the switch descriptions are detailed below.

Hazard warning switch Side and head light switch Differential lock switch Parking brake switch 4 Wheel drive select switch Ride control switch

HB1003CD60

(1) Side lights and headlights switch (1 ① This switch use to operate the side lights and head lights by two steps. ·1st step : Side lights come ON. ·2nd step : Head lights come ON. HB1003CD23

3-7

(2) Hazard warning lights switch (2 ① Press to switch on the hazard warning lights. A light on the instrument panel flashes with the outside light.

HB1003CD24

(3) 4 Wheel drive select switch (3 ① Press this switch for 4 wheel drive mode. ※ Use 2 wheel drive mode when driving long distance or high speed. ※ Use 4 wheels drive mode when operating in heavy duty site conditions, for instance, deep mud, undulating surfaces, slurry etc.

HB1003CD25

(4) Differential lock switch (4 ① This switch is used to apply differential lock.

The differential lock gives equal power to both rear wheels and is used in conditions when traction is poor.

HB1003CD67

※ Make sure that this switch must be on when machine is stationary and neutral position of FNR lever.

Do not switch on driving. Otherwise it will cause the failure of differential and differential lock system.

(5) Parking brake switch (5 ① This is used to apply the parking brake. ※ Refer to page 3-17 for details.

HB1003CD56

(6) Ride control switch (if fitted) (6 ① This switch is used to operate the ride control system. ② The ride control system will smooth the ride of the machine during traveling uneven grounds.

HB1003CD29

3-8

3) SIDE CONSOLE SWITCHES Each switch has an insert with a graphic symbol, this symbol and the switch descriptions are detailed below. The pilot lamp is turned ON when operating these switches.

USB & socket assy Side shift lock switch Beacon switch Rear wiper switch Rear work lights switch Front work lights switch Return to dig switch Low speed control switch HB1003CD61

(1) USB & socket (1 ① MP3 player can be connected to the USB port.

AUX

USB

② In addition, it is possible to use input port for ear phone or other instruments, implements etc.

HB1003CD63

(2) Side shift lock switch (2 ① This switch is used to move the side shifting the backhoe. ※ Refer to page 4-17 for side shifting the backhoe.

HB1003CD34

(3) Beacon switch (3 ① Press to switch on the flashing beacon.

HB1003CD26

3-9

(4) Rear window wiper switch (4 ① Press to switch on the rear window wiper. Press again to operate the washer. Note that the wiper will self-park when switched off.

HB1003CD31

(5) Rear work lights switch (5 ① Press down to switch on the rear work lights. The work lights will work independently of the main lights circuit.

HB1003CD32

(6) Front work lights switch (6 ① Press to switch on the front work lights. The work lights will work independently of the main lights circuit.

Do not drive on the road with the work lights switched on. You can interfere with other drivers visibility and cause an accident.

HB1003CD27

(7) Return to dig switch (7 ① This switch is use to roll the shovel from the rolled forward position into digging position quickly and easily. ※ Refer to page 3-19 for details.

HB1003CD36

(8) Low speed control switch (8 ① This switch is used to slow down the loader operation. ② If this switch is pressed, the flow from one of two hydraulic pumps is drained to the hydraulic tank directly. ※ Press on this switch when traveling on the road.

HB1003CD30

3-10

SWITCHES ES 4) REAR CONSOLE SWITCH

Control pattern change switch Safety switch

HB1003CD62

(1) Safety switch (backhoe and stabilizer) (1 ① Press down to switch off safety switch.

The control lever of backhoe and stabilizer lever are disabled from operation. ※ Be sure to switch off position when leaving from operator's seat.

HB1003CD10A

(2) Control pattern change switch (if fitted) (2 1 2

① This switch is used to change the backhoe controls. ·Position ① : ISO type (+) pattern ·Position ② : Hyundai A type (+) pattern ※ Refer to the page 3-20 for the details.

HB1003CD11

3-11

5) MULTI-FUNCTION SWITCH Left turning

Right turning

(1 Turning switch (1) ① This switch is used to warn or signal the turning direction of the machine to other vehicles or equipment. ② Push the lever up for turning left, pull the lever down for turning right.

HB1003CD37C

J O I II

HB1003CD37E

(2 Windscreen wiper (2) ① Rotate the lever barrel to switch the window screen wipers on and off. The following functions are available.

J Intermittent wipe I Slow O OFF II Fast ② The wipers will self-park when switched off.

(3) Windscreen washer (3 Push the button towards the steering wheel to operate the windscreen washer.

Washer switch

HB1003CD37F

Up

M

Down HB1003CD37D

Horn switch

(4 Dimmer switch (4) ① This switch is used to turn the head lights direction. ② Switch positions ·Up : To flash for passing ·Middle : Head lights low beam ON ·Down : Head lights high beam ON ③ If you release the switch when it's in up position, the switch will return to middle.

(5) Horn (5 Push the button on the top of the multifunction switch, the horn will sound.

HB1003CD37G

3-12

6) SWITCHES ON CONTROL LEVERS

Multi function switch

Clutch cut-off switch Low speed control switch

Dipper switch(Extend) Dipper switch(Retract)

Breaker operation switch

Horn switch

HB1003CD65

(1) Extending dipper switch (if fitted) (1 C D

① This switch is at the top of left side (backhoe side) control lever.

On pressing switch "C", the dipper extends.

On pressing switch "D" the dipper retracts.

C D

※ Refer to the page 4-18 details.

(LH) HB1003CD12

(2) Breaker (2 reaker operation switch (if fitted) ① This switch is at the top of right side control lever (backhoe side).

On pressing this switch, the breaker operates.

(RH) HB1003CD13

3-13

(3) Horn (3 orn switch ① This switch is at the top of right side control lever (backhoe side).

On pressing this switch, the horn sounds.

(RH) HB1003CD14

(4) Low (4 ow speed control switch ① This switch is at the top of right side control lever (loader side).

The speed of loader is slow while pressing the switch. ② To use this switch intermittently (for instance, when entering a stockpile), refer to the page 3-10.

(RH) HB1003CD15

(5) Clutch (5 lutch cut-off switch ① This switch is at the top of right side control lever (loader side).

On pressing, the transmission is cut-off from the engine. This gives more power to the loader.

(RH) HB1003CD08

7) MASTER SWITCH (1) This switch is used to shut off the entire electrical system.

I

O

(2) I : The battery remains connected to the electrical system.

O : The battery is disconnected to the electrical system. ※ Never turn the master switch to O (OFF) with the engine running. Engine and electrical system damage could result.

OFF HB1003CD70

8) CAB INTERIOR LIGHT (1) Press ON/OFF to switch on the cab interior light.

Make sure the light is turned off when you intend to leave the machine for a long period of time.

73033CD24

3-14

4. DRIVE CONTROLS

Parking switch Steering wheel Gear selector switch FNR lever

Multi function switch Accelerator pedal

Brake pedal Tilt adjust lever

Hand throttle lever

HB1003CD19

Left

1) STEERING WHEEL

Right

(1) Two multi-motion cylinders in the center of the machine will operate the steering function.

(2) If the steering wheel is turned to left, the machine will move to the left and turn it to the right, the machine will move to the right.

2) STEERING WHEEL LEVER Lever

HB1004OP02

(1) By pushing the lever down, the wheel is adjustable to tilt.

Make sure the steering column is locked in position. Do not adjust the steering column while driving.

3) GEAR SELECTOR SWITCH (1) This lever is used for gear selection, forward 4 stages and reverse 3 stages.

(2) If you turn the gear selector lever forward, the machine increases the speed, but if you turn the gear selector lever backward, the machine reduces the speed.

HB1004OP03

3-15

4) FNR LEVER ※ The engine will only start if the lever is at neutral.

(1) This lever controls the travel direction of the machine.

(2) To travel forward, lift the lever and push to forward position.

Forward Neutral Reverse HB1004OP06

(3) To travel reverse, lift the lever and pull to backward position. ※ Be sure to stop the machine when changing the direction forward or backward while traveling.

5) ACCELERATOR PEDAL (1) This pedal controls the engine speed. The engine speed will increase in proportion to the degree of force applied to this pedal.

(2) Unless this pedal is pressed, the machine will run at low idling.

Accelerator pedal

Do not use the hand throttle lever to set the engine speed while driving.

HB1004OP04

6) HAND THROTTLE LEVER (1) This lever is used to increase or decrease the engine speed.

Do not use the hand throttle lever to set the engine speed while driving.

Hand throttle lever

HB1004OP07

3-16

7) BRAKE PEDALS (1) Left brake pedal By pushing this pedal, the left brake is operated.

(2) Right brake pedal By pushing this pedal, the right brake is operated.

Brake pedal

Locking pin Lever Engaged

Always lock the pedals together when driving on the road in any gear or when you operate the machine 3rd or 4th gear. If not, you and others can be killed or injured. ※ The stop lights should come on when the brakes are applied.

Locking pin Lever

(3) Lock and unlock ·Lock Lock : Move the lever up and slide the locking pin to right into the lock engaged position. ·Unlock Unlock : Move the lever up and slide the locking pin to left into the lock disengaged position.

Disengaged HB1004OP05

8) PARKING BRAKE SWITCH (1) This switch is pressed, the parking brake will start to operate and the gauge panel warning lamp will comes ON. ※ When operating the gear selector switch, be sure to release the parking brake. If the machine is operated with the parking brake engaged, the brake will overheat and may cause the brake system to go out of order.

Parking switch

HB1004OP08

3-17

5. OPERATING LEVERS 1) LOADER CONTROLS ※ Confirm the operation of control lever and working device.

(1) Control lever operates the boom and the bucket.

(2) When you release the control lever, control lever returns to neutral position automatically.

(3) When the control lever operates to the position of boom float, boom raise and bucket roll back ; these function is completed, then the control lever returns to the neutral position.

Control lever 1 Control lever 2

Low speed control switch Return to dig switch

HB1004OP64

(4) Control lever 1 5

Boom lower (1) Push the control lever forward in order to lower the boom.

4

1

2

3

Boom raise (2) Pull the control lever backward in order to raise the boom.

Control lever 1 5

3 2

Bucket roll back (3) Move the control lever toward the left in order to tilt the bucket backward.

1

Bucket dump (4) Move the control lever toward the right in order to dump a load from the bucket.

4

Boom float (5) Push the control lever forward into the detent.

The boom will lower to the ground.

The boom will float along the contour of the ground.

3 2 4

1 HB1004OP65

3-18

(5) Control lever 2 This lever operates the clam shovel.

1 1

Open clam (1) Push the control lever forward in order to open the clam.

2

Close clam (2) Pull the control lever back in order to close the clam.

2 Control lever 2

1 2

HB1004OP81

(6) Return to dig It allows the shovel to return quickly to dig position from the dump position.

Return to dig switch

① Return to dig switch : ON - Pull the control lever 1 further from the bucket roll-back position, then release the lever.

- Here, the lever returns to neutral and the bucket returns to dig position. ② Return to dig switch : OFF - When the return to dig function is not necessary, then press the switch to OFF position.

ON

Control lever 1

HB1004OP82

3-19

2) BACKHOE CONTROLS ※ Confirm the operation of control lever and working device.

(1) Left control lever controls dipper and boom swing.

(2) Right control lever controls boom and bucket.

(3) When you release the control lever, control lever returns to neutral position automatically.

(4) ISO type (+) pattern : standard When the control pattern change switch is selected position ①. (if equipped). Refer to the page 3-11.

Dipper & boom swing lever

Boom & bucket lever Stabilizer lever

HB1004OP73

① Dipper & boom swing lever 1 Dipper roll-out 2 Dipper roll-in 3 Boom swing right 4 Boom swing left

1 3 4 2

3 4 1 2

HB1004OP69

3-20

② Boom & bucket lever 5 Boom lower 6 Boom raise 7 Bucket roll-out 8 Bucket roll-in

5 8 7 6

6

5

7 8

HB1004OP70

(5) Hyundai A type (+) pattern : optional When the control pattern change switch is selected position ②. (if equipped). Refer to the page 3-11.

Boom & boom swing lever

Dipper & bucket lever Stabilizer lever

HB1004OP74

3-21

① Boom & boom swing lever 1 Boom lower 2 Boom raise 3 Boom swing right 4 Boom swing left

1 3 4 2

3 4 2

1

HB1004OP67

② Dipper & bucket lever 5 Dipper out 6 Dipper in 7 Bucket roll-out 8 Bucket roll-in

5 8 7 6

5 6

7 8

HB1004OP68

3-22

3) STABILIZER When digging, lower the stabilizer to the ground.

The stabilizer must be controlled from the driver's seat.

When the stabilizer is lowered, the rear tires must be off from the ground.

2 4

1 3

1

3

(1) Down (2, 4) (1 Pull the levers towards the rear of the operator in order to lower the stabilizer.

(2) Up (1, 3) Push the levers towards the front of the operator in order to raise the stabilizer.

2 (LH)

4 (RH) HB1004OP18

Raise the stabilizer completely prior to driving.

OK

NOT OK

Stabilizer HB1004OP83

3-23

6. SAFETY EQUIPMENT 1) BOOM LOCK Lock the boom and swing prior to driving the machine on the road.

If the lock does not engage securely, then the boom stop (1) must be adjusted. (Consult with Hyundai dealer.)

The control lever must be operated from the driver's seat. ※ It is recommended to engage the swing lock prior to the boom lock.

3

2 1

HB1004OP112

(1) Engaging ① Align the backhoe in a straight line with the machine and lower it to the ground. ② Lift the boom lock (2) completely and if necessary, lift the lock using the control lever (3). ③ Close the boom ram. (raise the boom.) ④ Lower the control lever (3) to lower the boom lock (2) and check if the lock is securely engaged in the boom rug. ⑤ Lower the boom slightly for secure lock.

(2) Disengaging ① Raise the boom slightly to release the lock. ② Lift the control lever (3) to raise the boom lock.

3-24

2) SLEW LOCK Lock the boom and swing prior to operating the machine on the road.

The control lever must be operated from the driver's seat.

Be careful when two people are working. Incorrect or sudden operation of the lever could cause casualties. ※ It is recommended to engage the swing lock prior to the boom lock.

(1) Engaging ① Swing the backhoe to required position. ② Align the hole (4) in the king post with the hole(5) in the main frame. ③ Stop the engine. ④ Insert the swing lock pin (6) into the aligned holes.

Do not insert the swing lock pin (6) while sitting in the driver's seat.

6

4

Stowage position

5

HB1004OP113

(2) Disengaging ① Stop the engine. ② Take out the swing lock pin (6) and restore to its original position.

3) Warning beacon Beacon switch

Beacon lamp

(1) Turn ON the warning beacon switch to turn ON the warning beacon. ※ Turn ON the warning beacon when driving on public roads.

HB1004OP85

3-25

7. OPENING AND CLOSING WINDOWS 1) THE SIDE WINDOW (1) Open ① Unlock latch (1). ② Push lever (2) towards the front of the machine then lift the lever, while pushing window outwards, until it latches down.

(2) Close ① First lift the lever then pull the window inwards. ② Lower the lever (2) and (1) to latch it.

