MAINTENANCE

1. INSTRUCTION

1) INTERVAL OF MAINTENANCE

(1) You may inspect and service the machine by the

period as described at page 6-11 based on hour
meter at control panel.
(2) Shorten the interval of inspect and service
depending on site condition. (such as dusty
area, quarry, sea shore and etc.)
2
22
22

Service
(3) Practice the entire related details at the same meter
time when the service interval is doubled.
For example, in case of 100hours, carry out all
the maintenance「Each 100hours, each 50
hours and daily service」at the same time.
3009SH6MA01

2) PRECAUTION
(1) Start to maintenance after you have the full
knowledge of machine.
(2) The monitor installed on this machine does not
entirely guarantee the condition of the machine.
Daily inspection should be performed according
to clause 4, maintenance check list.
(3) Engine and hydraulic components have been
preset in the factory.
Do not allow unauthorized personnel to reset
them.
(4) Ask to your local dealer or Hyundai for the
maintenance advice if unknown.
(5) Drain the used oil and coolant in a container and
handle according to the method of handling for
industrial waste to meet with regulations of each
province or country.

6-1
3) PROPER MAINTENANCE
(1) Replace and repair of parts
It is required to replace the wearable and
consumable parts such as bucket tooth, side
cutter, filter and etc., regularly.
Replace damaged or worn parts at proper time
to keep the performance of machine.
(2) Use genuine parts.
(3) Use the recommended oil.
(4) Remove the dust or water around the inlet of oil
tank before supplying oil.
(5) Drain oil when the temperature of oil is warm.
(6) Do not repair anything while operating the
engine.
Stop the engine when you fill the oil.
(7) Relieve hydraulic system of the pressure before
repairing the hydraulic system.
(8) Confirm if the cluster is in the normal condition
after completion of service.
(9) For more detail information of maintenance,
please contact local Hyundai dealer.
※ Be sure to start the maintenance after fully
understand the chapter 1, safety hints.

6-2
4) RELIEVING THE PRESSURE IN THE HYDRAULIC SYSTEM
※ Spouting of oil can cause the accident when
loosening the cap or hose right after the oper-
ating of machine as the machine or oil is on
the high pressure on the condition.
Be sure to relieve the pressure in the system
before repairing hydraulic system.
(1) Place machine in parking position, and stop the
engine.

38096MA03

(2) Set the safety lever completely in the release

position, operate the control levers and pedals Lever Pedal
fully to the front, rear, left and right, to release
the pressure in the hydraulic circuit.
※ This does not completely release the pressure,
so when serving hydraulic component, loosen
the connections slowly and do not stand in the
direction where the oil spurt out.

21096MA03

(3) Loosen the cap and relieve the pressure in the

tank by pushing the top of the air breather.

Air breather

3009SH6MA02

6-3
5) PRECAUTION WHEN INSTALLING HYDRAULIC HOSES OR PIPES
(1) Be particularly careful that the joint of hose, pipe
and functioning item are not damaged.
Avoid contamination.
(2) Assemble after cleaning the hose, pipe and joint
of functioning item.
(3) Use genuine parts.
(4) Do not assemble the hose in the condition of
twisted or sharp radius.
(5) Keep the specified tighten torque.

6-4
6) PERIODICAL REPLACEMENT OF SAFETY PARTS
(1) It is desirable to do periodic maintenance the
machine for using the machine safely for a long
time.
However, recommend to replace regularly the
parts related safety not only safety but maintain
satisfied performance.
(2) These parts can cause the disaster of life and
material as the quality changes by passing time
and it is worn, diluted, and gets fatigued by
using repeatedly.
These are the parts which the operator can not
judge the remained lifetime of them by visual
inspection.
(3) Repair or replace if an abnormality of these
parts is found even before the recommended
replacement interval.
Periodical replacement of safety parts Interval

Fuel hose (tank-engine)

Every
Engine Heater hose 2 years
(heater-engine)

Pump suction hose

Main Pump delivery hose Every
circuit 2 years
Hydraulic Swing hose
system Boom cylinder line hose
Working Every
Arm cylinder line hose
device 2 years
Bucket cylinder line hose
※1.
1. Replace O-ring and gasket at the same
time when replacing the hose.
2. Replace clamp at the same time if the
hose clamp is cracked when checking
and replacing the hose.

6-5
2. TIGHTENING TORQUE

Use following table for unspecified torque.

