Hyundai-r210lc-7 Shop Manual

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 2) turbocharger housing 3) housing radiator 4) refueling 5) battery corrosion 6) battery explosion 7) the hydraulic oils 8) hydraulic lubrication oil 9) Beware! Do not stand close! 10) Lifting Loop 11) Record the name companies and car models 12) loading ideogram excavator 13) Do not stand close to the side side! 14) Stay still

15) Be careful with the engine!

The danger of a cut limb 16) Do not stand on the hood engine 17) Transporting 18) Engine low level of gaseous emissions 19) control ideogram 20) control ideogram (left-hand side) 21) control ideogram (Right side) 22) Guide operating 23) Maximum height 24) Windshield safety glass 25) safety rear glass 26) air conditioner filter The inclination of the remote control box safety lever

0-5

29) The model name (left side) 30) The model name (right side) 31) Logo (ROBEX) 32) Brand HYUNDAI (On the boom) 33) Brand HYUNDAI (On the counterweight) 34) Free from staff working area 35) Noise level LPA 36) Noise level LWA 37) Instructions operating 38) Driving the car lift 39) caterpillar 40) collision 41) lock the lock

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 turbokompreslitter. 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 information on p. 4-13.

detailed

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 information on p. 4-13.

detailed

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, kV 6.6 33.0 66.0 154.0 275.0

Min. secure distance m 3 4 5 8 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 WITHDRAWAL

DIGGER

AND

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 tank

box

Main pump

Tank hydraulic fluid

Engine Radiator

Battery Tooth

Ladle

Rotary drive motor hinge rotation

hydraulic cylinder Handle

hilt

Main distributive valve

hydraulic cylinder Arrow

oil cooler

Preliminary air cleaner Cabin

arrows

Muffler

hydraulic cylinder bucket Coupling pull side cutter

tension roller

carrying asterisk rink

Connective stock

bearing rink

2-1

Caterpillar

Counterweigh t drive motor

2. SPECIFICATIONS

D

F

C

G

I (I ')

E

H

one) R210LC-7 Model

J

M

K

N B (L)

A

Name Operating weight Accommodates standard bucket (PCSA on standards) Overall length BUT The overall width of 600 mm with Trakom IN headroom FROM The width of the superstructure D cabin height E The distance of the counterweight from the ground F Height to engine covers G Minimum ground clearance back Size The radius of the rear edge of the turn Distance between axes The length of the undercarriage The width of the undercarriage The distance between the centers of the tracks Track width, standard

H I I' J K L M N low high

speed Swing speed Gradeability Ground pressure (the caterpillar 600 mm)

U rev.

Value

kg

21700 0.92 9520 2990 2990 2700 2920 1060 2320

m3

mm

km / h rev / min Hail(%) kg / cm2

2-2

480 2770 2830 3650 4440 2990 2390 600 3.4 5.3 12.5 35 0.46

OPERATING LIMITS Models R210LC-7 (with 5.68 m boom length) A A'

B

B'

C

E

D

F

8ft

Name The maximum radius BUT digging, mm The maximum radius BUT' digging at the ground level, mm Maximum depth IN digging, mm Maximum depth Digging (level 2.5 m), IN' mm Maximum depth vertical digging FROM wall, mm Maximum height D digging, mm Maximum height E unloading, mm minimum radius F turning, mm

Digging force of the bucket

SAE ISO SAE

Digging force on the handle ISO

Handle 2.0 m

Handle 2.40 m

Handle 2.92 m

Handle 3.90 m

9140

9500

9940

10910

8960

9330

9780

10770

5820

6220

6740

7720

5580

6010

6550

7580

5280

5720

6120

7240

9140

9340

9470

10110

6330

6520

6670

7290

3750

3740

3640

3650

133 [146] kN 133 [146] kN 133 [146] kN 133 [146] kN 13600 [14840] kgf 13600 [14840] kgf 13600 [14840] kgf 13600 [14840] kgf 152 [166] kN 152 [166] kN 152 [166] kN 152 [166] kN 15500 [16910] kgf 15500 [16910] kgf 15500 [16910] kgf 15500 [16910] kgf 135 [148] kN 113 [123] kN 13800 [15050] kgf 11500 [12550] kgf 142 [155] kN 118 [128] kN 14500 [15820] 12000 [13090] kgf kgf

[ ]: The boosting of

2-3

97 [106] kN 9900 [10800] kgf 101 [110] kN 10300 [11240] kgf

79 [87] kN 8100 [8840] kg 85 [93] kN 19170 [20910] kgf

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) Tools and machinery front of the machine assembly (Arrow 6.5 m, 3.05 m handle bucket 1.27 m3 by PCSA) Boom assembly 6.5m

1320

The handle assembly 3.05m

705

3

4050 1500

Bucket 1.27 m by PCSA boom cylinder assembly

660 180

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 reach

Radius download Altitude loading

3.0m

4.5m

6.0m

7.5m

cargo lifting

Reach m

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

capacity with cap, m3

0.92m3

Width

Weight, kg

By CECE

Without cutting edge

FROM cutting edge

0.51

0.45

700

820

580

0.80

0.70

1000

1120

650

0.80

1130

1250

710

1.20

1.00

1400

-

770

1.34

1.15

1550

-

800

By PCSA

0.92

1.20 m3

Recommendation Arrow 6.25 m Handle 2,1 m

Handle 2.5 m

: 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

1.34 m3

Handle 3.05 m

Handle 3,6 m

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

Buckets 0.74, 0.87, 1.05 m3

with a cap on the SAE

Capacity, m3

0.87 m3 bucket

Bucket 0.75 m3

with a cap on the SAE

with a cap on the SAE

Recommendati on Arrow 5.68 m

Width

hat on CECE

Without cutting edge

FROM cutting edge

Weight, kg

0.74

0.65

915

-

750

0.90

0.80

1070

-

790

1.05

0.92

1220

-

870

0.87

0.75

1140

-

860

0.65

1810

-

880

hat on SAE

??0.75

Handle 2.0 m

: 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

Handle 2.4 m

Handle 2.92 m

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

R210LC-7

R210LC-7 with a long arrow R210LC-7 increased cross-country

Options

Width Total weight Inheritance. ground pressure Full width Width Total weight Inheritance. ground pressure Full width Width Total weight Inheritance. ground pressure Full width

mm kg

600 21700

700 21980

800 22270

-

kg / cm2 mm mm kg

0.46 2990 -

0.40 3090 -

0.35 3190 800 24360

-

kg / cm2 mm mm

-

-

0.42 3190

600

700

800

double grouser

kg

23160

23440

23730

710 23770

kg / cm2 mm

0.49 3395

0.43 3495

0.38 3595

0.43 3505

Number of rollers and Truckee each side Name

Number on the side

leading rollers Road wheels track shoes

2 nine 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 600 mm triple grouser 700 mm triple grouser 800 mm triple grouser 800 mm triple grouser (Model with a long arrow)

Features Standard Option Option Standard

Category shoe A B C C

Table2 Category shoe BUT

IN

FROM

Using Rocky soil, floodplains, plain the soil. Normal soil, soft soil.