1 E

C2 HB1003CD02

2) REAR WINDOW ※ Be careful when opening and closing windows since they may come in contact with the bucket tooth.

Be careful when opening and closing windows since they are heavy.

(1) Open ① Hold on the grip of the lever on both sides, then press the button. ② Push the window forward and up. ③ Verify full opening of the window, then release the lever. ④ Check for window lock in its locking position.

(2) Close ① Close the window in reverse order of open. ※ Close the rear window prior to driving the machine.

3-26

Button

Handle HB1003CD71

8. SEAT CONTROLS 1) SEAT This seat is adjustable to fit the comforts of the operator's body. It will reduce operator fatigue due to long work hours and enhance work efficiency.

A

(1) Adjustable headrest (A) Apply force upward or downward force to adjust height.

(2) Flip-up armrest (B) The arm will "flip-up" out of the way for easy egress and entry.

B

C D

I J

E G F H

HB1003CD05

(3) Armrest angle adjust (C) The angle of the armrest can be adjusted by rotating the knob.

(4) Armrest adjustment (D) The location of the armrest can be modified by loosening the bolts and relocating the armrest.

(5) Seat belt (E) Retractable seat belt.

(6) Backrest angle control (F) The recliner is spring loaded and will move forward when released it can easily be relined with a slight amount of force (back tilt adjust 21° forward and 33° rearward from the standard position).

(7) Tether straps (G) The tether straps are to be mounted to the cab floor.

(8) Weight adjust (H) The handle can be turned to adjust the suspension for different weight operators.

(9) Swivel control (I) Lifting up the handle will allow the seat to rotate 180 degrees.

(10) Slide control (J) Lifting the handle will allow the seat to slide forward and backward the can be done at the same time as the seat is being rotated. (forward-backward total adjustment 152 mm).

3-27

2) SEAT BELT Check the condition of the seat belt and mounting hardware before operating the machine.

Replace the seat belt at least once every three years regardless of appearance.

Always use seat belts when operating your machine.

(1) BUCKLING UP ① Buckling up. Be sure that you put on the seat belt. Connect and adjust the seat belt strap to a snug, comfortable position.

Always wear your seat belt when operating a lift truck.

Failure to wear seat belt will result in injury or death in an event of an accident.

160D7OM11

3-28

9. AIR CONDITIONING AND HEATER SYSTEM Air conditioner and heater are equipped for pleasant operation against outside temperature.

Switch panel

Fan switch

Temperature contol switch

A/C ON/OFF switch

Re-circulation switch HB1003CD51

1) FAN SWITCH

HB1003CD52

(1) It is possible to control the fan to four steps. : Low · : Medium-Low · : Medium-High · : High ·

2) RE-CIRCULATION SWITCH (1) Rotate this switch to position A to allow fresh air to enter the cab.

(2) Position B gives re-circulated air and should be used when operating in a dusty working environment.

A

B HB1003CD53

※ Position B can also be used increase the heater performance during cab warm up, and whilst operating the machine on light duties.

3-29

3) TEMPERATURE CONTROL SWITCH (1) Rotate this switch clockwise to decrease the temperature.

(2) Rotate anti-clockwise to increase the temperature.

Red

Blue HB1003CD54

4) AIR CONDITIONING ON/OFF SWITCH (1) To operate the air conditioning, press this switch to the ON position (the switch will be illuminated).

HB1003CD55

Rotate the temperature control switch clockwise to decrease the temperature from ambient to cold. To obtain best results from the air conditioning system ensure that all doors and windows are closed.

Air conditioning performance is improved when the re-circulation switch is in position B. ※ Operate the air conditioning for at least 10 minutes per month.

3-30

10. RADIO AND USB / MP3 PLAYER 14

3 4

1 13

LCD display

2

5

6

7

8

9

10

11 12 75793CD62

■FRONT FRONT PANEL PRESENTATION 1

SEL

2 3

MODE

4

-------- Sound function selection button (audio selection)

10 6 -------- Preset memory button 6 D+ --------------- Directory up

-------- Power and volume button

11

-------- Mode button (select RADIO / USB / AUX) ------- UP / DOWN tuning button

12

BSM

-------- Preset scan (PS) Best station memory (BSM)

13

MUTE

-------- Audio mute button

14

AM/FM

-------- AM / FM button (radio)

1

5

------- Preset memory button 1 DISP ---------- ID3 v2 display

6

------- Preset memory button 2 SCN ------------ File scan

7

3

------- Preset memory button 3 RPT ------------ Repeat play selector

8

------- Preset memory button 4 RDM ------------ Random play selector

9

5

-------- Aux function

2

4

------- Preset memory button 5 D- ---------------- Directory down

3-31

1) GENERAL (1) Power and volume button ① Power ON/OFF button Press power button to turn the unit ON or OFF shortly.

When the power is ON, the previous mode (last memory) will appear. olume up / down control ② Volume 75793CD66 Turn volume up / down button right to increase the volume level. The level will be shown in VOLUME xx on the LCD display. Turn it left to decrease the volume level. After 5 seconds of volume indication, display will return to the previous mode.

(2) Sound function selection button (audio selection) ① This button is to adjust the sound. Each time you press power button shortly, LCD displays each mode as follows : SEL

BASS

TREBLE

BAL

BEEP

LOUD

VOLUME

75793CD65

※ When this button is pressed, LCD display shows selected function for 5 seconds and then returns back to the previous mode. On selected function, level can be controlled by turning this button. The display will automatically return to normal indication in 5 seconds after the last adjustment is made or when another function is activated. ② Bass ass control To adjust the bass level, first select the bass mode by pressing the select button until BASS indication appears on the LCD display.

Within 5 seconds of choosing the bass mode, turn power button right / left to adjust the bass level as desired.

The bass level will be shown on the LCD display from a minimum of BASS –10 to a maximum of BASS +10.

The display will automatically return to the normal indication in 5 seconds after the last adjustment or when another function is activated.

SEL

③ Treble reble control To adjust the treble level, first select the treble mode by pressing the select button until TREBLE indication appears on the LCD display. Within 5 seconds of choosing the treble mode, turn power button right / left to adjust the treble level as desired.

The treble level will be shown on the LCD display from a minimum of TREBLE -10 to a maximum of TREBLE +10.

The display will automatically return to the normal indication in 5 seconds after the last adjustment or when another function is activated.

SEL

3-32

④ Balance alance control To adjust the left-right speaker balance, first select the balance mode by pressing the select button until the BAL indication appears on the LCD display.

Within 5 seconds of choosing the balance mode, turn power button right / left to adjust the balance as desired.

The balance position will be shown on the LCD display from BAL 10L (full left) to BAL 10R (full right).

When the volume level between the left and right speakers is equal, BAL L=R will be shown on the LCD display panel.

The display will automatically return to the normal indication in 5 seconds after the last adjustment or when another function is activated.

SEL

⑤ Beep eep control To adjust the beep mode, first select the beep mode by pressing the select button until BEEP indication appears on the LCD display.

The beep mode will be shown on the LCD display from BEEP 2ND, BEEP OFF and BEEP ON by turning power button right / left.

The display will automatically return to the normal indication in 5 seconds after the last adjustment or when another function is activated.

Select BEEP ON when you wish to hear the BEEP sound whenever any function button is pressed.

Select BEEP 2ND when you wish to hear the BEEP sound whenever any tuner pre-set button and/or tune seek buttons are pressed for more than 3 seconds.

SEL

⑥ Loud oud control When listening to music at low volume levels, this feature will boost the bass and treble response.

This action will compensate for the reduction in bass and treble performance experienced at low volume.

To select the loudness feature, press select button until LOUD ON or LOUD OFF is displayed, then turn power button left or right to activate or deactivate loudness.

SEL

(3) Mode button ① Press mode button to select RADIO / USB / AUX. MODE

75793CD67

(4) Audio mute button

MUTE

① Press mute button momentarily to mute volume and MUTE mark will blink on the LCD display.

Press the button again to return to the mode in use before the mute mode was activated.

75793CD77

3-33

2) RADIO (1) AM / FM / LW band selector ① Each time this button is pressed, the radio button is changed.

Each time this button is pressed, LCD displays each band as AM/FM follows : FM1

FM2

FM3

AM

LW

75793CD78

※ LW band is only available for Europe.

(2) Up / down tuning

75793CD68

① To automatically select a radio station, momentarily press the up or down tune seek button for less than 3 tune seek button seconds to search for the closest radio station.

To manually select a radio station, press the up tuning & down tuning button for longer than 3 seconds.

The radio frequency will move up or down step by step each time you press button.

(3) Station pre-set button 1

2

3

4

5

6 75793CD69~74

① Pressing these buttons shortly will recall your favorite pre-set radio stations.

To store your favorite stations into any of the 6 pre-set memories in each band (AM/FM/LW), use the following procedure : a. Turn the radio ON and select the desired band. b. Select the first station to be pre-set using the manual up/ down or automatic seek tuning control button. c. Press the chosen pre-set button to store your selected station into and continue to hold it in. The beep sound will be momentarily heard and the pre-set number will appear on the LCD display indicating that the station is now set into that pre-set memory position and can be recalled at any time, by pressing that pre-set button.

3-34

(4) Pre-set scan (PS) / Best station memory (BSM) button ① Pre-set scan (PS) Press BSM button shortly to scan the 6 pre-set station stored the BSM memories on each band (AM/FM/LW).

The unit will stop at each pre-set station (the pre-set number on the LCD display will flash during pre-set scan operation) and remain on 75793CD76 the selected frequency. Press the button momentarily again to remain on the station currently being heard. ② Best station memory (BSM) Pressing BSM button for longer than 2 seconds will activate the BSM tuning feature which will automatically scan and enter each station into memory.

If you have already set the pre-set memories to your favorite stations, activating the BSM tuning feature will erase those stations and enter the new ones.

This BSM feature is most useful when traveling in a new area where you are not familiar with the local stations.

3) USB PLAYER (1) USB function

75793CD81

① Connect a USB device through USB/AUX cable if you want to listen to MP3 file in a USB device. ② If a USB device is not connected before, MP3 files in USB device will be playing by automatically changing to USB mode when a USB device is inserted. ③ If a USB device is already inserted, MP3 files in a USB device will be playing after changing USB mode by pressing MODE button.

3-35

(2) File selection & cue / review button ① File ile selection function This button is used to select file up / down. Each time the forward file select is pressed, file number is increased.

Each time the backward file select is pressed, file number is decreased.

75793CD68 ② Cue ue / review functions High-speed audible search of file on a USB can be made by this button (the cue and review functions).

Press and hold the cue button to advance rapidly in the forward direction or the review button to advance rapidly in the backward direction.

(3) MP3 directory / file searching ① The power button is used to select a particular directory and file.

Press and hold for more than 3 seconds while playing MP3 file.

Turn right / left the power button to search the directory. Press the button when you find the wanted directory.

For example, the directory search generally changes in two methods depending on the order of writing as follows. ·Method 1 : ROOT

Dir01

Dir02

Dir03

Dir04

Dir05

Dir06

Dir07

·Method 2 : ROOT

Dir01

Dir02

Dir05

Dir03

Dir06

Dir04

Dir07

If you want to search the file in the located directory, turn right / left the power button consecutively. Press the button when you find the wanted file. The unit will then play the selected file.

For instance, the file search changes in Dir01 as follows.

File01

File02

File03

File04

※ MP3 direction / file configuration ROOT Directory01 File01 File02 File03 File04 Dir02

Dir03

File05 File06 Dir05 File07 File08 Dir06

3-36

Dir04 File09 File10 Dir07

(4) ID3 v2 display

1 DISP 75793CD82

① Disp button is used to change the display information.

While playing an MP3 file, you can change the file information shown on the LCD display.

Each time you press DISP (display), the display changes to show the following. ※ If the MP3 disc does not have any ID3 information, the display will show NO ID3 on LCD display.

Directory name / file name (normal mode) Album name / performer / title File number / elapsed time

(5) File scan (SCN)

2 SCN 75793CD83

① During USB play, press SCN button to play the first 10 seconds of each file on the whole file on the USB (SCN mark will appear on the LCD display).

When a desired file is reached, press the SCN button again to cancel the function.

The unit will then play the selected file. ※ In case of playing MP3 file, when the SCN (scan) button is pressed and held for longer than 2 seconds, the SCN mark will blink on the LCD display and all files in the selected directory will be introduced until the file scan mode is cancelled by pressing the SCN button again or by activating the random or repeat functions.

(6) Repeat play selector (RPT) ① During USB play, press RPT button to play the selected file repeatedly (RPT will appear on the LCD display).

RPT Play of the file will continue to repeat until this button is pressed 3 again and the RPT disappears from the LCD display. ※ In case of playing MP3 file, when the RPT button is pressed and 75793CD84 held longer than 2 seconds, the RPT mark will blink on the LCD display and play all files in the selected directory and will be repeated until the directory repeat mode is cancelled by pressing the repeat button again or by activating the scan or random functions (RPT mark will disappear from LCD display).

3-37

(7) Random play selector (RDM) ① During USB play, press RDM button to play the files on the USB in a random shuffled order (RDM will appear on the LCD display). The file select function will also select file in the random order instead of 4 RDM the normal process.

The random play mode can be cancelled by this button again.

75793CD85 ※ In case of MP3 file, when the random button is pressed and held longer than 2 seconds, the RDM mark will blink on the LCD display and play all files in directory randomly until the directory random mode is cancelled by pressing the random button again or by activating the scan or repeat functions (RDM mark will disappear from LCD display).

(8) Directory down ① Press D- button briefly while playing MP3. The previous directory is located each time you press this button.

5

D75793CD86

(9) Directory up

6 D+ 75793CD87

① Press D+ button briefly while playing MP3 . The next directory is located each time you press this button. ※ If the MP3 file does not have a directory, the unit play MP3 at 10-file intervals. ※ If any MP3 file does not exist in USB, this button can not operate.

4) AUX PLAYER (1) Aux function

75793CD75

① If you want to listen to music of a external audio device, connect a external audio device through USB/AUX cable. ② Change AUX mode by pressing MODE button.

If audio file of audio device is playing, you can listen to music through car audio speaker.

3-38

4. OPERATION 1. SUGGESTION FOR NEW MACHINE 1) It takes about 100 operation hours to enhance its designed performance.

2) Operate according to below three steps and avoid excessive operation for the initial 100 hours.

Service meter

Load

Until 10 hours

About 60%

Until 100 hours

About 80%

After 100 hours

100%

Avoid excessive operation for initial 100 hours

※ Excessive operation may deteriorate the potential performance of machine and shorten lifetime of the machine.

3) Be careful during the initial 100 hours operation.

(1) Check daily for the level and leakage of coolant, engine oil, hydraulic oil and fuel.

(2) Check regularly the lubrication and fill. Grease daily all lubrication points.

(3) Tighten bolts.

(4) Warm up the machine fully before operation.

(5) Check the gauges during operation.

(6) Check if the machine is operating normally during operation.

4) Replace followings after initial operation hours.