1) BOLT AND NUT

(1) Coarse thread

8T 10T
Bolt size
kgf·m lbf·ft kgf·m lbf·ft
M 6×1.0 0.9 ~ 1.3 6.5 ~ 9.4 1.1 ~ 1.7 8.0 ~ 12.3
M 8×1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.7 ~ 4.1 19.5 ~ 29.7
M10×1.5 4.0 ~ 6.0 28.9 ~ 43.4 5.5 ~ 8.3 39.8 ~ 60.0
M12×1.75 7.4 ~ 11.2 53.5 ~ 81.0 9.8 ~ 15.8 70.9 ~ 114
M14×2.0 12.2 ~ 16.6 88.2 ~ 120 16.7 ~ 22.5 121 ~ 163
M16×2.0 18.6 ~ 25.2 135 ~ 182 25.2 ~ 34.2 182 ~ 247
M18×2.5 25.8 ~ 35.0 187 ~ 253 35.1 ~ 47.5 254 ~ 344
M20×2.5 36.2 ~ 49.0 262 ~ 354 49.2 ~ 66.6 356 ~ 482
M22×2.5 48.3 ~ 63.3 349 ~ 458 65.8 ~ 98.0 476 ~ 709
M24×3.0 62.5 ~ 84.5 452 ~ 611 85.0 ~ 115 615 ~ 832
M30×3.5 124 ~ 168 898 ~ 1214 169 ~ 229 1223 ~ 1656
M36×4.0 174 ~ 236 1261 ~ 1704 250 ~ 310 1808 ~ 2242

(2) Fine thread

8T 10T
Bolt size
kgf·m lbf·ft kgf·m lbf·ft
M 8×1.0 2.2 ~ 3.4 15.9 ~ 24.6 3.0 ~ 4.4 21.7 ~ 31.8
M10×1.25 4.5 ~ 6.7 32.5 ~ 48.5 5.9 ~ 8.9 42.7 ~ 64.4
M12×1.25 7.8 ~ 11.6 56.4 ~ 83.9 10.6 ~ 16.0 76.7 ~ 116
M14×1.5 13.3 ~ 18.1 96.2 ~ 131 17.9 ~ 24.1 130 ~ 174
M16×1.5 19.9 ~ 26.9 144 ~ 195 26.6 ~ 36.0 192 ~ 260
M18×1.5 28.6 ~ 43.6 207 ~ 315 38.4 ~ 52.0 278 ~ 376
M20×1.5 40.0 ~ 54.0 289 ~ 391 53.4 ~ 72.2 386 ~ 522
M22×1.5 52.7 ~ 71.3 381 ~ 516 70.7 ~ 95.7 511 ~ 692
M24×2.0 67.9 ~ 91.9 491 ~ 665 90.9 ~ 123 658 ~ 890
M30×2.0 137 ~ 185 990 ~ 1339 182 ~ 248 1314 ~ 1796
M36×3.0 192 ~ 260 1390 ~ 1880 262 ~ 354 1894 ~ 2562

6-6
2) PIPE AND HOSE (FLARE type)
Thread size (PF) Width across flat (mm) kgf·m lbf·ft

1/4" 19 4 28.9
3/8" 22 5 36.2
1/2" 27 9.5 68.7
3/4" 36 18 130.2
1" 41 21 151.9
1-1/4" 50 35 253.2

3) PIPE AND HOSE (ORFS type)

Thread size (UNF) Width across flat (mm) kgf·m lbf·ft

9/16-18 19 4 28.9
11/16-16 22 5 36.2
13/16-16 27 9.5 68.7
1-3/16-12 36 18 130.2
1-7/16-12 41 21 151.9
1-11/16-12 50 35 253.2

4) FITTING

Thread size Width across flat (mm) kgf·m lbf·ft

1/4" 19 4 28.9
3/8" 22 5 36.2
1/2" 27 9.5 68.7
3/4" 36 18 130.2
1" 41 21 151.9
1-1/4" 50 35 253.2

