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210LC-7

CONTENT

introduction 0-1
Before servicing the machine 0-2
Approved by the Commonwealth of European countries 0-3
Table for entering the serial number and the distributor 0-4
safety signs 0-5
Guide to this manual 0-14

TIPS FOR SAFETY


1. Before starting work 1-1
2. During machine operation 1-6
3. During maintenance 1-13
4. parking 1-16

SPECIFICATIONS
1. Essential elements 2-1
2. Specifications 2-2
3. operating range 2-3
4. weight elements 2-4
5. capacity 2-5
6. Bucket Selection Guide 2-6
7. Undercarriage 2-8
8. Technical characteristics of the basic elements 2-11
9. Recommended oils 2-15

CONTROLS
1. cockpit devices 3-1
2. Panel displays and touch switches 3-2
3. switches 3-9
4. Levers and pedals 3-14
5. Air conditioning and heating 3-17
6. Other devices 3-20
JOB
1. Recommendations for a new car 4-1
2. Check before starting the engine 4-2
3. Starting and stopping the engine 4-3
4. operating mode selection system 4-7
5. Manage working equipment 4-13
6. machine movement 4-14
7. The effective work 4-17
8. Work on the construction site with special conditions 4-21
9. Normal operation of the excavator 4-23
10. Lowering operating equipment 4-24
11. Storage 4-25
12. Driving machine control via joysticks 4-27
13. Connection of the hydraulic circuit of the system 4-28

TRANSPORTATION
1. Preparing for Shipment 5-1
2. Dimensions and weight 5-2
3. Loading machine 5-6
4. Fixing the machine 5-8
5. Loading and unloading by crane 5-9

MAINTENANCE
1. Instructions for the 6-1
2. tightening torques 6-6
3. The requirements applicable to fuel, coolant and lubricants 6-9
4. The list of parameters to be checked during servicing 6-11
5. Maintenance Map 6-16
6. for the maintenance guide 6-18
7. Electrical 6-39
8. Air conditioning and heating 6-42

TROUBLESHOOTING GUIDE
1. Engine 7-1
2. Electrical 7-2
3. other 7-3
⠀ ⤀ĀᜀĀĀᜀ HYDRAULIC HAMMER AND FAST LOCK

1. Selection of the hydraulic hammer 8-1


2. The configuration of the hydraulic circuit 8-2
3. Maintenance 8-3
4. Safety rules for the hammer 8-4
5. Quick clip 8-6
INTRODUCTION

Guide contains a series of warnings and recommendations relating to driving, loading or


unloading, lubrication, maintenance, inspection and installation of a wheel excavator.
Instructions should facilitate the safe maintenance and improve machine performance.

Keep this manual nearby and favor the periodic reading instruction staff.

case of sale of the machine, make sure that you gave instructions to the new owner.

This machine complies with the instructions of the EU "89/392 / EEC."

Before operating the machine read and understand these instructions.

These instructions for the operator may include information about attachments and optional
equipment that is not in your area. Please refer to the request and advice on such products to your
local HYUNDAI Distributor.

Improper operation and maintenance of the machine can be dangerous and cause serious injury
or even death.

Some actions during operation and maintenance of the machine can cause injury if they are not
met by the method described in this manual.

Some operations and the precautions listed in this manual are used only for certain purposes
when using the machine.

If you use the machine in any not intended for this purpose, which is not specifically prohibited,
you must be sure that it is safe for you and for others. Under no circumstances neither you, not
the other person should not use the machine for any prohibited purpose as described in this
manual.

inspect the job site and follow the safety recommendations in the section on safety instructions
before working on the machine.

When replacing parts, use original spare parts HYUNDAI.


We strongly point out that Hyundai does not bear any responsibility for
malfunction caused by the use of non-original parts or improper repair.
In such cases, HYUNDAI is not responsible for any damage.

Improving the design of the machine may lead to changes in the details, which may not be
reflected in this manual. Or contact the HYUNDAI HYUNDAI your distributor for the latest
information on your car or on issues related to the information presented in this manual.

0-1
BEFORE MACHINE MAINTENANCE

It is the responsibility of the owner and all personnel involved in maintenance


repair, is to avoid accidents and injuries, for correct maintenance and repair.
It is also the responsibility of the owner and the entire staff for technical repairs
service is to avoid accidents and serious injury when servicing the machine.

No one should perform maintenance or attempt to repair the machine without proper training and
supervision.
All personnel concerned with technical repairs and maintenance, must be thoroughly familiar
with the established schemes and precautions contained in this manual.
All staff should also be aware of federal, state, provincial or local laws or regulations relating to
the use and maintenance of construction equipment.
Scheme set out in this manual, do not replace any requirements,
established federal, state, regional or local
legislation.

HYUNDAI Company can not anticipate all possible circumstances or environmental conditions
under which the machine can be used or produced its maintenance.
All personnel must be prepared for potential hazards.
Work within your level of training and qualification.
Contact your supervisor if you have any doubts about the performance of a specific task. Do not
try to do too much too quickly.
Based on common sense.

TIER II: excavator with a certified valuation engine gas components.

0-2
APPROVED BY THE COMMONWEALTH OF EUROPEAN STATES

Noise level (EN474-1 ANNEX4.10 and 2000/14 / EC) complies with the following
parameters:

LWA: 106 dB (European Union only)


LPA: 73 dB

seat vibration indicators operator below standard indicators


(EN474-1 ANNEX 4.3.1.3)

0-3
TABLE, FOR THE SERIAL NUMBER AND DISTRIBUTOR

The serial number of the machine

Engine serial number

Year of issue

Manufacturer Hyundai Heavy Industries co., Ltd.

Address 1 Chonha-Dong, Dong-Ku


Ulsan
The Republic of Korea

Distributor in the US Hyundai Heavy Industries USA, Inc

Address 955 Estes Avenue EIK Grove village


IL, 60001
USA

Distributor in Europe Hyundai Heavy Industries Europe NV

Address Vossendal 11
2240 Geel
Belgium

Dealer

Address

0-4
SAFETY SIGNS
location
Always pay attention to the purity of these signs, plates. In case of loss or damage to
any of them again, attach or replace a new one.

1) the air cleaner filter 15) Be careful with the engine! 29) The model name (left
2) turbocharger housing The danger of a cut limb side)
3) housing radiator 16) Do not stand on the hood 30) The model name (right
4) refueling engine side)
5) battery corrosion 17) Transporting 31) Logo (ROBEX)
6) battery explosion 18) Engine low 32) Brand HYUNDAI
7) the hydraulic level of gaseous emissions (On the boom)
oils 19) control ideogram 33) Brand HYUNDAI
8) hydraulic lubrication 20) control ideogram (On the counterweight)
oil (left-hand side) 34) Free from staff
9) Beware! Do not stand 21) control ideogram working area
close! (Right side) 35) Noise level LPA
10) Lifting Loop 22) Guide 36) Noise level LWA
11) Record the name operating 37) Instructions
companies and car models 23) Maximum height operating
12) loading ideogram 24) Windshield safety 38) Driving the car lift
excavator glass 39) caterpillar
13) Do not stand close to the side 25) safety rear 40) collision
side! glass 41) lock the lock
14) Stay still 26) air conditioner filter
The inclination of the
remote control box
safety lever

0-5
Description
The main body of the machine, there are several specific warning signs.
Please memorize the values of these warning signs.
If any of the warning signs are damaged or missing, replace it with a new one.

AIR CLEANER FILTER (sign 1)

This warning label is located on the air cleaner


housing.

Periodic and thorough inspection,


cleaning and replacement of elements extend
engine life and contribute to the quality of
his work.

TURBOCHARGER HOUSING
(Sign 2)
This warning label is located on the
turbocharger housing.
Do not touch the body turbokompres-
litter. It can cause severe burns.

BODY RADIATOR (sign 3)

This warning label is located on the heat sink.


Never Do not open the fuel cap when the engine is
running or at a high temperature coolant.

REFUELING (sign 4)

This warning sign is located on the right side of


the refueling mouth.
Stop engine before refueling. Refuel at a
safe distance from the fire.

0-6
CORROSION OF BATTERY

(Sign 5)
This warning label is located
the battery housing
The electrolyte comprises sulfuric acid
and can cause severe burns. Avoid contact
with the skin,
eyes or clothing. When
contact, flush with plenty of water and
consult a doctor immediately.
Keep the electrolyte at the
recommended level. Add
distilled water in the battery only when you
turn on and never when the engine is
switched off.
Maintaining the electrolyte at the proper
level avoids suction gas battery, since
minimal amounts of space allocates these
gases.

EXPLOSION OF THE BATTERY


(Sign 6)
This warning label is located on the battery
case
battery check is performed away from
open flames and any smoldering objects.
Do not use matches, lighters or burner
near the battery, as it can emit explosive gas.
Do not allow non-specialists to charge the
battery or use the transformer cables.

⠀ ⤀ĀᜀĀᜀ the hydraulic


OIL (sign 7)
Warning sign located on the left side of the
hydraulic oil level sensor.
Lower the bucket to the ground when you
serve the hydraulic system.
Check the oil level sensor. Top up with
the recommended type of
the hydraulic oil to the correct level if
necessary.

0-7
8) LUBRICATION hydraulic oil (the sign
8)
This warning label is located on the right side
of the air breather.
Do not mix different grades of oil.
Never open the fuel cap when the engine
is running or at a high temperature coolant.
Slowly remove the cap and release the
internal pressure

BEWARE! Do not stand


CLOSE! (Sign 9)
This warning label is located on the
counterweight.
To avoid serious injury or death, do not
stand in the turning radius of the
machine.
Do not wash or peel off the sticker from
the car.

Lifting loop (sign 10)

This warning label is located on the


counterweight.
Notlift the machine by the lifting eyes on the
counterweight. Overloading of lifting loops will
lead to their failure and possible personal injury.
Suitable excavator lifting method
described on p. 5-7.

0-8
Do not stand near the side of the
DIGGER!
(Sign 13)
Warning label is located on the side wing of
the counterweight.

To avoid serious injury or death, do not


stand in the turning radius of the
machine.
Do not wash or peel off the sticker from
the car.

AVAST motionless! (Sign 14)

Warning sign located on the side of the


housing.

Make sure that the machine is stationary


when the door is opened. Carefully open
the door can be slammed shut by the action
of external forces or natural (eg., A strong
wind).

CAUTION WITH THE ENGINE!


LIMB danger of cuts (sign 15)
Warning sign is located on the engine bonnet.

Do not open engine hood while it is


running.
Do not touch the exhaust pipe, it may
cause severe burns.

0-9
Do not stand on the hood
ENGINE (sign 16) Warning sign is located
on the engine bonnet.
Do not step on the engine cover.

TRANSPORTATION (sign 17)


Warning label is located on the right side of the
upper frame.
Before transporting the excavator
Read this manual; Attach the wire rope
handle of the boom and the caterpillar to
the trailer platform.
transporting items cm. at p. 5-6

KONTROLNAYAIDEOGRAMMA
(Sign 19)
Warning label located on the right cab glass.
Check,whether this machine control circuit diagram
of this label. If they do not match, replace the label on
the excavator to work.
mismatch machine control circuit and the circuit in
the label may result in injury or death.
contact per detailed
information on p. 4-13.

CONTROL ideograms (left side) (sign


20)
Warning sign located on the left side of the
remote control box.

Check,whether this machine control circuit diagram


of this label. If they do not match, replace the label on
the excavator to work.
mismatch machine control circuit and the circuit in
the label may result in injury or death.
contact per detailed
information on p. 4-13.

0-10
CONTROL ideograms (right side)
(sign 21)
Warning label is located on the right side of the
control box.
Check,whether this machine control circuit diagram of
this label. If they do not match, replace the label on the
excavator to work.

mismatch machine control circuit and the circuit in the


label may result in injury or death.
Contact for details on p. 4-13.

MANUAL
(Sign 22)
Warning label located on the right side of the
cockpit window operator.
detail Read the instruction manual before operating the
excavator.

MAXIMUM HEIGHT
(Sign 23)
This warning label is located on the right side of
the cockpit window operator.
Contact the machine with power lines can
cause serious injury or death. As a result,
finding a simple machine in the area of the
operator of transmission lines may get an
electric shock. The minimum distance must
be maintained depending on the line voltage
(see. S. 1-7)

SAFETY WINDSHIELD
(Sign 24)
Warning sign is located on the inside of the
windshield.
Be careful, the windshield can be suddenly
closed on the lock.

0-11
Emergency exit (sign 25)
Warning sign is located on the inner side of the
rear window.
The rear window can serve as an
emergency exit.
To remove the rear window, pull the ring
and press out the window.

Air Conditioning Filters


(Mark 26)
Warning label is located on the conditioner
housing.
Periodic and thorough inspection,
cleaning and replacement of the filter
prolongs the life of the air conditioner
service and contributes to the quality of
his work.

Inclination BOX CONTROL STATION


(sign 27)

Before leaving the machine make sure


that the slope of the left control box.

LEVER SAFETY
(Sign 28)
Warning label is located on the body of the
safety lever.

Before leaving the machine make sure


that the safety lever is placed in the
"locked" position.

0-12
FREE FROM STAFF
ZONE (sign 34) Warning sign is not
counterweight.
To avoid serious injury or death, do not
stand in the turning radius of the
machine.
Do not wash or peel off the sticker from
the car.

ᜀĀᜀĀ COLLISION (sign 40)

Warning label located on the right cab


window.
be careful when working in an excavator equipped
with a quick locking or extension cords.
Bucket can hit the cab or the boom of the
boom cylinders when approaching them.

LOCKING CLIP
(Sign 41)

Warning label located on the right cab


window.
runaway the bucket can cause serious injury or
death.

Job on or without the excavator with quick lock


switch unlocked
locking rod
Security in a moving hook
It may be the cause of failure of the bucket.

0-13
GUIDE TO THESE INSTRUCTIONS

DIRECTION OF TRAVEL

This manual is indicated by the direction of


travel of the excavator "forward", "back", "right"
and "left" standard, where the engine is in the rear
of the machine and the machine is moving in the
normal direction.

SERIAL NUMBER

If you order the parts of the excavator or machine


malfunction, inform the following:
The machine's serial number.
It is located right in the bottom of the operator's
cab.

The engine serial number.


It represents the numbers appearing on the plate on
the engine.

SYMBOLS

It indicates important safety measures

Indicates causes serious damage to the car or the environment.

Important information for the operator.

0-14
TIPS FOR SAFETY
BEFORE STARTING WORK

First of all think about security.


special situations wear protective clothing,
including safety helmets, safety shoes, protective
gloves, goggles and devices for hearing protection
according to the specific operating conditions.
Almost all accidents occur due to neglect simple and
fundamental safety rules.

Before you begin, make sure that you really


understand correctly the provisions of this manual.

Fully aware of the details and the whole process of


the implementation of construction works before you
started to work.
If you find any dangerous operation
process, consult
supervisor on preventive safety measures before
beginning work on the machine.

Do not operate the truck when you are tired or


after consuming alcohol or drugs.

1-1
Carry out daily visual inspection in accordance
with the manual.
Repair damaged parts and tighten loosen the bolts.

Check for engine oil leaks working fluid, fuel, and


coolant.
Keep the machine clean, regularly clean the
machine from dirt and wash it.

Do not operate the machine if it requires


maintenance.
Get to work after the completion of repair work.

Be prepared to eliminate the possibility of fire.


Keep a fire extinguisher handy, and the number of
fire services - near the phone.

1-2
Protection against falling or flying objects

If there is a danger to the operator from falling or flying


objects, install the protective flap to protect the operator
in such situations. Make sure the lock is closed
windshield.
Before starting work.
Make sure that the personnel, other than the operator is
away from the area falling or flying objects.
Please contact the distributor of HYUNDAI
Europe, if you need the top and the front protective
flaps and FOPS (protective barrier against flying objects).

unauthorized modification

Any changes to the car, made without the permission of


the company HYUNDAI, can cause danger. Consult
distributor HYUNDAI before you make modifications to
the machine system. HYUNDAI company is not
responsible for injury or damage resulting from
unauthorized modifications to the excavator system.

PREPARING FOR AN EMERGENCY

Only in case of emergency break the windshield with


a hammer and gently leave the occupants of the cab.

Be sure to keep a fire extinguisher in the cockpit and a


first aid kit and use them in fire or accidents.
Make sure you know the phone numbers of people who
can help you in an emergency.

1-3
flashing beacon

When working on the road or near the road inclusion


of the flashing light to avoid traffic accidents.
To install the flashing light on your machine, please refer to
HYUNDAI distributor.

SAFETY DURING INSTALLATION AND USE


OF ADDITIONAL WORK EQUIPMENT

Before installing and using the optional additional


working equipment, read the relevant section of the
manual and all the information in the manuals related to
this work equipment. Do not install an additional
operating equipment by unauthorized or your distributor
HYUNDAI HYUNDAI. Installing unauthorized
equipment can pose a security risk or adversely affect the
course of the excavator and even shorten the life of the
machine.
HYUNDAI company is not liable for injuries, accidents,
damage caused by unauthorized use of additional working
equipment.

1-4
SAFETY REGULATIONS
Only an experienced and authorized personnel may
work on the excavator and maintained it. Follow all
safety rules, precautions and instructions when working
on the machine and its maintenance.
Working with a partner or other personnel on the
jobsite, be sure that the whole staff understands hand
signals to the jobsite.

SAFETY ITEMS

Make sure that all protective grilles and dampers are at


the right place. Repair them if damaged.
Use properly such safety items, such as locking pin and
the seat belt.

Never Do not remove safety parts.


Always keep them in good working order.
Inept use of safety components can cause injury or
death.
Driving machine control cm. 16)

Approval number 65 of California


According to the laws of the State of California diesel
exhaust components can cause cancer, birth defects, or
damage to fertility.
The terminals and the poles of batteries and related
accessories contain lead and lead compounds.
Wash your hands AFTER SERVICE RELATED
ITEMS!

1-5
During machine operation

Use the handrail and footrest when zalezanii excavator


and exit.
Do not jump on the excavator and jump with him.

Before you start beeps to alert to nearby personnel to


start the machine.
For better visibility, clean the glass of the extraneous
materials, eg., By icing.

Carefully manage excavator, paying attention to the lack


of personnel, people and other objects inside the
working area.
If necessary, install guards working area.

When using work equipment watch out for construction


site.

1-6
When working in a confined space provide sufficient
ventilation to avoid the danger of poisoning by exhaust
fumes of the engine operator.

Check the location of underground utilities gas and water


and provide proper them and their safety before work
and at work.

Work near power lines is dangerous.


Carry out work on the next safe distance below:

Voltage, Min. secure


kV distance m
6.6 3
33.0 4
66.0 5
154.0 8
275.0 10

If the machine touches the high-voltage wire, stay sitting


at his workplace in the cockpit
warn staff that the one does not touch the excavator to
turn off the current in the power line. Jump out from the
cabin, avoiding contact with the metal structure.

1-7
Remember interference.
Be especially careful and follow the free space around
the machine in rotation.

When operating the machine with a hydraulic hammer or working


where possible falling rocks, for adequate protection
is necessary to provide a roof railing and head
protection.

Do not work on a ledge or on soft ground, as there is


danger of capsize. If you work on a ledge or on soft
ground is inevitable, set the excavator at right angles so
that you can easily get out of the car. The drive wheels
must be placed in the opposite side of where the
digging.

When lifting works, consider the power of the machine,


the weight and width of the load.
Try not to overload the machine as this may cause
damage to the machine or an accident.

1-8
Working on slopes is dangerous.
Avoid carrying out work on a slope of more than 10 °.

If operating on a slope, you start it only after how to


prepare a horizontal surface.

Rotation on a slope facing rollover.


Do not carry the machine rotation with the filled bucket
on the slopes, as this may lead to loss of stability.

Try not to leave the car on the slopes.


If necessary, lower the parking bucket to the ground and
block the wheels.

1-9
Avoid driving in the transverse direction on a slope, as
this may cause tipping or slipping.

Moving the hill is dangerous.


When driving down a slope, make sure that the control
slowly and keep the bucket at a height of 20-30 cm
above the ground so that it can be used as a brake in
emergency situations.

Dangerous turn the machine when driving on slopes. If


required change the travel direction, turn the machine on
a horizontal surface and on solid ground.

Tensile engine inclination angle is 35 °.


In any case, do not work at an angle greater than the
limiting angle of engine inclination.

1-10
Before driving the car give a beep to alert people in the
vicinity.

Reduce speed when driving over bumps.

When working on soft terrain place flooring or wooden


panel under the track to prevent bogging excavator.

When working in water or in moving in shallow lakes


check the condition of the soil at the bottom, the depth
and rate of flow of water, and then make sure that the
water level does not exceed the height of the roller
bearing.

1-11
Landing on EXCAVATOR DIGGER AND
WITHDRAWAL

Never do not jump and do not jump from the excavator.

Sit down and go on an excavator with an excavator is


always facing him. In this case, use the handrails, step by
excavators and crawler frame, track shoes.
An additional step can be installed if the machine has wide
tracks. In this case, contact the distributor of HYUNDAI.