Checking items Engine oil Engine oil filter element

Hours Replace

4-1

HB1004OP71

2. CHECK BEFORE STARTING THE ENGINE 1) Make sure that the park brake is engaged.

2) Look around the machine and under the machine to check for loose nut or bolts, collection of dirt, or leakage of oil, fuel or coolant and check the condition of the work equipment and hydraulic system.

Check also loose wiring, and collection of dust at places which reach high temperature.

Check before starting

※ Refer to the daily check on the chapter 6, Maintenance.

3) Adjust seat to fit the contours of the operator's body for the pleasant operation.

4) Make sure that the machine is equipped with a lighting system that is adequate for the job conditions. Ensure that all lights are in proper working condition.

5) Adjust the rear view mirror.

6) Make sure that there are no personnel in the area before you start the engine. Make sure that there are no personnel in area before you move the machine. Make sure that there are no personnel on the machine, underneath the machine, or around the machine.

If a warning tag is attached to the start switch or to the controls, do not start the engine. Also, do not move any controls.

4-2

HB1004OP72

3. STARTING THE ENGINE 1) Check if the parking brake is locked (with the parking switch ON).

2) Check if the FNR lever is in the neutral position.

FNR lever Parking brake switch Hand throttle lever

3) Check if the hydraulic safety switch (backhoe) is in the lock position.

4) Set the hand throttle lever to minimum and the low speed control switch is ON position.

5) NORMAL ENGINE START ※ Sound the horn to warn the surroundings after checking if personnel or obstacles are in the area.

(1) Turn the starting switch to START position to start the engine. ※ If the engine does not start, allow the starter to cool for about 2 minutes before attempting to start the engine again.

(2) Release the starting switch instantly after the engine starts to avoid possible damage to the starting motor.

4-3

Low speed control switch Safety switch (backhoe) HB1004OP36

8) COLD WEATHER ENGINE START ※ Sound horn to warn surroundings after checking if there are obstacles in the area. ※ Replace the engine oil and fuel referring to recommended oils at page 6-8.

OFF

(1) Fill the anti-freeze solution to the coolant as required.

(2) Turn the starting switch to ON position, and wait the air heater working lamp OFF. ※ When the air heater working lamp is turned ON, the preheating function is actuated within 10~20 seconds in accordance with coolant temperature.

START ON

OFF

(3) Start the engine by turning the starting switch to START position after the glow warning lamp OFF.

77074OP05

(4) Release starting switch immediately after starting engine. The starting switch will automatically return to the ON position. ※ After engine started, the preheating function is actuated to reduce the white smoke.

9) INSPECTION AFTER ENGINE START Inspect and confirm the following after engine starts.

(1) Is the level gauge of hydraulic oil tank in the normal level?

(2) Are there leakages of oil or water?

(3) Are all the warning lamps turned OFF? (4) Are the engine sound and the color of exhaust gas normal?

(5) Are the sound and vibration normal?

Air cleaner Engine oil pressure

Warning lamp

※ Do not increase engine speed quickly after starting, it can damage engine and/or turbocharger. ※ If there are problems in the cluster, stop the engine immediately and correct problems as required.

4-4

Charge Air heater Transmission oil temperature

HB1004OP75

10) WARMING-UP OPERATION ※ The most suitable temperature for the hydraulic oil is about 50˚C (122˚F ).

It can cause serious trouble in the hydraulic system by sudden operation when the hydraulic oil temperature is below 25˚C (77˚F ).

Then temperature must be raised to at least 25˚C (77˚F ) before starting work.

(1) Run the engine at low idle speed for 5 minutes.

(2) Speed up the engine by accel dial and run the engine at mid-range speed.

(3) Operate bucket lever for 5 minutes. ※ Do not operate anything except bucket lever.

(4) Run the engine at the high speed and operate the bucket lever and arm lever for 5-10 minutes. ※ Operate only the bucket lever and arm lever.

(5) This warming-up operation will be completed by operation of all cylinders several times, and operation of swing and traveling. ※ Increase the time for warming-up during winter.

4-5

50 C

HB1004OP76

4. STOPPING AND PARKING THE MACHINE ※ If the engine is abruptly stopped before it has cooled down, engine life may be greatly shortened. Consequently, do not abruptly stop the engine apart from an emergency. ※ In particular, if the engine has overheated, do not abruptly stop it but run it at medium speed to allow it to cool gradually, then stop it.

1) Stop the machine on the flat and safe place.

2) Check if the parking brake is locked (with the parking switch ON).

3) Check if the FNR lever is in the neutral position.

4) Check if the hydraulic safety switch (backhoe) is in the lock position.

5) Down the stabilizer legs on the ground.

HB1004OP45

6) Lower the loader arms and backhoe to the ground completely.

7) Run the engine at low idle rpm for 5 minutes before shut down.

FNR lever Parking brake switch Hand throttle lever

8) Return the key of starting switch to the OFF position and remove the key.

9) Lock the cab door.

Low speed control switch Safety switch (backhoe) HB1004OP36

4-6

5. TRAVELING OF THE MACHINE 1) BASIC OPERATION (1) Traveling position ① It is the position which the backhoe is in the rear and the loader is forward. ② Lift the boom so that the bucket is placed 40-50cm above the ground. ③ Set the attachments to the their travelling positions.

40~50cm

HB1004OP86

(2) Preparation ① Engage the boom lock and slew lock devices. ※ Please refer to the page 3-24, 25. ② Do not jump on or off the machine. ③ Wear the seat belt. ④ Keep riders off the machine. ※ Riders on a machine are subject to injury such as being struck objects and being thrown off the machine.

Only allow the operator on the machine. Keep riders off. ⑤ Press the low speed control switch when traveling on the roads.

(3) Traveling operation Sound the horn to warn nearby personnel before operating the machine.

Be sure that the brake works normally on the safe place before fast traveling. ※ When warm-up operation is completed after the engine is started, move the machine according to the following procedure. ① Select the wheel drive mode.

- Use 2 wheel drive mode when driving long distance or high speed.

- Use 4 wheels drive mode when operating in heavy duty site conditions, for instance, deep mud, undulating surfaces, slurry etc. ② Release the parking brake. ③ Lift up the stabilizer. ④ Select traveling speed by the gear speed switch. ⑤ Select traveling direction by the FNR lever. ⑥ Press gently the accelerator pedal to move the machine.

4-7

4 wheel drive select switch

Steering wheel Gear selector switch FNR lever

Brake pedal

Parking switch Accelerator pedal

Stabilizer lever

HB1004OP114

(4) Changing speed If you want to change the speed, select the gear select desired position.

High speed

Low speed HB1004OP87

(5) Changing direction (forward/reverse) ① Be sure to stop the machine when changing the direction forward or backward while traveling. ② Put the FNR lever in the desired position to change direction. ※ When changing direction, check beforehand there is no obstacle in the direction you will be headed. ※ It could be cause of machine failure to change the direction forward or backward while traveling.

(6) Turning the machine ① Turn the machine by moving the steering wheel into the desired direction. ② You can turn the machine to the left or right. ※ Do not turn the machine abruptly when traveling at high speed and avoid turn on a slope.

Steering does not function with engine OFF.

Forward Neutral Reverse

HB1004OP89

Left

Lever

Right

Steering wheel HB1004OP90

4-8

(7) Precautions when driving The operators must be familiar with the following precautions including general safety hints. ① If the warning lamp lights up on the cluster, stop the machine immediately and check carefully whether the relevant parts are out of order or not. ② Do not allow the engine to run at overload. ③ Stop the engine and check as soon as finding out abnormal noise or smell. ④ Do not allow passengers or riders on the machine while it is running or in operation. ⑤ Never get on or off the machine while it is moving.

Direction indicator(Left) Main beam indicator Direction indicator(Right)

Indicator lamp

Differential lock indicator Parking indicator Master warning indicator

FRONT CONSOLE

Engine oil pressure Air cleaner

Warning lamp

Transmission oil temperature Air heater Charge

SIDE CONSOLE HB1004OP115

2) TRAVELING ON A SLOPE Never travel down a slope in neutral.

(1) Lower the loader 20 to 30 cm (1 ft) to the ground so that it can be used as a brake in an emergency.

20~

30c

m

(2) If the machine starts to slide or loses stability, lower the loader immediately and brake the machine.

(3) When parking on a slope, use the loader as a brake and place blocks behind the tires to prevent sliding. ※ Machine can not travel effectively on a slope when the oil temperature is low. Do the warming-up operation when it is going to travel on a slope. ※ Be careful when working on slopes. It may cause the machine to lose its balance and turn over.

0cm

3 20~

HB1004OP92

4-9

3) PARKING THE MACHINE To park the machine, keep the steps below.

(1) Release the accelerator pedal slowly.

(2) Depress the brake pedal.

(3) Place the FNR lever in the neutral.

(4) Set the parking switch to lock position and release the brake pedal.

(5) Lower the loader, backhoe and stabilizer to the ground.

(6) Stop the engine, place the start key switch in the OFF and remove the key.

Forward Neutral Reverse

(7) Set the safety switch (backhoe and stabilizer) to lock position.

(8) Lock the cab door. ※ Whenever parking on a slope, always block the tires after lowering the loader, backhoe and stabilizer to the ground.

START Parking switch Safety switch

ON HB1004OP93

4) PRECAUTIONS FOR OPERATION (1) Permissible water depth ① Do not immerse the machine in water by more than the permissible depth (axle center). ② For parts that have been immersed in water for a long time, pump in grease until the old grease comes out from the bearings.

Front axle center HB1004OP94

(2) When the brake does not operate ① If the machine does not stop even though the brake pedal is applied, put the parking position to activate the emergency brake by the parking brake switch. ※ After using the parking brake as an emergency brake, ask Hyundai dealer to check complete brake system.

Never use emergency brake, except when the service brake fails.

(3) When driving on a slope When turn on a slope, lower the work equipment to lower its center of gravity. Avoid turn on a slope if possible.

4-10

Brake pedal

Parking switch

HB1004OP95

6. EFFICIENT WORKING METHOD 1) THINK-SAFETY FIRST In special situation, wear protective clothing including a safety helmet, safety shoes, gloves, safety glasses and ear protection as required by the job condition. Almost every accident are caused by disregarding the simple and fundamental safety hints.

Be sure to understand thoroughly the operator’s manual before operating the machine.

Fully understand the details and process of the construction before starting the work.

If you find anything dangerous on the job, consult with the job supervisor for preventive measures before operating the machine.

Do not operate when tired, or after drinking. Alcoholic beverages, or any type of drugs.

Check daily according to the operator’s manual. Repair the damaged parts and tighten the loosened bolts.

Check for leakage of engine oil, hydraulic oil, fuel and coolant.

Do not operate the machine if it requires repairs. Operate after complete repair.

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 or your distributor. Use of unauthorized attachments could create a safety problem and adversely affect the proper operation and useful life of the machine.

Only trained and authorized personnel can operate and maintain the machine.

Follow all safety rules, precautions and instructions when operating the machine.

When working with another operator or a person on worksite traffic duty, be sure all personnel understand all hand signals that are to be used.

Always use seat belts when operating your machine.

4-11

2) LOADER OPERATION (1) General ① Use the handle and footstep when getting on or off the machine.

Do not jump on or off the machine. ② Sound the horn to warn nearby personnel before operating the machine. ③ Operate carefully to make sure all personnel or obstacles are clear within the working range of the machine.

Place safety guards if necessary. ④ Check the locations of underground gas pipes or water line and secure the safety before operation. ⑤ When the bucket is loaded, avoid sudden swinging or starting. Overloading is dangerous.

Make sure the load does not exceed the permissible level. ⑥ The operation on a slope is dangerous.

Avoid operating the machine on a slope of over 10 degree.

Operate the machine after making ground flat when operation is required on a slope. ⑦ Steering of the machine while traveling on a slope is dangerous.

When an inevitable turning of direction is required, turn on the flat and solid ground. ⑧ Avoid operating on a cliff, or soft ground as there is danger of rolling over.

Take necessary precautions when working after rain, or blasting because the ground may not be firm enough. ⑨ The ride control switch (if fitted) will smooth the ride of the machine during traveling uneven grounds.

4-12

40~50cm

HB1005TA01

(2) Shovel work ※ As the machine loads on the bucket with traveling, tires may start to slip because of heavy load.

Then lift the bucket slightly to reduce load.

Clutch cut-off switch Low speed control switch

※ The low speed control switch is used to give more traction force and slow down the loader operation. Use only this switch intermittently such as entering the stockpile. ※ The clutch cut off switch is used to give more power to the loader and speed operation.

HB1004OP77

① Keep the bucket shovel parallel to the ground. ※ If the bucket is pushed in a non-horizontal position, power may be reduced, and the bucket cannot dig deeply into the heap of soil.

73034OP04

② When the bucket is sufficiently deep into the pile, advance the machine with the control lever pulled down. And by placing the control lever in the bucket roll-back position, fill the bucket with soil.

73034OP05

③ When it is difficult to dig into the soil, move the bucket control lever forward and backward to move the bucket teeth up and down. ④ If the machine operates with its front tires liftlifted, its driving force will deteriorate and excessive force will be applied to the rear tires. Avoid operating in that posture.

73034OP06

4-13

(3) Job layout Set up the work cycle as short as possible. Truck positioning is very important for fast cycles.

Spend a few minutes leveling off the work area, if necessary. Smooth runways for the machine and a level parking area for trucks will speed up the job.

Operating a loader with a full bucket on a hillside can cause the machine to roll over. If possible, avoid turning the machine and always move forward up the hill and back down. Always keep the load low. If you do not follow these instructions, you can be injured or killed.

When you operate the machine, keep the loader bucket as low as possible. This low position gives better balance and permits you to see more clearly. If the bucket is full and you move the machine over ground that is rough or surfaces that can cause the machine to slide, always operate at slow speed. If you do not use this procedure, the machine can go out of control and roll-over.

4-14

HB1004OP49

3) BACKHOE WORK (1) 1) General ① Use the handle and footstep when getting on or off the machine.

Do not jump on or off the machine. ② Position the machine for the digging work. ③ Set the FNR lever to the neutral position. ④ Set the parking brake switch to the lock position.

HB1004OP96

⑤ Lower the loader bucket and stabilizer on the ground. ⑥ Sound the horn to warn nearby personnel before operating the machine. ⑦ Operate carefully to make sure all personnel or obstacles are clear within the working range of the machine. Place safety guards if necessary. ※ Check the locations of underground gas pipes or water line and secure the safety before operation. ※ Avoid operating on a cliff, or soft ground as there is danger of rolling over. Take necessary precautions when working after rain, or blasting because the ground may not be firm enough.

4-15

(2) Tipping lever adjusting The bucket tipping lever can be set A or B positions.

A : Maximum tear out force B : Maximum rotation When knocking the pin in with a hammer, metal particles may fly and cause serious injury, particularly if they get into your eyes.

When carrying out this operation, always wear goggles, helmet, gloves, and other protective equipment.

When performing joint work, make sure signals to each other and work carefully for safety’s sake.

A B

① Lower the bucket on the ground as the picture shown in the right. ② Set the safety switch to the LOCK position. ③ Loosen the bolt and nut, then remove the tipping pin.