6-7
 4) TIGHTENING TORQUE OF MAJOR COMPONENT
Torque
No. Descriptions Bolt size
kgf·m lbf·ft
1 Engine mounting bolt, nut (engine-bracket) M16 × 2.0 29.7 ± 5.0 215 ± 36.2
2 Engine mounting bolt, nut (bracket-frame) M20 × 2.5 46.4 ± 4.0 336 ± 29
3 Engine Radiator mounting bolt M16 × 2.0 29.7 ± 4.5 215 ± 32.5
4 Coupling mounting socket bolt M20 × 2.5 46 ± 2.0 333 ± 14.5
5 Main pump housing mounting bolt M10 × 1.5 4.8 ± 0.3 35 ± 2.2
6 Main pump mounting bolt M20 × 2.5 44 ± 6.6 318 ± 47.7
7 Main control valve mounting nut M20 × 2.5 57.9 ± 8.7 419 ± 62.9
Hydraulic
8 Fuel tank mounting bolt M20 × 2.5 45 ± 5.1 325 ± 36.8
system
9 Hydraulic oil tank mounting bolt M20 × 2.5 45 ± 5.1 325 ± 36.8
10 Turning joint mounting bolt, nut M16 × 2.0 29.7 ± 4.5 215 ± 32.5
11 Swing motor mounting bolt M20 × 2.5 58.4 ± 6.4 422 ± 46.2
12 Swing bearing upper part mounting bolt M24 × 3.0 100 ± 10 723 ± 72.3
13 Power Swing bearing lower part mounting bolt M24 × 3.0 100 ± 10 723 ± 72.3
train
14 system Travel motor mounting bolt M20 × 2.5 57.9 ± 8.7 419 ± 62.9
Sprocket mounting bolt (-#0414) M20 × 2.5 57.9 ± 6.0 419 ± 43.4
15
Sprocket mounting bolt (#0415-) M22 × 2.5 77.4 ± 7.5 560 ± 54.2
16 Carrier roller mounting bolt, nut M16 × 2.0 29.7 ± 3.0 215 ± 21.7
17 Track roller mounting bolt M24 × 3.0 100 ± 10 723 ± 72.3
18 Under Track tension cylinder mounting bolt M22 × 1.5 87.2 ± 12.5 631 ± 90
19 carriage Track shoe mounting bolt, nut M24 × 3.0 140 ± 5.0 1012 ± 36
20 Track guard mounting bolt M24 × 3.0 100 ± 15 723 ± 108
22 Adjustable track gauge bolt M33 × 3.5 220 ± 20 1590 ± 145
23 Counterweight mounting bolt M42 × 3.0 390 ± 40 2821 ± 289
24 Others Cab mounting bolt M12 × 1.75 12.8 ± 3.0 92.6 ± 21.7
25 Operator's seat mounting bolt M 8 × 1.25 4.05 ± 0.8 29.3 ± 5.8
※ For tightening torque of engine and hydraulic components, see engine maintenance guide and
service manual.

6-8
3. FUEL, COOLANT AND LUBRICANTS

1) NEW MACHINE
New machine used and filled with following lubricants.
Description Specification
Engine oil SAE 10W-30 (API CH-4), ★SAE 5W-40 (API CH-4)
Hyundai genuine long life hydraulic oil (ISO VG 32, VG 46, VG 68)
Hydraulic oil
Coventional hydraulic oil (ISO VG 15★)
Swing and travel reduction gear SAE 80W-90 (API GL-5)
Grease Lithium base grease NLGI No. 2
Fuel ASTM D975-No. 2
ASTM D6210
Coolant (DCA4) Mixture of 50% ethylene glycol base antifreeze and 50% water.
Mixture of 60% ethylene glycol base antifreeze and 40% water.★

SAE : Society of Automotive Engineers ★Cold region

API : American Petroleum Institute Russia, CIS, Mongolia
ISO : International Organization for Standardization
NLGI : National Lubricating Grease Institute
ASTM : American Society of Testing and Material
DCA4 : Brand name of Chemical Additive
manufactured by the Cummins Fleetguard Co

6-9
 2) RECOMMENDED OILS
Use only oils listed below. Do not mix different brand oil.
Please use HYUNDAI genuine oil and grease.
Ambient temperature˚C(˚F)
Capacity
Service point Kind of fluid
ℓ (U.S. gal) -50 -30 -20 -10 0 10 20 30 40
(-58) (-22) (-4) (14) (32) (50) (68) (86) (104)

★SAE 5W-40

SAE 30
Engine
Engine oil 38 (10.0) SAE 10W
oil pan
SAE 10W-30

SAE 15W-40

Type 1 :
5.0(1.3)×2
Swing drive ★SAE 75W-90
Type 2 :
7.0(1.85)×2
Gear oil
Type 1, 2 :
7.5(1.98)×2
Final drive SAE 80W-90
Type 3, 4 :
12(3.17)×2

Tank: ★ISO VG 15
262
ISO VG 32
(69.2)
Hydraulic tank Hydraulic oil
System: ISO VG 46
480
(127) ISO VG 68

★ASTM D975 NO.1

Fuel tank Diesel fuel 621 (164)
ASTM D975 NO.2

★NLGI NO.1
Fitting
Grease As required
(grease nipple) NLGI NO.2

Mixture of
Ethylene glycol base permanent type (50 : 50)
Radiator antifreeze
50 (13.2)
(reservoir tank) and soft
★Ethylene glycol base permanent type (60 : 40)
water★1