Very soft soil (Marshy soil)

Precautionary measures • On uneven surfaces with large obstructions (Boulders, fallen trees) maintain the small speed. • 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. • Use this type of shoe is only provided if a 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 Model Type of cooling method Number of cylinders and their arrangement ignition order Type combustion chamber Bore and Stroke Cylinder capacity (per stroke piston) Compression ratio Rated power, hp on SAE J1995 (See. The identification plate) Maximum torque The volume of oil in the engine dry weight Maximum engine speed (Idle) Minimum engine speed (Idle) Fuel consumption, theoretical

starter motor Generator Accumulator battery

Specifications Cummins B5.9-C * Cummins 6BTAA Four-stroke diesel engine with turbo Water cooling Six cylinders in a row 1-5-3-6-2-4 direct injection 102 × 120mm 5880 cubic meters. cm 17.4: 1 155 hp at 2100 rev. / min

* 17.3: 1

* 150 hp at 1950 vol. / min 62.1 kgf · m at 1600 rpm. / Min * 62.6 kgf · m at 1500 rev. / Min 24 l 400 kg * 496kg * 2180 ± 50 vol. / 2250 ± 50 vol. / Min Min 950 ± 100 rev. / Min 171.5 g / bhp * hr at 2100 rev. / min Nippon denso (24V-5.5 kW) Delco Remy 24V-50A 2 × 12V 160Ach

* 1050 ± 50 vol. / Min * 164.8 g / bhp * hr at 1950 vol. / min

*: Models with engines TIER II.

2) The main pump Name Type of Performance maximum pressure Nominal oil flow Rated speed

[

Specifications Steering twin axial piston 2 × 105 cm3/about 330 kgs *m [360 kgf · m] 2 × 220 L / min 2100 rev. / Min

]: The boosting of

2-11

* 2 × 113 cm3/about

* 1950 vol. / Min

GEAR PUMP Name Type of

Performance maximum pressure Nominal oil flow

Specifications Single-stage unregulated fif te en cm3 /about. 35 kgf / cm2 31.5 l / min

the main distributor Name Type of inclusion of the principle of Pressure setting of the main safety valve The maximum pressure relief valve

[

Specifications 9-spool hydraulic control 330 kgf / cm2 [360 kgf / cm2] 390 kgf / cm2

]: The boosting of swing motor Name

Type of Performance Pressure valve settings Brake system braking moment Pressure brake unclamping gearbox type Rotational speed

Specifications Two fixed axial piston motor 151 cm3/about 240 kgf / cm2 Automatic, with hydraulic spring control. 59 kgs* m 33-50 kgf / cm2 The two-stage planetary gear 12.5 vol. / Min

Drive Motors Name Type of Operating pressure gearbox type Brake system Pressure brake unclamping braking moment

Specifications Adjustable axial piston 330 kgf / cm2 * 325 kg / cm2 The two-stage planetary gear Automatic, with hydraulic spring control. 6 kgf / cm2 * 11 kg / cm2 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 Operating pressure power stroke

Minimum Maximum Lever arm

Decompression Type 6.5 kgf / cm2 26 kgf / cm2 61 mm

Pedal

123 mm

CYLINDERS Name the boom cylinder cylinder handle bucket cylinder

Specifications Ø piston rod Ø × × stroke shock absorber Ø piston rod Ø × × stroke shock absorber Ø piston rod Ø × × stroke shock absorber

Ø 120 × Ø85 × 1210mm to nominate only Ø 140 × Ø 100 × 1510 mm Extension and retraction Ø 125 × Ø85 × 1055mm 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

Count

Overall

primer kgf / cm2

links

Width, mm

Option

600 700 800

0.46 0.40 0.35

49 49 49

2990 3090 3190

Standard

800

0.42

49

3190

Name

R210LC-7

R210LC / LR -7 (With the extension. Arrow)

specific

Width Standard

pressure on

: Double grouser

2-13

LADLE Capacity According to the PCSA, By CECE,

Name

m3

Standard

R210LC-7

Option

0.92 0.51 0.80 1.20 1.34 0.74 0.90 1.05 0.87 ◙0.75

Count

Width without side On the side

m3

teeth

cutting edge mm

cutting edge mm

0.80 0.45 0.70 1.00 1.15 0.65 0.80 0.92 0.75 0.65

5 3 5 6 6 5 5 5 5 -

1130 700 1000 1400 1550 915 1070 1220 1140 1810

1250 820 1120 -

: 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.

location

Type of fluid

Capacity, l

-twenty

Ambient temperature, 0 FROM twent -10 0 10 y

SAE

Pallet crankcase engine

motor oil

thir ty

thir ty

SAE 10W

24

SAE 10W-30 SAE 15W-40

Turning reducer onboard broadcast

gear housing Zion oil

6.2

SAE 85W-140

5,4h2 ISO VG 32

Tank hydraulic

Fuel tank

nipple grease

hydraulic cal oil

Buck: 180 System: 270

diesel fuel

320

grease grease

grease Radiator (rasshirition tank)

ISO VG 46

ISO VG 68

ASTM D975 №1 ASTM D975 №2

NLGI №1

how many neobho-

NLGI №2

Dimo Mixture antifreeze water 50:50

35

Permanent type based on ethylene glycol

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

40

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 operation breaker right stick

switch panel Car 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 to rest his feet

Emergency shift lever 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 Fuel level sensor temperature sensor hydraulic fluid temperature sensor

Control lamp temperature hydraulic fluid The control lamp for overheating coolant

coolant

engine

engine

The control lamp pollution of the air cleaner

Control lamp test CPU controller

The warning lamp Low engine oil pressure

signal lamp boost signal lamp heater

The control level of the lamp battery charge The control lamp machine overload

signal lamp engine warm-up

check engine lamp (Only in models with

Signal light frequency engine speed The warning lamp Low coolant level liquids

engine TIER II)

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 red range

- Green range: 30-105ºS - 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

red range

It shows the coolant temperature. White range: Below 30 ° C Green range: 30-105ºS - Red range: above 105 ° C (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 speed

regimes user Switch automatic

switch the buzzer 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( conditions.

) Lamp lights the selected load

• H: Mode of high load S: Mode standard load

The switch controls the speed (Travel Speed) This switch controls the speed.When choosing a highspeed (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 Switch sound when movement

switches Switch

switch heater washer switch wiper switch

machine overload 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 - ON - START

All electrical circuits are disabled. All machine systems are functioning. 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

I

O

DISCONNECT SWITCH

OFF

This switch is used to switch off the entire electrical system as a whole. I: the battery is connected to electric : The battery is disconnected 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.

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 (2nd)

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

signal lamp (1st)

wiper switch signal lamp (2nd)

signal lamp (1st)

This switch is used to drive the window wiper in 2 positions. 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 in the on position (ON), can damage wiper motor.