Do not hold the levers of control while landing on an


excavator or exit from the excavator.

For the safety of lean at least three cars (hands, feet), using
the handrails, steps or caterpillar tracks.

Always clean the railings, stairs and track shoes from oil or
dirt. If they are damaged, repair them and tighten all loosen
the bolt.

If you are planting or gathering with the excavator you hold


the door handle, open the door and secure it in the open
position. Otherwise, the door may suddenly move and you
lose your balance and fall.

1-12
DURING SERVICE

Stop the engine immediately if you notice any


machine malfunctions.
Immediately determine the cause of malfunction, such
as vibration, overheating or malfunction of the device,
and then fix the problem.

Park the machine on flat ground and stop the engine


for inspection and repairs. Put relevant information
sign next to the machine, indicating that the machine is
in an inoperable state (Remove the ignition key of the
car). During the maintenance work, you must be
especially careful. May require additional barriers and
protection means serving individual parts and
assemblies.

Do not remove the radiator cap from a hot engine.


Open the cover after the engine has cooled below
50°C. Otherwise, you may get injured by the spray or
steam hot coolant.

Do not work under the machine.


When working under the machine, a bucket or a lever
mechanism with a raised bucket must be installed
under the bucket and / or linkage reliable support.

1-13
Fuel and oil - Combustible liquid.
Keep them in a cool, dry place away from open
flames.

Do not touch the exhaust pipe, as this may cause


serious burns.

Do not open the engine hood with the engine


running.

During an inspection of the engine, be careful not to


hit the edge of the lid.

1-14
Be careful, because the front window can be closed
quickly.
Make sure that the support stands firmly at the open side
door.
Be careful, since the open side door can be closed by an
external force, such as a strong wind.

Anti-skid stickers must be replaced if worn or lost.

When you work on the top of the frame, producing


engine maintenance and / or other components, be
careful not to slip and fall.

The high pressure gas


The machine comprises a high pressure gas.
To avoid an explosion and personal injury, do not
approach the fire, do not make near the machine
works on welding and drilling.
Relieve pressure before draining fluids. LIFTING
EARS can break
When lifting the tank containing the liquid, lifting
eyelets or the tank can be damaged and cause
traumatic cases personnel.
Before lifting the tank, drain the entire liquid.

1-15
PARKING

Leaving the car at the parking place, lower the bucket to


the ground and completely turn the safety lever
parking position, and then remove the key.
Securely lock the cabin door.

Park the machine on a flat and safe place.

We hope that following all the above safety rules, you


can easily and securely work on the machine.
For safe operation, observe all safety rules.

1-16
SPECIFICATIONS
ESSENTIAL ELEMENTS

Instrumental fuel Main


box tank Tank pump
hydraulic
fluid

Engine

Radiator

Battery
Tooth Ladle Rotary drive motor Main oil cooler
hinge rotation distributive
valve

hydraulic
cylinder hydraulic cylinder Preliminary
Muffler
Handle hilt Arrow arrows air cleaner
Cabin

hydraulic cylinder
bucket
Counterweigh
Coupling tension carrying asterisk t
pull roller rink
side cutter Connective bearing Caterpillar drive motor
stock rink

2-1
2. SPECIFICATIONS

one) R210LC-7 Model

H
E
I (I ') D

G
C

F
J M
K N
B
A (L)

Name U rev. Value


Operating weight kg 21700
Accommodates standard bucket (PCSA on standards) m3 0.92
Overall length BUT 9520
The overall width of 600 mm with Trakom IN 2990
headroom FROM 2990
The width of the superstructure D 2700
cabin height E 2920
The distance of the counterweight from the ground F 1060
Height to engine covers G 2320
mm
Minimum ground clearance H 480
back Size I 2770
The radius of the rear edge of the turn I' 2830
Distance between axes J 3650
The length of the undercarriage K 4440
The width of the undercarriage L 2990
The distance between the centers of the tracks M 2390
Track width, standard N 600
low 3.4
speed km / h
high 5.3
Swing speed rev / min 12.5
Gradeability Hail(%) 35
Ground pressure (the caterpillar 600 mm) kg / cm2 0.46

2-2
OPERATING LIMITS

Models R210LC-7 (with 5.68 m boom length)

A
A'
F

D
E

C
B'
B

8ft

Handle Handle Handle Handle


Name
2.0 m 2.40 m 2.92 m 3.90 m
The maximum radius
BUT 9140 9500 9940 10910
digging, mm
The maximum radius
BUT' 8960 9330 9780 10770
digging at the ground level, mm
Maximum depth
IN 5820 6220 6740 7720
digging, mm
Maximum depth
Digging (level 2.5 m), IN' 5580 6010 6550 7580
mm
Maximum depth
vertical digging FROM 5280 5720 6120 7240
wall, mm
Maximum height
D 9140 9340 9470 10110
digging, mm
Maximum height
E 6330 6520 6670 7290
unloading, mm
minimum radius
F 3750 3740 3640 3650
turning, mm
133 [146] kN 133 [146] kN 133 [146] kN 133 [146] kN
SAE 13600 [14840] kgf 13600 [14840] kgf 13600 [14840] kgf 13600 [14840] kgf
Digging force of the bucket 152 [166] kN 152 [166] kN 152 [166] kN 152 [166] kN
ISO
15500 [16910] kgf 15500 [16910] kgf 15500 [16910] kgf 15500 [16910] kgf
135 [148] kN 113 [123] kN 97 [106] kN 79 [87] kN
SAE
13800 [15050] kgf 11500 [12550] kgf 9900 [10800] kgf 8100 [8840] kg
Digging force on the handle
142 [155] kN 118 [128] kN 101 [110] kN 85 [93] kN
ISO 14500 [15820] 12000 [13090] 10300 [11240] 19170 [20910]
kgf kgf kgf kgf
[ ]: The boosting of

2-3
WEIGHT ELEMENTS

1) R210LC-7 Models, R210NLC-7


Element R210LC-7
Mass, kg
The upper assembly structure 8950
Welded main frame assembly 2600
Engine assembly 430
Engine assembly (excavator with engine TIER II) 530
The main pump assembly 120
The main valve assembly 200
Motor rotation actuator assembly 190
A hydraulic fluid tank assembly 240
The fuel tank assembly 195
Counterweight 3800
Cab assembly 310
The undercarriage assembly 8700
Weldment undercarriage 2720
pivot bearing 260
Drive motor assembly 305
Turntable 55
Tensioner with a spring return stroke 270
tensioner 170
leading rink twenty
support roller 40
Caterpillar assembly (standard triple grouser 600 mm) 1320
Tools and machinery front of the machine assembly
(Arrow 6.5 m, 3.05 m handle bucket 1.27 m3 by PCSA) 4050
Boom assembly 6.5m 1500
The handle assembly 3.05m 705
3
Bucket 1.27 m by PCSA 660
boom cylinder assembly 180
Cylinder handle assembly 290
Bucket cylinder assembly 175
Bucket lever assembly 170

2-4
LOAD

R210LC-7 Model
Arrow 5.68 m, 2.00 m handle is equipped with a bucket 0.92 m3 (By PCSA) and Tracians 600
mm triple grouser.

: Allowable front : Allowable value of the side or at 360 deg.

With a maximum
Radius download reach
Altitude
cargo
loading 3.0m 4.5m 6.0m 7.5m Reach
lifting

Note 1. Load capacities justified SAE J1097 and ISO 10567.


ROBEX series Lifting capacity does not exceed 75% of tipping load, with the
installation of the machine on firm ground or 87% of the power of hydraulics.
The load point is a hook located on the back of the bucket.
* Indicates the load limited by hydraulic capacity.

2-5
BUCKET SELECTION GUIDE

NORMAL BUCKET

The maximum amount of the bucket PCSA

0.51 m3 0.80 m3 0.92m3 1.20 m3 1.34 m3

capacity with Recommendation


cap, m3 Width Weight, Arrow 6.25 m
Without FROM kg
By By Handle Handle Handle Handle
cutting cutting
PCSA CECE edge edge 2,1 m 2.5 m 3.05 m 3,6 m

0.51 0.45 700 820 580

0.80 0.70 1000 1120 650

0.92 0.80 1130 1250 710

1.20 1.00 1400 - 770

1.34 1.15 1550 - 800

: Standard bucket

Applies to materials having a density 2000kgs / m3 or less.

Applies to materials with a density of 1600 kg / m3 or less.

Applies to materials with a density of 1100 kg / m3 or less.

2-6
TOOVSHI for heavy loads, To work on rocky soil and For leveling SLOPES

Buckets 0.74, 0.87, 1.05 m3 0.87 m3 bucket Bucket 0.75 m3


with a cap on the SAE with a cap on the SAE with a cap on the SAE

Recommendati
on
Capacity, m3 Width Arrow 5.68 m
Without FROM Weight, kg
hat on hat on Handle Handle Handle
cutting cutting
SAE CECE edge edge 2.0 m 2.4 m 2.92 m

0.74 0.65 915 - 750

0.90 0.80 1070 - 790

1.05 0.92 1220 - 870

0.87 0.75 1140 - 860

??0.75 0.65 1810 - 880

: Ladle for heavy loads

: Bucket works on rocky soils

: Leveling bucket for slopes

Applies to materials having a density 2000kgs / m3 or less.

Applies to materials with a density of 1600 kg / m3 or less.

Applies to materials with a density of 1100 kg / m3 or less.

2-7
Undercarriage

CATERPILLAR
The center frame of the bogie-type X-leg is welded with reinforced rectangular sections.
This design includes tracks with dry compounds lubricated rollers, tensioning rollers,
sprockets, hydraulically adjustable trucks with absorbing shocks and springs caterpillar type
tractor trucks with triple grouser.

TYPES Truckee

triple grouser

Model Options

R210LC-7 Width mm 600 700 800 -


Total weight kg 21700 21980 22270 -
Inheritance. ground
pressure kg / cm2 0.46 0.40 0.35 -
Full width mm 2990 3090 3190 -
R210LC-7 Width mm - - 800 -
with a long Total weight kg - - 24360 -
Inheritance. ground
arrow pressure kg / cm2 - - 0.42 -
Full width mm - - 3190 -
R210LC-7 Width mm double
600 700 800 grouser
increased
710
cross-country
Total weight kg 23160 23440 23730 23770
Inheritance. ground
pressure kg / cm2 0.49 0.43 0.38 0.43
Full width mm 3395 3495 3595 3505

Number of rollers and Truckee each side

Name Number on the side

leading rollers 2
Road wheels nine
track shoes 49

2-8
METHOD OF SELECTION Track Shoe

According to the operating conditions on the excavator you need to select the appropriate track
shoes.

Selection Method Shoe


Select soil category in Table 2, then use Table 1 to select the truck. Wide tracks (categories B and C)
can not be used on all types of ground. Before using the wide shoe explore precautions. then
carefully study the operating conditions to determine whether this type of shoe is suitable.
Choose the narrow tracks to achieve the desired permeability and ground pressure. Using the shoe
wider than recommended will cause unforeseen difficulties, such as the curvature of the shoe, the
cracks in the links, the axis of failure, loosening bolts in Truckee and others.

Tableone

caterpillar track Features Category shoe


600 mm triple grouser Standard A
700 mm triple grouser Option B
800 mm triple grouser Option C
800 mm triple grouser Standard
C
(Model with a long arrow)

Table2

Category
shoe Using Precautionary measures

BUT Rocky soil, • On uneven surfaces with large obstructions


floodplains, plain (Boulders, fallen trees) maintain the small
the soil. speed.
IN Normal soil, • This type of shoe can not be used on uneven
soft soil. surfaces with large obstructions (boulders
fallen trees).
• High speed turn on a flat
surface.
• If you can not move obstacles Keep
low speed.
FROM Very soft soil • Use this type of shoe is only provided if a
(Marshy soil) the car gets stuck in the ground and you can not use tracks
Category A or B.
• This type of shoe can not be used on uneven
surfaces with large obstructions (boulders
fallen trees).
• High speed turn on a flat
surface.
• If you can not move obstacles Keep
low speed.

2-9
SPECIFICATIONS MAIN COMPONENTS

ENGINE

Name Specifications

Model Cummins B5.9-C * Cummins 6BTAA


Type of Four-stroke diesel engine with
turbo
cooling method Water cooling
Number of cylinders and their arrangement Six cylinders in a row
ignition order 1-5-3-6-2-4
Type combustion chamber direct injection
Bore and Stroke 102 × 120mm
Cylinder capacity (per stroke 5880 cubic meters. cm
piston)
Compression ratio 17.4: 1 * 17.3: 1
Rated power, hp on SAE J1995 155 hp at 2100 rev. / min
(See. The identification plate)
* 150 hp at 1950 vol. / min
Maximum torque 62.1 kgf · m at 1600 rpm. / Min
* 62.6 kgf · m at 1500 rev. / Min
The volume of oil in the engine 24 l
dry weight 400 kg * 496kg
* 2180 ± 50 vol. /
Maximum engine speed 2250 ± 50 vol. / Min Min
(Idle)
Minimum engine speed 950 ± 100 rev. / Min * 1050 ± 50 vol. / Min
(Idle)
Fuel consumption, theoretical 171.5 g / bhp * hr * 164.8 g / bhp * hr
at 2100 rev. / min at 1950 vol. / min
Nippon denso (24V-5.5
starter motor kW)
Generator Delco Remy 24V-50A
Accumulator battery 2 × 12V 160Ach

*: Models with engines TIER II.

2) The main pump

Name Specifications

Type
of Steering twin axial piston
Performance 2 × 105 cm3/about * 2 × 113 cm3/about
maximum pressure 330 kgs *m [360 kgf · m]
Nominal oil flow 2 × 220 L / min
Rated speed 2100 rev. / Min * 1950 vol. / Min

[ ]: The boosting of

2-11
GEAR PUMP

Name Specifications

Type of Single-stage unregulated


fif
te
Performance en cm3 /about.
maximum pressure 35 kgf / cm2
Nominal oil flow 31.5 l / min

the main distributor

Name Specifications

Type
of 9-spool
inclusion of the principle of hydraulic control
Pressure setting of the main
safety valve 330 kgf / cm2 [360 kgf / cm2]
The maximum pressure relief
valve 390 kgf / cm2

[ ]: The boosting of

swing motor

Name Specifications

Type of Two fixed axial piston


motor
Performance 151 cm3/about
Pressure valve settings 240 kgf / cm2
Brake system Automatic, with hydraulic spring
control.
braking moment 59 kgs* m
Pressure brake unclamping 33-50 kgf / cm2
gearbox type The two-stage planetary gear
Rotational speed 12.5 vol. / Min

Drive Motors

Name Specifications

Type of Adjustable axial piston


Operating pressure 330 kgf / cm2 * 325 kg / cm2
gearbox type The two-stage planetary gear
Brake system Automatic, with hydraulic spring
control.
Pressure brake unclamping 6 kgf / cm2 * 11 kg / cm2
braking moment 40.6 kgs* m * 49.3 kgf* m

for High Walker type excavators with high ground clearance

2-12
DISTRIBUTION MANAGEMENT

Name Specifications

Type of Decompression Type


Operating pressure Minimum 6.5 kgf / cm2
Maximum 26 kgf / cm2
power stroke Lever arm 61 mm
Pedal 123 mm

CYLINDERS

Name Specifications

the boom cylinder Ø piston rod Ø × × stroke Ø 120 × Ø85 × 1210mm


shock absorber to nominate only
cylinder handle Ø piston rod Ø × × stroke Ø 140 × Ø 100 × 1510 mm
shock absorber Extension and retraction
bucket cylinder Ø piston rod Ø × × stroke Ø 125 × Ø85 × 1055mm
shock absorber to nominate only

Discoloration of the cylinder rod may occur if the fluid replacement, which increases the friction
coefficient has been added to the grease and the rod penetrated the surface.

Discoloration does not cause any damage to the quality of the work cylinder.


CATERPILLAR

specific Count Overall


Name Width pressure on
primer kgf / cm2 links Width, mm

R210LC-7 Standard 600 0.46 49 2990


700 0.40 49 3090
Option 800 0.35 49 3190
R210LC / LR -7
(With the Standard 800 0.42 49 3190
extension. Arrow)
: Double grouser

2-13
LADLE

Capacity Width
According to Count without side On the side
Name the PCSA, By CECE,
m3 m3 teeth cutting cutting
edge mm edge mm
Standard 0.92 0.80 5 1130 1250
0.51 0.45 3 700 820
0.80 0.70 5 1000 1120
1.20 1.00 6 1400 -
1.34 1.15 6 1550 -
R210LC-7
Option 0.74 0.65 5 915 -
0.90 0.80 5 1070 -
1.05 0.92 5 1220
0.87 0.75 5 1140 -
◙0.75 0.65 - 1810 -

: Ladle for heavy loads


: Bucket works on rocky soils (such as "ESCO")
-Kovsh for profiling slopes

2-14
Recommended Oil

Use only the oils listed below, or their substitutes.

Do not mix oils of different brands.

Capacity, Ambient temperature, 0 FROM


location Type of fluid twent thir
l -twenty -10 0 10 y ty 40

thir
SAE ty

Pallet SAE 10W


motor 24
crankcase
oil
engine SAE 10W-30

SAE 15W-40

Turning
gear housing 6.2
reducer Zion SAE 85W-140
onboard
oil 5,4h2
broadcast
ISO VG 32
hydraulic Buck: 180
Tank cal System: ISO VG 46
hydraulic oil 270
ISO VG 68

diesel ASTM D975 №1


Fuel tank 320
fuel
ASTM D975 №2

nipple grease how many NLGI №1


grease neobho-
grease
NLGI
grease Dimo №2

Radiator Mixture
(rasshiri- antifreeze 35 Permanent type based on ethylene glycol
tion tank) water 50:50

SAE - Society of Automotive Engineers


API - American Petroleum Institute
ISO - International Organization for Standardization
NLGI- National Institute of oils and lubricants
ASTM- American Society for Testing and Materials

2-15
3. CONTROLS
coupling Cab

Ergonomic control panel design and suspension seat provides operator comfort when
working.

ELECTRONIC SYSTEM Displays


Centralized electronic mapping system allows the operator to see at a glance the status and
working conditions of the machine.
It is equipped with alarm security system for the early detection of machine faults
and they alert the operator.

Switch
sound switch panel
switch operation
breaker Car
right stick vent
display panel Audio speakers

"Glove compartment"

operator's seat

Box
electrical devices

CPU controller
Resistor
Fuse box
Main switch
Switch
air conditioner and heater
spin-down button
a pressing motor
boost switch
movement of the lever
The left joystick controls

pedal safety lever


The reference platform Emergency shift lever
to rest his feet Engine speed
(ORT)
(Excl. Models
engine TIER II)

3-1
Panel display and touch switch

Panel displaying sensors and lamps


On the panel there are sensors that function, as will be noted below, to alert the operator to
abnormal operation of the machine, as well as the timing of certain activities and the status of
the machine as a whole.
Sensors: show the status of the machine.
Indicator lamps: displaying a fault in the car (red).
Signal lights: indicate the status of the machine (yellow).
Monitor mounted on the machine displays all indicators and working conditions
of the machine. Daily visual inspection should be carried out in accordance with
the recommendations in Part 6 "Maintenance".
If the monitor shows a warning signal immediately identify your problem and
follow the appropriate action to resolve it.

The control lamp


Low Fuel The display shows
Control lamp temperature Fuel level sensor
hydraulic fluid temperature sensor
The control lamp for overheating hydraulic fluid
coolant temperature sensor
engine coolant
engine
The control lamp
pollution of the air cleaner Control lamp test
CPU controller
The warning lamp Low
engine oil pressure signal lamp
boost
The control level of the lamp signal lamp
battery charge heater
The control lamp
machine overload
signal lamp
check engine lamp engine warm-up
(Only in models with
Signal light frequency
engine TIER II) engine speed
The warning lamp Low
coolant level
liquids

case of any malfunction in the car the control lamp lights up and an audible buzzer. In
this case, press the buzzer switch, and the buzzer stops. But the warning lamp will light
up until the fault is corrected.

3-2
The display shows
This indicator shows the current time and information
machine: engine speed, coolant temperature and hydraulic
fluids, hydraulic fluid pressure in the engine, and fault
codes.
Cm. More information on p. 4-11.

FUEL GAUGE
This indicator shows the quantity of fuel in the fuel tank.
(2) Fill the tank with fuel when flashing white range or
white range lightbulb .
If a white or light range light sensors, even if the machine
is filled up, check the wiring, as the cause of the sensor readings
may be a poor electrical connection in the system or in the
sensor.

TEMPERATURE SENSOR hydraulic oil


This indicator shows the temperature of the hydraulic oil.
White range: Below 30 ° C
- Green range: 30-105ºS
red range
- Red range: above 105 ° C
Green range of light when working.
Before working on the machine continues to maintain the engine
at low idle until the green range lights.
If the red range lights up, it is necessary to reduce the load on
the system. If the sensor continues to show red range, stop the
machine and find out the cause of the fault.