SAE : Society of Automotive Engineers ★ : Cold region

API : American Petroleum Institute Russia, CIS, Mongolia
ISO : International Organization for Standardization ★1 : Soft water
NLGI : National Lubricating Grease Institute
City water or distilled water
ASTM : American Society of Testing and Material

6-10
 4. MAINTENANCE CHECK LIST

1) DAILY SERVICE BEFORE STARTING

Check items Service Page
Visual check
Engine oil level Check, Add 6-18
Coolant level Check, Add 6-20
Fan belt tension Check, Adjust 6-25
Air cleaner (oil bath) Check, Clean, Add 6-26-1, 2
Fuel tank Check, Refill 6-27
Prefilter Check, Clean 6-28
Hydraulic oil level Check, Add 6-30, 6-30-1
侏#Attachment pin and bushing (R480,520LC-9S) Lubricate 6-40
余Boom cylinder tube end
余Boom foot
余Boom cylinder rod end
余Arm cylinder tube end
余Arm cylinder rod end
余Boom + Arm connecting
余Bucket cylinder tube end
侏#Attachment pin and bushing (R520LC-9S FS) Lubricate 6-40-1
Control panel & pilot lamp Check, Clean 6-41
侏 Lubricate every 10 hours or daily for initial 100 hours.

2) EVERY 50 HOURS SERVICE

Check items Service Page
Fuel tank (water, sediment) Drain 6-27
Swing reduction gear oil Check, Add 6-33
Track tension Check, Adjust 6-36
Bucket linkage pin & bushing Lubricate 6-37
余Bucket cylinder rod end
余Bucket + Arm connecting
余Bucket control link + Arm
余Bucket control rod
Attachment pin and bushing (R520LC-9S FS) Lubricate 6-40-1

6-11
 3) INITIAL 50 HOURS SERVICE
Check items Service Page
Bolts & Nuts Check, Tight 6-8
·Sprocket mounting bolts
·Travel motor mounting bolts
·Swing motor mounting bolts
·Swing bearing mounting bolts
·Engine mounting bolts
·Counterweight mounting bolts
·Turning joint locating bolts
·Track shoe mounting bolts and nuts
·Hydraulic pump mounting bolts

4) EVERY 200 HOURS SERVICE

Check items Service Page
★ Return filter Replace 6-32
★ Drain filter cartridge Replace 6-32
★ Element in hydraulic tank breather Replace 6-32
★ Pilot line filter Replace 6-33
★ Replace 4 filters for continuous hydraulic breaker operation only.

5) INITIAL
NITIAL 250 HOURS SERVICE
Check items Service Page
Engine oil Change 6-18
Engine oil filter Replace 6-19
Fuel filter Replace 6-27
Prefilter (water, element) Replace 6-28
Drain filter cartridge Replace 6-32
Hydraulic return filter Replace 6-32
Pilot line filter Replace 6-33
Swing reduction gear oil Change 6-33
Travel reduction gear oil Change 6-34

6-12
 6) EVERY 250 HOURS SERVICE
Check items Service Page
Bolts & Nuts Check, Tight 6-8
·Sprocket mounting bolts
·Travel motor mounting bolts
·Swing motor mounting bolts
·Swing bearing mounting bolts
·Engine mounting bolts
·Counterweight mounting bolts
·Turning joint locating bolts
·Track shoe mounting bolts and nuts
·Hydraulic pump mounting bolts
·Adjustable track gauge bolt
Swing bearing grease Lubricate 6-34
Attachment pin and bushing Lubricate 6-40
·Boom cylinder tube end
·Boom foot
·Boom cylinder rod end
·Arm cylinder tube end
·Arm cylinder rod end
·Boom + Arm connecting
·Bucket cylinder tube end
Battery electrolyte Check, Clean 6-41
Aircon & heater fresh air filter Check 6-44

7) EVERY 500 HOURS SERVICE

Check items Service Page

★Engine oil Replace 6-18
★Engine oil filter Replace 6-18, 19
Coolant test (DCA4 concentration) Test, Add 6-20-1, 2
Radiator, cooler fin and charge air cooler Check, Clean 6-23
☆Air cleaner element (primary) Check, Clean 6-26
Fuel filter element Replace 6-27
Prefilter Change 6-28
Corrosion resistor Replace 6-29

☆ Clean the primary element only after 500 hours operation or when the air cleaner warning lamp blinks.
Replace primary element and safety element after 4 times cleanings of primary element.
★ If you use high sulfur containing fuel above than 0.5% or use low grade of engine oil reduce change
interval.