Tipping lever

Nut

※ When removing the pins, place the bucket so that it is in light contact with the ground. ※ If the bucket is lowered strongly to the ground, the resistance will be increased and it will be difficult to remove the pins.

Tipping pin

Bolt

※ After remove the pins, make sure that they do not become contaminated with sand or mud. ④ Reposition the tipping lever and align the pin hole. ⑤ Insert the pivot pin and secure with the bolt and nut.

4-16

HB1004OP97

(3) Backhoe side shifting ※ Prior to backhoe side shifting, clean around the swing post carriage rail. ① Lower the bucket on the ground as the picture shown in the right. ② Lower the stabilizer on the ground to make the machine stable and horizontal. ③ To release 4 side shift lock cylinders, press the side shift lock switch to the ON position.

Side shift lock switch

④ For the swing post carriage movement, operate the boom up/downward momentarily. ⑤ Swing the backhoe to the opposite side of its movement required. ⑥ Move the swing post carriage to desired position and turn OFF the side shift lock switch to secure the 4 side shift lock cylinders.

Swing post carrige

Side shift lock cylinder HB1004OP98

4-17

(4) Using the extending dipper Use the extending dipper to extend digging and dumping works.

Disengage the lock pin to use the extending dipper.

Self locking pin Lock pin

Dipper

① Follow the steps below to disengage the lockpin: a. Remove the self-locking pin. b. Remove the lock pin to the release position. c. Reinsert the self-locking pin to the release position.

Lock

Release

HB1004OP99

② Raise the bucket slightly from the ground. ③ Extend or retract the extending dipper as desired by using the extending dipper switch.

D

※ Be careful when the extending dipper is extended since stability and recovery capability is lowered.

C D

※ Do not extend or retract the extending dipper while operating.

(LH)

④ Engage the extending dipper function when it is not required. a. Remove the self-locking pin. b. Push in the lock pin to lock position. c. Reinsert the self-locking pin into the lock position.

4-18

C

HB1004OP100

(5) Excavating work ① Do the digging work by arm.

Use the pulling force of arm for digging and use together with the digging force of the bucket if necessary.

HB1004OP101

② When lowering and raising the boom operate softly for the beginning and the end.

In particularly, sudden stops while lowering the boom may cause damage to the machine.

Operate soft for the begining and the end

HB1004OP102

③ The digging resistance and wearing of tooth can be reduced by putting the end of bucket tooth to the digging direction.

HB1004OP103

④ Set the tracks parallel to the line of the ditch to be excavated when digging ditch. Do not swing while digging.

Parallel

HB1004OP105

4-19

⑤ Dig slowly with keeping the angle of boom and arm, 90-110 degree when maximum digging force is required.

90~110

HB1004OP106

⑥ Operate leaving a small safety margin of cylinder stroke to prevent damage of cylinder when working with the machine.

Margin

HB1004OP107

⑦ Keep the bucket to the dumping position and the arm horizontal when dumping the soil from the bucket.

Operate bucket lever 2 or 3 times when hard to dump.

Do not use the impact of bucket tooth when dumping.

HB1004OP108

4-20

(6) Never carry out excessive operations Operation exceeding machine performance may result in accident or failure.

Carry out lifting operation within specified load limit.

Never carry out operations which may damage the machine such as overload or over impact load.

Never travel while carrying a load.

HB1004OP110

4-21

(7) BUCKET WITH HOOK When carrying out lifting work, the special lifting hook is necessary.

The following operations are prohibited. ·Lifting loads with a wire rope fitted around the bucket teeth. ·Lifting loads with the wire rope wrapped directly around the boom or arm.

When performing lifting operation, securely hook the wire rope onto the special lifting hook.

When performing lifting operation, never raise or lower a person.

Due to the possible danger of the load falling or of collision with the load, no persons shall be allowed in the working area.

Before performing lifting operation, designate an operation supervisor.

Always execute operation according to this instructions. ·Execute operating methods and procedures under his direction. ·Select a person responsible for signaling.

Operate only on signals given by such person.

Never leave the operator's seat while lifting a load.

4-22

Hook

HB1004OP111

7. OPERATION IN THE SPECIAL WORK SITES 1) OPERATION THE MACHINE IN A COLD WEATHER (1) Use proper engine oil and fuel for the weather.

(2) Fill the required amount of antifreeze in the coolant.

(3) Refer to the starting engine in cold weather.

Start the engine and extend the warming up operation.

50 C

(4) Be sure to open the heater cock when using the heater.

(5) Always keep the battery completely charged. ※ Discharged batteries will freeze more easily than fully charged.

(6) Clean the machine and park on the wood plates.

2) OPERATION IN SANDY OR DUSTY WORK SITES (1) Inspect air cleaner element frequently. Clean or replace element more frequently, if warning lamp comes ON and buzzer sounds simultaneously, regardless of inspection period.

(2) Inspect radiator frequently, and keep cooling fins clean.

(3) Prevent sand or dust from getting into fuel tank and hydraulic tank during refilling.

(4) Prevent sand or dust from penetrating into hydraulic circuit by tightly closing breather cap of hydraulic oil tank. Replace hydraulic oil filter frequently.

(5) Keep all lubricated part, such as pins and bushings, clean at all times.

(6) If the air conditioner and heater filters clogged, the heating or cooling capacity will drop. Clean or replace the filter element more frequently.

4-23

HB1004OP76

3) SEA SHORE OPERATION (1) Prevent ingress of salt by securely tightening plugs, cocks and bolts of each part.

(2) Wash machine after operation to remove salt residue.

Pay special attention to electrical parts and hydraulic cylinders to prevent corrosion.

(3) Inspection and lubrication must be carried out more frequently.

Supply sufficient grease to replace all old grease in bearings which have been submerged in water for a long time.

4) OPERATION IN MUD, WATER OR RAIN WORK SITES (1) Perform a walk around inspection to check for any loose fittings, obvious damage to the machine or any fluid leakage.

(2) After completing operations, clean mud, rocks or debris from the machine. Inspect for damage, cracked welds or loosened parts.

(3) Perform all daily lubrication and service.

(4) If the operations were in salt water or other corrosive materials, make sure to flush the affected equipment with fresh water.

4-24

8. TOWING THE MACHINE Personal injury or death can result when you tow a disabled machine incorrectly.

Read the following recommendations. ※ Towing the backhoe loader is not recommended.

If your machine is disabled, you must make a judgement if the machine can be moved without damage. If possible, repair the machine at the job site.

The towing machine must have power, steering and braking ability to stop both machines. The speed at switch the disabled machine is moved, must not exceed 10 km per hour (6 mph).

The machines must be attached as closely as possible.

The disabled machine must be moved only far enough to reach a safe repair location or onto a trailer.

Before moving a disabled machine you must be able to answer these questions : - Does the towing machine have braking and steering capacity for both machines?

- Does the towing hardware, chains, cables, have the proper capacity to move the machine safely?

- Will the disabled machine have steering and braking capability?

- Will moving the machine cause damage to drivetrain or moving parts that lack lubrication?

Additional considerations : - Be certain that all personal involved are shielded in the event that towing apparatus might break.

- An operator may only be allowed on the towed vehicle if the has steering and braking capability.

- Always block the disabled machines wheels before releasing the brakes or drivetrain component. ※ The backhoe loader engine may not be started by towing the machine. The drivetrain components will be damaged.

1) ENGINE RUNNING (1) Engage the parking brake.

(2) Block the wheels with wheel chocks.

(3) Place the FNR lever in neutral.

(4) Place the 4 wheel drive select switch in off position.

(5) Raise all tools and attachments off the ground.

(6) Attach a rigid drawbar to the machine. Make sure the towing machine has enough power and braking ability to move and stop both machines.

(7) Remove wheel chocks.

(8) Release the parking brake.

(9) No riders - keep all other persons completely out of the area.

(10) Tow the disabled machine at a maximum speed of 10 km (6 mph). Do not exceed this speed.

4-25

2) ENGINE STOPPED (1) Engage the parking brake.

(2) Block the wheels with wheel chocks.

(3) Place the transmission in neutral.

(4) Place the FNR lever in neutral.

(5) Place the 4 wheel drive select switch in off position.

(6) Raise all tools and attachments off the ground.

(7) Attach a rigid drawbar to the machine. Make sure the towing machine has enough power and braking ability to move and stop both machines.

(8) Manual release for parking brake ① Loosen lock nut and turn in adjusting screws evenly until preload of the cup spring is compensated and the disc pack is released. ※ Evenly turning in the two adjusting screws prevents the brake piston from twisting. ② Any time the parking brake has been actuated due to an emergency braking (e.g. caused by a hydraulic system failure on the machine), replace the discs of the parking brake.

Lock nut HB1004RA178

Adjusting screw

Ensure operability of the parking brake after dislocating the machine or after repair work. For this purpose turn both adjusting screws evenly back to their initial position and lock by lock nuts.

Adjust installation dimension Y = 29+2 mm Lock nut Adjusting screw

See figure - on both adjusting screws. ·Tightening torque (lock nut, M10×1) : 4.69 kgf·m (33.9 lbf·ft) (9) Remove wheel chocks.

(10) Release the parking brake.

(11) No riders - keep all other persons completely out of the area.

(12) Tow the disabled machine at a maximum speed of 10 km (6 mph). Do not exceed this speed.

4-26

Y

HB1004OP78

9. STORAGE Maintain the machine taking care of following to prevent the deterioration of machine when storing the machine for a long time, over 1 month.

1) CLEANING THE MACHINE Clean the machine.

Grease each lubrication part.

2) LUBRICATION POSITION OF EACH PART Change all oil. ※ Be particularly careful when you reuse the machine.

As oil can be diluted during storage.

Apply an anticorrosive lubricant on the exposed part of piston rod of cylinder and in places where the machine rusts easily.

3) MASTER SWITCH Turn OFF the master switch and store the machine.

4) Be sure to mix anticorrosive antifreezing solution in the radiator.

5) PREVENTION OF DUST AND MOISTURE Keep machine dry. Store the machine setting wood on the ground. ※ Cover exposed part of piston rod of cylinder. ※ Lower the bucket to the ground and set a support under tires.

6) DURING STORAGE Start engine and move the machine and working equipment once a month and apply lubrication to each part. ※ Check the level of engine oil and coolant and fill if required when starting engine. ※ Clean the anticorrosive on the piston rod of cylinder. ※ Operate the machine such as traveling, turning, and work equipment operation to make sure enough lubrication of all functional components.

4-27

5. TRANSPORTATION 1. ROAD TRAVELING If it is necessary to travel on a road, observe the followings.

1) Comply with regulations regarding this machine for the sake of safety.

2) Perform daily inspection before starting the machine.

3) Check the air pressure of tires and traveling speed limitations. ·Air pressure (front) : 5.0 kgf/cm2 (71 psi) ·Air pressure (rear) 18.4-26 : 3.4 kgf/cm2 (48 psi) 16.9-28 : 3.5 kgf/cm2 (50 psi) 21L-24 : 2.4 kgf/cm2 (34 psi)

40~50cm

4) When traveling for a long distance, stop every hour or every 40 km (25 mile) to allow tires and other components to cool down and check any abnormality.

5) Drive with the bucket empty.

HB1005TA01

6) Travel at a mid-range speed and be careful to drive within the limited speed when driving on a public road.

5-1

2. PREPARATION FOR TRANSPORTATION 1) When transporting the machine, observe the various road rules, road transportation vehicle laws and vehicle limit ordinances, etc.

2) Make sure the cooling system has proper antifreeze if moving machine to a cold climate.

Overall width

3) Select proper trailer after confirming the weight and dimension from the page 2-2.

4) Check the whole route such as the road width, the height of bridge and limit of weight and etc., which will be passed.

Overall height

5) Get the permission from the related authority if necessary.

Overall length HB1005TA02

6) Prepare gangplank for safe loading referring to the below table and illustration.

A

B

1.0

3.65 ~ 3.85

1.1

4.00 ~ 4.25

1.2

4.35 ~ 4.60

1.3

4.75 ~ 5.00

1.4

5.10 ~ 5.40

1.5

5.50 ~ 5.75

Loading plate of trailer A Block

B Gan gplan k 15 ~ 16。

73035TA01

5-2

3. LOADING THE MACHINE 1) Load and unload the machine on a flat ground.

2) Use the gangplank with sufficient length, width, thickness and gradient.

3) Move slowly and carefully when the machine is on the gangplank.

Do not change the direction of the machine while it is on the gangplank.

HB1005TA03

4) Do the following after loading the machine to the trailer.

(1) Lower the working equipment gently after the location is determined. ※ Place rectangular timber under the bucket cylinder to prevent the damage of it during transportation.

Do not operate any other device when loading.

Balance the load.

5-3

HB1005TA04

4. FIXING THE MACHINE

HB1005TA06

1) Anchor the machine to the trailer with wire-rope or chain.

2) Push the parking brake switch.

3) Push the safety switch to the OFF position to prevent the hydraulic system from operating.

4) Stop the engine, turn the starting switch off and remove the key.

5) Secure all locks.

5-4

6. MAINTENANCE 1. INSTRUCTIONS 1) INTERVAL OF MAINTENANCE (1) You may inspect and service the machine by the period as described at page 6-13 based on hour meter in the rpm gauge.

(2) Shorten the interval of inspect and service depending on site condition. (Such as dusty area, quarry, sea shore and etc.)

(3) Practice the entire related details at the same time when the service interval is doubled.

For example, in case of 250 hours, carry out all the maintenance 「each 250 hours, each 100 hours and daily service」 at the same time.

Hour meter

HB1004OP51

2) PRECAUTION (1) Start maintenance after you have the full knowledge of machine.

(2) The cluster and monitor installed on this machine do not entirely guarantee the condition of the machine.

Daily inspection should be performed according to chapter 6, Maintenance Maintenance.

(3) Engine and hydraulic components have been preset in the factory.

Do not allow unauthorized personnel to reset them.

(4) Ask to your local dealer or Hyundai for maintenance advise if unknown.

(5) Drain the used oil and coolant in a container and handle according to the method of handling for industrial waste to meet with regulations of each province or country.

6-1

3) PROPER MAINTENANCE (1) Replace and repair of parts It is required to replace the wearable and consumable parts such as bucket tooth, cutting edge, filter and etc., regularly.

Replace damaged or worn parts at proper time to keep the performance of machine.

(2) Use genuine parts.

(3) Use the recommended oil.

(4) Remove the dust or water around the inlet of oil tank before supplying oil.

(5) Drain oil when the temperature of oil is warm.

(6) Do not repair anything while operating the engine.

Stop the engine when you fill the oil.

(7) Relieve hydraulic system of the pressure by opening of breather when repairing the hydraulic system.

(8) Confirm if the warning and indicator lamps are in the normal condition after completion of service.

(9) For more detail information of maintenance, please contact local Hyundai dealer. ※ Be sure to start the maintenance after fully understand the chapter 1, Safety hints.