WATER TEMPERATURE SENSOR ENGINE

It shows the coolant temperature.


White range: Below 30 ° C
Green range: 30-105ºS
- Red range: above 105 ° C
red range (2) Green light range at an operating condition.
Before working on the machine continues to maintain the engine
at low idle until the green range lights.
If the needle is in the red zone, stop the engine, check
radiator and engine.

3-3
WARNING LAMP LOW FUEL

(1) This flashes and a buzzer sounds an alarm if the fuel level is
less than 40 liters.
(2) Immediately fill the tank with fuel, if the lamp flashes.

WARNING LAMP TEMPERATURE FLUID

This lamp is lit simultaneously with the buzzer signal and


hydraulic fluid temperature above 105°FROM.
When you turn on the lamp, check the level of labor
liquid.
Check for dirt between the oil cooler and the radiator.

CONTROL lamp for overheating engine coolant


This lamp blinks and the buzzer sounds signal when the coolant
temperature exceeds a normal - 110°FROM.
(2) Check the cooling system when you turn on the lamp.

WARNING LAMP LOW ENGINE OIL PRESSURE

After starting the engine, the lamp blinks and the buzzer
sounds an alarm if the engine oil pressure is low.
(2) When the lamp during operation of this stop the engine
immediately. Check the oil level.

LIGHT POLLUTION CONTROL AIR CLEANER

(1) The lamp flashes when the air negative pressure due to
contamination of the air filter.
If the lamp flashes, check the filter and clean or replace it.

3-4
WARNING LAMP LOW COOLER

This light flashes and the buzzer sounds an alarm if the level
a radiator coolant in the tank below the lowest permissible
level (LOW).
Check the radiator tank with the flashing of the lamp.

Approx. The indicator may not be involved in a car

CONTROLLER DIAGNOSTIC INDICATOR LAMP central processing unit (CPU)

This lamp flashes and sounds a buzzer if there is


a problem due to the CPU controller.
If this lamp flashes, all other indicator lights on the display
panel will be turned off.

WARNING LAMP battery discharge


This lamp flashes and a beep sounds when you turn on the
buzzer
start switch and goes off after the engine starts.
(2) When this lamp during engine operation check the battery
charging circuit.

INDICATOR LIGHT OVERLOAD MACHINE

When the machine is overloaded and the overload switch


is ON. Flashes the lamp.

LAMP DIAGNOSIS ENGINE (only in vehicles with engine


TIER II)

This lamp flashes and sounds a buzzer in case of violation


Communication between the CPU and the electronic
controller ECU.
(2) Check communication line therebetween.

Approx. The indicator may not be involved in a car

3-5
WARNING LIGHT BOOST

This lamp lights up when the switch is pressed


forcing the left control lever.

WARNING LIGHT ENGINE spin-down at the touch

This lamp lights up when the system is turned on or


avtozamedleniya engine spin-down button on the left control
lever.

WARMING WARNING LIGHT ENGINE COOLANT

This light illuminates when the temperature of the cooling


liquid below 30 ° C.
(2) Automatic heating is switched off when the cooling
liquid temperature 30 ° C, or if the engine since the start of
10 minutes has passed.

WARNING LIGHT HEATER

This lamp illuminates when the heating function


cold weather.
Start the engine, when the light goes out.

3-6
PANEL touch switch

Switch Switch
modes of
operation load conditions

Switch Switch
regimes speed
user

Switch switch the buzzer


automatic Function buttons
slow
a display screen
engine speed

Mode switch (Work mode)

This switch is used to select the operating modeexcavator.


Normal work regime of hard work and mode of operation of the
breaker.
By pressing this switch, you can select one of the following modes:
: Mode of hard work
Normal operation:
Operating mode breaker

For detailed information see. On p. 4-7



Switch User mode (User mode)

This switch is used to select settingsuser. This switch you can


change the engine power and pump installation, and enter data
into memory as modes M I and M II of your choice.
For detailed information, see.on p. 4-7

3-7
automatic deceleration switch (Auto Decel)

He used to turn avtozamedleniya function. When this engine


speed is automatically reduced when the all the levers and the pedal in
a neutral position and there is fuel economy.
Lamp is lit (ON): automatic deceleration function is enabled.
Light is off (OFF): automatic deceleration function is cancelled,
so that the engine speed will increase to a previously established
indicator.
When the automatic deceleration function lightswarning light
deceleration engine speed on the display panel.
Switch load mode (Power mode)

By pressing this switch( ) Lamp lights the selected load


conditions.

• H: Mode of high load


S: Mode standard load

The switch controls the speed (Travel Speed)

This switch controls the speed.When choosing a high-


speed (symbol "Rabbit") - Press the switch once, choosing a
low rate (Symbol "Turtle") - press once again.

Horn switch buzzer

When the start switch is usually within2seconds buzzer


sounds. At this time, the lamp diagnosis.
If there is a fault in the car,red lightslamp and the buzzer
beeps. In this case, press the switch, and the buzzer off. But the
red light will continue to burn as long as the fault is corrected.

Selection Switch (Select)

This switch is used to select functions,displayed


on the display.
See. Information on p. 4-11.
Keep the switch pressed for3secondsandYou can set the
time as follows.
Watches - switch avtozamedleniya ( )
Minutes - switch buzzer signal ( ). After that,how do
you set the time,click again on theSwitch Select. You will return
to the clock display.

3-8
SWITCHES

Switch
flashing beacon
button operation
breaker
speed switch
engine speed

trigger switch
Panel
Switch cabin lighting
switches
Switch sound when movement
Switch
switch heater
machine overload washer switch
Switch wiper switch
quick lock
Switch the main headlights

Safety switch

Switch
sound
Switch
work breaker
main power
switch

spin-down button
a pressing motor
boost switch

trigger switch

(1) There are 3 positions:.. OFF (OFF), ON (ON) and START (START)

- OFF All electrical circuits are disabled.


- ON All machine systems are functioning.
- START Used when the engine is started. After
starting immediately release the key.

With the engine ignition key is in the ON position (ON). This helps
maintain the normal functioning of electrical and hydraulic systems, and
avoid serious damage to the machine.

3-9
MAIN POWER SWITCH

This switch is used to switch off the entire electrical system


O I as a whole.
I: the battery is connected to electric
: The battery is disconnected
DISCONNECT SWITCH
Never put the main power switch to ON (OFF) when the engine is
running. As a result, this can damage the engine and the electrical system.
OFF

SWITCH ENGINE SPEED

There are 10 units, from 1 to 10.


1 - low speed
10 - high speed
Turn the switch Accel dial to the right, you increase the engine speed, turning
left - decreases.

SWITCH BASIC LIGHTING

signal lamp This switch is used to turn on lights and task lighting in 2 positions.
(2nd) - First step: turn on the headlights.
- Second stage: Turning work lights.

signal lamp
(1st)

wiper switch

signal lamp This switch is used to drive the window wiper in 2 positions.
(2nd) First position: Intermittent operation.
The second position: Constant slow work.
Wiper motor does not work,if the front slidingthe door is open.
If the wiper motor is not running when thewiper, immediately turn
off the switch and determine the cause of the problem. If the switch is left
signal lamp in the on position (ON), can damage wiper motor.
(1st)

washer switch

the washer fluid is supplied and wipers operate only when this button is
pressed.
When the washer switch lights
lamp.

3-10
SWITCH HEATER

This switch is used when the engine is started in cold weather.


When it is pressed into the engine cylinders is injected liquid to
facilitate starting of the engine.
The indicator lamp in the bottom of the switch lights when it
pressed.
Never hold the switch for longer than 30 seconds, it may damage the
electric solenoid valve.

SWITCH AUDIO SIGNAL WITH TRAFFIC (optional)

This switch is used to feed surrounding the signal to start forward or


back the machine.
By clicking sound signal is supplied to the switch only when
motion machine.

LAMP SWITCH cabin lighting

When you open the car door to light the lamp cabin illumination; when
closing - this lamp is extinguished.
The lamp cabin lighting can be switched on and off
special switch.

SWITCH OVERLOAD MACHINE

By pressing this switch buzzer beeps and


overload warning lamp in the event that the machine is overloaded.
(2) and the buzzer silent warning lamp turns off When switching off of this
button.

SWITCH RAPID CLIP (optional)

This switch serves to engage or disengage the movable latch hook


quickly.

See details on p. 8-6.

3-11
BUTTON OPERATION Hydraulic Hammer

This button selects the work breaker.

Hydraulic works only when this button is pressed.









SWITCH flashing beacon (optional)

When you click on this switch turns on a rotating flashing beacon


on the cab.

The indicator lamp in the bottom of the switch lights when it


pressed.

SWITCH SOUND

Switch beep This switch is located at the top of the right joystick control.
When it is pressed, a beep is issued.

right stick
management

BUTTON OPERATION Hydraulic Hammer

Switch operation When you press this button, hydraulic works only if the switch on the panel
breaker
included the selection of the work breaker button.

right stick
management

3-12
BUTTON spin-down at the touch ENGINE

Slowing the engine at the This button is used to quickly enable engine speed deceleration function.
touch
The motor speed increases to the previously set after the button is
pressed again.

left stick
management

SWITCH BOOST

(one) This switch activates the maximum power.


Switch When it is pressed, the power transmitted from the hydraulic pump to the
boost
working equipment, increases approximately 10% for 8 seconds.
After 8 seconds, forcing off automatically, even if the switch is in the
depressed position.

Do not use for lifting operations.


left stick
management

3-13
Arms and Pedals

right stick
management

The left joystick controls

safety lever
movement of the lever Emergency shift lever
engine speed (ORT)
pedal (Excl. Models with engines TIER II)

LEFT JOYSTICK CONTROL

(1) This joystick is used to control the turntable and handle.


(2) For detailed information, please refer to Section 4 "Management of work
equipment."

RIGHT JOYSTICK CONTROL


This joystick is used to control the boom and bucket.
(2) For detailed information, please refer to Section 4 "Management of
work equipment."

3-14
EMERGENCY change lever ENGINE SPEED (optional, excl. TIER II)
This lever is used to increase or decrease the motor speed when the
controller malfunctions. to use
this lever switch emergency stop switch in the "emergency" position. .
See also page 3.26
(2) Press the button and pull the lever towards you to increase the speed or
push the by himself - to reduce, until you set the desired engine speed.
To stop the engine, turn the key to "OFF." And push the emergency
lever to the end in the down position.

* METHOD FOR MOUNTING emergency lever CHANGE SPEED (optional, excl. TIER II)

lever throttle Open the bonnet and disconnect the rod from the throttle lever in point A.
engine valve
Connect the cable to the emergency lever throttle lever in point B.
A

Cable

Low speed high idle idling

CONNECTOR Emergency Starting


If the CPU controller is removed, the engine will not start.
(2) to start the engine before it and reconnect the CN-92 A and B.
Do not connect these terminals when the controller CPU.

LEVER SAFETY

When installing the lever to "block" all pedals and levers are locked.
When you exit the cab, make surethat the safety lever is moved to
theto "blocked".
When installing the lever to the "free" all pedals and levers deblocked and
excavator can do the job. Do not hold the safety leverIf you sit on the
Free
excavatoror go with him.
blocked

movement of the lever

(1) This lever is mounted on the pedal movement and is used to control
the movement of the machine by hand.
The principle of operation is similar to the lever principle of the movement of the pedal.
For more information, refer to Chapter 4, "The movement of the
machine."

3-15
PEDAL The directional

(1) This pedal is used to move forward or back the machine.


If you press the left pedal, the left will move GoosenItza. If a by
pressing the right pedal will move the right track.
for Bolee detailed information, refer to Section 4 "Movement cars".

8) LEVER ADJUSTMENT OF SEAT AND CONTROL PANEL

(1) The lever is used to move the seat operasAtor and remote control in the most
comfortable position for the operator.
(2) Pull the lever to adjust the "back and forth" between 220 mm.

Lever arm
adjustment

3-16
AIR CONDITIONING AND HEATING

Air conditioning and heating are designed to create comfortable conditions for the operator in the cab
regardless of the ambient temperature.

LOCATION OF AIR CHANNELS

switch panel

Switch
air intake
flow switch
air in the cab
temperature controllerozduha
switchfan scab
power switch
C switch

3-17
POWER SWITCH

This switch includes simultaneously (ON) or disable (OFF)


system and LED display.
(2) The default settings

Speed air flows Fence


Function Air conditioning Temp.
fan in the cockpit air
Value OFF Maksim. Level
one recirculation
(OFF). cold head

CONDITIONER SWITCH (compressor)

(1) The switch includes simultaneously (ON) or disable (OFF) the


compressor and the LED display.
In accordance with the temperature of the compressor evaporator
or shut down automatically without affecting the display.

Air conditioner removes moisture evaporation and pumps out through


the drainhose. If the vacuum valve of the drain hose has a fault, moisture
can get into the cab. In this case, replace the vacuum valve.

FAN SPEED SWITCH

fan switch has four speeds.


(2) Pressing the first and fourth speed is accompanied by five beeps.

TEMPERATURE CONTROL AIR

The controller 9 has a temperature positions of maximum cold to the


maximum heat that can be selected step by step sequential switching
up or down.
Provisions maximum it cooling and maximum heat
Cold
accompanied by five beeps.
Warmly Provisions for maximum cooling and maximum heat following
settings are the best:

Speed air flows Fence


Temperature Air conditioning
fan in the cockpit air
Max.
ON (ON). 4 level head recirculation
cooling
Max.
OFF (OFF). 3 In feet Fresh air
heating

3-18
SWITCH AIR FLOW IN THE COCKPIT

(on
e) There are 4 positions air
flow
Position
Mode
switch

A
streams
air B

When the defroster air intake is performed in FRESH mode (fresh air) and air conditioning is turned on.
For heating (5 mode to "Maxim. The Heating"), air conditioning is not turned on.

SWITCH AIR INTAKE

It is possible to change the air intake method.

Fresh Fresh air


air
The absorption of fresh air from outside the cabin without
disturbing the cabin sealing.
Retsirku-
lyatsiya Periodically check the intake of fresh air filter for the efficient operation of
the latter.

recirculation
It occurs circulating the warmed or cooled air inside the cabin, which
improves work efficiency.

From time to time change the air in the cabin, if you are a long time use
recycling.

Periodically check the recirculation filter for the efficient operation of the
air intake.

recirculation function is only active when you turn off the car system, but can be
changed at any time as needed.

3-19
OTHER DEVICES

remote unit
radio control Car

operator's seat
12V socket

Resistor

CPU controller
Cigarette lighter (CPU)

Hour meter RS232 serial connector


Fuse box

Head Unit
For operator comfort features high-quality sound system in the cabin.

frequency button
rewind the tape
sound adjustment eject button
sound balance button Switching cassette Cavity back forward
(Left / right) radio stations cassette insertion

PROG
BAL BAS TRE

ON
BAND HYUNDAI AUTO REVERSE
VOL

SEEK one 2 3
power button
adjustment
volume TUNE 4 5 6
MTL

Search Button Setup Button memorizing button Display


radio stations Radio Waves radio stations

3-20
The power button and volume control

ON
V OL
By turning this switch is turned to the right player,butthen the
sound is amplified.
By turning the switch to the left will weaken the sound,and
thenradio turns off.
radio volume control does not work while in the ON position the
power knob on the remote control unit.

radio stations Search Button

When you press this button, the radio will automatically stop onthe
SEEK
following radio frequencies.

TUNE

Radio Wave Setting button

When you press"+"Channels are selected with a


SEEK higherfrequency.
When you press"-"Channels are selected with a
TUNE lowerfrequency.
Are common
AM band: changes after 9 kHz from 531 to 1602 kHz.
FM range: 0.1 kHz through changes from 87.5 to 108.0 kHz.
America
AM band: 10 varies from 530 kHz to 1710 kHz.
FM range: 0.2 changing over from 87.9 kHz to 107.9 kHz.
Europe
LW range: changes after 9 153 kHz to 279 kHz.
MW range: changes after 9 from 522 kHz to 1620 kHz.
FM range: 0.05 is changed over from 87.5 kHz to 108.0 kHz

radio memorizing buttons


By pressing these buttons you can immediately, withoutSearch
enable the channel, which is stored in the memory of this button.
one 2 3
Remember how in the radio's memory.
4 5 6
MTL You can store 6 channels in each of the AM and FM bands.
To store a channel in the memory hold the button down for more
than 2 seconds.

3-21
5) Display

G eneral & America General frequency and America


When the radio is on, the display shows the stereo (ST), AM, FM, FM2,
MTL and frequency of the currently running station.
Europe
E urope
When the radio is on, the display shows the stereo (ST), LW, MW, FM,
FM2, MTL and frequency of the currently running station.
When running the tape, shown on the display
indicator arrows .

sound balance button (left / right)


After clicking it snaps and can be rotated.
B AL
The strength of the sound on the left and right speakers will be
controlled by turning the button to the left - right.
After the adjustment, press the button again to fix
thesettings.

frequency sound adjustment button


low frequencies(BASS)
B AS TR E
After clicking it snaps and can be rotated.
When rotating the button to the right increases the bass sound,
left - decrease.
High frequencies(TREBLE)
You can change the Treble button is pressed on.
When rotating the key to the right high-frequency sound
rise, the left - are reduced.
After the adjustment, press the button again to fix
thesettings.
switching stations

Pressing this button turns on the radio,and you can listen


totransmission in the AM and FM bands.
AND

Rewind the tape back / forward


When pressed, this button during the playing timecassette tape
PROG
direction is reversed.
When you click one of these buttons cassette tape willskip
forward or backward, and if at that time you press another button - to
the playback mode.

3-22
REMOTE CONTROL UNIT Magnitoly

D
N
A
B

K
E
E
S

radio switch button


ON L
O
V

poi buttonSka radio

The power button and volume control

The power button and volume control

By turning this switch is turned to the right player,butthen the


sound is amplified.
By turning the switch to the left will weaken the sound,and
ON
VOL thenradio turns off.
This control does not work while in the ON position the power
knob on the radio panel.

2) radio stations Search Button

When you press this button, the radio will automatically stop onthe
following radio frequencies.
SEEK

switching stations

Pressing this button turns on the radio,and you can listen


totransmission in the AM and FM bands.
BAND

3-23
SEAT
For the convenience of the operator's seat is adjustable and takes the position in
accordance with the operator's body contours.
Comfortable operator position allows it to reduce fatigue during prolonged use and improve
efficiency.

Adjusting the back and forward (A)


Pull arm A to move back
forward or backward.
The seat can be moved back and forth in
between 170 mm and fixed at 9 positions.
(2) Adjusting the up-down (B)
tighten The lever for displacement seat
up or down.
lateral adjustment back and forth can
B performed only when tilted to one side
In the lever means.
Tilt (C)
Tighten the lever C to tilt adjustment
D seatback.
(4) Adjustment of armrests (E)
This operation is performed by rotating the handle
right or left.
E (5) Adjusting the pads for the head (B)
It is adjustable up and down at the request of the
operator
C (6) Adjusting the seat cushion (F)
F Adjust the position of the handle in the cushions
A according to the weight of the operator

LIGHTER
It can be used when the ignition key to the ON position.
The cigarette lighter can be used when it will pop out of their sockets after a short time after they click on it.
nine service socket
Cigarette lighter socket can be used in emergency cases. Not
Use a cigarette lighter 24V, 100W.

OUTLET 12V (Option)

Use a voltage of 12 volts as necessary (not exceeding


12V, 30W.)

3-24
fuse box

For vehicles with a conventional engine Only for cars with engines TIER II

20A 10A 5A 20A 10A 5A


W W W W W W
B B B
U BU U BU BU U
T T T HOLDER T T T HOLDER
P P P P P P
B B B
U BU U BU BU U
T T T T T T
F F F
R R R
O FRO O FR FRO O
M M M OM M M
10A
20A

10A

15
20

10
A
20A
HEADLI

A
LOCK WORKING

30
LOCK GLASS- DOP.TOPL.

A
GHTS HEADLIGHT RESERVE ECM
Igniting. CLEAR. PUMP
Igniting. S

10A
5A

10
5
20A

10A

CAB SWITCH. 3

A
10A
5A

CAB CLEAR. CAB ILLUMINATI HEADLIGH


ILLUMINATI ON. PANEL TS SOLENOID
ON. GLASS- LIGHT. RESERVE

10A

10A
transformatio

5A

5A
Condition. n WORKING CRASH.
Condition. CUTOFF DOP.TOPL. AND HEADLIGH
5A 20A

10A 10A

AND beacon HEAT. ZOVATEL TS SOLENOID


10A 5A

20A 5A

HEAT. FUEL PUMP

10A
20A

10A

10A
CLEAR. SWITCH. AND HEAT. 3 Condition. LIGHT. SOLENOID
GLASS- PANEL Condition. SOLENOID AND CPU
HEAT. CAB one

10A

10A
transformatio

5A

5A
n SOUND. CRASH.
10A10A

CPU GLASS- IAHS. beacon TRAFFIC


A 5A
20A5A

10A5A

ZOVATEL SIGNAL SOLENOID CLEAR.