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 breaker

When you press this button, hydraulic works only if the switch on the panel 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 touch

This button is used to quickly enable engine speed deceleration function. 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 boost

When it is pressed, the power transmitted from the hydraulic pump to the 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 Emergency shift lever engine speed (ORT)

movement of the lever

(Excl. Models with engines TIER II)

pedal

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

lever throttle engine valve A

Cable

B

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 excavatoror go with him.

Free 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

A A

C B

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 Function

Air conditioning

Speed fan

Temp.

air flows in the cockpit

Fence air

Value

OFF (OFF).

one

Maksim. cold

Level head

recirculation

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

Cold

Warmly

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 accompanied by five beeps. Provisions for maximum cooling and maximum heat following settings are the best: Temperature

Air conditioning

Speed fan

air flows in the cockpit

Fence air

ON (ON).

4

level head

recirculation

OFF (OFF).

3

In feet

Fresh air

Max. cooling Max. heating

3-18

SWITCH AIR FLOW IN THE COCKPIT (on e) There are 4 positions air flow

Mode

Position switch A streams air

B C

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

air

Retsirku-

lyatsiya

Fresh air The absorption of fresh air from outside the cabin without disturbing the cabin sealing. 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 (CPU)

Cigarette lighter

RS232 serial connector

Hour meter

Fuse box

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

frequency button rewind the tape sound adjustment sound balance button Switching (Left / right) radio stations

eject button cassette

Cavity cassette insertion

back forward

PROG BAL

BAS TRE

ON VOL

power button adjustment volume

HYUNDAI AUTO REVERSE

BAND SEEK TUNE

one

2

3

4

5

6

MTL

Search Button Setup Button radio stations Radio Waves

3-20

memorizing button radio stations

Display

The power button and volume control ON

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.

V OL

radio stations Search Button

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

SEEK

TUNE

Radio Wave Setting button When you press"+"Channels are selected with a higherfrequency. When you press"-"Channels are selected with a 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

SEEK

TUNE

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

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.

MTL

3-21

5) Display G eneral & America

E urope

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 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

PROG

When pressed, this button during the playing timecassette tape 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 thenradio turns off. This control does not work while in the ON position the power knob on the radio panel.

ON VOL

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.

B

(2) Adjusting the up-down (B) The lever for displacement tighten up or down. adjustment back and forth lateral performed only when tilted to one side In the lever means.

seat can

Tilt (C) Tighten the lever C to tilt adjustment seatback.

D

(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

F A

(6) Adjusting the seat cushion (F) Adjust the position of the handle in the cushions 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 Only for cars with engines TIER II

For vehicles with a conventional engine

20A 10A 5A

RELA Y POWER

RELA Y compressor COPA Condition.

CR -35

CR-7

EMERGENCY RELA Y

CR -5

F R O M

HEADLIGH TS

TRAFFIC

RELA Y POWER

RELAY SOUND. SIGNAL

CR-2

CR -35

10A

5A

10A

10A PANEL DISPLAYS

ECM

beacon

Condition. AND HEAT. SOUND. SIGNAL

RELA Y compressor COPA Condition.

CR-7

RELA Y ANTIRESTART

RELAY FEED ETHER

CR -5

CR -36

5A

IAHS.

CRASH.

SOLENOID one

CAB

CPU

ECM

LIGHT.

3

SOLENOID

10A

one SOLENOID

WORKING HEADLIGH TS

10A

GLASSCLEAR.

CPU

20A

CRASH. SOLENOID

Condition. AND HEAT.

ZOVATEL

5A

3 SOLENOID

transformatio n

DOP.TOPL. PUMP

SOLENOID

5A

PANEL

10A

PUMP

Condition. AND HEAT.

10A

SWITCH.

GLASSCLEAR.

10A

CAB ILLUMINATI ON.

30 A

10 A

ECM

10 A

FRO M

15 A

20 A 5A

FR OM

10A

HEATING

BU T

HOLDER

10A

IAHS.

Vatel PRIKURI-

10A

10A

CPU

SOUND. SIGNAL

BU T

LOCK Igniting.

W B U T P B U T

5A

transformatio n ZOVATEL

AND HEAT. Condition.

DOP.TOPL.

20A

SWITCH. PANEL

beacon

BU T P

RESERVE

10A

FUEL

20A 5A

CUTOFF

10A10A

Condition. FAN.

PANEL DISPLAYS

CAB

RESERVE

LIGHT.

10A

CPU

10 A 5A

CLEAR. GLASS-

CLEAR. GLASS-

5A 20A

Condition. AND HEAT.

20A

CAB ILLUMINATI ON.

5A

10A

20A5A

10A 5A

5A

Igniting.

WORKING HEADLIGHT S

W

BU T P

10A

HEADLI GHTS

W

30A

LOCK

20A

FRO M

F R O M

10A

BU T

HOLDER

10A 10A

BU T P

5 A

W B U T P B U T

10A5A

W

5A

20A

F R O M

10A 5A

10A

W B U T P B U T

10A

20A

TRAFFIC

HEATING

PRIKURIVatel

RELAY SOUND. SIGNAL

CR-2

RELAY FEED ETHER

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

light bulbs

YRG

MO DE PART L: R

OB NO:

EX 21N8290LC-

To harmonize the engine torque to the torque of the hydraulic pump, the CPU controller regulates the pressure at the outlet of the valve EPPR (ElectroProportional Pressure Reducer proportional pressure reducing valve) that provides control of the pump output when the engine speed falls in accordance with various operation modes set by it. Three LED lights on the controller CPU indicate the following:

32102 7

LED lamp "G" pregnant ON. "G" and "R" pregnant ON.

malfunction

Remedy

Missing

-

fault in CPU or RAM.

• Replace controller. • Check, Do not break

"G" and "Y"

The problem is in

pregnant

consistent

ON.

trunk.

All three LED lamps disabled

The problem is with voltage supply to central processor.

connecting the data line between the controller and the panel instruments. • Check, Do not disconnect power supply line voltage (24V, grounded) controller. • 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

HOUR METER

This counter indicates the total number of hours worked by the machine. When operating the machine, always make sure the health meter. Carry out 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

Grasp the handles on the top and bottom of the upper frame windshield and push the glass toward the top.

A pen

Grasp the handles on the top and bottom of the upper frame 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.

A pen

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 listed

below

3 stages and avoid 100 hours

excessive loads on the machine for the first 100 hours. Hours Until 10 o'clock Up to 100 hours

Load Approximately 60% Approximately 80% one hundred%

After 100 hours

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 work.

Avoid excess loads on the car during the first

warm up

fro (5) Time m work functioning sensors.

car

before

time check in

time

(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 The oil in the motor Engine oil filter Element drain line filter hydraulic working fluid drain pipe filter element of the fluid container with the fluid The filter elements in the circuits Fuel filter

Service

replace the

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, fuel or coolant, and check the condition of the work equipment 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

Check before

Begin

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 buzzer. 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.

ON OFF

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 working area for the presence of her people and obstacles.

S TART ON OFF

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

starter Box electrodevices

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 ON

Immediately release key after engine start.

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. S TART

Operation Warm the machine runs automatically.