4) RELIEVING THE PRESSURE IN THE HYDRAULIC SYSTEM ※ Spouting of oil can cause the accident when loosening the cap or hose right after the operating of the machine as the machine or oil is on the high pressure on the condition.

Be sure to relieve the pressure in the system before repairing hydraulic system.

(1) Place the machine in parking position, and stop the engine.

Low idling for 5 minutes

HB1006MA66

6-2

(2) Rotate the cap nut counter-clockwise by hand and push the rod to release the air pressure.

Cap nut Pushing Air breather

HB1006MA43

5) PRECAUTION WHEN INSTALLING HYDRAULIC HOSES OR PIPES (1) Be particularly careful that the joint of hose, pipe and functioning item are not damaged.

Avoid contamination.

(2) Assemble after cleaning the hose, pipe and joint of functioning item.

(3) Use genuine parts.

(4) Do not assemble the hose in the condition of twisted or sharp radius.

(5) Keep the specified tighten torque.

6) PERIODICAL REPLACEMENT OF SAFETY PARTS (1) These are the parts which the operator can not judge the remained lifetime of them by visual inspection.

(2) Repair or replace if an abnormality of these parts is found even before the recommended replacement interval.

Periodical replacement of safety parts

Interval

Fuel hose (engine-tank) Hose of steering system Every 2 years

Packing, seal and O-ring of steering cylinder Hose of brake system Piston seal and packing of boom, bucket cylinder

※ 1. Replace the O-ring and gasket at the same time when replace the hose. ※ 2. Replace clamp at the same time if the hose clamp is cracked when checking and replacing the hose.

6-3

2. TIGHTENING TORQUE Use following table for unspecified torque.

1) BOLT AND NUT (1) Coarse thread 8T

10T

Bolt size kg·m

lb·ft

kg·m

lb·ft

M 6×1.0

0.85 ~ 1.25

6.15 ~ 9.04

1.14 ~ 1.74

8.2 ~ 12.6

M 8×1.25

2.0 ~ 3.0

14.5 ~ 21.7

2.73 ~ 4.12

19.5 ~ 29.8

M10×1.5

4.0 ~ 6.0

28.9 ~ 43.4

5.5 ~ 8.3

39.8 ~ 60

M12×1.75

7.4 ~ 11.2

53.5 ~ 79.5

9.8 ~ 15.8

71 ~ 114

M14×2.0

12.2 ~ 16.6

88.2 ~ 120

16.7 ~ 22.5

121 ~ 167

M16×2.0

18.6 ~ 25.2

135 ~ 182

25.2 ~ 34.2

182 ~ 247

M18×2.5

25.8 ~ 35.0

187 ~ 253

35.1 ~ 47.5

254 ~ 343

M20×2.5

36.2 ~ 49.0

262 ~ 354

49.2 ~ 66.6

356 ~ 482

M22×2.5

48.3 ~ 63.3

350 ~ 457

65.8 ~ 98.0

476 ~ 709

M24×3.0

62.5 ~ 84.5

452 ~ 611

85.0 ~ 115

615 ~ 832

M30×3.0

124 ~ 168

898 ~ 1214

169 ~ 229

1223 ~ 1655

M36×4.0

174 ~ 236

1261 ~ 1703

250 ~ 310

1808 ~ 2242

(2) Fine thread 8T

10T

Bolt size kg·m

lb·ft

kg·m

lb·ft

M 8×1.0

2.17 ~ 3.37

15.7 ~ 24.3

3.04 ~ 4.44

22.0 ~ 32.0

M10×1.25

4.46 ~ 6.66

32.3 ~ 48.2

5.93 ~ 8.93

42.9 ~ 64.6

M12×1.25

7.78 ~ 11.58

76.3 ~ 83.7

10.6 ~ 16.0

76.6 ~ 115

M14×1.5

13.3 ~ 18.1

96.2 ~ 130

17.9 ~ 24.1

130 ~ 174

M16×1.5

19.9 ~ 26.9

144 ~ 194

26.6 ~ 36.0

193 ~ 260

M18×1.5

28.6 ~ 43.6

207 ~ 315

38.4 ~ 52.0

278 ~ 376

M20×1.5

40.0 ~ 54.0

289 ~ 390

53.4 ~ 72.2

386 ~ 522

M22×1.5

52.7 ~ 71.3

381 ~ 515

70.7 ~ 95.7

512 ~ 692

M24×2.0

67.9 ~ 91.9

491 ~ 664

90.9 ~ 123

658 ~ 890

M30×2.0

137 ~ 185

990 ~ 1338

182 ~ 248

1314 ~ 1795

M36×3.0

192 ~ 260

1389 ~ 1879

262 ~ 354

1893 ~ 2561

6-4

2) PIPE AND HOSE (FLARE type) Thread size

Width across flat (mm)

kgf·m

lbf·ft

1/4"

19

4

28.9

3/8"

22

5

36.2

1/2"

27

9.5

68.7

3/4"

36

18

130

1"

41

21

152

1-1/4"

50

35

253

Thread size

Width across flat (mm)

kgf·m

lbf·ft

9/16-18

19

4

28.9

11/16-16

22

5

36.2

13/16-16

27

9.5

68.7

1-3/16-12

36

18

130

1-7/16-12

41

21

152

1-11/16-12

50

35

253

Thread size

Width across flat (mm)

kgf·m

lbf·ft

1/4"

19

4

28.9

3/8"

22

5

36.2

1/2"

27

9.5

68.7

3/4"

36

18

130

1"

41

21

152

1-1/4"

50

35

253

3) PIPE AND HOSE (ORFS type)

4) FITTING

6-5

5) TIGHTENING TORQUE OF MAJOR COMPONENT No.

Descriptions

Bolt size

1

Engine mounting bolt, nut (4EA)

2

Torque kgf·m

lbf·ft

M16×2.0

29.7±4.5

215±32.5

Engine mounting bolt (bracket)

M12×1.75

10.7±1.6

77.4±11.6

Fan mounting bolt

M10×1.5

6.9±1.4

49.9±10.1

4

Radiator mounting bolt

M12×1.75

12.8±3.0

92.6±21.7

5

Fuel tank mounting bolt

M16×2.0

29.7±4.5

215±32.5

6

Air cleaner mounting bolt

M8×1.25

2.5±0.5

18.1±3.6

7

Main pump housing mounting bolt

M12×1.75

12.8±3.0

92.6±21.7

8

Main control valve mounting bolt

M12×1.75

12.8±3.0

92.6±21.7

Steering unit mounting bolt Hydraulic 10 Brake valve mounting bolt system 11 Remote control lever mounting bolt

M10×1.5

6.9±1.4

49.9±10.1

M8×1.25

2.5±0.5

18.1±3.6

M6×1.0

1.1±0.2

8.0±1.4

12

Pilot supply unit mounting bolt

M10×1.5

6.9±1.4

49.9±10.1

13

Hydraulic oil tank mounting bolt

M16×2.0

29.7±4.5

215±32.5

14

Transmission mounting bolt

M16×2.0

29.7±4.5

215±32.5

Transmission mounting bolt (bracket)

M16×2.0

18.4±2.0

133±14.5

Rear axle support mounting bolt, nut

M20×1.5

57.9±8.5

419±61.5

Tire mounting nut

M22×1.5

79±2.5

570±18.1

Drive shaft joint mounting bolt

5/16-24UNF

3.43±0.6

24.8±4.3

Operator's seat mounting bolt

M12×1.75

12.8±3.0

92.6±21.7

ROPS cab mounting bolt (4EA)

M16×2.0

29.7±4.5

215±32.5

3 Engine

9

15 16 17

Power train system

18 19 Others 20

6-6

3. FLUIDS, LUBRICANTS AND CAPACITIES 1) NEW MACHINE New machine used and filled with following lubricants.

Description

Specification

Engine oil

SAE 15W-40 (API CH-4)

Hydraulic oil

Hyundai genuine long life hydraulic oil (ISO VG 46, VG 68 only) Conventional hydraulic oil (ISO VG 32)

Transmission oil

SAE 15W-40

Axle oil

UTTO

Brake oil

Mineral oil

Grease

Lithium base grease NLGI No. 2

Fuel

ASTM D975-No. 2

Coolant

Mixture of 50% ethylene glycol base antifreeze and 50% water

·SAE : Society of Automotive Engineers ·API : American Petroleum Institute ·ISO : International Organization for Standardization ·NLGI : National Lubricating Grease Institute ·ASTM : American Society of Testing and Material ·UTTO : Universal Tractor Transmission Oil

6-7

2) RECOMMENDED LUBRICANTS Use only oils listed below or equivalent.

Do not mix different brand oil.

Service point

Kind of fluid

Capacity ℓ (U.S. gal)

Ambient temperature˚C (˚F) -20 (-4)

-10 (14)

0 (32)

10 (50)

20 (68)

30 (86)

SAE 30 SAE 10W Engine oil pan

Engine oil

12 (3.2) SAE 10W-30 SAE 15W-40

SAE 10W-30

Torque converter Transmission

Engine oil

Axle

UTTO

Front : 8 (2.1) Rear : 16 (4.2)

Hydraulic oil

Tank: 60 (15.9) System: HB100 : 115 (30.4) HB90 : 110 (29.1)

Hydraulic tank

18 (4.6) SAE 15W-40

UTTO

ISO VG 32 ISO VG 46 ISO VG 68

ASTM D975 NO.1 Fuel tank

Diesel fuel

160 (42.3) ASTM D975 NO.2 NLGI NO.1

Fitting (grease nipple)

Grease

Radiator

Mixture of antifreeze and water 50 : 50

As required NLGI NO.2

Ethylene glycol base permanent type

19 (5.0)

·SAE : Society of Automotive Engineers ·API : American Petroleum Institute ·ISO : International Organization for Standardization ·NLGI : National Lubricating Grease Institute ·ASTM : American Society of Testing and Material ·UTTO : Universal Tractor Transmission Oil

6-8

40 (104)

4. MAINTENANCE CHECK LIST Scheduled maintenance is the normal maintenance necessary to provide proper and efficient machine operation. To protect your investment and prolong the service life of your machine, follow the scheduled maintenance list below.

1) EVERY 10 HOURS SERVICE Check items

Service

Page

·Engine oil

Check, Add

6-26

·Radiator coolant

Check, Add

6-30

Check

6-25

·Brake oil

Check, Add

6-20

·Radiator, oil cooler, charge air cooler

Check, Clean

6-30

Service

Page

★ Engine oil

Replace

6-26

★ Engine oil filter

Replace

6-27

★ Hydraulic oil return filter

Replace

6-40

★ Pilot line filter element

Replace

6-41

★ Fuel filter element

Replace

6-36

★ Fuel pre filter element

Replace

6-37

Tires (air)

Check

6-43

Wheel nuts

Check, Tighten

6-43

Clean

6-37

Front axle U-joint

Check, Lubricate

6-19

Attachment pins

Lubricate

6-16

Extending dipper

Check, Lubricate

6-18

Service

Page

Transmission oil

Change

6-40

Transmission oil filter

Replace

6-40

Front axle oil

Change

6-45

Rear axle oil

Change

6-45

·Belt tension and damage

2) EVERY 50 HOURS SERVICE Check items

Fuel prefilter (water separator)

★ : Initial 50 hours service

3) INITIAL 100 HOURS SERVICE Check items

6-9

4) EVERY 250 HOURS SERVICE Check items

Service

Page

Lubricate

6-18

Check, Drain

6-35

Battery (voltage)

Check

6-21

Hydraulic oil return filter

Replace

6-39

Hydraulic tank air breather element

Replace

6-38

Cab fresh air filter

Clean

6-50

Air cleaner element (primary)

Clean

6-29

Service

Page

Drive shaft (U-joint)

Lubricate

6-19

Front axle pivot

Lubricate

6-18

Radiator, oil cooler, charge air cooler

Clean

6-30

Service

Page

Engine oil

Change

6-26

Engine oil filter

Replace

6-27

Fuel filter element

Replace

6-36

Fuel prefilter element

Replace

6-37

Service

Page

Pilot line filter element

Replace

6-40

Transmission oil

Change

6-41

Transmission oil filter

Replace

6-41

Cab fresh air filter

Replace

6-50

Service

Page

Front axle oil

Change

6-45

Rear axle oil

Change

6-45

Drive shaft (spline) Fuel tank (water, sediment)

5) EVERY 500 HOURS SERVICE Check items

6) EVERY 600 HOURS SERVICE Check items

7) EVERY 1000 HOURS SERVICE Check items

8) EVERY 1500 HOURS SERVICE Check items

6-10

9) EVERY 2000 HOURS SERVICE Check items

Service

Page

Hydraulic oil ★1

Change

6-38

Radiator coolant

Change

6-30

Belt tension and damage

Replace

6-34

Engine valve clearance

Check, Adjust

-

Change

6-20

Check, Clean

6-40

Replace

6-51

Service

Page

Change

6-38

Brake oil Suction strainer Air conditioner and heater inner filter ★1

: Conventional hydraulic oil

10) EVERY 5000 HOURS SERVICE Check items Hydraulic oil ★2 ★2

: Hyundai genuine long life hydraulic oil

11) WHEN REQUIRED Whenever you have trouble in the machine, you must perform the service of related items, system by system.

Check items

Service

Page

Drive shaft (spline)

Check, Lubricate

6-19

Drive shaft (U-joint)

Check, Lubricate

6-19

Front axle pivot

Check, Lubricate

6-18

Brake oil

Check, Add

6-20

Radiator, oil cooler, charge air cooler

Check, Clean

6-30

Transmission oil

Check, Add

6-40

Cab fresh air filter

Clean, Replace

6-50

Air conditioner and heater inner filter

Replace

6-50

Air cleaner element (safety)

Replace

6-29

Air cleaner element (primary)

Replace

6-29

6-11

5. MAINTENANCE CHART

6

10

5

22

3

12

20

18

27

13 21

4

22

2

28

10

15

16

17

1

19

7

7

11

7 29

14 25

8

11

24

23

9

16

8

26

7

HB1006MC01

Caution 1. Service intervals are based on the hour meter reading.

2. The service intervals in this sign cannot be fit for rough work condition.

3. Be sure of engine stop when refilling.

4. Do not open the cap or drain plug while hot temperature of fluid to prevent unexpected spouting.

5. Open the cap slowly to relieve pressure.

6. Always keep the surfaces of control & instrument panels clean.

In case of damage or malfunction detected in panels, replace it by a new one.

7. Read "Maintenance check list" for details.

6-12

Service interval 10 Hours or daily

50 Hours or weekly

250 Hours

500 Hours

600 Hours

1000 Hours

1500 Hours

2000 Hours

5000 Hours

As required

★1

No.