10A
10A

20A

10A
10

Condition. Vatel one


FAN. PRIKURI- SOLENOID CPU PANEL Condition. HEATING
CPU DISPLAYS AND HEAT.
10A

10A

30A

10A

10A
5A
5A

5A

PANEL SOUND. PRIKURI-


DISPLAYS IAHS. HEATING TRAFFIC ECM ECM
SIGNAL Vatel
RELA RELA RELA RELA
Y Y RELAY Y Y RELAY
POWER compressor SOUND. POWER compressor SOUND.
COPA SIGNAL COPA SIGNAL
Condition. Condition.
CR -35 CR-7 CR-2 CR -35 CR-7 CR-2

RELA
EMERGENCY RELAY Y RELAY
RELA ANTI- FEED
Y FEED RESTART ETHER
ETHER
CR -5 CR -36
CR -5 CR -36

Fuses protect the electrical devices and connections from burnout.

On the cover of the fuse box is applied about amperage for each fuse and circuit protected them.

Replace fuses of the same amperage.

Before replacing the fuse, make sure that the ignition switch is in the OFF position.

3-25
CONTROLLER CPU

LED To harmonize the engine torque to the torque of the hydraulic pump, the CPU
light bulbs controller regulates the pressure at the outlet of the valve EPPR (Electro-
Proportional Pressure Reducer -
proportional pressure reducing valve) that provides control of the pump output
YRG
when the engine speed falls in accordance with various operation modes set by
it.
Three LED lights on the controller CPU indicate the following:
MO
DE
PART L: R
OB
NO: EX
21N8-
290LC-

32102 7

LED
malfunction Remedy
lamp
"G"
pregnant Missing -
ON.
"G" and "R" fault in
pregnant CPU • Replace controller.
ON. or RAM.
• Check, Do not break
"G" and "Y" The problem is in
connecting the data line
pregnant consistent
between the controller and the panel
ON. trunk.
instruments.
All three The problem is with • Check, Do not disconnect
LED voltage supply to power supply line voltage (24V,
lamps central grounded) controller.
disabled processor. • Check the fuse.

Green, R: red, Y: yellow

EMERGENCY resistor (optional)

This resistor is used for the emergency lever engine rotational speed change. It is
connected to the wiring (CN-47) in case of failure of the CPU controller.
C
this case the machine operates in a mode corresponding to the mode S.
HM

The resistor must be disconnected whenever the controller CPU is operating


normally.
Never connect the resistor to the wiring (CN-19), if the controller CPU
in the normal condition.

Normal position: CN-19 is connected to CN-19A


Emergency mode: CN-19 is connected to CN-19B
9) COUNTER HOURS

This counter indicates the total number of hours worked by the machine.
When operating the machine, always make sure the health meter. Carry out
HOUR METER inspection and maintenance of the excavator in accordance with the number of
operating hours as indicated and Section 6, Maintenance.

3-26
RS232 serial connector

CPU controller receives information about the machine


from the main onboard computer via the RS232 connector.

UPPER WINDSHIELD
To open the upper front window, follow these steps:
Slide both latches.
valve 1
A pen Grasp the handles on the top and bottom of the upper frame
windshield and push the glass toward the top.
Grasp the handles on the top and bottom of the upper frame
A pen windshield, put the glass in its original position before
mating with an automatic valve (2), move the levers
Both valves in the blocking position. Click on the levers
toward the rear of the cab to lock the upper
windshield in position.
To close the upper front window, follow these steps:
valve 2
Turn the lever of automatic valves(2)in accordance withdirection
of the arrow, thereby pushing the latch.
Perform the above steps 1-3 in reverse order to close the upper windshield.

3-27
4. OPERATION
1. RECOMMENDATIONS FOR A NEW MACHINE

1) To achieve the inherent technical


0characteristics excavator must work
about 100 hours.
2) Perform operation on the machine in accordance with Avoid excess
loads on the car
during the first
listed below 3 stages and avoid
100 hours
excessive loads on the machine for the first
100 hours.

Hours Load
Until 10
o'clock Approximately 60%
Up to 100 hours Approximately 80%
one
After 100 hours hundred%
Excessive exercise can worsen
pledged technical characteristics
machines and reduce its service life.
3) Be especially careful during the first 100
hours of work. excavator.
(on and
e) Daily check level availability
leakage coolant, engine oil,
hydraulic fluids and fuel.
Availabili an
(2) Regularly check ty grease d
add it. Daily lubricate all the points
lubrication.
(3) Tighten mounting bolts.
(4) fully warm up car before
work.
fro
(5) Time m time check in time
work functioning sensors.
(6) Watch out for the correct operation of the machine
when performing an operation in all modes.

4) Replace the following elements after the first 50


hours of
operation.

Element Service
The oil in the motor
Engine oil filter
Element drain line filter
hydraulic working fluid
replace
drain pipe filter element the
of the fluid container with the fluid
The filter elements in the circuits
Fuel filter
4-1
INSPECTION BEFORE STARTING THE ENGINE

Examine below the car around and in the presence of reduced


or lost attachment nuts or bolts, the presence of dirt, oil leaks, Check before
fuel or coolant, and check the condition of the work equipment Begin
and the hydraulic system. Check for loose wires and also the
presence of dust in places subject to high temperatures.
For more information, refer to Section 6 of this
manual, "Maintenance," in the part of the daily
inspection.

Adjust the position of the driver's seat for easy operation.
Adjust the position of the mirrors.

4-2
3. STARTING AND STOPPING THE ENGINE

1) CHECK INDICATOR LAMP


(1) Check whether all the controls are in
the neutral position.
(2) Turn the starter key to the ON position. (ON) and
check the following:
S TART
Whether all the lamps are lit after 2 hsekundnogo signal
ON
buzzer. OFF
After the lamp test version of the program panel
displays CL: 1.4 will be displayed on
Display monitor-Monitoring display (3) in
for 5 sec., then returns to the display panel
source indications. 3
After that, all the control and signal lamps
go out, except for the following:
- Battery discharge control lamp (2)
- Lamp oil pressure in the engine (1) one
2

2) STARTING (normal
temperature)
A beep will sound to alert you
others after you have examined S TART
working area for the presence of her people and
obstacles. ON

OFF
(1) Turn the ignition key to "START" and
start the engine.
If the engine does not start, let starter
cool for about 2 minutes before
Box
include a starter again. electro-
(2) Immediately release key after engine start devices

avoid damage to the starter motor.

Main
net
switch

4-3
STARTING IN COLD WEATHER
Free beep to alert others after you have examined the work area for
the presence in it of people and obstacles.
Replace the engine oil and fuel in accordance with the
guidelines given on pp. 2-16.
Add the antifreeze coolant in accordance with the ambient
temperature.
Check if all levers are in the neutral position
Inject ester pressing heater switch
After injection ester start the engine by turning the key switch to
the START pointer.
If the engine does not start, allow the starter to cool for 2
minutes, then try to start the engine again.
TART
Immediately release key after engine start. ON
OFF
Operation Warm the machine runs automatically.
STARTING IN COLD WEATHER (TIER II Engine)
Free beep to alert others after you have examined the work area for
the presence in it of people and obstacles.
Replace the engine oil and fuel in accordance with the
guidelines given on pp. 2-16.
Add the antifreeze coolant in accordance with the ambient
temperature.
Check if all levers are in the neutral position.
Turn the key switch to the indicator ON and wait until the glow
indicator light will turn off (OFF).
OFF
Start the engine by turning the key switch to the START pointer
after turning off the heating signal lamp.
If necessary, use a heating switch.
If the engine does not start, allow the starter to cool for 2
minutes, then try to start the engine again.
Immediately release key after engine start.
Operation Warm the machine runs automatically. S TART

ON
OFF

4-4
4) INSPECTION AFTER STARTING THE ENGINE
After starting the engine, check and verify
following:
(1) Normally, if the hydraulic fluid level in the tank?
(2) Are there any oil or water leakage?
(3) Are all control lamps (1-7) are off? one
(4) Are the sensor readings of the indicator nine
temperature water (8) and temperature 8
a hydraulic fluid (9) in the green zone? 2 7
3
(5) if the noise is normal engine running, and 4
Is the exhaust color normal?
Whether noise rate and
(6) vibration?
5 6
It should not dramatically increase the speed rate
directly after starting the engine, so
as this may cause damage
engine and turbocharger system.
If there is a fault in the control
panel, stop the engine immediately and
Repair.

running up engines
The optimal temperature for the hydraulic fluid is
50°C. At the outbreak of the machine when the oil
temperature is below 25°With the potential for
serious failure in the hydraulic system. hydraulic oil
temperature must be raised at least to 25°FROM. fifty C

Run the engine at low idle speed for 5 minutes.


Increase the engine speed and run at medium speed.
Operate bucket control lever for 5 minutes.
Do not use anything other than a bucket control lever.
Run the engine at high speeds and work at this time of the
controls bucket and stick for 5-10 minutes.
Do not use anything other than the controls and
bucket handle.
Operation of heating of the hydraulic fluid in the hydraulic
system will be completed after you
several times to direct the all cylinders, as well as
turning platform and excavator machinery movement.

Increase the duration of the warm-up procedure


when operating the machine in winter.

4-5
To stop the engine
If the engine stops abruptly without cooling, its
service life can be significantly reduced. Therefore, 5 minutes
do not suddenly stop the engine except in an at low speed
emergency. idle move
Specifically, if the engine is overheated, do not stop it
suddenly, and let it run at medium speed to ensure
gradual cooling, and only then switch off the engine.
Lower the bucket to the ground, and then move the control
levers in the neutral position.
Run the engine for 5 minutes at low idle.
Turn the starter key to the OFF position
(OFF).
In order to avoid the use of an excavator others, remove the
starter key from the ignition and move the safety lever to the
lock (LOCK).
Lock the car door
.
S TART

ON
OFF

4-6
SYSTEM OPERATION MODE SELECTION

STRUCTURE OF SARO

SARO (Computer Aided Power Optimization) - is the name


of the computer system of the mode of operation of the 6
machine, developed by HYUNDAI in order to optimize the
work of the excavator.

modes of operation

Three operating modes can be selected for optimal speed of


the machine.
Mode of hard work
Main boom solenoid is activated to increase the speed of one 2
the boom.
Normal operation: 5
When the ignition switch this mode is automatically 3
selected. In this case, the speed of rotation is higher than in
the regime of hard work. 4
Operating mode breaker
This mode activates maximum supply solenoid and the supply
pump results in hydraulic working movement.
o
load modes n
load modes are designed to work with different load and e. modes of operation
2. load modes
high efficiency combined with a reduction in fuel
3. user modes
consumption.
4. automatic mode
Mode H: high load
deceleration
Mode • S: Standard load 5. speed modes
6. The display shows
user modes
Using two modifications - M I and M II, you can change
the engine and pump power
enter them in the memory of your own.
• M I: mode I in mind
• M II: mode II in mind

How to change the settings in the memory

Each mode has a memory sourcedata set: the


average maximum engine speed, the automatic
deceleration of the engine speed (revolutions / min.) and
the pressure at the inlet valve EPPR.
When selecting the mode M I or M II are shown on the
display panel.

4-7
To change the high-revving engine, presswhile user
mode switch (USER Mode) and a selection (Select).
Thereafter ACCEL indicator (acceleration) flashes at intervals
of 0.5 sec c.
pressing  or  you increase or decrease the number of
segments on the display.
To change the number of slow speedEngine, click
the user mode switch (USER Mode) and select switch
(Select) again. Thereafter Decel LED (Slow) flashes at
intervals of 0.5 sec c
pressing  or  you increase or decrease the number of
segments on the display.
To change the pressure valve EPPR click User mode switch
(USER Mode) and select switch (Select) again. Thereafter
EPPR c indicator flashes in intervals of 0.5 seconds.
- Press  or  you increase or decrease the number of
segments on the display.
• Number of segments on display and
according to parameter
Segment ACCEL DECEL EPPR
( ) (Rev / min) (Rev / min) (MA)
low speed
one High-speed 900 150
800 * 700
2 High-speed 800 1050 * 800 200
3 High-speed 700 1100 * 900 250
4 High-speed 600 1150 * 1000 300
slowdown
5 High-speed 500 (Rev / min) 350
1200 * 1100
6 High-speed 400 1250 * 1200 400
7 High-speed 300 1300 * 1250 450
8 High-speed 200 1350 * 1300 500
nine High rotation 100 1400 * 1350 550
10 high speed 1500 * 1400 600
* Only cars with an engine TIER II.
To memorize the final installationsPress again
and the USER Mode Select.

automatic deceleration mode


Engine rotation (Auto decel)
It allows you to quickly slow the rotation of the motor.
speed mode

: Low speed

: High speed

4-8
The mapping system
Information on the status of the machine is read by the
CPU controller and displayed.
Cm. More information on p. 4-11

self-diagnostic system
Problems in SAPO system, occurred as a result of
malfunction of electrical devices, as well as a result of
opening of the contacts and short
circuit detected the CPU controller and displayed in the
form of faults.

"Anti-restart" system (against re


start-up)
This system protects against accidental starter restart when
the engine is already running.

How to operate the system selection mode

When starting the engine key is turned to


ON.
The display shows
When starting the engine key is turned toON., all the
lights come on and after 5 seconds. automatically go
out. Only warning lamp Battery charging warning lamp
and engine oil pressure will burn before turning the
engine.
After flashlamp diagnostic plateCL: 1.4(Display
panel version of the program) will be displayed for 2
seconds. on a display screen.
The panel display returns tosettings, the default. In
this case it includes:
the engine speed,
warning lamp battery charging,
Lamp oil pressure in the engine, but also includes
Mode S,
avtozamedleniya (Auto decel) mode
low-speed movement ( "turtle" icon).
The default for these installations can
self-diagnosis function, comprising detecting faults in
the electrical system.
Cm. More information on p. 4-11.

4-9
After starting the engine,
When the engine is already running, the three lamps are on as
shown below.
Mode Status
mode of operation ON. (ON)
load conditions S Incl. (ON)
Mode Low (low
Incl. (ON)
of movement speed )
mode avtozamedleniya Incl. (ON)
Under these conditions, the tachometer indicates low engine
speed - 800 ± 100 rev / min / 700 ± 100 revolutions / min (TIER
II).
If the coolant temperature is below 30 ° C, for 10 seconds. the
engine speed increases to
1200 ± 100 rev / min / 1000 ± 100 revolutions / min (TIER II).
This happens automatically for warming up the car engine.
After 2-3 minutes, you can choose any mode depending on the
work required.
Self-diagnosis function just as well couldperformed, since
the start switch is in the ON position.
Cm. More information on p. 4-11
SELECTING THE LOAD
mode S
motor speed switch Accel dial stands in the 10; avtozamedleniya
disconnected mode mode
selected.
Vol. / Min the effect
1950 ± 50 The same power as that of the machine, not
1800 ± 50 * these modes having
Only cars with an engine TIER II.
When the engine speed switch Accel dial mode is lower
than 9 units, one unit of switch reduces engine speed
approximately 100 rpm. / Min.
H mode
motor speed switch Accel dial stands in the 10; avtozamedleniya
disconnected mode mode
selected.
Vol. / Min the effect
Approximately 110% of capacity and speed
2090 ± 50
compared to S or machine mode without
1950 ± 50 *
these modes having
Only cars with an engine TIER II.
When the engine speed switch Accel dial mode is lower
than 9 units, one unit of switch reduces engine speed
approximately 100 rpm. / Min.

4-10
The display shows
Information about the state of the machine is read by the CPU and controller may be displayed on the
display panel when the operator selects a display mode by pressing the SELECT BUZZER STOP
switch or button on the display panel as shown below.
Group How to select the display mode What does the panel
The map Select group Selecting Name displays
zheniya indicators display
the original engine speed,
position rev / min

press SELECT Time


1 time
Path 1:
Ignition switch press SELECT Changing the force
Gruppa0(d

ON position or 2 times pressure (EPPR valve)


efault)

START.
Auto avto zamedleniy a
press SELECT
3 times
Model and version
CP program

Path 2: 3 times CP program


press
switch press SELECT Model and version

Decel when pressed


Opt

nov
(tol

sliu
koe

kda
ion

niy
dat
chi
len

vle
sta

a)

BUZZER STOP SELECT The pressure in line


Group 1-4 4 times first pump
SELECT The pressure in line
5 times second pump
SELECT The pressure of the pilot
6 times lines
versiyapro
davlenieE
Group1V

temperatu

grammy)
oltage,

PPR,

charging voltage
re,

the original the battery (B)

press SELECT Voltage


Press SELECT one 1 time potentiometer (B)
times while
pressing BUZZER press SELECT Voltage
STOP. 2 times a gearshift
In this group, (IN)
LED Temperature
lightbulb press SELECT hydraulic oil
switch 3 times (° C)
SELECT illuminated
(ON)
press SELECT Temperature
coolant
4 times
(° C)
* Press SELECT External pressure (kPa)
(

time
Press SELECT two Current fault
group2fault)

times while
switch kid ney
the original
pressing BUZZER
STOP. Recorded in the memory
In this group, press SELECT failure (only
1 time
LED lamprophyllite when the key)
Delete recorded in
sound press  and
memory failure
(code

buzzer (BUZZER SELECT


STOP flashes) simultaneously (Only if the
s

the ignition key)

4-11
Group How to select the display mode What shows
Select group selection display panel
mappin indicators regime Name
g- display
zheniya
Soft switch
the original pump or

SELECT pressure switch or


Press SELECT three 1 time avtozamedleniya system
times while SELECT lift switch
)

pressing BUZZER or
2 times voltage
STOP.
3

In this group, SELECT pressure switch


or
LED 3 times engine oil
button's lamp switch deceleration
SELECT blinks SELECT engine rotational one or
intervals of 0.5 seconds. 4 times pressing
SELECT emergency switch or
5 times movement signal when
SELECT
switch heater
6 times or

the original Hour meter or

SELECT Neutral relay (relay or


1 time "Anti-restart")
Press SELECT 4 SELECT speed solenoid or
times while
2 times
pressing BUZZER
SELECT Boost solenoid (2-
4

STOP.
)

or
In this group, 3 times position relief valve)
LED SELECT The valve is cycling
or
button's lamp 4 times arrows
SELECT blinks SELECT Alarm during
interval 1 sec. 5 times of movement or

SELECT Solenoid highest feed


or
6 times system pressure
SELECT or
Heating relay system
7 times

One press of the SELECT button at the same time BUZZER STOP switches the display
group in the following order.

Eg., Group 0 one 2 3 4 0

on - Included, o FF - switched off

Only a machine with an engine TIER II

4-12
MANAGEMENT Tools and machinery

Verify that the controls and working


equipment.

The left joystick controls used to manage the handle and


rotate the platform.

Right joystick control is used to control the boom


July
and bucket. 6
5 8
When you release the joystick control, it will
automatically return to the neutral position. 3 2
one 4

When controlling the rotation of the platform


take into account the distance, further
extending the turntable due to its inertia.







The left joystick controls

Rotate the handle away from the excavator


(clockwise).
Rotate the handle to the side to the excavator (counter
clockwise). 3
one
The rotation of the turntable to the right (clockwise).
4
The rotation of the turntable to the left (counter-
clockwise).
2

The
 right joystick controls
5. Lower the boom.
6. Lift the boom.
7. Rotation of the bucket excavator (clockwise).
8. Turning to the excavator bucket (counter
clockwise).
6

4-13
HANDLING EQUIPMENT

BASIC OPERATIONS
(1) Transport position In move
This position, wherein movement of the engine is located
behind a front working equipment of excavator.
Be careful, because when the platform is
rotated through 180 ° the direction of
movement is reversed.

Implementation of the movement


Moving the machine by means of a lever or pedal
movement.
It should not move continuously for a long time.
Reduce the engine speed and move at a low speed when Travel motor
moving on an uneven surface.

The movement back and forth
When the left and right levers or pedals are pressed at the
same time, the excavator will move forward or backward.
Speed of movement is determined by the course of the
pressed pedal or lever motion and the motion direction -
the direction of impact (forward or backward) on the
lever or pedal.

excavator Rotation
When you click on one lever or pedal changes the
direction of movement of the excavator by rotating only
one track.

Turning on the spot


It is used to change the direction of movement of the
original site by the rotation of the left and right track in
opposite directions.
This is achieved by simultaneously pressing the left and
right pedals or levers in opposite directions.

4-14
2) MOTION FOR INCLINES
(1) Make sure the correct position of the lever
traffic and transport engine.
(2) Dip the ladle to a height of 20-30 cm from the surface
earth, so that emergencies can be
It was used in order to brake.
(3) If the car begins to slide or lose
resistance, immediately lower the bucket and
brake the movement of the machine.
(4) When parking on slopes, use a bucket in
as a brake and put under the wheels of the support for
slip prevention. Travel motor

The excavator can not effectively move


the slope at a low temperature of the working
liquid. Before driving on slopes
make the working fluid in the heating
the hydraulic
system.
Be careful when working on slopes, so
in this case the possible loss of stability
Travel motor
machine and its rollover.
When driving on slopes, make sure that
speed switch is in 20 ~ 30cm (1ft)
SMALL position (LOW- symbol turtle).