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 temperature water (8) and temperature a hydraulic fluid (9) in the green zone? (5) if the noise is normal engine running, and Is the exhaust color normal? Whether noise rate and (6) vibration?

nine 8 7

2

3

4

It should not dramatically increase the speed rate directly after starting the engine, so as this may cause damage engine and turbocharger system.

5

6

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. 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

fifty C

To stop the engine If the engine stops abruptly without cooling, its service life can be significantly reduced. Therefore, do not suddenly stop the engine except in an emergency.

5 minutes at low speed 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

4-6

OFF

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 machine, developed by HYUNDAI in order to optimize the work of the excavator.

6

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 the boom. Normal operation: When the ignition switch this mode is automatically selected. In this case, the speed of rotation is higher than in the regime of hard work. Operating mode breaker This mode activates maximum supply solenoid and the supply pump results in hydraulic working movement. load modes load modes are designed to work with different load and high efficiency combined with a reduction in fuel consumption. Mode H: high load Mode • S: Standard load 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

one 3 4

o n e. modes of operation 2. load modes 3. user modes 4. automatic mode deceleration 5. speed modes 6. The display shows

2 5

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. 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

The display shows

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 Mode

S

Incl. (ON)

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 1950 ± 50 1800 ± 50 *

the effect The same power as that of the machine, not 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 The map zheniya

How to select the display mode Select group Selecting indicators display

Name engine speed, rev / min

Path 1: Ignition switch ON position or START.

press SELECT 1 time

Time

press SELECT

Changing the force

2 times

pressure (EPPR valve)

press SELECT 3 times

Model and version CP program

switch

press SELECT

Model and version

Decel when pressed BUZZER STOP Group 1-4

SELECT 4 times

Auto avto zamedleniy a

Path 2:

CP program

The pressure in line second pump

SELECT 6 times

The pressure of the pilot lines charging voltage the battery (B)

the original

Press SELECT one

The pressure in line first pump

SELECT 5 times

Group1V oltage, temperatu re, davlenieE PPR, versiyapro grammy)

press

3 times

Opt ion (tol koe sliu sta nov len dat chi kda vle niy a)

Gruppa0(d efault)

the original position

press SELECT 1 time

Voltage potentiometer (B)

press SELECT

Voltage

times while

pressing BUZZER STOP.

In this group, LED lightbulb switch SELECT illuminated (ON)

2 times

a gearshift

(IN) Temperature hydraulic oil (° C)

press SELECT 3 times press SELECT 4 times

Temperature coolant

(° C)

(

* Press SELECT

External pressure (kPa)

(code s

group2fault)

time Press SELECT two times while pressing BUZZER STOP. In this group, LED lamprophyllite

Current fault the original

switch kid ney

sound buzzer (BUZZER STOP flashes)

press SELECT 1 time

press  and SELECT simultaneously

4-11

Recorded in the memory failure (only when the key) Delete recorded in memory failure (Only if the the ignition key)

What does the panel displays

How to select the display mode Select group selection indicators regime display

Group mappin gzheniya

Name

)

the original

Press SELECT three times while pressing BUZZER

3

STOP. In this group, LED button's lamp SELECT blinks intervals of 0.5 seconds.

or

SELECT 1 time

pressure switch avtozamedleniya system

SELECT 2 times

lift switch voltage

or

SELECT 3 times

pressure switch engine oil

or

or

switch deceleration

SELECT 4 times SELECT 5 times SELECT 6 times

engine rotational one pressing emergency switch movement signal when switch heater

the original

) 4

Soft switch pump

What shows display panel

or or

or

Hour meter

or

SELECT 1 time

Neutral relay (relay "Anti-restart")

or

speed solenoid

or

LED

SELECT 2 times SELECT 3 times SELECT

button's lamp SELECT blinks interval 1 sec.

4 times SELECT 5 times

arrows Alarm during of movement

SELECT 6 times

Solenoid highest feed system pressure

SELECT 7 times

Heating relay system

Press SELECT 4 times while pressing BUZZER STOP. In this group,

Boost solenoid (2position relief valve) The valve is cycling

One press of the SELECT button at the same time BUZZER STOP switches the display group in the following order. Eg., Group 0

on - Included, o FF

one

2

3

4

0

- switched off

Only a machine with an engine TIER II

4-12

or or

or or or

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 and bucket.

July 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). The rotation of the turntable to the right (clockwise). The rotation of the turntable to the left (counterclockwise).

3

one 4

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

7 5 8

4-13

HANDLING EQUIPMENT BASIC OPERATIONS (1) Transport position 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 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

In move

Travel motor

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 Travel motor

slip prevention. 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 SMALL position (LOW- symbol turtle).

20 ~ 30cm (1ft)

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 out by towing follows.

Correctly

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. wire rope

Never make towing the excavator using only the towing 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 in damage to the machine.

boom begins work

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 hydraulic cylinders.

Power reserve

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

Wrong

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 the performance of lifting operations, contact your local distributor firms

Wrong

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 exposed to more easily freeze on Compared to a fully charged state.

batteries

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 be heard about the rotary motor.

can

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 Left Right joystick joystick

to the right

to the left

Function management

to the right to th e le ft

type A

to the left

Type ISO HYUNDAI Scheme



Hose connection (Port) Joy Changing the port stick

Handle - from excavator Hilt - to the excavator Right Swing Left Swing lowering the boom Lifting the boom Bucket - from excavator Bucket - to the excavator lowering the boom Lifting the boom Right Swing Left Swing Handle - from excavator Hilt - to the excavator Bucket - from excavator Bucket - to the excavator lowering the boom Lifting the boom

to the right

A

Bucket - from excavator B Handle - from excavator J Hilt - to the excavator H Right Swing F Left Swing G Loosen the bolt lever Control (21) turn the entire system on the joystick 90 ° counter clockwise arrows; then set. To put the control lever to the right position, unscrew the nut (20) and rotate only the joystick 90 ° clockwise.

to the right

type C

to the left

type B

Buc ket - to the excavator

From D E A B J H F G D E A B J H F G D E

The same as in the ISO type.

4-27

On J H D E J H G

F D E A B

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.

Before

(1) A unidirectional flow (hydraulic 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 to comply with traffic rules, laws on the movement of vehicles and restrictions input on certain types of machinery.

must

transportation

2) Select appropriate trailer weight specification and dimensions Excavator under Section 2 of this manual "Specifications".

Overall width

after

3) Check the movement route, which will transporting produced excavator on the subject of road width, height of bridges, limitation of the total mass, etc.

Overall height

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. Platform

BU T

IN

1.0 1.1 1.2

3.65-3.85 4.00-4.25 4.35-4.60

gangway

trailer A 15 ~ 16

1.3 1.4 1.5

timb er

4.75-5.00 5.10-5.40 5.50-5.75

5-1

?

DIMENSIONS AND WEIGHT R210LC-7 Model (1) the machine as a whole

Value 4990 2920 2990 17410

H

units Symbol Description measurement L Length mm H Height mm W Width mm Wt Weight kg caterpillars600mm triplegrouser and the counterweight 3800 kg.