Description

2 4 5 13 21 7 8 11 20 22 29 9 12 14 15 16 27 28 9 10 21 2 3 19 20 17 23 24 27 25 26 1 4 5 6 13 18 27 1 9 9 10 13 21 23 27 27 28 28

Engine oil Radiator coolant Belt tension and damage Brake oil Radiator, oil cooler, charge air cooler Attachment pins Tires (air) Wheel nuts Fuel prefilter (water separator) Front axle U-joint Extending dipper Drive shaft (spline) Fuel tank (water, sediment) Battery (voltage) Hydraulic oil return filter Hydraulic tank air breather element Cab fresh air filter Air cleaner element (primary) Drive shaft (U-joint) Front axle pivot Radiator, oil cooler, charge air cooler Engine oil Engine oil filter Fuel filter element Fuel prefilter element Pilot line filter element Transmission oil Transmission oil filter Cab fresh air filter Front axle oil Rear axle oil Hydraulic oil ★1 Radiator coolant Belt tension and damage Engine valve clearance Brake oil Suction strainer Air conditioner and heater Inner filter Hydraulic oil ★2 Drive shaft (spline) Drive shaft (U-joint) Front axle pivot Brake oil Radiator, oil cooler, charge air cooler Transmission oil Cab fresh air filter Air conditioner and heater Inner filter Air cleaner element (safety) Air cleaner element (primary)

Conventional hydraulic oil

★2

Service Oil action symbol Check, Add EO Check, Add C Check Check, Add BO Check, Clean C Lubricate Check Check, tighten Clean Check, Lubricate PGL Check, Lubricate PGL★3 Lubricate PGL Check, Drain Check Replace Replace Clean Clean Lubricate PGL Lubricate PGL Clean Change EO Replace Replace Replace Replace Change EO Replace Replace Change UO Change UO Change HO Change C Replace Check, Adjust Change BO Check, clean Replace Change HO Lubricate PGL Lubricate PGL Lubricate PGL Check, Add Check, Clean Check, Add EO Clean, Replace Replace Replace Replace -

Hyundai genuine long life hydraulic oil

★3

Capacity ℓ(U.S.gal) 12 (3.2) 19 (5.0) 12 (3.2) 18 (4.6) 8 (2.1) 16 (4.2) 60 (15.9) 19 (5.0) 0.4 (0.1) 60 (15.9) 18 (4.6) -

Shell Retinax HDX2

※ Oil symbol Please refer to the recommended lubricants for specification.

EO : Engine oil PGL : Grease HO : Hydraulic oil UO : UTTO BO : Brake oil, mineral C : Coolant 6-13

Service points No. 1 1 2 1 1 44 4 2 1 2 1 1 1 1 1 1 1 1 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 4 1 1 1 1 1 4 1 1 1 1 1 1 1 1

6. ROPS/FOPS STRUCTURE Your machine has a roll-over protectives structure (ROPS) and a falling-object protective structures (FOPS).

Always operate machine with proper ROPS/ FOPS installed.

Do not attempt to repair a rollover protective structure (ROPS) after an accident.

Repaired structures do not provide the original structure and protection.

Test and approved as a protective CAB according to ROPS and FOPS standard.

Meets : ISO 3471 / 3449 / 3164 SAE J1040 / J231 / J397 1) Check for cracks, rust or holes in the ROPS/FOPS structure. Age, weather and accidents can cause damage to the ROPS/FOPS structure. If you have any doubt the ROPS/FOPS structure, contact your Hyundai distributor. Failure to take these precautions could result in death or injury to the operator.

2) Check that the mounting bolts are installed and undamaged. Tighten them to the correct torque if necessary. ·Tightening torque (A A and B) : 29.7 kgf·m (215 lbf·ft)

A A

B B

HB1006MA05

6-14

7. LOADER BOOM SAFETY STRUT 1) SUPPORTING If you service the machine with the loader boom raised, always use the loader boom support strut.

Otherwise, you can be killed or injured by falling the loader boom.

Wing bolt

(1) Raise the loader boom fully.

(2) Stop the engine and remove the starter key.

(3) Loosen the two wing bolts and remove strut from its stowage position.

(4) Place the strut onto the lift cylinder and secure the strut by tightening the wing bolts shown as figure.

(5) Slowly lower the boom onto the strut.

Stowage position

Supporting position

※ When lowering the loader, operate the control lever very slowly.

2) LOWERING (1) Raise the loader boom to take the weight off the strut.

(2) Stop the engine and remove the starter key.

(3) Loosen the wing bolts and remove the strut carefully.

(4) Reinstall the strut onto its stowage position using the wing bolts.

6-15

HB1006MA71

8. LUBRICATION ※ Supply grease through the grease nipple, using grease gun. ※ After lubricating, clean off spilled grease.

Press the parking brake switch and set the FNR lever to neutral.

Set the work equipment in a stable position and turn the hydraulic safety switch (backhoe) into the lock position.

1) LOADER For each grease point shown, there is another on the other side of the machine.

Total 22 grease grease points.

1,2

3,4

7,8

15,16 5,6 9,10 11,12 13,14

17,18

19,20

21,22

HB1006MA08

6-16

2) BACKHOE ※ 22 Grease points Figure shows a standard boom and dipper arrangement.

16

15

17

18

14 19 12

13

4 1

20

3

21 22

HB1006MA09

6-17

3) EXTENDING DIPPER ※ Extending dipper slides Grease : Shell Retinax HDX2

HB1006MA10

4) FRONT AXLE ※ 3 Grease points 1 (U-joint)

3 (Pivot pin)

2 (U-joint)

※Remote type grease nipple is installed.

2

1

HB1006MA62

6-18

5) DRIVESHAFTS

3

(1) Front driveshaft 3 Grease points

2

1

HB1006MA11

(2) Rear driveshaft 2 Grease points

2

1

HB1006MA12

6) CLAMSHOVEL 3 Grease points each end Total 6 grease points

1, 2 3, 4

5, 6 HB1006MA13

7) KINGPOST 9 Grease points

9 1 3 2 4 5

6

6-19

78

HB1006MA17

9. CHECKING THE FOOT BRAKE FLUID LEVEL Faulty brakes can kill. Do not use the machine until the fault has been put right.

1) Park the machine on firm level ground, engage the park brake and set the FNR lever to neutral.

C D

2) Lower the loader arms and the backhoe to the ground. Switch OFF the engine and remove the starter key.

3) Pull the handle and open the engine cover.

4) Visually check the level, MAX level is marked on the reservoir D. 5) Add fluid if necessary. ※ If the level has fallen a long way below the MAX mark, get the system checked by your Hyundai dealer.

Handle

6) Refit the reservoir cap. Wipe up any spillage.

HB1006MA21

6-20

10. ELECTRICAL SYSTEM 1) WIRING, GAUGES Check regularly and repair loose or malfunctioning gauges when found.

73036MI27

2) BATTERY (1) Clean ① Wash the terminal with hot water if it is contaminated, and apply grease to the terminals after washing.

Battery gas can explode. Keep sparks and flames away from batteries.

Always wear protective glasses when working with batteries.

Do not stain clothes or skin with electrolyte as it is acid.

Be careful not to get the electrolyte in eyes.

Wash with clean water and go to the doctor if it enters the eyes.

36070FW05

(2) Recycle Never discard a battery.

Always return used batteries to one of the following locations. ·A battery supplier ·An authorized battery collection facility ·Recycling facility

(3) Method of removing the battery cable Remove the cable from the ground connection terminal side) and reconnect it last first ( when reassembling.

Ground

Battery relay R5576MA98

6-21

3) STARTING THE ENGINE WITH A BOOSTER CABLE Keep following order when you are going to start engine using booster cable.

(1) Connection of booster cable ※ Use the same capacity of battery for starting ① Connect the red terminal of booster cable to the battery(+) terminal between exhausted and new battery. ② Connect the black terminal of the booster cable to the battery(-) terminal between exhausted and new battery. ※ Keep firmly all connection, the spark will be caused when connecting finally.

Connection of booster cable Red ③

②

①

Trouble (exhausted) machine Black ④ To chassis of trouble machine Normal (new) machine

Connection order : ①→②→③→④ R5576MA99

(2) Starting the engine ① Start engine with starting key. ② If you can not start it by one time, restart the engine after 2 minutes.

START OFF

ON

77074OP04

(3) Taking off the booster cable ① Take off the booster cable black). ② Take off the booster cable (red) connected to the (+) terminal. ③ Run engine with high idle until charging the exhausted battery by alternator, fully.

Explosive gas is generated while using the battery or charging it. Keep away flame and be careful not to cause the spark. ※ Charge the battery in the well ventilated place. ※ Place the machine on the earth or concrete.

Avoid to charge the machine on the steel plate. ※ Do not connect (+) terminal and (-) terminal when connecting booster cable because it will be shorted.

6-22

Disconnection of booster cable Red ③

②

Normal (new) machine

Black

①

Trouble (exhausted) machine

To chassis of trouble machine

④

Disconnection order : ④→③→②→①

R5576MA99

4) Welding repair Before star t to welding, follow the below procedure.

(1) Shout off the engine and remove the starting switch.

(2) Disconnect ground cable from battery by master switch.

(3) Before carrying out any electric welding on the machine, the batter y cables should be disconnected and the connectors pulled out of the electronic control units (alternator, dashboard etc).

(4) Connect the earth (ground) lead of the welding equipment as close to the welding points as possible. ※ Do net weld or flame cut on pipes or tubes that contain flammable fluids. Clean them thoroughly with nonflammable solvent before welding or flame cutting on them.

Do not attempt to welding work before carry out the above.

If not, it will caused serious damage at electric system.

6-23

Master switch

OFF

Battery

RH LH

HB1006MI32

5) FUSES (1) The fuses protect the electrical parts and wiring from burning out.

(2) The fuse box cover indicates the capacity of each fuse and circuit it protects. ※ Replace a fuse with another of the same capacity.

Before replacing a fuse, be sure to turn OFF the starting switch.

Fuse No.

Circuit

Fuse rating

F1

Front work lamp

15A

F2

Stop & turn lamp

15A

F3

Gauge, radio

15A

F4

Solenoid 1

15A

F5

Solenoid 2

15A

F6

Cigar, option

15A

F7

Rear work lamp

20A

F8

Solenoid 3

15A

F9

Rear wiper

20A

F10

AC

30A

F11

Grid control

20A

20A 30A 10A

20A

10A

Back buzzer

10A

Beacon

F14

Illumination

10A

Illumination 1

F15

Wiper-front

20A

30A 5A 5A Illumination 2

F17

Room lamp, gauge, cassette B+

10A

F18

Beacon

30A

F19

Illumination 1

5A

F20

Illumination 2

5A

F14

15A

F3

15A

F4

15A

Solenoid 1

F15

F5

15A

Solenoid 2

F16

F6

15A

Cigar, option

F17

Room lamp, gauge cassette B+

F13

F2

Gauge, radio

Head light

30A

20A

F13

Wiper-front

20A

15A

Stop & turn lamp

Illumination

TM control

Head light

F12

Back buzzer

10A

F1

Work lamp-front

TM control

F12

F16

F11

Grid control

F18

F7

20A

Rear work lamp

F8

15A

Solenoid 3

F19

F9

20A

Rear wiper

F20

F10

30A

AC HB1006MA67

6-24

6) RELAYS The relays listed below are located in the side console underneath cover. ※ All the relays are shown including optional equipment relays. Your machine may not be equipped with all the relays shown.

DASH BOARD

MAIN HARNESS

Location Relay No.

Circuit

CR-2

Horn

CR-5

Key power

CR-10

Buzzer

CR-13

Telescope 1

CR-14

Telescope 2

CR-15

Unloading

CR-16

NPN sensor

CR-62

Breaker

CR-4

Wiper 1

CR-6

INT wiper

CR-11

Flasher

CR-26

Wiper 2

CR-58

Back buzzer

CR-63

Stop lamp

CR-95

Wiper 3

Main harness CR-5

CR-16 NPN sensor

Key power

CRSpare

CR-2 Horn

CR-15 CR-62 CRSpare Unload Breaker -ing

CRSpare

CRSpare

CR-10 CR-13 CR-14 Buzzer Telesc Telesc -ope 1 -ope 2

Dashboard harness

CR-150 TM delay CR-151 K3 CR-152 K2 CR-153 K5 CR-154 K4 CR-155 Differential lock

CR- 154 K4

CR-151 K3

CR-153 K5

CR-26 Wiper 2

CR-152 K2

CR-155 Diff. lock

CR-4 Wiper 1

CR-63 Stop lamp

CR-58 Back buzzer

CR-95 Wiper 3

CR-6 Int. wiper

CR-11 Flasher CR-150 TM delay

HB1006MA68

6-25

11. ENGINE 1) CHECK THE OIL LEVEL ※ Check the oil level with the machine on a flat ground before starting. ※ If the oil is contaminated or diluted, change the oil regardless of the regular change interval.

Check oil level after engine has been stopped for 15 minutes.

Do not operate unless the oil level is in the normal range.

(1) Make sure the park brake is engaged and the FNR lever set to neutral. Lower the loader arms and the backhoe to the ground, switch OFF the engine and remove the starter key.

Filler

(2) Pull the handle and open the engine cover.

(3) Check that the oil level is between the maximum and minimum marks on the dipstick.

(4) Add the recommended oil through filler to the maximum level if necessary.

Dipstick

Do not exceed the correct level of engine oil in the sump. If there is too much engine oil, the excess must be drained to the correct level. An excess of engine oil could cause the engine speed to increase rapidly without control.

(5) Fit filler cap and dipstick, make sure that they are fully inserted and tightened.

Handle HB1006MA28

6-26

2) REPLACEMENT OF ENGINE OIL AND FILTER (1) Operate the engine until the coolant temperature reaches about 60°C (140°F).

(2) Make sure the park brake is engaged and the FNR lever set to neutral. Raise the loader arms and support the safety strut (refer to page 6-15).

Lower the backhoe to the ground, switch OFF the engine and remove the starter key.

O-ring Plug

(3) Pull the handle and open the engine cover.

Make the machine safe before working underneath it. Park the machine on level ground, lower the attachments to the ground. Block both sides of all four wheels.

(4) Place a container of suitable size beneath the sump drain plug. ※ Oil will gush from the hole when the drain plug is removed. Hot oil and engine components can burn you.

(5) Drain the engine oil.

Handle

① Machine with a sump plug, remove the sump drain plug and its O-ring. Let the oil drain out, then clean and refit the drain plug with a new O-ring. ·Tightening torque : 4.1 kgf·m (30 lbf·ft)

6-27

HB1006MA29

(6) Clean the area around the oil filter head.

(7) Remove the oil filter, use a filter wrench if necessary.

(8) Clean the seal face of the filter head.

(9) Fit new filter. ① Smear the seal on the new filter with clean engine oil.

Filter

② Screw the filter on until it just contacts the filter head. ③ Turn the filter at least a further 3/4 of a turn.

Do not over fill the engine with oil.

(10) Through filler point, fill the engine oil to the MAX mark on the dipstick. Wipe off any split oil, refit the filler cap and make sure it is secure.

(11) Operate the engine at low idle and inspect for leaks at the filter and the drain plug.

Shut the engine off and check oil level with dipstick. Allow 15 minutes for oil to drain down before checking.

Filler

Dipstick

Do not overfill the engine with oil.