3) Movement on soft ground

If possible, avoid working on soft


soils. 90 ~ 110
(1) Move forward as long as the machine can
go its own way.

Be careful that the machine is not stuck too deep in the soft
ground, where it is impossible to towing.

When the movement of the machine under its own power is


not possible, lower the bucket and use the arrow and a handle
for pulling machines. At the same time operate the boom, arm
and movement of the lever in order to prevent bogging
machines.

4-15
TOWING THE MACHINE
When the excavator cannot move their own way, carried Correctly
out by towing follows.

Tow excavator using a different machine after attaching the


cable to the frame of the towed an excavator, as shown on
the right.

Hook towed cable towed behind the frame of the excavator


and enclose sponge under each branch cable in order to
prevent breakage.

Never make towing the excavator using only the towing wire rope
unit, as this may cause damage to the machine.
Wrong
Make that none of the staff are not located next to the tow
rope.

towing Wire rope sling

4-16
METHOD OF EFFECTIVE WORK

Perform excavation operation using the handle.


Use the pulling force on the handle for digging,
and use it together with a digging force of the
bucket if necessary.

The beginning and end of the operation to raise or lower


the boom slowly spend Quick stops, especially when
lowering at the beginning and end of the boom, can result
boom begins work
in damage to the machine. and end smoothly

Resistance digging bucket teeth and wear can be reduced


by arranging the teeth in the direction of the digging
bucket.

Install caterpillar excavator digs a trench parallel to the


line. Do not rotate the turntable during digging.

caterpillars parallel
line trench

4-17
Dig slowly, keeping the angle between the boom and the
jib in the range of 90-110 deg. If necessary, the maximum
digging force.

90 ~ 110

When the machine leaves a small safety clearances for


hydraulic cylinders turn in order to avoid damage to the
Power reserve
hydraulic cylinders.

When unloading the soil from the bucket keep the handle in
a horizontal position, and the ladle discharge position. In
the event of difficulties in unloading the soil from the
bucket treat the bucket control lever 2-3.

When unloading the soil does not produce shock bucket


teeth.

When stopping the rotation of the turntable take into


account the inertia forces that are further rotated turntable
after rotation of the control lever return to a neutral
position.
Inertia

rotation stop

4-18
Wrong
Do not use the weight of the power of the working
equipment for digging, hammering into the soil
pile elements.
The machine can be damaged by the impact.

Do not use a shovel to destroy solid pieces of rock, such


Wrong
as concrete or
a rock.
This can cause damage to the teeth,
fingers or bend the boom.

Wrong

NEVER MAKE operations that exceeds the


specifications of possible machines.

Performing these operations may result in an


accident or damage to the machine.
Hoisting operations are conducted within
the conditions set for the specific machine
capacity.
Never perform operations which may harm
the machine, such as: in case of overload or
excessive shock loads.
Never move with a raised load.
If you need to install the device, signaling overload in Wrong
the performance of lifting operations, contact your local
distributor firms
HYUNDAI.

4-19
BUCKET WITH HOOK
In carrying out lifting operations requires a special
bucket with lifting hook. Lifting
hook
The following operations are prohibited:
Hoisting lifting cables during
engagement of a tooth of the bucket.
Hoisting upon engagement lifting cables
directly behind the boom or stick.

In carrying out lifting operations safely hook


the lifting ropes for lifting hook bucket.

In carrying out lifting operations never lift or lower the


people.

because of the risk of possible fall or die and fall load


any of the working personnel are not allowed to be in the
working area borders.

Before carrying out lifting operations, define the


person who will lead these operations.

Always follow the instructions in the


performance of lifting operations.

Perform all his instructions.


Assign a signalman.
Perform all signals and commands signalman.

Never leave the operator's station with


a raised load.

4-20
8. job site with special conditions.
on
e) WORK ON THE MACHINE IN COLD
WEATHER
(on
e) Use fuel and engine oil,
appropriate weather conditions. 50 C
(2) Add in the cooling system necessary
antifreeze in the correct proportions.
(3) Refer to "Starting the engine in
cold weather. "
Start the engine and increase the time
warm-up sequence of the machine systems.
(4) Make sure you open the heater crane at
the need to use it.
(5) Always keep the battery
fully charged.
discharged rechargeable batteries
exposed to more easily freeze on
Compared to a fully charged state.
Clean the machine and produces its car park on a wooden
stand.

WORK on a sandy or dusty construction site


Frequently check the condition of the air filter element. To
clean or replace the filter element more frequently if the
warning lamp lights up and simultaneously with the signals
distributed to the buzzer, despite the periodicity of the filter
change.
After 6 times the internal and external cleaning of the filter
elements replace them.
Frequently check and keep the radiator cooling fin clean.
Prevent the ingress of sand and dust in the fuel tank and a
hydraulic tank during refueling.
Prevent the ingress of sand and dust in the hydraulic system
by hydraulic tank breather tight closing covers. Most filters
replace the hydraulic fluid.
Always keep all components and lubrication points, such as
in a clean pins and bushings and greased form.
If the air conditioning and heater filters clog, it will lead to
a decrease in the efficiency of the air conditioner and
heater. Clean or replace the filter elements more frequently.

4-21
WORK offshore
Prevent ingress salt by securely tightening the caps and screw
taps in all the elements of the machine design.
Wash the machine after the operation to remove salt residues.
Pay special attention to the elements of the electrical
system and wiring, as well as the hydraulic cylinders in
order to prevent corrosion.
Checking inspections and lubrication should be conducted more
frequently.
Replace the old grease in the bearing assemblies, which
were immersed under water for a long time, a sufficient
amount of new grease.

4-22
NORMAL works Excavators

because of design features a hydraulic excavator with him


during the following may occur:

When rotating the handle toward the handle excavator is


stopped for a short time at the point X shown in the figure,
and then restores its passage speed point H.
The reason for this phenomenon is that the velocity of
the handle due to its own weight faster than the rate of
flow of hydraulic fluid in the cylinder.
When lowering the boom is heard a continuous sound.
This is due to the working fluid flow in the valve
system.
Movement in case of overload will be accompanied by
sounds produced by pressure relief valves installed to
protect the elements of the hydraulic system from
overload.
When starting or stopping the rotation of the turntable can
be heard about the rotary motor.
This noise arises from the activation of the brake valve
rotary motor.

4-23
Lowering of attachments (Engine stopped)

On excavators equipped with hydropneumatic, within a short


period of time (2 minutes) after the engine has stopped
working equipment will sink under its own weight if the work
equipment control lever is moved to "LOWER» (LOWER).
This lowering of the process will only happen if the start
switch is ON (ON), and the safety lever -. In the
"UNLOCKED» (UNLOCK).
After stopping the engine move the safety lever to
"block"
(LOCK).
Before lowering the boom, make sure that nobody
stands under or near the equipment.

The battery is filled with nitrogen gas under high pressure and
is extremely dangerous device when it is assembled or
mounted incorrectly. Always observe the following rules:
Never attempt to make a hole in the battery or expose
the battery to open flames and hot air.
Nothing is welded to the battery.
When performing maintenance or disassembly
maintenance battery, as well as when it is necessary to
remove cleaning the pressurized gas from the accumulator.
This operation requires a special valve to release the air, so
in case of the need for this work, contact your local
distributor of HYUNDAI.

4-24
STORAGE

For prolonged storage truck for 1 month or more in order


to maintain the machine efficiency is necessary to carry
out the following work.

CLEAN MACHINE
Clean the machine from dust and dirt. Check and adjust
the tracks. Lubricate all lubrication units.

Lubrication points of each element Replace all the


oil.

Be especially careful when using the appliance after


storage. During storage possible oil leaks. Apply grease
with anti-corrosion additives for lubricating
protrusions
 rods and cylinders
places easily corroded.

MAIN POWER SWITCH Turn off the main power


switch in the electrical equipment box and put the
machine into storage.

Make sure that the radiator is filled with anti-freeze with


anti-corrosion additive.

Protection against dust and moisture


Keep the machine dry. Install the wooden supports under
the machine when it is stored.

Lubricate and close the exposed displacement rod


cylinders.

Lower the bucket to the ground and place a support
under the bucket and tracks, as well as stops under the
tracks.

4-25
During storage
Time in month run engine and
by moving the working equipment as well as
moving machine for the lubrication of all machine
components.
When starting the engine, check the engine oil and
coolant.

Clean the piston rods of hydraulic cylinders from
corrosion lubricant.

Spend such labor movements of the machine, as the
movement, rotation of the turntable, and follow the
movement of the working elements of the equipment
to ensure sufficient lubrication of all the functional
elements of the machine.

4-26
SCHEME OF THE MACHINE with the joystick

Whenever
 in the machine control circuit
changes occur, produce the
same changes on plate control
circuit in the cabin. Driving on
 the plate MUST
dolzhnasovpadats
this circuit driving.

work joysticks Hose connection (Port)


Function
Left Right Joy Changing the port
management
Type ISO HYUNDAI Scheme

joystick joystick stick From On


Handle - from excavator D -
to the

Hilt - to the excavator E -


left

Right Swing A -
Left Swing B -
to the

lowering the boom J -


right

Lifting the boom H -


Bucket - from excavator F -
Bucket - to the excavator G -
lowering the boom D J
to the

Lifting the boom E H


left

Right Swing A -
type A

Left Swing B -
to the

Handle - from excavator J D


right

Hilt - to the excavator H E


Bucket - from excavator F -
Bucket - to the excavator G -
to
th

le
ft
e

lowering the boom


Buc ket - to the excavator
D A
JG

Lifting the boom E H


type B

Bucket - from excavator B F


to the

Handle - from excavator J D


right

Hilt - to the excavator H E


Right Swing F A
Left Swing G B
Loosen the bolt lever Control (21)
turn the entire system on the joystick 90 ° counter clockwise
to the

arrows; then set.


left

To put the control lever to the right


position, unscrew the nut (20) and rotate only the joystick
type

90 ° clockwise.
C

to the
right

The same as in the ISO


type.

4-27
CONNECTING THE HYDRAULIC CIRCUIT

Combined hydraulic circuit system has the ability to produce


single or double action.
Trehplineyny distributor may choose either circuit hydraulic
single-acting or double-acting circuit.
Before selecting the hydraulic transport mode circuit
hydraulic excavator set in position, as shown in the figure.
Stop the engine.
Use the hand lever to rotate
three-way control valve. Make sure you turn the
distributor
until it stops.

(1) A unidirectional flow (hydraulic Before


the hammer).
The lever parallel to the pipe (B).

(2) Unidirectional flow(Grab work


bucket or vertical cut at the bucket).
Set Arm perpendicular pipes (C).

4-28
5. TRANSPORTATION
1. PREPARATION FOR TRANSPORT

1) at transportation cars must


to comply with traffic rules, laws
on the movement of vehicles and
restrictions input on transportation Overall
width
certain types of machinery.
2) Select appropriate trailer after
weight specification and dimensions
Excavator under Section 2 of this manual
"Specifications".
3) Check the movement route, which will Overall
transporting produced excavator on height
the subject of road width, height of bridges,
limitation of the total mass, etc.
total length
4) If the need to obtain the necessary
permission to follow up on this route
from the respective organizations.
5) Prepare a suitable power for the trailer
transporting an excavator.
6) Prepare ramps for safe loading
an excavator on a trailer in accordance with
The following tables and figures.
gangway
BU Platform
T IN trailer
1.0 3.65-3.85
1.1 4.00-4.25 A
1.2 4.35-4.60
15 ~
16
timb
1.3 4.75-5.00 er ?
1.4 5.10-5.40
1.5 5.50-5.75

5-1
DIMENSIONS AND WEIGHT

R210LC-7 Model

(1) the machine as a whole

units
Symbol Description measurement Value
L Length mm 4990
H Height mm 2920

H
W Width mm 2990
Wt Weight kg 17410
L W
caterpillars600mm
triplegrouser and the counterweight
3800 kg.

BOOM ASSEMBLY

units
Symbol Description measurement Value

H
L Length mm 5900
H Height mm 1550 L
W Width mm 700
Wt Weight kg 1950
The boom cylinder 5.68 m with a handle
(including a system of pipes and fingers)

STICK ASSEMBLY

units
Symbol Description measurement Value
H

L Length mm 3910
H Height mm 870 L
W Width mm 350
Wt Weight kg 1050
Handle with hydraulic cylinder 2.95 m ladle
(including linkage and fingers)

BUCKET ASSEMBLY

units
Symbol Description measurement Value
H

L Length mm
H Height mm L
W Width mm
Wt Weight kg
3
Bucket 0.91 m by standard PCSA (including teeth
and side cutting edges).
Hydraulic
cylinders
5-2 BOOM
units
Symbol Description measurement Value
L Length mm 1960

H
H Height mm 230
W Width mm 330
Wt Weight kg 380 L
Including a system of pipes

OPERATOR ASSEMBLY

units
Symbol Description measurement Value

H
L Length mm 1962
H Height mm 1676
W Width mm 1288
Wt Weight kg 310 L W

COUNTERWEIGHT

units
H

Symbol Description measurement Value


L Length mm 2700
H Height mm 1050 L W
W Width mm 560
Wt Weight kg 3800

5-3
LOADING MACHINE

Loading and unloading machines are


manufactured on a flat piece of land.

Use Gangway sufficient length, width and thickness as


well as the corresponding angle of inclination.

Install excavator safety lever to the lock (LOCK) before


mounting on the trailer platform. Make sure that the
excavator is mounted parallel to the trailer platform.
Transport excavator engine must be back at the trailer
loading excavator
front - when unloading.

Perform the following steps after loading the


excavator into the trailer.
Stop the loading process, when the excavator is positioned
horizontally to the rear wheels of the trailer.

After rotating platform set at 180 degrees of rotation of the


turntable lock lever to the lock position (LOCK).

5-4
Gently and carefully lower the working equipment after
class excavator transport position.
Place a rectangular wooden block under the
bucket cylinder to prevent damage during
transportation.
Make sure that during the loading and unloading
of excavators transport speed selector is set to
"SMALL» (LOW), which corresponds to the
 character
turtle.
Avoid the use of working equipment
to facilitate the process of loading and
unloading, as it is very dangerous.
When loading do not operate yet any mechanism
or device.
Be careful on the borders of the trailer platform, as
carelessness can
lead to a loss of balance as the submerged
excavator and trailer as a whole.

During transportation or movement of an


excavator boom with a long boom and the
handle should be bonded with a rack.

Rack

Method bracket rack

Release cylinder handle a maximum length.


Mark on the rod a distance of 5-7 cm from the
m
end of the tube. 5~
7m

m
Pull the handle to the cylinder of the mark. 7m
5~

Rack
Adjust the rack mounting bracket and then
secure the stand to the right plozheniya.

Bracket
rack

5-5
FIXING THE MACHINE

Lower the work equipment to the loading platform of


the trailer. trigger switch

Establish a safety lever to the rotation lock


(LOCK).

Turn off all the switches (position OFF) and remove


the key from the lock.

Lever arm
security

Close all the locks. Instrumental


box and the fuel tank

Hood
engine

Side
Cabin
housing

In order to prevent the machine moves forward,


backward, left or right during
transport on a trailer enclose
wood bars under the track and securely
strengthen them by cables.

Chain

5-6
5. Loading and unloading with a crane

1) Check the weight, length, width and height of the machine


according to Section 2 "Specifications"
before loading crane machines. wire rope
Rack
2) Use a wire rope and to ensure the rack
clearances to avoid contact
of the lifting elements with an excavator.

3) The locations of contact with the rope structure 0.5 ~ 1.0m


Excavator install rubber gasket.
between the support Between
rollers №1 and №2 support
4) Install the valve in the proper place. and roller
tensioner
5) Place the rack and cable, as shown in the figure.
Wire
cable
Check if you have selected the correct length Rack
cable.

Establish a safety lever and lever


blocking rotation of the turntable in
lock position (LOCK) with a view to
prevent the movement of the machine and its
elements during loading.
BACK VIEW
Improper slinging and installation of cables
It can result in damage to the machine.

Do not load very quickly.

Clean the work area from the staff.

5-7
MAINTENANCE
INSTRUCTIONS FOR THE

Maintenance intervals
It should check the serviceability of the machine and
carry out its maintenance at the intervals described
on pp. 6-11, based on the hour meter readings,
located on the control panel.
Reduce the test intervals and service depending on
the operating conditions of the machine (eg, during
operation in dusty areas, quarries, offshore, etc.).
Spend the full range of
Maintenance for maintenance, including
operations, included in the previous charts. For
example, engine hours at 100 conduct operations
simultaneously
Maintenance, 100 corresponding to each engine
hours, every 50 hours, and daily maintenance. Counter
SAFETY REGULATIONS hours
Proceed to maintenance execution only after a full
examination of the machine design.
Monitor mounted on the machine,
fully guarantees the display of all
machine parameters. Daily check-up and
maintenance should be carried out in accordance
with Section 4 of this
guide "Maintenance".
Engine and hydraulics adjusted to
factory. Do not allow unauthorized to carry out these
works personnel to these units.
If you do not know how to manage any device, please
contact your local dealer HYUNDAY.
Drain the used oil and the coolant in closed
containers and keep them as industrial waste in
accordance with applicable regulations.

6-1
CORRECTNESS OF SERVICE
Replacement and repair of defective parts and
assemblies.
Need to replace wearing
are contaminated (clogged), details, such as bucket
teeth, the cutting edge of the bucket, filters, etc.

Use original parts.

Use the recommended oils.

Remove dust and water around the filler opening of the


oil tank to the oil fill.

To change the oil, drain it after warming up.

Do not carry out repairs with the engine running.


When refilling oil stop the engine.

Before repairing the hydraulic system must be reset from


its pressure.

Make sure that after the technical


service, the display is in working condition.

For more detailed information on maintenance please


contact your local HYUNDAI dealer.

Before you start maintenance, make sure that you fully


understand the provisions of Section 1, "Safety Instructions."

6-2
PRESSURE RELIEF
FLUID
The jet of oil may result in an accident when
removing covers or loose hoses immediately after the
operation of the machine, as the oil in the hydraulic
system of the machine is under high pressure. Before
the repair of elements of the hydraulic system, make
sure that you relieve the pressure from it.

Install the excavator in the parking position and stop the


engine.

Pressure relief in the control circuit, set the safety lever to Lever arm Pedal
the full position it off and set the control stick and pedals
to the denial of the situation forward, backward, left and
right
When this happens the complete removal of the pressure,
so when service hydraulic components should slowly
detach components and not to stand in the direction in
which oil may leak.

Cap
press
(3) Relieve pressure in the tank by loosening the breather tube
and pressing on its tip.

Breather

6-3
SAFETY DURING INSTALLATION hoses and
pipelines
Make sure that the connection hose assemblies, tubing and
working parts are not damaged.
Avoid connecting places of contamination.

Purification of hoses, pipes and the fittings functional


elements make the necessary connections.
Use original accessories.
Do not connect the hoses when they are in a twisted or
folded-over condition.
Perform tightness compounds in accordance with the
torques.

6-4
6) PERIODIC REPLACEMENT PARTS secure
To secure long-term operation of the machine
periodically carry out maintenance.
Nevertheless, we recommend regular replacement of
the security detail not only from the standpoint of
compliance with safety conditions, but also to ensure
satisfactory operation of the machine.
These parts could cause danger to life and materials, as
with the passage of time changes the quality of the
material - wear, thinning, and with repeated use of
accumulated fatigue of the material.
These are the details about which services the
remaining term of the operator can not be judged by
the results of the external examination.
If in such detail found any anomalies should be repaired
or replaced independently of the recommended
replacement frequency.

Periodic replacement of parts periods


security periodicity
fuel hose
(Tank-engine) every
Engine hose heating
device (heater 2 years
- engine)
The suction hose
pump
the main
Sleeve outlet every
chain
pump 2 years
Sleeve hinge line
Hydro-
system The sleeve cylinder line
arrows
working The sleeve cylinder line every
Device in hilt 2 years
The sleeve cylinder line
bucket

1. Replace the O-rings and gaskets when replacing hoses.


2. If the hose is cracked collar, then when checking
and replacing the hose and replace the hose
clamp.

6-5
2.MOMENTY TIGHTENING

Use the tables below for compounds with unspecified torques.