L

W

BOOM ASSEMBLY

H

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

L

STICK ASSEMBLY

Value 3910 870 350 1050

H

units Symbol Description measurement L Length mm H Height mm W Width mm Wt Weight kg Handle with hydraulic cylinder 2.95 m ladle (including linkage and fingers)

L

BUCKET ASSEMBLY

H

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

L

5-2

Hydraulic cylinders BOOM

Value 1960 230 330 380

H

units Symbol Description measurement L Length mm H Height mm W Width mm Wt Weight kg Including a system of pipes

L

OPERATOR ASSEMBLY units Description measurement Length mm Height mm Width mm Weight kg

Value 1962 1676 1288 310

H

Symbol L H W Wt

L

W

Symbol L H W Wt

units Description measurement Length mm Height mm Width mm Weight kg

H

COUNTERWEIGHT

Value 2700 1050 560 3800

L

5-3

W

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 end of the tube. Pull the handle to the cylinder of the mark. Adjust the rack mounting bracket and then secure the stand to the right plozheniya.

m 7m

7m

m

5~

5~

Rack

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

Cabin

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

Side housing

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 Excavator install rubber gasket.

0.5 ~ 1.0m

Between support and roller tensioner

between the support rollers №1 and №2

4) Install the valve in the proper place. 5) Place the rack and cable, as shown in the figure. Check if you have selected the correct length 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. 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

Wire cable Rack

BACK VIEW

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. SAFETY REGULATIONS 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

Counter hours

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 the full position it off and set the control stick and pedals to the denial of the situation forward, backward, left and right

Lever arm

Pedal

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 security Engine

the main chain Hydrosystem working Device in

fuel hose (Tank-engine) hose heating device (heater - engine) The suction hose pump Sleeve outlet pump Sleeve hinge line The sleeve cylinder line arrows The sleeve cylinder line hilt The sleeve cylinder line bucket

periods periodicity every 2 years

every 2 years

every 2 years

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 kgf · m 0.9-1.3

10T kgf · m 1.1 - 1.7

2.0-3.0 4.0-6.0 7.4 - 11.2 12.2 - 16.6 18.6 - 25.2 25.8 - 35.0 36.2 - 49.0 48.3 - 63.3 62.5 - 84.5 124 - 168 174 - 236

2.7 - 4.1 5.5 - 8.3 9.8 - 15.8 16.7 - 22.5 25.2 - 34.2 35.1 - 47.5 49.2 - 66.6 65.8 - 98.0 85.0 - 115 169 - 229 250 - 310

M8 × 1,0

8T kgf · m 2.2 - 3.4

10T kgf · m 3.0 - 4.4

M10 × 1,2 M12 × 1,25 M14 × 1,5 M16 × 1,5

4.5 - 6.7 7.8 - 11.6 13.3 - 18.1 19.9 - 26.9

5.9 10.6 17.9 26.6 -

M18 × 1,5 M20 × 1,5

28.6 - 43.6 40.0 - 54.0

38.4 - 52.0 53.4 - 72.2

M22 × 1,5

52.7 - 71.3

70.7 - 95.7

M24 × 2,0 M30 × 2,0

67.9 - 91.9 137 - 185

90.9 - 123 182 - 248

M36 × 3,0

192 - 260

262 - 354

Razmerbolta M6 × 1,0 M8 × 1,25 M10 × 1,5 M12 × 1,75 M14 × 2,0 M16 × 2,0 M18 × 2,0 M20 × 2,5 M22 × 2,5 M24 × 3,0 MZ0 × 3,0 M36 × 4,0 fine thread Razmerbolta

6-6

8.9 16.0 24.1 36.0

Tubes and hydraulic hoses Razmerrezby

Width across flats mm

Moment kgf · m

1/4 "

nineteen

3/8 "

22

4

1/2 "

27

5

3/4 " one"

36 41

12 14

Width across flats mm

Moment

3

FITTING thread size

kgf-m 1/4 "

nineteen

4

3/8 " 1/2 " 3/4 " one"

22 27 36 41

5 6 thirteen fifteen

6-7

TORQUE MAIN COMPONENTS

Name

#

Razmerbolta

Moment tightening

kgf · m

1

Bolts and nuts for engine mount Bolts and nuts for engine mount (Front bracket, TIER II) Bolts and nuts for engine mount (Rear bracket, TIER II)

M24 × 3,0

90 ± 7,0

M20 × 2,5

55 ± 3,5

M24 × 3,0

90 ± 7,0

Bolts of fastening of a radiator

M16 × 2,0

25.7 ± 4,0

Tightening bolts Bolts main pump housing

M20 × 2,5 M10 × 1,5

44 ± 4,5 2.8 ± 0.3

Withdrawal of the main pump mounting bolts

M20 × 2,5

42 ± 4,5

Bolts of fastening of the main distributor Bolts of fastening of a fuel tank

M12 × 1,75 M20 × 2,5

12.2 ± 1,3 46 ± 5,0

Hydraulic tank mounting bolts

M20 × 2,5

46 ± 5,0

Bolts and nuts turntable

M12 × 1,75

Bolts rotary motor mount bolts top of the jog hinge Bolts fastening the lower part of the rotary hinge

M24 × 3,0

12.3 ± 1,3 one hundr ed ± 10

M24 × 3,0

97,8 ± 10

M24 × 3,0

97,8 ± 10

Bolts of fastening of the motor vehicle

M24 × 3,0

one hundr ed ± 10

Bolts of fastening of an asterisk Bolts and nuts of the roller bearing

M20 × 2,5 M16 × 2,0

57 ± 6,0 29.7 ± 4,4

21

Track roller bolts

22 23 24

Bolts track tension cylinder

M20 × 2,5 M12 × 1,25 M22 × 1,5

57.9 ± 8,6 15 ± 0,5 115 ± 5,0

M20 × 2,5 M36 × 3,0 M12 × 1,75

46 ± 5,0 297 ± 33 12.2 ± 1,3

M8 × 1,25

2.5 ± 0.5

2

4 5 6

Engine

3

7

Another part of the Powertrain hydraulics

8 9 10 11 12 13 14 15

19 20

Chassis

16 17 18

Bolts and nuts links caterpillars Bolts guide tracks Counterweight mounting bolts Cab mounting bolts The bolts fastening the operator's seat

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 hydraulic oil Gearboxes and rotary vehicle engines grease

ISO VG 46

Fuel

ASTM D975-№2

Coolant

Antifreeze mixture based on ethylene glycol and 50% 50% water

SAE85W-140 (API GL-5) NLGI №2 based on lithium

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.

location

Type of fluid

Capacity, l

Ambient temperature, 0 FROM -20

-10

0

10

20

30

SAE 30

Pallet crankcase engine

motor oil

SAE 10W

24

SAE 10W-30 SAE 15W-40

Turning reducer onboard broadcast

gear housing Zion oil

6.2

SAE 85W-140

5,4h2 ISO VG 32

Tank hydraulic

Fuel tank

nipple grease

hydraulic cal oil

Buck: 180 System: 270

diesel fuel

320

grease grease

grease Radiator (rasshirition tank)