HB1006MA30

6-28

3) CLEANING OF AIR CLEANER

Cover

(1) Primary element ① Loosen the wing nut and remove the element. ② Clean the inside of the body. ③ Clean the element with pressurized air. ·Remove the dust inside of the element by the pressurized air (below 3 kgf/cm , 40 psi) forward and backward equally. ④ Inspect for cracks or damage of element by putting a light bulb inside of the element. ⑤ Insert element and close cover. ※ Replace the primary element after 4 times cleanings.

2

(2) Safety element ※ Replace the safety element only when the primary element is cleaned for the 4 times. ※ Always replace the safety element. Never attempt to reuse the safety element by cleaning the element.

Pressurized air 3kgf/cm2 below

R5576MA20

21076MA11A

6-29

4) CHECK COOLANT LEVEL Visually check the coolant level daily, do not depend on the coolant level indicator to illuminate before adding coolant.

Do not remove the radiator cap from a hot engine. Wait until the coolant temperature is below 50 50°(120 (120°)) before removing the radiator cap. Heated coolant spray or steam can cause personal injury. ※ Do not add cold coolant to a hot engine ; engine castings can be damaged. Allow the engine to cool to below 50° (120°) before adding coolant.

HY

UN

DA

FU

LL

I

LO

W

Coolant reservoir HB1006MA32

OK

NOT OK

(1) Make sure the park brake is engaged and the FNR lever set to neutral. Lower the loader arms and the backhoe to the ground, switch OFF the engine and remove the starter key.

(2) Open the engine cover.

(3) The coolant level should be between the LOW and the FULL marks on coolant reservoir.

(4) Carefully loosen cap on the coolant reservoir.

Let any pressure escape before removing the cap. Add the mixture of water and antifreeze until it reaches the correct level.

6-30

HB1006MI07

5) FLUSHING AND REFILLING OF RADIATOR (1) Change coolant 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.

HB1006MI08

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 handing of used antifreeze.

Wait until the temperature is below 50˚C (120˚F) before removing the coolant system radiator cap. Failure to do so can cause personal injury from heated coolant spray.

Drain the cooling system by turning the stopper to the open position.

A drain pan with a capacity of 45 liters (11.9 U.S.gallons) will be adequate in most applications.

HB1006MI09

(2) Flushing of cooling system ① Fill the system with a mixture of sodium carbonate and water (or a commercially available equivalent).

OK

※ Use 0.5 kg (1.0 pound) of sodium carbonate for every 23 liters (6.0 U.S. gallons) of water. ※ Do not install the radiator cap. The engine is to be operated without the cap for this process.

7803A6MI16

6-31

※ The system must be filled properly to prevent air locks.

During filling, air must be vented from the engine coolant passages. Wait 2 to 3 minutes to allow air to be vented; then add mixture to bring the level to the top. · Adequate venting is provided for a fill rate of 19 liters/minute (5 U.S.gal/minute).

② Operate the engine for 5 minutes with the coolant temperature above 80˚C (176˚F).

Shut the engine off, and drain the cooling system.

OFF

HB1006MI10

③ Fill the cooling system with clean water. ※ Be sure to vent the engine and aftercooler for complete filling. ※ Do not install the radiator cap or the new coolant filter.

7803AMI38

④ Operate the engine for 5 minutes with the coolant temperature above 80˚C (176˚F).

Shut the engine off, and drain the cooling system. ※ If the water being drained is still dirty, the system must be flushed again until the water is clean.

OFF

HB1006MI10

6-32

(3) Cooling system filling ※ The system must be filled properly to prevent air locks.

During filling, air must be vented from the engine coolant passages. Wait 2 to 3 minutes to allow air to be vented; then add mixture to bring the level to the top. · The system has a design fill rate of 19 liters per minute (5 U.S.gallons per minute). ① Use a mixture of 50 percent water and 50 percent ethylene glycol antifreeze to fill the cooling system. ※ Coolant capacity (engine only); 9ℓ (2.4 U.S.gallons) ※ Use the correct amount of DCA4 corrosion inhibitor to protect the cooling system.

18036MI22

② Install the radiator 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 system is full of coolant.

NOT OK

HB1006MI11

6-33

6) CLEAN RADIATOR AND OIL COOLER

NOT OK uv{Gvr

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.

550kPa (80psi)

(2) Use 550 kPa (80 psi) air pressure to blow the dirt and debris from the fins.

Blow the air in the opposite direction of the fan air flow.

7803AMI39

(3) Visually inspect the radiator for bent or broken fins. ※ If the radiator must be replaced due to bent or broken fins which can cause the engine to overheat, refer to the manufacturer's replacement procedures.

(4) Visually inspect the radiator for core and gasket leaks.

7803AMI40

7) DRIVE BELT (1) Inspect the belts daily. Check the belts for intersecting cracks. Transverse (across the belt width) cracks are acceptable.

Longitudinal (direction of belt length) cracks that intersect the transverse cracks are not acceptable. Replace a belt if is frayed or has pieces of material missing.

OK

NOT OK 73036MI23

8) INSPECTION OF COOLING FAN 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. ※ Rotate the crankshaft by using the engine barring gear. ※ 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 damaged.

6-34

NOT OK

21076MI10B

12. FUEL SYSTEM 1) FUEL TANK (1) Fill fuel fully when system the operation to minimize water condensation, and check it with fuel gauge before starting the machine.

Fuel filler cap

(2) Drain the water and sediment in the fuel tank by opening the plug. ※ Be sure to LOCK the cap of fuel tank. ※ Remove the strainer of the fuel tank and clean it if contaminated.

Stop the engine when refueling.

All lights and flames shall be kept at a safe distance while refueling.

Drain plug HB1006MA36

6-35

2) CHANGE FUEL FILTER AND BLEEDING THE FUEL SYSTEM Only proceed with the engine stopped and at a low temperature, so as to avoid the risk of burning.

Only use filters with a filtration level equivalent to the ones you are replacing.

(1) Remove the filter (1) by unscrewing it.

HB1006MA69

(2) Check that the new filter has performance levels that satisfy the needs of the engine.

(3) Damp the new filter seal with diesel or engine oil.

(4) Hand screw the new filter into place until the seal gasket touches the support, then lock by a further 3/4 of a turn.

(5) Pay particular attention to the electrical fuel preheater (if available) and relevant electrical connection. ※ Do not fill up the new filter before it is fitted to the support, to avoid inserting harmful impurities into the injection system and circuit. ※ In case any operation has been executed on the components of the feed circuit, it is necessary to execute bleeding of air within the system.

(6) Loosen the air bleed screw (3) on the fuel filter (1) and operate the bleed lever for the priming pump (2) repeatedly.

(7) Continue executing this operation until when fuel drains from the bleeder vent screw.

(8) Tighten the air bleed screw (3) to a torque (0.7~0.9 kgf·m).

6-36

HB1006MA40

3) PREFILTER ※ Inspect or drain the collection bowl of water daily and replace the element every 600 hours.

(1) Drain water ① Open bowl drain valve to evacuate water. ② Close drain valve.

Bowl Drain valve Open

Close

HB1006MI20

(2) Replace element ① Drain the unit of fuel. Follow "Drain water" instructions above. ② Remove element and bowl from filter head. ※ The bowl is reusable, do not damage or discard. ③ Separate element from bowl. Clean bowl and seal gland.

Open Element Bowl Open

HB1006MI31

④ Lubricate new bowl seal with clean fuel or motor oil and place in bowl gland. ⑤ Attach bowl to new element firmly by hand. ⑥ Lubricate new element seal and place in element top gland. ⑦ Attach the element and bowl to the head.

Filter head

Close Element Bowl Close HB1006MI30

6-37

13. HYDRAULIC SYSTEM 1) HYDRAULIC OIL CHECK

Sight gauge

(1) Lower the bucket on the ground at a flat location as in the illustration.

Stop the engine and then leave for about 5 minutes.

(2) Check the oil level at the sight gauge. The sight gauge is located on the left side of the hydraulic oil tank.

HB1006MA70

(3) The sight gauge should indicate the middle position. ※ Add hydraulic oil, If necessary.

2) FILLING HYDRAULIC OIL Escaping fluid under pressure can penetrate the skin causing serious injury.

(1) Stop the engine to the position of level check.

Cap nut Pushing Air breather

(2) Rotate the cap nut counter-clockwise by hand and push the rod to release the air pressure.

(3) Remove the breather on the top of oil tank and fill the oil to the specified level.

(4) Start engine after filling and operate the work equipment several times.

(5) Check the oil level at the level check position after engine stops.

HB1006MA43

6-38

3) CHANGING RETURN FILTER ELEMENT Clean and replace the return filter in the following manner.

Rotate the cap nut counter-clockwise by hand and push the rod to release the air pressure.

Escaping fluid under pressure can penetrate the skin causing serious injury.

Bolt Cover

(1) Remove the cover.

O-ring

(2) Remove spring, by-pass valve and return filter from the tank.

Spring Bypass valve

(3) Replace element with new one and assemble spring and by-pass valve after cleaning.

Return filter

(4) Install the cover on the tank. ·Tightening torque : 6.9±1.4 kgf·m (50±10 lbf·ft) HB1006MA64

6-39

4) CHANGING THE SUCTION STRAINER Rotate the cap nut counter-clockwise by hand and push the rod to release the air pressure.

Filler cap

Escaping fluid under pressure can penetrate the skin causing serious injury.

(1) Park the machine on level ground, lower the attachments to the ground. Apply the park brake, put the FNR lever in neutral and stop the engine.

Block both sides of all four wheels. Stop the engine. Remove the starter key.

(2) Remove hydraulic tank filler cap.

(3) Place a container beneath the hydraulic tank the catch the oil, remove drain plug and drain the hydraulic tank. Make sure the container is large enough to hold the tank contents.

Strainer

(4) Fit a new strainer.

HB1006MA44

(5) Reconnect suction hose.

(6) Refit drain plug.

(7) Refill hydraulic tank, fit and tighten the filler cap.

5) REPLACE OF PILOT LINE FILTER (1) Loosen the nut positioned on the filter body.

(2) Pull out the filter element and clean filter housing.

(3) Install the new element and tighten using specified torque.

HB1006MA65

6-40

14. TRANSMISSION 1) CHECK TRANSMISSION OIL LEVEL Level gauge

The oil level check must be carried out as follows;

COLD

(1) Oil level check (weekly).

ZONE " HOT"

(2) At horizontally standing machine.

(3) Set the FNR lever in neutral position.

(4) In cold start phase, the engine must be running about 2~3 minutes at idling speed, and the marking on the oil level gauge must then be lying above the cold start mark COLD. (5) At operating temperature of the transmission (about 80~90°C).

(6) At engine idling speed.

(7) Loosen oil level gauge, remove and clean it.

(8) Insert oil level gauge slowly into the oil level tube until contact is obtained, and pull it out again.

Level gauge HB1006MA49

(9) On the oil level gauge, the oil level must be lying in the zone HOT. (10) Insert the oil level gauge again.

When checking, press the parking brake switch and fix the front and rear frames with the safety lock bar.

2) REPLACEMENT OF TRANSMISSION OIL AND FILTER ELEMENT (1) Operate the machine for a few minutes in order to warm the transmission oil.

(2) Move the machine to flat ground. Lower the bucket to the ground and slightly apply downward force.

1

(3) Press the parking brake switch and stop the engine.

3

(4) Open transmission air breather to relieve internal air pressure.

(5) Remove the transmission drain plug. Allow the transmission oil to drain into a suitable container.

2 1 Level gauge with breather 2 Oil drain plug 3 Filter HB1006MA50

6-41

(6) Remove the transmission oil filter cartridge.

Dispose of the used transmission oil filter cartridge properly.

(7) Clean the filter cartridge mounting base.

Remove any part of the filter cartridge gasket that remains on the filter cartridge mounting base.

(8) Apply a light coat of oil to the gasket of a new transmission oil filter cartridge.

73036MI14

(9) Install the new transmission oil filter cartridge.

Screw the filter in until contacts with the sealing surface is obtained and tighten it now by hand about 1/3 to 1/2 turn.

(10) Fill the oil through level gauge inlet and check if the oil is at the appropriate level.

Level gauge COLD

(11) The proper oil amount is 18 liters. (4.8 U.S. gallons)

ZONE " HOT"

As the machine is hot after operation wait until the temperature has dropped.

It is imperative to pay attention to absolute cleanliness of oil and filter.

Binding is in any case the marking on the oil level gauge.

Level gauge HB1006MA49

6-42

15. TIRES AND WHEELS 1) TIRE PRESSURE (1) Inappropriate tire pressure is a primary cause for tire damage. Insufficient tire pressure will damage internal carcass of tire. Repeated excessive bending will damage or break the carcass.

Excessive pressure will also cause premature damage of tire.

(2) Recommended tire pressure : Refer to page 5-1.

(When tire is cooled) (3) Continuous operation will produce heat and increase pressure on tire. But such phenomenon was already taken into account when designing a tire. Do not try to remove normally increased air because tires may be crushed or overinflated.

(4) The three major causes for excessive heat and pressure of tire are insufficient pressure, excessive load and overspeed. Avoid excessive load and overspeed in order to keep tires in good shape.

Do not inflate tires using flammable gases or alcohol injector.

This cause explosion or personal injury.

Inflate tires at the pressure level recommended by the manufacturer, and check periodically pressure and wear of tires.

When replacing the inflated tire, do not stand near the tire. ※ Check the tire when the tire is at normal temperature and the machine is not loaded.

Do not use recycled wheel parts.

When removing lockering or inflating tire, use safety cable or chain to ensure safety.

Be sure to bleed air before removing lockering.

Never inflate tires unless the lockering is assembled in its place. ※ Avoid the followings when traveling. ① Rubbing tires against road bank or rack at cargo-unloading spot. ② Tires slippage during working. ③ Abrupt starting of machine. ④ When oil, grease or gasoline smeared on tire, clean those. Otherwise it may cause of permanent deformation.

Normal

Too low pressure

Excess pressure

73036MI10

6-43

2) REPLACEMENT OF TIRE Disassembly, reassembly, replacement and repair of tire requires special skills and equipment. Contact a tire repair shop.

The correct torques are shown as below. ·Front / Rear : 79 kgf·m (570 lbf·ft)

3) STORING TIRES AFTER REMOVAL As a basic rule, store the tires in a warehouse which unauthorized persons cannot enter. If the tire are stored outside, always erect a fence around the tires and put up "No Entry" and other warning signs that even young children can understand.

Stand the tire on level ground, and block it securely so that it cannot roll or fall over.

If the tire should fall over, get out of the way quickly. The tires for construction equipment are extremely heavy, so trying to hold the tire may lead to serious injury.

6-44

Block

60 - 70° 73036MI20

16. AXLES 1) CHECK AND SUPPLY DIFFERENTIAL OIL

Front Front

Park the machine on level ground, lower the attachments to the ground. Block both sides of all four wheels.

(1) Park the machine on level ground. Engage the park brake. Set the FNR lever to neutral. Lower the attachments to the ground. Stop the engine and remove the starter key.

(2) Clean the area around fill/level plug, then remove the plug and its sealing washer. Oil should be level with the bottom of the hole. Add recommended oil if necessary.