BOLTS AND NUTS

coarse thread

8T 10T
Razmerbolta
kgf · m kgf · m
M6 × 1,0 0.9-1.3 1.1 - 1.7
M8 × 1,25 2.0-3.0 2.7 - 4.1
M10 × 1,5 4.0-6.0 5.5 - 8.3
M12 × 1,75 7.4 - 11.2 9.8 - 15.8
M14 × 2,0 12.2 - 16.6 16.7 - 22.5
M16 × 2,0 18.6 - 25.2 25.2 - 34.2
M18 × 2,0 25.8 - 35.0 35.1 - 47.5
M20 × 2,5 36.2 - 49.0 49.2 - 66.6
M22 × 2,5 48.3 - 63.3 65.8 - 98.0
M24 × 3,0 62.5 - 84.5 85.0 - 115
MZ0 × 3,0 124 - 168 169 - 229
M36 × 4,0 174 - 236 250 - 310

fine thread

8T 10T
Razmerbolta
kgf · m kgf · m
M8 × 1,0 2.2 - 3.4 3.0 - 4.4
M10 × 1,2 4.5 - 6.7 5.9 - 8.9
M12 × 1,25 7.8 - 11.6 10.6 - 16.0
M14 × 1,5 13.3 - 18.1 17.9 - 24.1
M16 × 1,5 19.9 - 26.9 26.6 - 36.0
M18 × 1,5 28.6 - 43.6 38.4 - 52.0
M20 × 1,5 40.0 - 54.0 53.4 - 72.2
M22 × 1,5 52.7 - 71.3 70.7 - 95.7
M24 × 2,0 67.9 - 91.9 90.9 - 123
M30 × 2,0 137 - 185 182 - 248
M36 × 3,0 192 - 260 262 - 354

6-6
Tubes and hydraulic hoses

Razmerrezby Width across flats mm Moment


kgf · m
1/4 " nineteen 3
3/8 " 22 4
1/2 " 27 5
3/4 " 36 12
one" 41 14

FITTING

thread size Width across flats mm Moment


kgf-m
1/4 " nineteen 4
3/8 " 22 5
1/2 " 27 6
3/4 " 36 thirteen
one" 41 fifteen

6-7
TORQUE MAIN COMPONENTS

Moment
# Name Razmerbolta tightening
kgf · m
1
Bolts and nuts for engine mount M24 × 3,0 90 ± 7,0
2 Bolts and nuts for engine mount
(Front bracket, TIER II) M20 × 2,5 55 ± 3,5
3 Bolts and nuts for engine mount
M24 × 3,0 90 ± 7,0
Engine

(Rear bracket, TIER II)


4
Bolts of fastening of a radiator M16 × 2,0 25.7 ± 4,0
5
Tightening bolts M20 × 2,5 44 ± 4,5
6
Bolts main pump housing M10 × 1,5 2.8 ± 0.3
7
Withdrawal of the main pump mounting bolts M20 × 2,5 42 ± 4,5
8
Another part of the Powertrain hydraulics

Bolts of fastening of the main distributor M12 × 1,75 12.2 ± 1,3


9
Bolts of fastening of a fuel tank M20 × 2,5 46 ± 5,0
10
Hydraulic tank mounting bolts M20 × 2,5 46 ± 5,0
11
Bolts and nuts turntable M12 × 1,75 12.3 ± 1,3
12 one
13 hundr
Bolts rotary motor mount M24 × 3,0 ed ± 10
14 bolts top of the jog
hinge
M24 × 3,0 97,8 ± 10
15 Bolts fastening the lower part of the rotary
hinge
M24 × 3,0 97,8 ± 10
16
one
17 hundr
18 Bolts of fastening of the motor vehicle M24 × 3,0 ed ± 10
Chassis

19 Bolts of fastening of an asterisk M20 × 2,5 57 ± 6,0


20 Bolts and nuts of the roller bearing M16 × 2,0 29.7 ± 4,4
21 Track roller bolts M20 × 2,5 57.9 ± 8,6
22 Bolts track tension cylinder M12 × 1,25 15 ± 0,5
23 Bolts and nuts links caterpillars M22 × 1,5 115 ± 5,0
24 Bolts guide tracks M20 × 2,5 46 ± 5,0
Counterweight mounting bolts M36 × 3,0 297 ± 33
Cab mounting bolts M12 × 1,75 12.2 ± 1,3
The bolts fastening the operator's seat
M8 × 1,25 2.5 ± 0.5

Detailed information on the tightening torques of the engine and hydraulic system components,
see maintenance manual of the engine and the operating instructions of the excavator.

6-8
REQUIREMENTS APPLICABLE fuel, coolant and lubricants

NEW CAR

The new machine is filled with the following operating fluids.

Description Characteristic
Motor oil SAE 15W-40 (API CG-4)

Hydraulic fluid - ISO VG 46


hydraulic oil
Gearboxes and rotary SAE85W-140 (API GL-5)
vehicle engines
grease NLGI №2 based on lithium

Fuel ASTM D975-№2

Coolant Antifreeze mixture based on ethylene glycol and 50%


50% water

SAE - Society of Automotive Engineers


API - American Petroleum Institute
ISO - International Organization for Standardization
NLGI- National Institute of plastic lubricants (USA)
ASTM- American Society for Testing and Materials

6-9
Recommended Oil

Use only the oils listed below, or their substitutes.

Do not mix oils of different brands.

Capacity, Ambient temperature, 0 FROM


location Type of fluid
l -20 -10 0 10 20 30 40

SAE 30

Pallet SAE 10W


motor 24
crankcase
oil
engine SAE 10W-30

SAE 15W-40

Turning
gear housing 6.2
reducer Zion SAE 85W-140
onboard
oil 5,4h2
broadcast
ISO VG 32
hydraulic Buck: 180
Tank cal System: ISO VG 46
hydraulic oil 270
ISO VG 68

diesel ASTM D975 №1


Fuel tank 320
fuel
ASTM D975 №2

nipple grease how many NLGI №1


grease neobho-
grease
NLGI
grease Dimo №2

Radiator Mixture
(rasshiri- antifreeze 35 Permanent type based on ethylene glycol
tion tank) water 50:50

SAE - Society of Automotive Engineers


API - American Petroleum Institute
ISO - International Organization for Standardization
NLGI- National Institute of plastic lubricants (USA)
ASTM- American Society for Testing and Materials

6-10
4.PERECHEN parameters, check during maintenance

DAILY SERVICE TO WORK


Check item Service Page
visual inspection

Fuel tank Check fill 6-25


Hydraulic oil level Check and top up 6-30

Engine oil level Check and top up 6-18

Coolant level Check and top up 6-20

Control panel and signal lamps Inspect and clean 6-39

water separator Check drain 6-26

fan belt tension Check, adjust 6-24

Maintenance every 50 hours WORK

Check item Service Page


Fuel tank merge 6-25
track tension Check, adjust 6-34
Bearing turntable grease 6-32
Oil turning gear Check and top up 6-32
axles and bushings lubrication points grease 6-38
- the boom cylinder piston cavity
- boom foot
- The journal sleeve boom cylinder
- Pin cylinder sleeve handle
- Hydraulic cylinder rod end of the handle
- Compound boom with a handle
- The journal of the bucket cylinder liner
- the rod end of the bucket cylinder
- A compound with a bucket arm
- Compound bucket and arm traction
- Traction Control Bucket

6-11
MAINTENANCE AFTER THE FIRST 50 HOURS OF WORK

Check item Service Page


Motor oil change 6-18, 19
Engine oil filter replace the 6-18, 19
Filter pilot line replace the 6-31
Drain hydraulic filter replace the 6-30
Drain hydraulic filter replace the 6-31
Fuel filter replace the 6-26
Bolts and nuts: Check, tighten 6-8
- bolts stars
- bolts of travel motor
- bolts of motor rotation
- Bearing bolts rotation
- engine bolts
- counterweight bolts
- locking bolts pivot joints
- bolts and nuts Shoe tracks
- a hydraulic pump bolts

Maintenance of the above objects is carried out only on the new machine, and then follow the
normal maintenance intervals.

MAINTENANCE EVERY 100 WORK HOURS

Check item Service Page

* Return filter replace the 6-30

* Filter the pilot line replace the 6-31

* Element hydraulic tank breather replace the 6-31

* Drain hydraulic filter replace the 6-31

In continuous operation of the hydraulic hammer replace these filter 4.

6-12
SERVICE EVERY 250 HOURS OF WORK
Check item Service Page
* Gear turning gear oil change 6-34
* Lubrication of turning gear drive Check add 6-34

battery electrolyte Check and top up 6-39


Drain the hydraulic oil filter replace the 6-30
Drain hydraulic filter replace the 6-31
** The filter engine air cleaner Check and replace if 6-25
necessity
Filter pilot line replace the 6-31
Preliminary air cooler Check Clear
Hydraulic tank breather element replace the 6-31
Bolts and nuts Check, tighten 6-8
fastening bolts of asterisks
bolts travel motor
bolts turning motor
fixing the rotation bearing bolts
engine bolts
counterweight mounting bolts
locking bolts pivot joints
bolts and nuts Shoe tracks
hydraulic pump bolts
Carry out the procedure after the first 250 hours of operation.

MAINTENANCE AFTER THE FIRST 500 HOURS OF WORK

Check item Service Page


* Oil bull gear change 6-34

Maintenance every 500 hours WORK

Check item Service Page


* Engine oil change 6-18, 19
* Engine Oil Filter replace the 6-18, 19
The radiator and the fan ribs Inspect, clean 6-23
** The filter engine air cleaner change 6-25
Fuel filter replace the 6-26
Oil running gear Check and top up 6-33
By using lower quality of engine oil by API CH shorten the interval between services to 250 hours!
Clean air after the outer filter element 500 hours of operation and when the control signal lamp
clogging of the air cleaner. After 4 purifications outer filter element is required to replace the outer
and inner filter elements.
6-13
MAINTENANCE EVERY 1000 HOURS OF WORK

Check item Service Page


Oil running gear change 6-34
Oil turning gear change 6-33
Lubrication of turning gear Add 6-33
Lubrication of transmission and gears turning
mechanism change 6-33

9) Every 2000 HOURS


Check item Service Page
Hydraulic Tank:

- * Hydraulic oil change 6-31


-Setchaty filter suction line Inspect and clean 6-31

Coolant change 6-20, 21,22,23

Change oil after every 600 hours of continuous operation of the hydraulic hammer!

6-14
MAINTENANCE AS NECESSARY
If you find any problems in the machine is necessary to conduct appropriate maintenance facilities
systems.

Check item Service Page


Fuel system:
- Fuel tank Drain and clean 6-25
- water separator To merge or replace 6-26
- Fuel filter replace the 6-26
Engine oil:
- Motor oil change 6-18, 19
- Engine oil filter replace the 6-18, 19
Cooling System:
- Coolant Top up or change 6-20, 21, 22, 23
- Radiator Clean or wash 6-20, 21, 22, 23
Air Motor System:
- The filter of the air cleaner replace the 6-25
Hydraulic system:
- Hydraulic oil Top up or change 6-29
- Filter drain line replace the 6-30
- Filter drain line replace the 6-31
- Filter pilot line replace the 6-31
- The filter breather replace the 6-31
- strainer in the suction line clean 6-30
Undercarriage:
- The tension of the caterpillars Check, adjust 6-34

Ladle:
- teeth replace the 6-36
- The lateral cutting edge replace the 6-36
- linkage adjust 6-37
- Bucket assembly replace the 6-35
Air conditioning and heater:
- Fresh air intake filter Clean, replace 6-42
- Recirculation Filter clean 6-43

6-15
CARD SERVICE

Attention
one . Service intervals are determined by the service meter hours.
Number each item shows the lubrication point on the machine.
When pouring the oil off the engine and do not use an open flame.
For other details, use this guide.

6-16
periodic numb View Symbol.
er Description EMK., L Dot
Nosta service grease
1 Fuel tank Check and top up DT 320 1
2 hydraulic oil level Check and top up GJ 180 1
10 hours 4 The engine oil level Check and top up MM 24 1
or 5 Radiator coolant Check and top up OJ 35 1
1
daily 6 Warning lamps panel Check, 1
management clean - -
7 Water separator (separator) merge - - 2
3 Tools and machinery (axis and
grease COP - 17
sleeves)
9 Strainer fuel tank Check,
50 hours clean - - 1
or 10 track tension Check,
one time in adjust COP 0.3 2
week 12 Grease the pivot bearing Check,
circle add COP - 3
17 The oil level in the gearbox
Check and top up MT 6.2 1
rotation
8 Battery (electrolyte) Check and top up - - 2
13 Drain hydraulic filter replace the - - 1
250 21 Filter element pilot line replace the - - 1
hours 22 Hydraulic sectional filter. drain line replace the - - 2
23 Element of the hydraulic tank breather replace the - - 1one
26 Pre. air cooler clean - - 1
4 Motor oil change MM 24 1
11 Engine oil filter replace the - - 1
500 14 The filter of the air cleaner clean - - 2
Check,
hours 15 Radiator and fan blades - - 1
clean
16 Fuel filter replace the - - 2
18 Reducer final drive Check and top up MT 5.4 2
17 Oil turning gear change MT 6.2 1
1000 18 Reducer final drive replace the MT 5.4 2
Check,
hours 20 belt tension and condition - - 1
adjust
24 Rotary transmission and gear replace the COP - 1
2 The oil in the hydraulic tank replace the GJ 210 1
2000 5 Radiator coolant replace the OJ 50 1
hours 19 Suction strainer Check, - - 1
hydraulic line clean
By Check,
the request of 25 air conditioning filters clean - - 2

Designation liquids symbols


Recommended for applying operating fluid, see the specification

Diesel: Diesel MT: Gear oil


MG: Oil hydraulic Coolant: Coolant
KS: Grease MM: Engine oil

6-17
6. INSTRUCTIONS FOR THE SERVICE

one) CHECKING THE ENGINE OIL


Checking the oil level is performed before starting
the engine when the machine is on level ground.

(1) Remove the probe of level of oil and wipe it clean


cloth.

(2) Check the oil level by immersing the probe in to failure


hole and pulling it out again.
Engine
(3) If the oil level is low (LOW), add oil TIER II
and check the level again.

When dirty or clogged oil


you must replace it, in spite of the instructions
at intervals of changing the engine oil.
When checking the engine oil level after
Engine stop, do it after 15 minutes.

When the engine oil level is below normal Fine


work on the machine is prohibited.
probe

2)REPLACEMENT OILS IN ENGINE AND Option


OIL FILTER
(1) Warm up the engine.

(2) Remove cap and pour oil.

- fitting Size: 1/2 - 3/8 mm.


To drain tray suitable capacity 25 liters.

Clean around the filter head, remove and clean the filter
surface of the seal.

Key size: 90-95 mm.

6-18
Before installing the filter to apply
sealing surface of thin layer Oil
lubricating oil.
Fill the filter with clean lubricating oil.

Install the filter in the filter head.


Over-tightening of the filter can crush thread
or damage the seal of the filter element.

Install the filter in accordance with the rules established by


the filter manufacturer.

(6) Fill engine with clean oil to the desired


level. Oil
- Quantity: 19 litters (16.4 l -TIER II)

(7) Run the engine at low revs and


Make sure there are no leaks through the filter and
drain plug.
Turn off the engine and check the oil level
with a feeler gauge. Before check allow the oil
a drain pan for 15 minutes.

6-19
CHECKING THE COOLANT
Check that the coolant level in the reservoir is between the
FULL (Full) and LOW (small amount).

If the coolant level is insufficient, remove the plug tray HYUNDAI

and add water antifreeze mixture. FULL

LOW

If the coolant level is below LOW, remove the radiator


cap and make sure the tray is empty.
If the damage is laying the radiator cap, replace it.
Onhot engine coolant from the radiator can splash out when
the cover is removed. Remove the radiator cap only after the
engine
sufficiently cooled (coolant temperature below 50 ° Correctly Wrong
C).

FLUSHING RADIATOR AND


CHANGING COOLANT

Replacing coolant
Avoid prolonged or frequent contact with the
skin surface antifreeze. Such contact can cause
skin disorders and other diseases.
Upon contact of the skin with antifreeze and
washings wash these body parts with clean
water.
Keep away from children
Environmental protection: storage and
disposal rules fusion antifreeze can be
regulated by federal and local laws and
regulations.
Drain and disposal of anti-freeze produce for
specific sites or in special parking garages,
where there are special containers for his
discharge.
If in doubt, contact your local authorities for
the rules of storage and disposal of antifreeze.

6-20
Wait until the temperature
coolant drops below 50°C and only then remove the
radiator cap. Failure to do so may result in burns hot
jet of coolant from the radiator.
Drain the coolant from the cooling system by opening
the drain cock on the radiator and removing the plug at
the bottom of the inlet conduit. sump capacity of 40
liters can be used to collect the coolant.

(2) Cleaning the cooling system


Fill the cooling system soda Correctly
solution with pure water or other
a similar solution.
Use the following solutions
concentration: 0.5 kg of soda in 23 liters of water.
Do not install the radiator cap. For
engine cooling system cleaning
I must work without cover.

During pouring the washing liquid


air must escape through the air
channels. Open the vent valve
engine.
The system must be filled slowly to avoid air
pockets. Wait 2-3 minutes so that the air went out
completely.
Then add coolant to the desired level.

Run the engine for 5 minutes at


temperature of the washing liquid above
80 ° C.
Stop the engine and drain wash liquid from the
cooling system.

START

ON
OFF

6-21
Fill the cooling system with clean water.
Make sure that the vents are opened to release the
air and the air completely out of the engine and
the radiator .. It is necessary to completely fill the
cooling system.
Do not install the radiator cap or the new coolant
filter.

Run the engine for5min atengine coolant


temperature above 80°S.Zaglushite engine and drain
the water from the cooling system.
If the drained water is contaminated, the
operation of flushing the cooling system to repeat
until the drained water is not clean.
START

ON
OFF

Pouring cooling system coolant


Use as coolantCooling system a mixture consisting
of 50% water and 50% ethylene glycol based
antifreeze.
The capacity of the cooling system (engine only): 9.5
L (9 l - TIER II).
For protection of cooling system elements from DCA
corrosion pour in the required amount of corrosion
inhibitor DCA4.

The maximum amount of filling of the


systemCooling is 14 l / min
(19 l / min -TIER II)
Do not exceed this level.

The system must be filled slowly to avoid air


pockets. During the air filling the cooling system
has to go through the vents.
Make sure that the air valve is open secondary
cooling of the engine.
Then add coolant to the desired level.

6-22
Install the radiator cap. Run the engine up until the ABNORMALLY
coolant temperature reaches 80°C and check for
leaks.

Again, check the coolant level. Make sure that the


cooling system is completely installed.

CLEANING The radiator and oil cooler Check and


clean if necessary,
dry outer surface of the radiator and oil cooler. After ABNORMALLY
working in dusty conditions, clean the radiator
produce more often.
Perform a visual inspection of the radiator for clogging
the cooling fins.
Under pressure of 550 kPa compressed air radiator
cooling fin clean from dust and dirt.
Air flow is directed sideways,
opposite the air flow generated by the fan.
Visually inspect the cooling fins of the radiator for 550 kPa
curvature and breakages.
If necessary, replacement of the radiator due
to its curvature, or damage to the cooling fins,
Core replacement procedure is carried out in
accordance with the manufacturer's instructions
for its replacement.
(4) visually check for leaks of coolant through the
housing and the heat sink gaskets.

6-23
FAN BELT TENSION

Measure belt slack on the longest stretch belt.


- The maximum permissible sag: 9,5-12,7 mm.

Inspect the transfer belt for damage.

FINE

ABNORMALLY

Examine the transmission belt tension bearing and fan


hub.

CHECK COOLING FAN


Damage to the fan blades can cause personal
injury.
Never pull the fan, and do not force him. This
can cause damage to the fan blades and cause a
denial of his work.
Rotate the crankshaft, a drive motor acting
on the gear.
Daily visual check inspection status of the
fan should be carried out.
Check spend for cracks, easing of rivets, bent or
loose blade attachment. BADLY
On examination, make sure the fan is securely
fastened. If necessary, tighten the screws. If any
damage to the fan, replace it.

6-24
8) CLEAN AIR CLEANER
(1) The operating
member
 Loosen the wing nut and remove
the filter element.
 Clean internal cavity housing
the air cleaner.
 Clean the filter element by blowing by
compresse remove
d air. the mud within
Compressed
filter element compressed stream air
2
under the pressure of not more than 3 kgf-cm more than air no more
(not 3 3 atmospheres
atmospheres), directed and the front and rear elements.
 Check the placement of the bulb inside the element
whet
filter, not her at it cracks or other Wing
damage. nut
 Insert the filter element into the housing
the air cleaner and tighten the wing nut.
Replace the new filter element through 4
washing.
(2) Replacement
element

Replace the spare element only when


work item was washed 4 times.

Never attempt to wash out the spare element and


use it again.

9) TANK
(1) work loader fully tuck
fuel tank to reduce
amount of water formed by condensation.
Check the fuel level sensor on the front of
you start the machine.
(2) Drain and fuel condensation in the fuel
the tank through the drain
cock.
Make sure that the fuel cap
the filter is in the closed position. Sensor
Remove the filter the fuel element level
the tank and, if it is dirty, clean it. fuel
When refueling muffle
engine
It is prohibited refuelling draining
in the vicinity of the open tap
fire and other heat sources.

6-25
10) a water separator (Separator)
Red
(1) Removing the drain plug, drain and line
sucks.
(2) Replace the drain plug.
(3) Check for leaks.
Regardless of the service period, drained water
if it has reached the level of 2/3 of the
capacity.
Drain the water tank after filling fuel.