ISO VG 46

ISO VG 68

ASTM D975 №1 ASTM D975 №2

NLGI №1

how many neobho-

NLGI №2

Dimo Mixture antifreeze water 50:50

35

Permanent type based on ethylene glycol

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

40

4.PERECHEN parameters, check during maintenance DAILY SERVICE TO WORK

Check item

Service

Page

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

visual inspection Fuel tank

Maintenance every 50 hours WORK

Check item

Service

Page

merge

6-25

Check, adjust

6-34

Bearing turntable

grease

6-32

Oil turning gear

Check and top up

6-32

grease

6-38

Fuel tank track tension

axles and bushings lubrication points - 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

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

Check, tighten

6-8

Motor oil

Bolts and nuts: - 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

change

6-34

Check add

6-34

Check and top up

6-39

Drain the hydraulic oil filter

replace the

6-30

Drain hydraulic filter

replace the

6-31

Check and replace if necessity

6-25

Filter pilot line

replace the

6-31

Preliminary air cooler

Check Clear

Hydraulic tank breather element

replace the

6-31

Check, tighten

6-8

* Gear turning gear oil * Lubrication of turning gear drive battery electrolyte

** The filter engine air cleaner

Bolts and nuts 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 * Oil bull gear

Service

Page

change

6-34

Service

Page

change

6-18, 19

replace the

6-18, 19

Inspect, clean

6-23

change

6-25

replace the

6-26

Check and top up

6-33

Maintenance every 500 hours WORK

Check item * Engine oil * Engine Oil Filter The radiator and the fan ribs ** The filter engine air cleaner Fuel filter Oil running gear

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

Add

6-33

change

6-33

Service

Page

change Inspect and clean

6-31 6-31

change

6-20, 21,22,23

Lubrication of turning gear Lubrication of transmission and gears turning mechanism 9) Every 2000 HOURS

Check item Hydraulic Tank: - * Hydraulic oil -Setchaty filter suction line Coolant

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

Drain and clean

6-25

To merge or replace

6-26

replace the

6-26

change

6-18, 19

replace the

6-18, 19

- Coolant

Top up or change

6-20, 21, 22, 23

- Radiator

Clean or wash

6-20, 21, 22, 23

replace the

6-25

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

clean

6-30

Check, adjust

6-34

- teeth

replace the

6-36

- The lateral cutting edge

replace the

6-36

adjust

6-37

replace the

6-35

Clean, replace

6-42

clean

6-43

Fuel system: - Fuel tank - water separator - Fuel filter Engine oil: - Motor oil - Engine oil filter Cooling System:

Air Motor System: - The filter of the air cleaner Hydraulic system: - Hydraulic oil

- strainer in the suction line Undercarriage: - The tension of the caterpillars Ladle:

- linkage - Bucket assembly Air conditioning and heater: - Fresh air intake filter - Recirculation Filter

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 Nosta

numb er

Description

10 hours or

1 2 4 5

Fuel tank hydraulic oil level The engine oil level Radiator coolant

daily

6

9

Warning lamps panel management Water separator (separator) Tools and machinery (axis and sleeves) Strainer fuel tank

10

track tension

12

500

8 13 21 22 23 26 4 11 14

Grease the pivot bearing circle The oil level in the gearbox rotation Battery (electrolyte) Drain hydraulic filter Filter element pilot line Hydraulic sectional filter. drain line Element of the hydraulic tank breather Pre. air cooler Motor oil Engine oil filter The filter of the air cleaner

hours

15

Radiator and fan blades

1000

16 18 17 18

Fuel filter Reducer final drive Oil turning gear Reducer final drive

hours

20

belt tension and condition

2000 hours

24 2 5 19

Rotary transmission and gear The oil in the hydraulic tank Radiator coolant Suction strainer hydraulic line

By the request of

25

air conditioning filters

7 3

50 hours or one time in week

17

250 hours

View

Symbol.

service Check and top up Check and top up Check and top up Check and top up

grease DT GJ MM OJ

Check, clean merge grease

1 1 1 1 1 1

-

-

-

-

2

COP

-

17

-

-

1

COP

0.3

2

COP

-

3

Check and top up

MT

6.2

1

Check and top up replace the replace the replace the replace the clean change replace the clean

MM -

24 -

2 1 1 2 1one 1 1 1 2

-

-

1

MT MT MT

5.4 6.2 5.4

2 2 1 2

-

-

1

COP GJ OJ -

210 50 -

1 1 1 1

-

-

2

Check, clean replace the Check and top up change replace the Check, adjust replace the replace the replace the Check, clean Check, clean

MT: Gear oil Coolant: Coolant MM: Engine oil

6-17

320 180 24 35

Check, clean Check, adjust Check, add

Designation liquids symbols Recommended for applying operating fluid, see the specification Diesel: Diesel MG: Oil hydraulic KS: Grease

EMK., L Dot

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 and check the level again.

TIER II

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 work on the machine is prohibited.

2)REPLACEMENT OILS

IN

ENGINE

Fine probe

AND

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

Option

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

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

Oil

(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 and add water antifreeze mixture.

HYUNDAI

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 ° 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

Correctly

Wrong

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 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.

Correctly

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 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

DCA

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

ABNORMALLY

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 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 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

ABNORMALLY

550 kPa

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. On examination, make sure the fan is securely fastened. If necessary, tighten the screws. If any damage to the fan, replace it. 6-24

BADLY

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 filter element compressed stream air 2 under the pressure of not more than 3 kgf-cm more than (not 3 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 damage.  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

Compressed air no more 3 atmospheres

Wing nut

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. Remove the filter the fuel element the tank and, if it is dirty, clean it. When refueling muffle engine It is prohibited refuelling in the vicinity of the open fire and other heat sources. 6-25

Sensor level fuel

draining tap

10) a water separator (Separator) Red line

(1) Removing the drain plug, drain and sucks. (2) Replace the drain plug. (3) Check for leaks. Regardless of the service period, drained if it has reached the level of 2/3 of the capacity. Drain the water tank after filling

water

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. The engine will not start if the fuel system there is air. Bleed air in accordance with nor described method, then run engine.

Cartridge filter

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 damaging the threads. To close the drain valve, turn stopper clockwise.

Open

close

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

6-26

close

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 the motor in a conventional manner.

START 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 has got into the air came out of the pipeline system. Tighten the fittings.

NONVilleneuve

key size: 19 mm. Start the engine and turn one after the bleed of high pressure pipelines, as long as the engine will not run smoothly.

START ON OFF

 30 seconds

Leaking fuel 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.

6-28

FIRE!