6-13
 8) EVERY 1000 HOURS SERVICE
Check items Service Page
Air breather element Replace 6-32
Hydraulic oil return filter Replace 6-32
Drain filter cartridge Replace 6-32
Swing reduction gear oil Change 6-33
Swing reduction gear grease Check, Add 6-33
Pilot line filter Replace 6-33
Grease in swing gear and pinion Change 6-34
Travel motor reduction gear oil Change 6-34

9) EVERY 2000 HOURS SERVICE

Check items Service Page
Coolant Change 6-20, 21, 22, 23
Air cleaner (oil bath) Disassemble, Clean, Change 6-26-1, 2
★1
Hydraulic oil Change 6-31
Hydraulic tank suction strainer Check, Clean 6-31
Hoses, fittings, clamps (fuel, coolant, hydraulic) Check, Retighten, Replace -
★1
Conventional hydraulic oil
★ Change oil every 600 hours of continuous hydraulic breaker operation.

10) EVERY 5000 HOURS SERVICE

Check items Service Page

Hydraulic oil ★2 Change 6-31

★2
Hyundai genuine long life hydraulic oil
★ Change oil every 1000 hours of continuous hydraulic breaker operation.

6-14
11) WHEN REQUIRED
Whenever you have trouble in the machine, you must perform the service of related items, system
by system.

Check items Service Page

Engine lubrication system

·Engine oil Change 6-18
·Engine oil filter Replace 6-19
Engine cooling system
·Coolant Add or Change 6-20, 21, 22, 23
·Radiator Clean or Flush 6-20-2, 21, 22, 23
·Charge air cooler Check 6-23
Engine air system
·Air cleaner element Replace 6-26
Fuel system
·Fuel tank Drain or Clean 6-27
·Fuel filter element Replace 6-27
·Prefilter Clean or Replace 6-28
Hydraulic system
·Hydraulic oil Add or Change 6-31
·Suction strainer Clean 6-31
·Return filter Replace 6-32
·Drain line filter Replace 6-32
·Element of breather Replace 6-32
·Pilot line filter Replace 6-33
Under carriage
·Track tension Check, Adjust 6-36
Bucket
·Bucket assy Replace 6-37
·Tooth Replace 6-38
·Side cutter Replace 6-38
·Linkage Adjust 6-39
Air conditioner and heater
·Fresh air filter Clean, Replace 6-44
·Recirculation filter Clean 6-45

6-15
 5. MAINTENANCE CHART

15 9 16 18 19 1 1 17 20

5
26
23
3
2
6

7 11 21 24 4

22 4

7 8 12 10 14 13 25
4809S6MA01

Caution
1. Service intervals are based on the hour meter reading.
2. The number of each item shows the lubrication point on the machine.
3. Stop engine while filling oil, and use no open flames.

Service Service Oil Capacity Service

No. Description
interval action symbol 再(U.S.gal) points No.
1 Hydraulic oil level Check, Add HO 262 (69.2) 1
2 Engine oil level Check, Add EO 38 (10.0) 1
4 Radiator coolant Check, Add C 45 (11.9) 1
10 Hours
5 Prefilter (water, element) Check, Clean - - 1
or daily
6 Fan belt tension and damage Check, Adjust - - 1
9 Fuel tank Check, Refill DF 621 (164) 1
22 Air cleaner (oil bath) Check, Clean, Add EO - 1

6-16
 Service Service Oil Capacity Service
No. Description
interval action symbol 再(U.S.gal) points No.
8 Bucket linkage pin & bushing Check, Add PGL - 6
50 Hours 9 Fuel tank (water, sediment) Check, Clean - - 1
or weekly 11 Swing reduction gear case Check, Add GO 5.0 (1.3) 1
14 Track tension Check, Adjust PGL - 2
7 Attachment pins & bushing Check, Add PGL - 11
250 10 Swing bearing grease Check, Add PGL - 2
Hours 15 Battery Check, Clean - - 1
21 Aircon and heater fresh air filter Check, Clean - - 1
2 Engine oil Change EO 38 (10.0) 1
3 Engine oil filter Replace - - 1
5 Prefilter Replace - - 1
500 22 Air cleaner element (primary) Check, Clean - - 1
Hours 23 Fuel filter element Replace - - 1
24 Radiator, oil cooler, charge air cooler Check, Clean - - 3
26 Corrosion resistor Replace - - 1
26 Coolant test (DCA4 concentration) Test, Add DCA4 - 1
11 Swing reduction gear case (TYPE 1) Change GO 5.0 (1.3) 1
11 Swing reduction gear case (TYPE 2) Change GO 7.0 (1.8) 1
12 Swing reduction gear grease (TYPE 1 only) Check, Add PGL 1.2 (0.3) 2
13 Swing gear and pinion grease Change PGL 14.0 kg (31 lb) 1
1000 16 Hydraulic oil return filter Replace - - 2
Hours 17 Drain filter cartridge Replace - - 1
18 Air breather element Replace - - 1
20 Pilot line filter element Replace - - 1
25 Travel reduction gear case (TYPE 1, 2) Change GO 7.5 (1.98) 2
25 Travel reduction gear case (TYPE 3, 4) Change GO 12 (3.2) 2
侏1
1 Hydraulic oil Change HO 262 (69.2) 1
4 Radiator coolant Change C 45 (11.9) 1