Fill/level plug

Drain plug

Rear

Rear

(3) Clean and refit the plug with O-ring.

Fill/level plug Drain plug HB1006MA52

2) CHECK AND SUPPLY HUB OIL Check each hub separately.

(1) Park the machine on level ground with the oil level mark horizontal. There is a tolerance of 5 mm (0.2 in) above or below the horizontal.

(2) Engage the park brake. Set the FNR lever to neutral. Lower the attachments to the ground.

Stop the engine and remove the starter key.

(3) Clean the area around the fill/level plug.

Remove the plug. Oil should be level with the bottom of the hole. If necessary, add the recommended oil. Clean the plug before refitting it.

6-45

Fill/level plug HB1006MA54

3) CHANGING THE DIFFERENTIAL OIL The axle oil is used to lubricate the brake components and cool the brake plates.

Park the machine on level ground, lower the attachments to the ground. Block both sides of all four wheels.

(1) Park the machine on level ground. Engage the park brake. Set the FNR lever to neutral. Lower the attachments to the ground. Stop the engine and remove the starter key.

(2) Place a container of suitable size beneath drain plug to catch the oil. Remove the drain plug and O-ring. Allow oil to drain out. The drain plug is magnetic. Wipe it clean. (Metallic particles should be carefully removed). Fit drain plug with O-ring. ·Tightening torque : 7.9 kgf·m (60 lbf·ft).

Fill/level plug

Drain plug HB1006MA56

(3) Fill with recommended oil through fill/level hole.

Clean and refit plug with O-ring. ·Tightening torque : 7.9 kgf·m (60 lbf·ft).

4) CHANGE HUB OIL Change the oil in each hub separately.

(1) Set the machine level, with the tires just clear of the ground. Manually rotate the wheels to bring the oil level mark on the hubs to the vertical position, with the fill/level plug at the bottom. ① Place a container of suitable size beneath plug to catch the oil. ② Remove fill/level plugs. Allow time for the oil to drain out.

(2) Set oil level marks to the horizontal. ① Fill the hubs with recommended axle oil, through the fill/level hole. Oil should be level with the bottom of the fill/level hole. ② Clean and refit fill/level plugs.

6-46

Fill/level plug HB1006MA55

17. WEAR PADS 1) EXTENDING DIPPER ※ Extending dipper is mounted with wear pads in 4 sections. ※ Wear pads provide support and guide when the inner dipper is extended or retracted. ※ Wear pads are replaceable and located on top and bottom of left and right side of the inner dipper.

A

※ The top wear pads are not adjustable, but the bottom wear pads are adjustable.

A

※ When replacing the top wear pads, replace the bottom wear pads as a set at a same time.

(1) Inspection of the top wear pads ① Park the machine on flat surface.

Top wear pad

② Engage the parking brake and put the FNR lever in neutral.

Chamfer

③ Retract the dipper and place a support block as shown in the figure.

Adjusting bolt

Bottom wear pad

④ Stop the engine and remove the key.

View A-A

⑤ Inspect the wear and tear on top wear pad and if worn down to the height of the chamfer in the figure, then replace the pad. ※ Increase the inspection frequency when Top wear pad approaches its wear limit. ※ When replacing the top wear pads, replace the bottom wear pads as a set at a same time.

6-47

HB1006MA58

(2) Adjustment djustment of the bottom wear pads ① Park the machine on flat surface. ② Engage the parking brake and put the FNR lever in neutral.

A

③ Clean the slippery side of the inner dipper with adequate solvent.

A

④ Start the engine, retract the dipper, and place a support block as shown in the figure. ⑤ Stop the engine and remove the key. ⑥ Measure the gap (C) between the inner dipper and the top wear pad. ·Spec : less than 1.5 mm

Top wear pad

Adjusting bolt

C

⑦ When the gap exceeds 1.5 mm, then use adjusting bolt to adjust both sides. ※ If the gap exceeds 1.5 mm even after the adjustment with adjusting bolt, then replace the top and bottom wear pads as a set at a same time.

Inner dipper View A-A

※ When the adjustment is completed, then lubricate the sliding side of the inner dipper with Grease HDX2 (Shell Retinax).

HB1006MA59

6-48

2) STABILIZER LEGS ※ Wear pads are mounted on upper and lower sides of the stabilizer legs. ※ Wear pads provide support and guide when the inner leg of the stabilizer extends and retracts. ※ 4 upper wear pads are mounted and fixed. ※ 2 fixed and 2 adjustable lower wear pads are mounted.

(1) Inspection of the upper wear pads ※ Upper wear pad has a 1 mm shim which is used to adjust gap of inner and outer legs.

A

① Park the machine on flat surface. ② Engage the parking brake and put the FNR lever in neutral.

B

③ Stop the engine and remove the key. ④ If the thickness of wear pad is less than 0.5 mm, replace it. ※ Consult our dealer when replacing upper wear pad since inner leg must be removed at that time.

(2) Adjustment of the lower wear pads

Wear pad Shim

Section A-A

① Park the machine on flat surface. ② Engage the parking brake and put the FNR lever in neutral.

Wear pad Shim

③ Retract the stabilizer moderately.

Adjustable pad

④ Stop the engine and remove the key. ⑤ Clean off foreign substances accumulated on the stabilizer cavities.

Section B-B

⑥ Follow the adjustment instructions below to maintain the gap of inner and outer legs of the stabilizer at 1 mm.

- Tighten adjustable pad until it just contacts the inner leg then loosen it 1/4 turn.

- Extreme tightening of adjustable pad may causes the pad being stuck and not detachable when loosening.

6-49

HB1006MA60

18. AIR CONDITIONER AND HEATER 1) CLEANING THE CAB FRESH AIR FILTER (1) Park the machine on firm level ground, engage the park brake and set the FNR lever to neutral.

Lower the attachments to the ground and stop the engine.

(2) Loosen the cover retaining screws and then remove the cover.

(3) Knock loose dust off the filter. Carefully blow compressed air through all the folds of the filter, blow in the opposite direction to the arrows marked on the filter. ※ The compressed air must be set at a pressure no greater than 2 kgf/cm2 (28 psi).

(4) Refit the cover and secure with the retaining screws.

(5) Refregerant amount : 700±30 g

6-50

Filter

Cover Screw HB1006MA34

TROUBLESHOOTING GUIDE 1. ENGINE ※ This guide is not intended to cover every conditions, however many of the more common possibilities are listed.

Trouble

Service

Engine oil pressure lamp fails to go · Add the oil to the specified level. off immediately after the engine is · Replace the oil filter. started. · Check oil leakage from the tube or the joint.

Steam is emitted from the top part of · Supply the cooling water and check leakage. the radiator (The pressure valve). · Adjust fan belt tension.

Engine coolant temperature gauge · Wash out inside of cooling system. indicates red range. · Clean or repair the radiator fin. · Check the thermostat. · Check the engine coolant temperature gauge. · Tighten the radiator cap firmly or replace the gasket of it.

Engine does not start when the · Add fuel. starting motor is turned over. · Repair where air is inhaled into fuel system. · Check the injection pump or the nozzle. · Check the valve clearance.

Exhaust gas is white or blue.

· Adjust to specified oil quantity. · Replace with specified fuel.

Exhaust gas occasionally turns · Clean or replace the air cleaner element. black. · Check the nozzle. · Check engine compression pressure. · Check or replace the turbocharger.

Combustion noise occasionally · Check the nozzle. changes to breathing sound. · Check the injection pump.

Unusual combustion noise or · Check with specified fuel. mechanical noise. · Check overheating. · Check the muffler. · Adjust valve clearance.

7-1

Remark

2. ELECTRICAL SYSTEM Trouble

Service

Voltmeter fluctuates largely even · Check for loose terminals open-circuit wiring. with the engine running at a constant · Adjust belt tension. speed.

Lamp does not glow brightly even when engine runs at high speed.

Lamp flickers while engine runs.

Voltmeter does not fluctuate even · Check the alternator. with an increase in the engine · Inspect and repair wiring. speed.

Starting motor does not turn when · Inspect and repair the wiring. starting switch is turned on. · Charge the battery. · Check starting switch. · Check battery relay switch. · Place the FNR lever in the neutral.

Starting motor turns the engine · Charge the battery. sluggishly. · Check the starting motor.

Starting motor disengages before · Check and repair the wiring. the engine starts up. · Charge the battery.

Engine oil pressure lamp does not · Check the lamp. light up when engine is stationary · Check the oil pressure switch.

(When the starting switch is in ON position).

Charge lamp does not light up when · Check the lamp. the engine is stationary. · Check and repair the wiring.

(When the starting switch is in ON position.)

7-2

Remark

3. POWER TRAIN SYSTEM Trouble

Service

Engine is running but machine · Release parking brake. will not move. · Put FNR lever in position properly. · Add oil to transmission case to the specified level.

Even at full throttle, machine · Add oil to transmission case to the specified level. moves slowly and lacks power. · Disassemble transmission strainer and clean.

Transmission oil overheats.

· Add oil to transmission case to the specified level or drain oil. · Use a suitable gear speed. · Reduce time using torque converter at stall speed. · Check engine.

Abnormal noise is produced.

· Add oil to transmission case to the specified level. · Add oil to axle case to the specified level.

Brake does not work when pedal · Raise hydraulic oil pressure to specified level. is depressed. · Add brake oil. · Bleed hydraulic oil from brake system.

Brake drags or stay when appli- · Clean breather and bleed air from brake system. ed.

Brake slips.

· Raise hydraulic oil pressure to the specified level.

Steering wheel is heavy.

· Repair or replace the pump. · Repair, clean and reset the relief valve. · Coat a grease to connections and bearings of steering gear. · Check the mounting of the steering column.

Slow steering.

· Check or replace the pump

Impossible to turn the steering · Clean spool and sleeve. wheel into neutral position.

7-3

Remark

4. HYDRAULIC SYSTEM Trouble

Service

Bucket lacks lifting power.

Bucket lifting speed is slow.

· Check the hydraulic oil level and add if necessary.

Bubbles in oil.

· Replace with specified oil.

· Replace filter in hydraulic tank.

· Add oil if needed.

Oil pressure is too low.

· Bleed air from oil line. · Add oil and bleed air.

Cylinder vibrates when operating. · Add oil.

7-4

Remark

INDEX A

G

Accelator pedal ----------------------------------------------- 3-16 After engine start -------------------------------------------- 4-4 Air breather element --------------------------------------- 6-38 Air cleaner filter ----------------------------------------------- 6-29 Air conditioner & heater ---------------------------------- 3-29 Air conditioner filter ----------------------------------------- 6-50 Axle gear oil ---------------------------------------------------- 6-45

Gauge --------------------------------------------------------------

3-4

H Hand throttle lever -------------------------------------------- 3-16 Hour meter ------------------------------------------------------- 6-1 Hydraulic oil changing --------------------------------------- 6-39 Hydraulic oil filling --------------------------------------------- 6-38 Hydraulic oil level ---------------------------------------------- 6-38

B

L

Backhoe work ------------------------------------------------- 4-15 Battery ------------------------------------------------------------ 6-21 Before starting engine ------------------------------------ 4-2 Brake pedal ----------------------------------------------------- 3-17 Bucket selection guide ------------------------------------ 2-6 Breaker ------------------------------------------------------------ 3-13

LCD indicator lamp ------------------------------------------- 3-2 LCD warning lamp -------------------------------------------- 3-4 Levers ------------------------------------------------------------- 3-13 Loader operation ---------------------------------------------- 4-12 Loading the machine ---------------------------------------- 5-3 Lubricant specification -------------------------------------- 6-7

C

M

Cab air filter ---------------------------------------------------- 6-50 Cab device ------------------------------------------------------- 3-1 Changing machine control pattern ------------------ 3-11 Cigar lighter ---------------------------------------------------- 3-5 Coolant ----------------------------------------------------------- 6-30 Cooling fan ----------------------------------------------------- 6-34 Coolant temperature gauge ---------------------------- 3-4

Maintenance check list ------------------------------------- 6-9 Major components -------------------------------------------- 2-1 Multifunction switch ------------------------------------------- 3-12

N New machine operation ------------------------------------

4-1

O

D

Oils ------------------------------------------------------------------ 6-8 Oil cooler ---------------------------------------------------------- 6-34 Operating levers ----------------------------------------------- 3-18

Drive shaft lubricate ---------------------------------------- 6-19 Drive control ---------------------------------------------------- 3-15

E

P

Engine oil filter ------------------------------------------------- 6-27 Engine oil level ------------------------------------------------ 6-26 Engine starting & stop --------------------------------------- 4-3 Engine starting by booster ------------------------------ 6-22 Engine stop ------------------------------------------------------- 4-6

Pedals -------------------------------------------------------------- 3-16 Periodical replacement parts ---------------------------- 6-3 Pilot line filter ---------------------------------------------------- 6-40 Prefilter ------------------------------------------------------------ 6-37

R

F

Radiator flushing ---------------------------------------------- 6-31 Radio & USB/MP3 player --------------------------------- 3-31 Recommended oils ------------------------------------------ 6-8 Return filter ------------------------------------------------------ 6-39 Road traveling -------------------------------------------------- 5-1

Fan belt ---------------------------------------------------------- 6-34 FNR lever ------------------------------------------------------ 3-16 Fuel filter -------------------------------------------------------- 6-36 Fixing the machine ----------------------------------------- 5-4 Fuel system bleeding -------------------------------------- 6-36 Fuel tank --------------------------------------------------------- 6-35 Fuse & relay box --------------------------------------------- 6-24 Fuel gauge ------------------------------------------------------ 3-4

RPM gauge ------------------------------------------------------

3-4

S Safety hints ------------------------------------------------------ 1-1

8-1

Safety labels ---------------------------------------------------- 0-6 Safety equipment --------------------------------------------- 3-24 Safety strut ------------------------------------------------------- 6-15 Seat belt ----------------------------------------------------------- 3-28 Seat controls ---------------------------------------------------- 3-27 Shovel work ----------------------------------------------------- 4-13 Speciation for major component ---------------------- 2-3 Specifications --------------------------------------------------- 2-2 Start switch ------------------------------------------------------ 3-7 Storage ------------------------------------------------------------ 4-23 Suction strainer ------------------------------------------------ 6-40 Slew lock ---------------------------------------------------------- 3-25 Switch (front console) -------------------------------------- 3-7 Switches ----------------------------------------------------------- 3-7 Switch (side console) --------------------------------------- 3-9

T Tires air pressure --------------------------------------------- 5-1 Torques-major component ------------------------------ 6-6 Towing machine ----------------------------------------------- 4-21 Transportation -------------------------------------------------- 5-1 Transmission ---------------------------------------------------- 6-41 Travelling position -------------------------------------------- 4-7 Troubleshooting guide ------------------------------------- 7-1

U USB socket ------------------------------------------------------ 3-10 USB player ------------------------------------------------------- 3-35

W Warming up operation ------------------------------------- 4-5 Warning lamps ------------------------------------------------- 3-4,5 Weight -------------------------------------------------------------- 2-2 Working ------------------------------------------------------------ 4-11 Working range ------------------------------------------------- 2-2

8-2