11) Replacing the fuel filter

(3) Completely new thread the fuel filter.


(4) Before installation grease filter gasket
engine oil.
When the gasket touches the filter head,
turn the cartridge an additional 3/4 - 1 turn.
(5) Bleed air filter after installation.
After starting the engine check for
fuel leakage. Cartridge
The engine will not start if the fuel system filter
there is air. Bleed air in accordance with
nor described method, then run
engine.

WATER SEPARATOR FUEL

- Open the drain valve by hand.


- Remove the oil drain valve on the 4 complete
turn counter-clockwise.
Stopper drops down to 2.5 cm.
- Drain fluid in the filter tank until
appears clean fuel.

Do not over tighten the valve plug that is not Open close
damaging the threads.
To close the drain valve, turn
stopper clockwise.
Fill the filter to the desired level, if blended more
than 60 ml of liquid in order to avoid the heavy
starter motor.
Refer to paragraph 12) to the information - (2) of the
pipelines and low pressure pumping
the fuel filter.

Open close

6-26
BLEEDING THE FUEL SYSTEM
Bleeding the air produced in the fuel injection pump via
the drain sump of the fuel system.
A small amount of air that gets into the system if the
filter is replaced or the injection pump supply pipe,
pumped automatically, if the fuel filter is replaced
in accordance with the instruction.
Additional air pumping is required if:
- The fuel filter is filled before installation.
- Replace the injection pump.
-As fuel system replaced the high pressure pipes.
Bleeding low pressure pipes and
the fuel filter.
Unscrew bleed screw
- Key size: 8 mm

Act on the lever


tighten the screw
- Tightening torque: 0.97 kg / m

Bleeding injection pumps Bleed the pump Lucas


CAV, as shown in the figure.
- Key size: 8 mm

6-27
If operates the solenoid valve of the fuel system, the air
/ fuel can be pumped away with a hand lever on the fuel
pumping pump discharge.

START

ON
OFF

Air may also be pumped out from the pump through the
conduit both drain collector when the starting motor.
Using the starter motor for the pumping system, not
turn it more than 30 seconds for 1 time and wait for
2-3 minutes between runs.
You need to place the engine start switch to RUN
(run). Since the engine can be started, make sure
that all necessary safety precautions are taken. START

Start the motor in a conventional manner. ON


OFF

30 seconds
Bleeding high pressure pipelines
The fuel pressure in the high-pressure pipelines is
so high that the jet fuel can break through the skin
of the operator and cause serious injury.
Loosen the fittings and turn the nozzlesengine that NON-
Villeneuve
has got into the air came out of the pipeline system.
Tighten the fittings.
key size: 19 mm.
Start the engine and turn one after the bleed of high START

pressure pipelines, as long as the engine will not run ON


OFF
smoothly.

Leaking fuel 30 seconds

Be careful, paying attention to cleanliness of fuel


hoses, nozzles, fuel filter and other elements of the
fuel system, since fuel leaks from these elements can
lead to fire. FIRE!

6-28
14) TEST OIL LEVEL
HYDRAULIC SYSTEM Red line
(1) After retracting the cylinder arm and bucket Level sensor
stop engine. lower arrow and oils
Set the bucket on the ground on flat ground as
shown.
(2) Check the oil level in the tank level gauge
the hydraulic system.
(3) In normal oil level lies between
red lines.

15) REFILLING hydraulic oil


SYSTEM cover breather
(1) Stop the engine at a position for press
check the level in the tank.
(2) Release the pressure by loosening the breather cover
and pressing the top of the breather.
Breath
(3) Remove cover the top of the oil tank. er
Torque: 1.44 ± 0.3 kgf · m

(4) After pouring the oil, start the engine and repeatedly
make a manipulation of the working equipment.

(5) the oil level when the engine stops in the level check
position.

OIL CHANGE HYDRAULIC


SYSTEM cover breather
(1)Lower the bucket to the ground, plunging the cylinder Cap
rods Breather tank
arm and bucket as much as possible. sealing
(2)Release the pressure by loosening the breather cap ring
And press to the top of the breather.

(3)Remove the lid on top of the oil tank.


Tightening torque: 6.9 ± 1.4 kgf · m
(4) Prepare an appropriate container.
(5) To drain the oil, unscrew the drain plug in the bottom of
the oil tank.
(6) Fill the desired number of the recommended oil.
(7) Install the breather into place.
(8)Bleed air from the hydraulic pump,
slightly unscrewing the cap at the top of
hydraulic pump.
Drain
(9)Start the engine and let it run some time. Bleed air from bung
the system, each moving the joystick to full speed before
failure.

6-29
CLEANING strainer in the suction line
It is necessary to clean the strainer of the suction line, Cap
observing the following instructions and taking action Breather
tank
when oil filling. sealing
ring

Remove the lid on top of the tank.


Tightening torque: 6.9 ± 1.4 kgf · m
Remove the strainer from the reservoir. screen filter

To clean rinse strainer gasoline or oil for the chemical


cleaning.
Replace strainer if it is damaged.
Assemble in reverse order.
Do not forget to install a new O-ring to the oil tank.

Unscrew the cover bolts slowly because when


removing the lid can jump by the spring.

REPLACEMENT FILTER DRAIN LINE

Replacement proceed as follows, paying attention to safety


precautions when performing these operations.

Remove the top cap from the working fluid.


Tightening torque: 6.9 ± 1.4 kgf · m. Tank cap

Remove the spring, and the filter bypass valve drain lines sealing
rings
in the tank with the fluid.
Spring
bypass
Replace the filter with a new element. valves
Filtering

6-30
Replacement of the filter element in the breather
TANK WITH WORKING FLUID cover breather
Nut
breather cap
(1) Remove the breather cap at the top of tank
The filter
working fluid and relieve excess pressure, pushing the
top of the breather.

(2) loosen nut air breather and remove the cap.

(3) Remove the filter element.

(4) Replace the new filter element.

(5) Perform the assembly in the reverse order.

REPLACEMENT FILTER DRAIN

Clean dust and dirt around the filter and replace with
a new filter element.

Once the cartridge comes into contact with the seal


body, make a tightness 2/3 turn.
Make replacement cartridge after the first 50 hours
of operation. Next, make replacement after every
250 hours of work.
Tank with
working
fluid

REPLACEMENT FILTER pilot line

Loosen the nut located on the filter housing

Remove the filter element and clean the filter housing.

Install the new filter element and tighten the nut in


accordance with the specified torque. Filter
pilot
Make replacement cartridge after the first 50 hours lines
of operation. Next, make replacement after every
250 hours of work.

6-31
CHECKING THE OIL LEVEL geared motor
turntable

Pull out the dipstick and clean it.

Re-insert the dipstick.

Remove the dipstick again and the oil level. When


insufficient oil refill.

OIL CHANGE geared motor turntable


Increase oil temperature in the gearbox of the turntable by
rotation of the turntable before changing the oil in the
gearbox and set the machine in a parking position on
the flat portion.
Loosen the drain plug.
Produce oil drain into a suitable container.
Rinse the drain plug and insert it through the gasket.
Pour the desired amount of the recommended oil.
- Oil capacity: 5 l

GREASE BEARING OUTPUT SHAFT GEAR

Remove the air channel plug.

Remove the filler plug lubricating oil and a place set


lubrication fitting.
Fill oil NLGI №2 with a grease gun until such time as the
new oil starts to flow out of the air duct openings.

Perform similar lubricant every 1000 hours.

Lubrication of the bearings of the turntable

Lubricant through the fitting 3.

Lubrication is performed every 50 hours.

6-32
26) engage and GEAR TURNING CIRCLE cap of filling

openings

(1) draining the used oil


Remove the bottom cover of the lower frame.
Remove the drain cap of the bottom frame.
Remove the top cap of the filling opening frame.

Make a full turn (360 °) rotary platform several times. the front of
the upper frame

Refilling new oil Install the drain


cap. Fill with new oil.
Install the filler cap.
- Oil capacity: 10.4 kg

Drain
Top bottom cap
frame

27) CHECKING THE OIL LEVEL GEARBOX


Travel Motors
(1) Move the machine on a flat portion, when Motor
vehicle drain plug is in lower position. fill

(2) Loosen the inspection plug and check the level


oil in the transport motor.
If the oil level corresponds to the level holes, it is
considered normal.
If the oil level insufficient, refill
Level
corresponding oil.
oils merge

28) CHANGING THE WAY gearbox oil


MOTOR
(1) First of all, increase the temperature of the oil by
movement of the machine.
(2) Stop the excavator when the drain bung fill
motor vehicle comes into the lower position.

(3) Loosen level plug and then drain plug.

(4) Drain oil in suitable containers.


(5) Tighten the drain plug, and then fill appropriate
Volume oils across hole. aspic merge
Oil level
(6) Tighten the level plug and make the slow movement
of the excavator with a view control of oil leaks.

6-33
GREASE joystick control

Remove all the housings and by means of a syringe


A B
make lubrication with grease articulation (A) and
moving parts
(IN).

30) TRACK TENSION ADJUSTMENT

To prolong the life of caterpillars in general


must produce
right adjusting
track tensioning. 90 ~ 110

Pins and suspension bushings depends


the operating conditions and the properties of the
excavator ground.

Therefore, you must periodically check bottom track Tracked


track tension and maintain it the proper level. frame frame

(1) Pick up chassis via arrows and hilt.


L

(2) Measure the distance between the bottom of


track frame and track shoe. Rear part Track shoes
Track shoes
Before measuring remove dirt by
caterpillars rotation.

Length (L)
When excess tension, remove the grease through the
360 ~ 390 mm 14.2 ~ 15.5 "
nipples, but with little - add lubrication.

Emission of grease under strong pressure can cause


injury or even death.

With the weakening of their nipples do not turn


more than one turn, as
it is possible to discharge the spring pin of the high
pressure due to the inside.

After removing the grease slowly rotate the tracks


forward and backward.

If the track tension is not enough, even after filling
with grease up to the maximum level, replace the
pins and bushings, as they have worn out.

6-34
REPLACING THE BUCKET

When you strike with a hammer on the connecting bolt,


metal particles can break away from the surface and cause
serious injury, especially if it enters the eye. Therefore, when
performing such work, always wear protective goggles,
helmets, gloves and other protective equipment.

 After removing the bucket, place it in a stable position.


In carrying out joint activities, make sure that your
signals are clear to others, and your co-operation
complies security.
Lower the bucket to the ground, as shown on the right.
Establish a safety lever to the lock (LOCK) and shut off
the engine. o
Remove the locking bolts (1) and the nut (2) and then n
e
pull the fingers (3 and 4) and remove the bucket. 3
one
When you remove your finger, place the bucket so that
2 4
it has a weak contact with the ground. 2
If the bucket to the ground drop sharply, by virtue of
the increased resistance to remove the fingers will be
quite difficult.

After removing the fingers, make sure that they are not
contaminated by sand, dust, and that the sealing
plugs on both sides of the bucket are not damaged.

Position along the handle openings (A) and the bucket


lever mechanism along openings (B), then lubricate
with grease and set pins (3, 4).

When installing the bucket can easily damage the O-


rings, so place them on the boss of the bucket, as
 shown in the figure.
After setting the fingers move the sealing ring into
place in the corresponding grooves.
A
Set the locking bolts (1) and nuts (2) for each finger, then
lubricate fingers.

sealing
ring

Nut

Bolt Sleeve
Boss
Ladle hilt

6-35
REPLACEMENT OF TEETH BUCKET

Terms of replacement
Check the amount of wear as shown in Figure Adapter
replace teeth before depreciation adapter process will
Tip tooth tooth
begin.

If overexploitation when worn tooth adapter, the


replacement tooth may be impossible.

Replacement instructions

Remove the finger by a pin punch or hammer,


preventing damage to lock washer.

Remove dust and dirt from a tooth surface using a


knife. Finger Adapter
tooth tooth
Insert lock washer to the appropriate position, and then lock
attach the tooth tip to the adapter. Tip
tooth washer

Insert the pin to contact the locking washer in its


groove on the finger.

The fall of the bucket can cause serious injury.

Lock the bucket during the replacement of teeth


tip or side cutting edges

6-36
33) GAP ADJUSTMENT BUCKET

(1) Lower the bucket to the ground, as shown in the right.

(2) Turn left and the turntable


Hold the handle lug in contact with bucket.

(3) Set the safety lever into position


Lock (LOCK) and stop the engine.

(4) Measure the gap A between the ladle and the boss
hilt. This value is a complete gap.
A
(5) Adjustment

Loosen screw 2 and washer 3, the plate 1 and gasket 4. one


2
Change the value of the gap via shims. 3
4

Assembly parts can in the reverse order disassembly process. Ladle Boss Sleeve
hilt
- Tightening torque: 29.6 ± 3.2 kgf · m
- Normal clearance: 0.5-1 mm

If the bucket position is not correct


adjusted, during work
Excavator noise may appear and
vibration, and damage
O-rings, connecting
pin and bushing.

6-37
GREASE connecting pins and bushings

Lubricate each finger of the working equipment.


Produce supply grease via the grease nipples according to
the lubrication intervals.
number
number Description lubrication 4 3 one
points
1 boom grease pipe 5
2 Finger boom cylinder 2
Finger connections and arrows
3 hilt 2
A finger grip cylinder
4 (Rod side) 1
Finger bucket cylinder 5 2
(Rod side) 2
Bucket Linkage
(Control rod) 3
5 Finger stick and compound
bucket 1
Finger stick and compound
linkage 1
Decrease lubrication intervals when working in water
or in dusty conditions.

In the rotating elements of the working equipment


installed wipers to increase the lubricating intervals.
When replacing the wipers set themprojections
outside.

If they are not installed correctly, there will be a rapid


wear of the pins and bushings, as well as increased
noise and vibration during operation of the
excavator.

Are installing seals in the direction shown on the right.
To replace the seal, use a plastic hammer.

external
side

6-38
ELECTRIC
WIRES, SENSORS
Regularly check the condition of the wiring and sensors.
Upon detection of a lack of contact or faults make the
necessary repairs.

13036MI29
ACCUMULATOR BATTERY
Check and repair
Check the electrolyte level in the battery
battery. If necessary, add distilled water to the desired
level.
Rinse with hot water at the terminals of
Bung
pollution,butthen cover with a layer of grease.
Must not come at the clothes
skin, since the electrolyte is an acid. Be careful, Top level
preventing electrolyte from entering the eyes. If Lower level
electrolyte gets in your eyes, wash with clean water and
consult a doctor. 10-15 mm

Do not allow open flames or sparks near


the battery.
The density of the electrolyte in the battery
the battery charge can be judged by the density of the
electrolyte therein. Check the degree of charging of the
accumulator according to instill to the following table.

Temperature
gravimeter
- (meter
twenty° 10°FRO 10°FR density)
Power FROM M OM Level
charge electrolyte
one hundred% 1.26 1.27 1.28
90% 1.24 1.25 1.26
Battery
80% 1.22 1.23 1.24
75% 1.21 1.22 1.23

The procedure for removing the wire from the battery


First, remove the wire going to the "mass" (terminal "-")
with battery. When connecting wires connect the earth wire
in the last turn.

"Weight" battery switch

6-39
STARTING WITH "Booster"
When starting the engine by means of "Booster"
following Steps.
The procedure for connecting wires
wiring
Use to start the battery of the same capacity as in red wire
the Exciting excavator.
3 2 1
Connect the red wire to the positive
terminals discharged and the current batteries.
Connect the black wire to the negative
The machine with the
terminals discharged and the current batteries. current machine with
(New) battery discharged
Ensure good contact with the battery wire
terminals. According to the wire connection end slip black wire battery
By "weight" machine 4
spark.
discharged battery
Engine starting
How to join:
Start the motor via starterswitch.
one 2 3 4
If the engine fails to start on the first attempt,Repeat
it to run in 2 minutes.

Removing the wires "Booster"


Remove the black wire.
Remove the red
wire,connectingpositive (+) terminal.
Run the engine at high revsidle as long as the TART
generator is not fully charge a discharged battery. ON
OFF
In operation, as well as battery charging stands
explosive gas. Do not allow open flames or sparks
near the battery.
Charge batteries in a well-ventilated
place. For disconnecting wires
Set the machine to the ground or concrete.
Do not charge the battery when the loader red wire
on the metal base.
3 2 1
Do not connect the positive terminal
to the negative terminal (-) with
"Booster", since it will lead to a short
circuit. The machine with the
current machine with
(New) battery discharged
black wire battery
By "weight" machine 4
discharged battery
For disconnecting:
4 3 2 one

6-40
Welding repairs
Before welding slide
the following actions.
Stop the engine, move the starter
switch to the OFF position (OFF) and
remove the key from him.
Remove the"Mass" (Terminal-)with wirethe
battery and take it to the side to prevent short circuits.
Disconnect the wiring from the generator.

In no case did not proceed to the welding work to


implement the above mentioned actions.
otherwise possible serious damage to the
electrical system of the excavator computer.

6-41
8. AIR CONDITIONING AND
HEATING
REPLACEM EXTERNA
1) CLEANING AND ENT L
FILTER
Before servicing the air conditioner is always External
filter
turn off the engine.
(1) move the seat adjustment lever and
remote control in accordance with the arrow on
Fig.
Lever armregularityAdjustment
knobtoand

Remove the outer filter.


When installing the filter to confuse the attention, not
filter direction.

Outside

FLOWR
within IA

(3) Clean the filter under a stream of compressed air


pressure of not more than 2 atmosphere.
within
In the application of the compressed air stream
Use protective glasses. Outside
(4) After cleaning of the filter condition. Compressed
air
If it is damaged or severely no more
dirty, replace with a new filter. 2 atmospheres

Cleaning and replacing the internal filter


Before servicing the air conditioner, always turn
off the engine.
Move the seat adjustment lever and control panel in
accordance with an arrow in the figure.

Lever arm
adjustment Interior
filter

6-42
Remove the inner filter.

Clean internal filter a stream of compressed air at a


pressure of 2 atmospheres or rinse water.
In the application of the compressed air stream
use protective glasses.
Dry the filter after washing with water.
After cleaning, check the filter status. If it is Compressed
damaged or heavily soiled, replace with a new filter. air
no more
2 atmospheres
PRECAUTIONS WHEN USING THE AIR
CONDITIONER
Dry the filter after washing it 
water.
When using the air conditioner for a long time open
the window every hour.
Try not to supercool the cabin.
Kabinaschitaetsya properly conditioned, if the
operator feels coolness getting into the cabin from
outside (air temperature in the cab must be 5
degrees below ambient temperature).

When conditioning alter the direction of air flow.


SEASONAL INSPECTION
Contact the service center in order to replenish the
coolant in an air conditioner or other kinds of service of
the conditioner to avoid deteriorated efficiency.
CHECK-season
Include air conditioning 2-3 times a month for a few
minutes in order to maintain the oil film in the
compressor.

6-43
TROUBLESHOOTING GUIDE
ENGINE
This guide cannot cover all possible problems, but it describes the most common ones, as
well as ways to address them.

malfunction elimination method


low pressure lamp - Top up to the required level of oil
the engine oil is not extinguished - Replace the oil filter cartridge
after engine start. - Check oil leakage from the hose and connections
- replace the sensor
From the top of the radiator - Top up with coolant and check the system
(Pressure valve) goes cooling for leaks
pairs. The control lamp - Adjust fan belt tension
the insufficient level of - Wash the inside of the cooling system
coolant - Clean or repair fins
off. - Check the thermostat
- Check the coolant temperature sensor
engine
- Tighten the radiator cap or replace the gasket
underneath.
- Replace the sensor
When turning the starter - pour fuel
the engine will not start - Perform repair of places of air leaks in the fuel system
- Check the fuel pump and injectors
- Check the valve clearance
- Check up a compression in cylinders
Exhaust gases or white - Adjust the amount of fuel
of blue color - Pour appropriate fuel
Traffic fumes - Clean or replace the air filter element
periodically have black - Check jets
Colour - Check the compression in the cylinders
- Clean or replace the turbocharger unit
Noise normal operation
engine spontaneously - Check jets
changes to sneezing.
Unusual noise in the chamber - Check the fuel brand compliance
combustion or mechanical - Check for overheating
noise - Check the muffler
- Adjust the valve clearance

7-1
2. ELECTRIC

malfunction elimination method


voltmeter - Check the wiring for the absence of
unstable, although the engine contacts or short circuit
working on constant speed. - Adjust fan belt tension
Bulbs do not burn brightly even when
the engine is running at high
revs.
Lamp flashes when the
engine.
Voltmeter not - Check the generator
vary with increasing frequency - Check and correct faults in the wiring
engine speed

The generator makes an unusual noise - Check the generator


Starter does not turn when - Check and correct faults in the wiring
turning the key in the ON position - Charge the battery
(ON) - Check the starter
- Check the safety relay
Periodically, the contact is broken - Charge the battery
engages the starter before - Check the safety relay
starting the engine
Starter cranks very poorly - Charge the battery
engine - Check the starter
The tripping of the starter - Check and correct faults in the wiring
before the engine starts - Charge the battery
Lamp heating of the motor is not - Check and correct faults in the wiring
lights - Check sensor
low oil pressure in the lamp - Check sensor
when the engine is not lit - Check the oil pressure switch lamps
idle engine and
the ignition key in the
ON position (ON)
Control lamp discharge - Check sensor
the battery does not illuminate when - Check and correct faults in the wiring
idle engine and
the ignition key in the
ON position (ON)

7-2
Other faults

malfunction elimination method


Caterpillars slip on - Adjust the tension of the caterpillars
place.
Excessive wear on the sprocket
Bucket or rises too - Add a working fluid to a desired level
slowly or does not rise
generally
Too low speed - Add a working fluid to a desired level
movement, rotation
turntable, moving
boom, arm and bucket
The pump is making an unusual noise - Clean the filter element hydro tank
excessive increase - Clean the oil cooler
Fluid Temperature - Adjust the fan belt tension
- add hydraulic fluid to a desired level

7-3
HYDRAULIC HAMMER AND FAST LOCK
SELECTION hydraulic hammer

Read this manual and


select the breaker corresponding to the specifications of
the machine.