2000 19 Hydraulic oil suction strainer Check, Clean - - 1

Hours Disassemble,
22 Air cleaner (oil bath) EO - 1
Clean, Change
Hoses, fittings, clamps Check, Retighten,
- - - -
(fuel, coolant, hydraulic) Replace
5000 1 Hydraulic oil 侏2 Change HO 262 (69.2) 1
Hours
21 Aircon & heater fresh filter Replace - - 1
As 22 Aircon & heater recirculation filter Clean, Replace - - 1
required
22 Air cleaner element (primary, safety) Replace - - 2
侏1 侏2
Conventional hydraulic oil Hyundai genuine long life hydraulic oil
ö Oil symbol
Please refer to the recommended lubricants for specification.
DF : Diesel fuel GO : Gear oil HO : Hydraulic oil
C : Coolant PGL : Grease EO : Engine oil

6-17
6. SERVICE INSTRUCTION

1) CHECK ENGINE OIL LEVEL

Check the oil level with the machine on a flat
ground before starting engine.
(1) Pull out the dipstick and wipe with a clean cloth.
(2) Check the oil level by inserting the dipstick
completely into the hole and pulling out again.
(3) If oil level is LOW, add oil and then check again.
※ If the oil is contaminated or diluted, change
the oil regardless of the regular change inter-
val.
※ Check oil level after engine has been stopped
for 15 minutes.
Do not operate unless the oil level is in the
normal range.

4809S6MA02

2) REPLACEMENT OF ENGINE OIL AND OIL FILTER

(1) Warm up the engine.
(2) Remove the plug and allow the oil to drain.
·Adaptor size : 1-18UNS
※ A drain pan with a capacity of 40 liters (11U.
S. gallons) will be adequate.

4809S6MA03

(3) Clean around the filter head, remove the filter

and clean the gasket surface.
·Wrench size : 120 mm (4.72 in)
※ The O-ring can stick on the filter head.
Make sure it is removed before installing the
new filter.

4809S6MA04

6-18
(4) Apply a light film of lubricating oil to the gasket
sealing surface before installing the filters. Oil
※ Fill the filters with clean lubricating oil.
Oil

18036MI09

(5) Install the filter to the filter head.

※ Mechanical over-tightening may distort the
threads or damage the filter element seal.
·Install the filter as specified by the filter
manufacturer.

4809S6MA05

(6) Fill the engine with clean oil to the proper level.
Oil
·Quantity : 38ℓ(10 U.S.gallons)

4809S6MA06

(7) Operate the engine at low idle and inspect for

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

4809S6MA07

6-19
3) CHECK COOLANT
(1) Check if the level of coolant in reservoir tank is
between FULL and LOW.
(2) Add the mixture of antifreeze and water after
removing the cap of the reservoir tank if coolant
is not sufficient.
(3) Be sure to add the coolant by opening the cap of
raditor when coolant level is below LOW. 4809S6MA08

(4) Replace gasket of radiator cap when it is

damaged.
Hot coolant can spray out if radiator cap is
removed while engine is hot. Remove the
cap after the engine has cooled down.
CLUSTER CLUSTER CLUSTER CLUSTER
TYPE 1 TYPE 2 TYPE 1 TYPE 2

OK NOT OK

4809S6MA09

6-20
3-1) COOLANT TEST STRIPS INSTRUCTIONS
(1) Pre-test instruction
Recommended testing frequency - at every
coolant filter change interval.
① Collect coolant sample from the radiator
drain valve.
- Do not collect from the coolant recovery or
overflow system
- Coolant must be between 10~54℃ when test-
ed
- Room temperature is best.
② For accurate results, test must be completed
within 75 seconds.
- Follow recommended test times. Use a stop- 380L6CT01

watch.
③ Record and track results.