14) TEST OIL LEVEL HYDRAULIC SYSTEM

Red line

(1) After retracting the cylinder arm and bucket stop engine. lower arrow and 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

Level sensor oils

cover breather

(1) Stop the engine at a position for check the level in the tank.

press

(2) Release the pressure by loosening the breather cover and pressing the top of the breather. Breath er

(3) Remove cover the top of the oil tank. 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 (1)Lower the bucket to the ground, plunging the cylinder rods arm and bucket as much as possible. (2)Release the pressure by loosening the breather cap And press to the top of the breather.

cover breather Cap Breather sealing ring

tank

(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. (9)Start the engine and let it run some time. Bleed air from the system, each moving the joystick to full speed before failure.

6-29

Drain bung

CLEANING strainer in the suction line It is necessary to clean the strainer of the suction line, observing the following instructions and taking action when oil filling.

Cap tank

Breather sealing

ring

Remove the lid on top of the tank. Tightening torque: 6.9 ± 1.4 kgf · m screen filter

Remove the strainer from the reservoir. 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 in the tank with the fluid.

sealing rings

Replace the filter with a new element.

valves

Spring bypass

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 working fluid and relieve excess pressure, pushing the top of the breather.

The filter

(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. Make replacement cartridge after the first 50 hours of operation. Next, make replacement after every 250 hours of work.

6-31

Filter pilot lines

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

cap of filling

26) engage and GEAR TURNING CIRCLE

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. the front of

Make a full turn (360 °) rotary platform several times.

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 frame

cap

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 corresponding oil.

Level 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 motor vehicle comes into the lower position.

fill

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

A

B

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 track tension and maintain it the proper level.

(1) Pick up chassis via arrows and hilt.

bottom track frame

Tracked frame

L

(2) Measure the distance between the bottom of track frame and track shoe.

Rear part Track shoes

Before measuring remove dirt by caterpillars rotation.

Track shoes

Length (L)

When excess tension, remove the grease through the 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

360 ~ 390 mm

14.2 ~ 15.5 "

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. Remove the locking bolts (1) and the nut (2) and then pull the fingers (3 and 4) and remove the bucket. When you remove your finger, place the bucket so that it has a weak contact with the ground. 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.

o n e one 2

3 4

2

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 Orings, 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 Ladle

6-35

Boss hilt

REPLACEMENT OF TEETH BUCKET Terms of replacement Check the amount of wear as shown in Figure replace teeth before depreciation adapter process will begin.

Adapter

Tip tooth

tooth

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. Insert lock washer to the appropriate position, and then attach the tooth tip to the adapter.

Finger

tooth Tip tooth

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

Adapter

lock washer

tooth

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. - 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

Ladle

Boss hilt

Sleeve

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 1 2 3 4

Description boom grease pipe Finger boom cylinder Finger connections and arrows

hilt A finger grip cylinder

(Rod side) Finger bucket cylinder

(Rod side)

number

lubrication points 5 2

4 3

2 1 5

2

Bucket Linkage

5

(Control rod) Finger stick and compound

bucket

3 1

Finger stick and compound

1 linkage 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.



one

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

2

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 pollution,butthen cover with a layer of grease.

Bung

Must not come at the clothes skin, since the electrolyte is an acid. Be careful, preventing electrolyte from entering the eyes. If electrolyte gets in your eyes, wash with clean water and consult a doctor.

Top level Lower level

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

Power charge

one hundred% 90% 80% 75%

twenty° FROM

10°FRO M

10°FR OM

1.26 1.24 1.22 1.21

1.27 1.25 1.23 1.22

1.28 1.26 1.24 1.23

gravimeter (meter density) Level electrolyte

Battery

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"

6-39

battery switch

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 the Exciting excavator.

red wire

3

Connect the red wire to the positive terminals discharged and the current batteries. Connect the black wire to the negative terminals discharged and the current batteries. Ensure good contact with the battery wire terminals. According to the wire connection end slip spark. Engine starting

2

1

The machine with the current (New) battery

machine with discharged

black wire By "weight" machine discharged battery

battery

4

How to join:

Start the motor via starterswitch.

one

If the engine fails to start on the first attempt,Repeat it to run in 2 minutes.

2

3

4

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 generator is not fully charge a discharged battery.

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. Set the machine to the ground or concrete. Do not charge the battery when the loader on the metal base. Do not connect the positive terminal to the negative terminal (-) with "Booster", since it will lead to a short circuit.

TART ON

OFF

For disconnecting wires red wire

3

2

1

The machine with the current (New) battery

machine with discharged

black wire By "weight" machine discharged battery For disconnecting:

4

6-40

3

2

one

battery

4

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 1) CLEANING FILTER

AND

REPLACEM EXTERNA ENT L

Before servicing the air conditioner is always turn off the engine.

External filter

(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.

FLOWR

Outside

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. (4) After cleaning of the filter condition.

Outside Compressed air

If it is damaged or severely dirty, replace with a new filter.

no more

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

6-42

Interior filter

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 damaged or heavily soiled, replace with a new filter. 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

Compressed air no more 2 atmospheres

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 low pressure lamp the engine oil is not extinguished after engine start. From the top of the radiator (Pressure valve) goes pairs. The control lamp the insufficient level of coolant off.

When turning the starter the engine will not start

Exhaust gases or white of blue color Traffic fumes periodically have black Colour

elimination method -

Top up to the required level of oil Replace the oil filter cartridge Check oil leakage from the hose and connections replace the sensor Top up with coolant and check the system cooling for leaks - Adjust fan belt tension - Wash the inside of the cooling system - Clean or repair fins - Check the thermostat - Check the coolant temperature sensor engine - Tighten the radiator cap or replace the gasket underneath. - Replace the sensor - pour fuel - 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 - Adjust the amount of fuel - Pour appropriate fuel - Clean or replace the air filter element - Check jets - Check the compression in the cylinders - Clean or replace the turbocharger unit

Noise normal operation engine spontaneously changes to sneezing. Unusual noise in the chamber combustion or mechanical noise

- Check jets -

Check the fuel brand compliance Check for overheating Check the muffler Adjust the valve clearance

7-1

2. ELECTRIC malfunction

elimination method

voltmeter unstable, although the engine working on constant speed. Bulbs do not burn brightly even when the engine is running at high revs. Lamp flashes when the engine. Voltmeter not vary with increasing frequency engine speed

- Check the wiring for the absence of contacts or short circuit - Adjust fan belt tension

The generator makes an unusual noise Starter does not turn when turning the key in the ON position (ON)

-

Check the generator Check and correct faults in the wiring Charge the battery Check the starter Check the safety relay Charge the battery Check the safety relay

-

Charge the battery Check the starter Check and correct faults in the wiring Charge the battery Check and correct faults in the wiring Check sensor Check sensor Check the oil pressure switch lamps

Periodically, the contact is broken engages the starter before starting the engine Starter cranks very poorly engine The tripping of the starter before the engine starts Lamp heating of the motor is not lights low oil pressure in the lamp when the engine is not lit idle engine and the ignition key in the ON position (ON) Control lamp discharge the battery does not illuminate when idle engine and the ignition key in the ON position (ON)

- Check the generator - Check and correct faults in the wiring

- Check sensor - Check and correct faults in the wiring

7-2

Other faults

malfunction Caterpillars slip on place. Excessive wear on the sprocket Bucket or rises too slowly or does not rise generally Too low speed movement, rotation turntable, moving boom, arm and bucket The pump is making an unusual noise excessive increase Fluid Temperature

elimination method - Adjust the tension of the caterpillars

- Add a working fluid to a desired level

- Add a working fluid to a desired level

- Clean the filter element hydro tank - Clean the oil cooler - 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. hydraulic fluid flow in accordance with engine speed.