To ensure the inherent characteristics of a thorough


selection, taking into account the working fluid flow,
pressure and force of impact.

When using a hydraulic hammer with the base machine


consult «HYUNDAI» local dealer for details of the
company.

8-1
CONFIGURATION hydraulic circuit

To connect the hydraulic lines to the hammer, use


an additional section of the main control valve.

Set the pressure required for the breaker to the drain line
valve.

Pressure in the hydraulic excavator ROBEX 290LC-7 is


330 kgf · m.

4) Adjustment of the working fluid flow hydraulic fluid flow in accordance with
engine speed.
(1) Select the breaker mode of working
modes. By default, the flow of the working fluid - 220 The rotation of the motor Flow
l / min at 1900 rev / min. To change these parameters rev / min l / min
Use the switch to the speed of rotation 1800 207
Engine Accel dial. 1700 195
(2) If the fluid pressure is not controlled 1600 184
properly, as a result of increasing strength 1500 172
impact or impact frequency may breaker 2

reduction of the term of the hammer and excavator When pressure drain200kgf / cm
whole.
The pressure and return lines of the hydraulic breaker should be used accumulators. In the
absence of hydraulic accumulators may be damaged due to pulsations in hydraulic fluid pressure
line.

Do not connect the drain line to the breaker main spool. Wiring the drain line to the oil cooler.

Do not connect the drain line to the drain lines hammer rotation of the turntable motor, the transport
motor or pump, since such a connection can cause damage to these devices.

To control the pilot can use either a solenoid valve or pedal.

One of the sections of the main control spool to be connected to the tank.

Choose the size piping, starting from the existing pressures.

For lines to be used without a tube shims. As high pressure hoses and seals should be applied original,
manufactured «HYUNDAI», or equivalent.

Weld bracket brackets with the high-pressure piping to avoid damaging them.

8-2
MAINTENANCE
Hammer

MAINTENANCE FLUID AND FILTER • Replace the following filters


simultaneously
When operating an excavator with a hydraulic - The filter in the return line of the hydraulic
hammer hydraulic fluid polluted rather quickly. system
- The filter in the pilot line
Therefore, without a relatively low-maintenance machine - the air filter element
can quickly fail. hydraulic tank
breather
To extend the life of the excavator, check and replace the - drain cartridge filter hydraulic tank
hydraulic fluid, and especially 4 types of filter elements.

In operation of the excavator with a hydraulic hammer for Scheme replacing filters in Hammers
a short time, replacement of the working fluid and produce
filter elements as shown in the right table.

RESET circuit pressure hydraulic one hundred


replacement time
hammer 80 filtering
element
At the end of the breaker switch off the engine and press the Avg. 60
load
foot switch or breaker for the purpose of pressure relief cars 40
circuit breaker. (%) 20
If after these steps, the pressure is not fully reset, it means
that the service life of the diaphragm accumulator is 0
50 100 150 200 250
reduced.
the amount of waste
Be particularly careful on the subject of preventing hours
clogging of the working fluid with dust, sand and
other impurities.
After contact with foreign particles in the hydraulic fluid Scheme replacing oil in Hammers
driving the pump will be subjected to excessive wear,
which will decrease the life of the pump or its breakage.
one hundred
When working with a hydraulic hammer. due to
vibration loads, possibly self-unfastening bolts and nuts. 80
replacement time
Therefore, you must periodically check and tighten them. Avg. 60 oils

mashinynagruzka 40
(%) twe
nty
0
Service Interval (Hours) 500 1000 1500 2000
the amount of waste
hours
type of work Load Working filter
equipment liquid element
Ladle 100% 2000 250
Hydraulic 100% 600 100

8-3
SAFETY AT WORK GIDROMOLOT

Do not split stone or a piece


Hardwood when lowering
Hydraulic Hammer
Since the weight of the breaker is greater than the
weight of the bucket, they need to manage slower. Too
quickly lowered hammer can damage the working
equipment.

DO NOT OPERATE hydraulic hammer during the


rotation of the turntable and do not use IT FOR
HANDLING STONES AND OTHER PIECES
hardwood.
This may cause damage to equipment or operating
the rotation mechanism.

WHEN USING DO NOT OPERATE hydraulic


hammer hydraulic cylinders at full speed. FOLLOW
clearance between the piston cylinders and its wall at
least 100 mm.
hammer work at full passages of hydraulic cylinders
may be damaged.

If there is excessive vibration HIGH PRESSURE


HOSES Constant high pressure hoses vibration will
adversely affect the mechanical condition of the machine,
namely lead to a weakening of bolts, oil leakage, damage
to the pump conduit and t. D.

8-4
Long continuous
WORK GIDROMOLOT a fixed position of the boom
and stick - less than one minute Beyond this limit there is
an increase of the working fluid temperature as well as the
battery are damaged and seals.

Pummel GIDROMOLOT not move the machine or self


GIDROMOLOT Do not change the position of the
breaker while applying them to blows.

This can result in damage to work equipment and swing


mechanism.

DO NOT operate a hydraulic hammer in the tilted


position Do not operate the hammer in the rotated position
of the rotary excavator platform.
This causes coupler crawler pad and leakage of oil in the
rollers.

Be careful not to damage the working bodies hydraulic


hammer ARROW When the hammer be careful when
impact on the lever arm and bucket.

8-5
QUICK LOCK

MOUNT BUCKET WITH QUICK CLIP


(1) Before the operation to mount the bucket remove
the safety locking finger with a movable hook.
(2) Moving the safety lever, press the fast lock switch,
thereby unlocking it. Thus, the movable hook is placed
in the free position.

By placing the handle of the bucket, implant fixed


hook quickly lock onto the pin of the bucket.

Joystick control, place the bucket in the position of


the "inside", ie. E. Towards the excavator. Thus, you
fix the movable hook on the connecting rod of the
bucket. Check if the fixed and movable hook
connecting rod bucket.

Lock the quick lock switch.


Joystick control, place the bucket in the position of the
"inside", ie. E. Towards the excavator.

Check the connection between the bucket rods


and hooks fast lock.

8-6
After checking the connection between the bucket pins and hooks fast move the movable retainer safety hook finger in the locked position.

REMOVAL BUCKET WITH RAPID CLIP procedure for removing ladle inverse procedure for its fixation.

PRECAUTIONS FOR USE FAST CLIP

at work on an excavator with quick lock, make sure that fast lock switch is in the locked position, and the movable finger of the hook safety also blocked.

at work on an excavator with a quick lock and unlocked quickly lock switch and the movable hook finger security bucket may come off and cause an accident.

Accident may result serious injury or death.


Bucket can hit the cab, boom and boom cylinders and damage them.

HYUNDAI company is not liable for injuries or damage caused if safety finger is not seated properly.

8-7
GROUP 5 ELECTRICAL CIRCUIT (#1001 and up, TIER II)

21074EC50

4-53
POWER CIRCUIT (#1001 and up, TIER II)
The negative terminal of battery is grounded to the machine chassis through master switch.
When the start switch is in the OFF position, the current flows from the positive battery
terminal as shown below.
OPERATING FLOW
Battery Battery relay Fusible link〔CN-60〕
Fuse box〔No.1〕 l/conn〔CN-8(12)〕 Start switch〔CS-2(1)〕
Power relay〔CR-35(30)]
Fuse box〔No.2〕 I/conn〔CN-10(6)〕 Room lamp〔CL-1(2)〕 Door switch〔CS-1〕
Cassette radio〔CN-27(11)〕
Fuse box〔No.3〕 l/conn〔CN-11(4)〕 AC & Heater controller〔CN -116(3, 4)〕
Fuse box〔No.4〕 I/conn〔CN - 5(4)〕 I/conn〔CN -17(5)〕 Wiper motor controller
〔CN-141(7)〕
Wiper motor〔CN-21(4)〕
Fuse box〔No.5〕 CPU controller〔CN-50(7)〕
Fuse box〔No.6〕 I/conn〔CN-11(5)〕 Relay(Hi, M2)
I/conn : Intermediate connector

CHECK POINT

Engine Start switch Check point Voltage

① - GND (Battery 1EA) 10~12.5V


② - GND (Battery 2EA) 20~25V
OFF OFF
③ - GND (Battery 2EA) 20~25V
④ - GND (Fusible link) 20~25V

GND : Ground

4-54
POWER CIRCUIT (#1001 and up, TIER II)

21074EL51

4-55
STARTING CIRCUIT (#1001 and up, TIER II)
OPERATING FLOW
Battery(+) terminal Battery relay〔CR-1〕 Reset button〔CS-61〕 Fuse box〔
No.1〕 I/conn〔CN-8(12)〕 Start switch〔CS-2(1)〕
(1) When start key switch is in ON position
Start switch ON〔CS-2(2)〕 I/conn〔CN-8(11)〕 Battery relay〔CR-1〕
Battery relay operating (All power is supplied with the electric component)
Start switch ON〔CS-2(3)〕 I/conn〔CN-8(10)〕 Power relay〔CR-35(86) →
(87)〕 Fuse box〔No.12〕 l/conn〔CN-2(5)〕 Fuel cut-off〔CN-79(1)〕
When start key switch is in START position
Start switch START〔CS-2(5)〕 I/conn〔CN-8(9)〕 Safety relay〔CR-5(86) → (30)〕
l/conn〔CN-3(2)〕 Start relay〔CR-23〕
l/conn〔CN-2(4)〕 Fuel cut off〔CN-79(2)〕

CHECK POINT

Engine Start switch Check point Voltage

① - GND(Battery)
② - GND(Start key)
③ - GND(Battery relay M4)
+
OPERATING START ④ - GND(Starter B ) 20~25V
⑤ - GND(Starter M)
⑥ - GND(Start relay)
⑦ - GND(Battery relay M8)

GND : Ground

4-56
STARTING CIRCUIT (#1001 and up, TIER II)

21074EL52

4-57
CHARGING CIRCUIT (#1001 and up, TIER II)
When the starter is activated and the engine is started, the operator releases the key
switch to the ON position.
Charging current generated by operating alternator flows into the battery through the
battery relay (CR-1).
The current also flows from alternator to each electrical component and controller through the fuse box.

OPERATING FLOW
Warning flow
Alternator "I" terminal I/conn〔CN-3(3)〕 CPU alternator level〔CN-
51(9)〕 Cluster charging warning lamp(Via serial interface)

Charging flow
+
Alternator "B " terminal Battery relay(M8) Battery(+) terminal
Reset button〔CN-60〕 Fuse box

2) CHECK POINT

Engine Start switch Check point Voltage

① - GND(Battery voltage)
② - GND(Battery relay)
+
Run ON ③ - GND(Alternator B terminal) 20~30V
④ - GND(Alternator I terminal)
⑤ - GND(CPU)
GND : Ground

4-58
CHARGING CIRCUIT (#1001 and up, TIER II)

21074EL53

4-59
HEAD AND WORK LIGHT CIRCUIT (#1001 and up, TIER II)
OPERATING FLOW
Fuse box (No.14) I/conn〔CN-7(7)〕 Switch panel〔CN-116(9)〕
Fuse box (No.15) I/conn〔CN-7(8)〕 Switch panel〔CN-116(10,11)〕
Head light switch ON
Head light switch ON〔CN-116(1)〕 l/conn〔CN-7(1)]
Head light ON〔CL-4(2)〕: Head lamp ON
l/conn〔CN-10(2)〕 Cassette radio illumination ON〔CN-27(7)〕
l/conn〔CN-11(8)〕 AC & Heater controller illumination ON
l/conn〔CN-6(8)〕 Cigar light〔CL-2〕

Work light switch ON


Work light switch ON〔CN-116(2,3)〕 l/conn〔CN-7(2)〕 l/conn〔CN-12(1)〕
Work light ON〔CL-5(2), CL-6(2)〕

2) CHECK POINT
Engine Start switch Check point Voltage

① - GND(Fuse box)
② - GND(Switch power input)
STOP ON 20~25V
③ - GND(Switch power output)
④ - GND(Head light)

⑤ - GND(Fuse box)
⑥ - GND(Switch power input)
STOP ON 20~25V
⑦- GND(Switch power output)
⑧ - GND(Work light)
GND : Ground

4-60
HEAD AND WORK LIGHT CIRCUIT (#1001 and up, TIER II)

21074EL54

4-61
BEACON LAMP AND CAB LIGHT CIRCUIT (#1001 and up, TIER II)
OPERATING FLOW
Fuse box (No.17) I/conn〔CN-8(3)〕 Beacon lamp switch〔CN-23(6)〕
Fuse box (No.16) I/conn〔CN-7(12)〕 Switch panel〔CN-116(16, 17)〕
(1) Beacon lamp switch ON
Beacon lamp switch ON〔CS-23(2)〕 Switch lndicator lamp ON〔CS-23(9)〕
l/conn〔CN-8(4)〕 l/conn〔CN-10(10)〕
Beacon lamp ON〔CL-7〕
(2) Cab light switch ON
Cab light switch ON〔CN-116(7, 8)〕 I/conn〔CN-7(6)〕 I/conn〔CN-
10(11)〕 Cab light ON〔CL-8(2), CL-9(2)〕

2) CHECK POINT
Engine Start switch Check point Voltage

① - GND(Fuse box)
② - GND(Switch power input)
STOP ON 20~25V
③ - GND(Switch power output)
④ - GND(Beacon lamp)

⑤ - GND(Fuse box)
⑥ - GND(Switch power input)
STOP ON 20~25V
⑦ - GND(Switch power output)
⑧ - GND(Cab light)
GND : Ground

4-62
BEACON LAMP AND CAB LIGHT CIRCUIT (#1001 and up, TIER II)

21074EL55

4-63
WIPER AND WASHER CIRCUIT (#1001 and up, TIER II)
OPERATING FLOW
Key switch ON
Fuse box (No.11) I/conn〔CN-7(5)〕 Switch panel〔CN-116(6)〕
Fuse box (No.4) I/conn〔CN-5(4)〕 I/conn〔CN-17(5)〕 Wiper motor controller〔CN-141(7)〕
Wiper motor〔CN-21(4)〕
Fuse box (No.13) I/conn〔CN-6(5)〕 l/conn〔CN-17(4)〕 Wiper motor controller〔CN-
141(6)〕 Washer pump〔CN-22(2)〕
Wiper switch ON : 1st step(Intermittent)
Wiper switch ON〔CN-116(15)〕 I/conn〔CN-9(4)〕 I/conn〔CN-6(10)〕 I/conn〔CN-17(8)〕 Wiper motor
controller〔CN-141(10) → (3)〕 Wiper motor intermittently operating〔CN-21(6)〕

Wiper switch ON : 2nd step(Low speed)


Wiper switch ON〔CN-116(4)〕 I/conn〔CN-7(3)〕 I/conn〔CN-6(9)〕 I/conn〔CN-17(2)〕
Wiper motor controller〔CN-141(2) → (4)〕 Wiper motor operating〔CN-21(2)〕
Washer switch ON
Washer switch ON〔CN-116(12)〕 I/conn〔CN-7(9)〕 I/conn〔CN-5(1)〕 I/conn〔CN-17(7)〕
Wiper motor controller〔CN-141(9) → (8)〕 I/conn〔CN-17(6)〕 I/conn〔CN-6(11)〕
Washer pump〔CN-22(1)〕 Washer operating
Fuse box(No.13) I/conn〔CN-6(5)〕 I/conn〔CN-17(4)〕
Wiper motor controller〔CN-141(6) → (4)〕 Wiper motor operating〔CN-21(2), Low speed〕
Auto parking(When switch OFF)
Switch OFF〔CN-116(15)〕 Wiper motor parking position by wiper motor controller

CHECK POINT

Engine Start switch Check point Voltage

① - GND(Fuse box)
24V
② - GND(Switch power input)
③ - GND(Switch power output)
STOP ON 0~5V
④ - GND(Wiper Power input)
⑤ - GND(Wiper power output)
0 or 24V
⑥ - GND(Wiper motor)
GND : Ground

4-64
WIPER AND WASHER CIRCUIT (#1001 and up, TIER II)

21074EL56

4-65
CONTROLLER CIRCUIT (#1001 and up, TIER II)

21074EL57

4-66
MONTORING CIRCUIT (#1001 and up, TIER II)

21074EL58

4-67
ELECTRIC CIRCUIT FOR HYDRAULIC(#1001 and up, TIER II)

21074EL59

4-68
7.CONNECTOR DESTINATION
Connector No. of Connector part No.
Type Destination
number pin Female Male
CN-1 Econoseal J 6 I/conn(Pump ps harness-Frame harness) S816-006002 S816-106002
CN-2 Econoseal J 12 I/conn(Engine harness 2-Frame harness) 2-85262-1 368301-1
CN-3 Econoseal J 8 I/conn(Engine harness 1-Frame harness) S816-008002 S816-108002
CN-4 Econoseal J 8 I/conn(Console harness LH-Frame harness) S816-008002 S816-108002
CN-5 Econoseal J 15 I/conn(Side harness RH-Frame harness) 2-85262-1 368301-1
CN-6 Econoseal J 12 I/conn(Side harness RH-Frame harness) S816-012002 S816-112002
CN-7 Econoseal J 15 I/conn(Console harness RH-Frame harness) 2-85262-1 368301-1
CN-8 Econoseal J 12 I/conn(Console harness RH-Frame harness) S816-012002 S816-112002
CN-9 Econoseal J 8 I/conn(Console harness RH-Frame harness) S816-008002 S816-108002
CN-10 DEUTSCH 12 I/conn(Cab harness-Frame harness) DT06-12S DT04-12P
CN-11 DEUTSCH 8 I/conn(Air-con harness-Frame harness) DT06-8S DT04-8P
CN-17 DEUTSCH 8 I/conn (Side harness RH-Wiper motor harness) DT06-8S DT04-8P
CN-92 SWP 1 Emergency engine starting connector S814-001001 S814-101001
CN-95 KET 2 Fusible link S813-030201 S813-130200
·Switch
CS-26A Econoseal J 2 Breaker pedal S816-002002 S816-102002

4-69
SECTION 3 HYDRAULIC SYSTEM
GROUP 1 HYDRAULIC CIRCUIT

10 11 8 9 Main pump
Main control valve
4 Swing motor
RED RED Travel motor
RCV lever(LH)
RCV lever(RH)
PBP
(XBp1) (XBp2) 7 RCV pedal
PaL Dr3 Fl Fr Dr2 2
8 Boom cylinder(LH)
9 Boom cylinder(RH)
XAa2
XAa1
Dr1
10 Arm cylinder
11 Bucket cylinder
XBa2
12 Turning joint
VA VB VB VA
XBa1 XAa2 13 Check valve
XBa2 XAk
14 Check valve
12 15 Hydraulic tank
XBk
XAb2 16 Oil cooler
Dr4
PbL
dr3 XAb2
17 Air breather
XBs
XAb
Pk As Ab1 18 Bypass valve
Bb1
Bs
3 XAs 19 Strainer
Pns XBb
XBtl
Dr6
20 Spin filter
XA0
XBs Atl
XB0
21 Line filter
SH Btl
25 XAtl 22 Solenoid valve
PG XAs
dr4 XAtr
Atr
23 Accumulator
Btr
24 Pressure switch
XBtr 25 Shuttle valve
C
R1
26 Last guard fill
PA PB
P2 R2
PH
Px

A B

Pz
P1 PG Py
SWING ARM 5 7 TRAVEL BUCKET BOOM 6 24

1 A1 A2

14 13
XAs XBs XBa1 XAa1 XBk XAk XAb1 XBb1 dr2~dr8 16
(1) (3) (2) (4) (3) (1) (2) (4)
XAtl XBtl XAtr XBtr
(1) (2) (3) (4)
17
23 26 15 Fl
Pm1 Pm2

20 (Pi1)
Fr
Pns Pk
Pm1 Pm2
PZ
22 dr1
(Pi2)

A5 A4 A3 A2 A1
18
M
P4 PG(S/Motor)
21 19 dr1
P3 PG(MCV)
P2 A3
P1

3-1