(2) Test instruction

① Remove one strip from bottle and replace cap
immediately. End pad A
Middle pad B
Do not touch the pads on the end of the strip. Top pad C
Discard kit if nitrite test pads of unused strips
have turned brown. Test strip, prior to testing
② Dip strip for 1 second in coolant sample,
remove, and shake strip briskly to remove
excess liquid.
380L6CT02

③ 45 seconds after dipping strip, compare results

to color chart and record in the following order: % GLYCOL/FREEZEPOINT ( F) (End Pad)
25% 40% 50% 60%
for
+10 -3 -10 -20 -30 -45 -60 F

SCA UNITS PER GALLON

④ All three readings must be completed no later

than 75 seconds after dipping strip.
⑤ If uncertain about the color match, pick the low
numbered block.
ex.) If nitrite color is not F, use column E.
⑥ Determine where the molybdate level intersect
the nitrite level on the chart. The amount of
Row 0
SCA units per gallon in the cooling system is
given where the molybdate row intersect the
nitrite column.
380L6CT03

6-20-1
(3) Maintenance actions based on results
① Above normal
- Do not replace the coolant filter
or add DCA4 liquid until additive
concentration falls below 3 units
per gallon.
- Test at every subsequent coolant
filter change interval.
② Normal
- Continue to replace the coolant
filter at your normal interval.
③ Below normal
- Replace the coolant filter and
add 1 pint of additive per each 4
380L6CT04
gallons of coolant.
- Replace the coolant filter and
add 40 cc of additive per each 1
liter of coolant.
※ If you need part number of Test kit or DCA4,
please see Parts Manual.

4) FLUSHING AND REFILLING OF RADIATOR CLUSTER TYPE 1 CLUSTER TYPE 2

(1) Change coolant

Avoid prolonged and repeated skin contact
with used antifreeze. Such prolonged
repeated contact can cause skin disorders or
other bodily injury.
Avoid excessive contact-wash thoroughly
after contact.
Keep out of reach of children.
※ Protect the environment : Handling and dis-
posal of used antifreeze can be subject to 4809S6MA10

federal, state, and local law regulation.

Use authorized waste disposal facilities,
including civic amenity sites and garages
providing authorized facilities for the receipt of
used antifreeze.
If in doubt, contact your local authorities for
guidance as to proper handling of used
antifreeze.

6-20-2
 Wait until the temperature is below 50˚C 50˚
(122˚F) before removing the coolant system
pressure cap.
Failure to do so can cause personal injury
from heated coolant spray.
Drain the cooling system by opening the drain
valve on the radiator and removing the plug in
the bottom of the water inlet. A drain pan with a
capacity of 45 liters (12U.S.gallons) will be
4809S6MA11
adequate in most applications.

(2) Flushing of cooling system OK

① Fill the system with a mixture of sodium
carbonate and water(or a commercially
available equivalent).
※ Use 0.5 kg (1.0 pound) of sodium carbonate
for every 23 liters (6.0 U.S. gallons) of water.
※ Do not install the radiator cap. The engine is
to be operated without the cap for this
process.
4809S6MA14

※ During filling, air must be vented from the

engine coolant passages. Open the engine
venting petcock.
The system must be filled slowly to prevent
air locks. Wait 2 to 3 minutes to allow air to
be vented, then add mixture to bring the
level to the top.

18036MI18

② Operate the engine for 5 minutes with the

coolant temperature above 80˚C
C (176˚F).
Shut the engine off, and drain the cooling
system. CLUSTER CLUSTER
TYPE 1 TYPE 2

START

ON
OFF 4809S6MA13

6-21
 到 Fill the cooling system with clean water.
侍 Be sure to vent the engine and aftercooler
for complete filling.
侍 Do not install the radiator cap or the new
coolant filter.

4809S6MA12

刱 Operate the engine for 5 minutes with the

coolant temperature above 80˚C (176˚F).
Shut the engine off, and drain the cooling
system. CLUSTER CLUSTER
TYPE 1 TYPE 2
侍 If the water being drained is still dirty, the
system must be flushed again until the water
is clean.
START

ON
OFF 4809S6MA13

(3) Cooling system filling

Sodium Soft
刮 Use a mixture of 50 percent soft water and 50 water
carbonate Water
percent ethylene glycol antifreeze to fill the
cooling system. Refer to the page 6-10.
Coolant capacity (engine only) : 10.4再(2.7 U.S.
gallons)
侍 Do not use hard water such as river water or
well water.

4809S6MA15

刯 The system has a maximum fill rate of 19 liters

(5.0 U.S. gallons)
Do not exceed this fill rate.
侍 The system must be filled slowly to prevent
air locks.
During filling, air must be vented from the
engine coolant passage.
Be sure to open the petcock.
Then add mixture to bring the level to the
18036MI23
top.