4) Adjustment of the working fluid flow

(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 When operating an excavator with a hydraulic hammer hydraulic fluid polluted rather quickly. Therefore, without a relatively low-maintenance machine can quickly fail.

To extend the life of the excavator, check and replace the hydraulic fluid, and especially 4 types of filter elements. In operation of the excavator with a hydraulic hammer for a short time, replacement of the working fluid and produce filter elements as shown in the right table.

• Replace the following filters simultaneously - The filter in the return line of the hydraulic system - The filter in the pilot line - the air filter element hydraulic tank breather - drain cartridge filter hydraulic tank

Scheme replacing filters in Hammers

RESET circuit pressure hydraulic hammer

one hundred

At the end of the breaker switch off the engine and press the foot switch or breaker for the purpose of pressure relief circuit breaker. If after these steps, the pressure is not fully reset, it means that the service life of the diaphragm accumulator is reduced.

Avg. load cars

replacement time filtering element

80

Be particularly careful on the subject of preventing clogging of the working fluid with dust, sand and other impurities. After contact with foreign particles in the hydraulic fluid driving the pump will be subjected to excessive wear, which will decrease the life of the pump or its breakage. When working with a hydraulic hammer. due to vibration loads, possibly self-unfastening bolts and nuts. Therefore, you must periodically check and tighten them.

(%)

60 40 20 0 50

100

150

200

250

the amount of waste hours

Scheme replacing oil in Hammers

one hundred 80 Avg.

60

replacement time oils

mashinynagruzka 40

(%)

0 500

Service Interval (Hours) type of work Load Working filter equipment liquid element Ladle 100% 2000 250 Hydraulic

100%

twe nty

600

100

8-3

1000 1500 2000 the amount of waste hours

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

OFF

OFF

Check point

Voltage

① - GND (Battery 1EA)

10~12.5V

② - GND (Battery 2EA)

20~25V

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〕 No.1〕 I/conn〔CN-8(12)〕 Start switch〔CS-2(1)〕

Fuse box〔

(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 ) ⑤ - GND(Starter M) ⑥ - GND(Start relay) ⑦ - GND(Battery relay M8)

GND : Ground

4-56

20~25V

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〔CN51(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) ④ - GND(Alternator I terminal) ⑤ - GND(CPU)

GND : Ground

4-58

20~30V

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)〕 Fuse box (No.15) I/conn〔CN-7(8)〕

Switch panel〔CN-116(9)〕 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)〕 l/conn〔CN-6(8)〕

AC & Heater controller illumination ON Cigar light〔CL-2〕

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

l/conn〔CN-12(1)〕

2) CHECK POINT Engine

Start switch

Check point

Voltage

① - GND(Fuse box) STOP

ON

② - GND(Switch power input) ③ - GND(Switch power output)

20~25V

④ - GND(Head light) ⑤ - GND(Fuse box) ⑥ - GND(Switch power input) STOP

ON

⑦- GND(Switch power output) ⑧ - GND(Work light)

GND : Ground

4-60

20~25V

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)〕 10(11)〕 Cab light ON〔CL-8(2), CL-9(2)〕

I/conn〔CN-

2) CHECK POINT Engine

Start switch

Check point

Voltage

① - GND(Fuse box) ② - GND(Switch power input) STOP

ON

③ - GND(Switch power output)

20~25V

④ - GND(Beacon lamp) ⑤ - GND(Fuse box) ⑥ - GND(Switch power input) STOP

ON

⑦ - GND(Switch power output) ⑧ - GND(Cab light)

GND : Ground

4-62

20~25V

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) Fuse box (No.4)

I/conn〔CN-7(5)〕 I/conn〔CN-5(4)〕

Switch panel〔CN-116(6)〕

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〔CN141(6)〕 Washer pump〔CN-22(2)〕 Wiper switch ON : 1st step(Intermittent) Wiper switch ON〔CN-116(15)〕 controller〔CN-141(10) → (3)〕

I/conn〔CN-9(4)〕

I/conn〔CN-6(10)〕

I/conn〔CN-17(8)〕 Wiper motor

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) ② - GND(Switch power input)

24V

③ - GND(Switch power output) STOP

ON

④ - GND(Wiper Power input)

0~5V

⑤ - GND(Wiper power output) ⑥ - GND(Wiper motor)

GND : Ground

4-64

0 or 24V

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 number

No. of Type

Connector part No. Destination

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

Econoseal J

2

Breaker pedal

S816-002002

S816-102002

·Switch CS-26A

4-69

SECTION 3 HYDRAULIC SYSTEM GROUP 1 HYDRAULIC CIRCUIT 10

11

8

9

Main pump Main control valve

Swing motor

4 RED

Travel motor

RED

RCV lever(LH) RCV lever(RH) (XBp1) PaL

Dr3

PBP

(XBp2)

Fl

Fr

7 RCV pedal

2

Dr2

8 Boom cylinder(LH) 9 Boom cylinder(RH)

XAa2 XAa1

10 Arm cylinder

Dr1

11 Bucket cylinder XBa2

VA

VB

VB

VA

XBa1

XBa2

12 Turning joint

XAa2

13 Check valve

XAk

14 Check valve

12

15 Hydraulic tank XBk

16 Oil cooler

XAb2 Dr4

dr3

XAb2 XAb

XBs

Pk

PbL

As

Bb1

Bs

3

XAs Pns

XBb

XBtl

SH

XA0 XB0

Atr Btr

XBtr C

P2

R2

PH Px

B

Pz

5

ARM

7

TRAVEL

BUCKET

BOOM

P1

6

PG

Py

24

1 14 XAs

XBs XBa1

XAa1

XBk

XAk XAb1

(1)

(3) (2)

(4)

(3)

(1)

XAtl

(1)

23 Pns A5

Pk

Pm1 A4

Pm2 A3

XBtl

XAtr

(2)

(3)

dr2~dr8

XBb1

A1

A2

13 16

(4)

XBtr

(4)

17

26

15

20

22

PZ A2

(2)

dr1

PG(S/Motor)

P3 P2

PG(MCV)

Fl Pm1

Pm2 Fr (Pi2)

(Pi1)

18

A1 P4

23 Accumulator 24 Pressure switch 25 Shuttle valve 26 Last guard fill

R1

PB

SWING

20 Spin filter 22 Solenoid valve

XAtl

XAtr

A

19 Strainer 21 Line filter

XAs

dr4

PA

18 Bypass valve

Btl

25 PG

Dr6

Atl

XBs

17 Air breather Ab1

19

21

M dr1 A3

P1

3-1