6-22
 ③ Install the pressure cap. Operate the engine
until it reaches a temperature 80˚CC (176˚F),
and check for coolant leaks.
Check the coolant level again to make sure the
system is full of coolant. NOT OK

CLUSTER CLUSTER
TYPE 1 TYPE 2 4809S6MA16

5) CLEAN RADIATOR AND OIL COOLER NOT OK

Check, and if necessary, clean and dry outside of
radiator and oil cooler. After working in a dusty
place, clean radiator more frequently.
(1) Visually inspect the radiator for clogged radiator
fins.
(2) Use 550 kPa (80 psi) air pressure to blow the dirt 550 kPa
and debris from the fins. (80 psi)
13036MI01
Blow the air in the opposite direction of the fan
air flow.
(3) Visually inspect the radiator for bent or broken
fins.
※ If the radiator must be replaced due to bent or
broken fins which can cause the engine to
ove r h e a t , r e fe r t o t h e m a nu fa c t u r e r ' s
replacement procedures.
(4) Visually inspect the radiator for core and gasket
leaks.
13036MI02

6) CHECK CHARGE AIR COOLER

Inspect the charge air cooler for dirt and debris
blocking the fins. Check for cracks, holes, or other
damage. If damage is found, please contact
Hyundai distributor.

36076MI02

6-23
7) FAN BELT TENSION
(1) Inspect the drive for damage. OK

NOT OK

13036MI03

(2) Inspect the drive belt and fan hub.

18036MI27

8) INSPECTION OF COOLING FAN

Personal injury can result from a fan blade
failure. Never pull or pry on the fan. This can
damage the fan blade and cause fan failure.
※ Rotate the crankshaft by using the engine
barring gear.
※ A visual inspection of the cooling fan is NOT OK
required daily.
Check for cracks, loose rivets, and bent or
loose blades. 21076MA10B
Check the fan to make sure it is securely
mounted. Tighten the capscrews if necessary.
Replace any fan that is damaged.

6-24
9) BELT TENSIONER, AUTOMATIC Adjustment
(1) Every 1000hours, or 1 year, whichever occurs
first, inspect the automatic belt tensioner.
With the engine turned off, check that neither the
top nor bottom tensioner arm stop is touching
the cast boss on the tensioner body. If either of
the stops is touching a boss, the alternator belt
must be replaced. Check to make sure the
correct belt part number is being used it either 7807AMI50

condition exists.

(2) Check the tensioner pulley and body for cracks.

If any cracks are noticed, the tensioner must be
replaced. Refer to a Cummins Authorized
Repair facility. Check the tensioner for dirt
buildup. If this condition exists, the tensioner
must be removed and steam-cleaned.

7807AMI51

(3) Check that the bottom tensioner arm stop is in

contact with the bottom tensioner arm stop boss
on the tensioner body. If these two are not
touching, the tensioner must be replaced.

7807AMI52

(4) Inspect the tensioner for evidence of the pivoting

tensioner arm contacting the stationary circular
base. If there is evidence of thess two areas
touching, the pivot tube bushing has failed and
the tensioner must be replaced.

7807AMI53

6-25
(5) A worn tensioner that has play in it or a belt that
"walks" off its pulley possibly indicates pulley
misalignment.
※ M a x i mu m p u l l ey m i s l i g n m e n t i s t h r e e
degrees. This measurement can be taken
with a straightedge and an inclinometer.
(6) Install the belt.

7807AMI54

10) CLEANING OF AIR CLEANER

(1) Primary element
① Loosen the clamps and remove the element. Clamp
② Clean the inside of the body.
③ Clean the element with pressurized air.
·Remove the dust inside of the element by the
pressurized air (below 3 kgf/cm 2, 40 psi)
forward and backward equally.
④ Inspect for cracks or damage of element by
putting a light bulb inside of the element.
⑤ Insert element and tighten wing nut.
Pressurized air
※ Replace the primary element after 4 times 3kgf/cm2 below
cleanings.
(2) Safety element
※ Replace the safety element only when the
primary element is cleaned for the 4 times.
※ Always replace the safety element. Never
attempt to reuse the safety element by
cleaning the element. 4809S6MA17

6-26
10-1) AIR CLEANER (OIL BATH)
Always cover the engine intake hole while the air
cleaner is being serviced.
(1) General service
刮 The oil bath air cleaner should be inspected
constantly for leaks and damage. 5
刯 The removable element assembly (4) should 3
be removed the from the oil cups (1, 2) and
inspected daily or at each oil cup service.
6
Watch all connections for mechanical tightness.
到 Be sure cleaner outlet pipe is not fractured.
If air cleaner has been dented or damaged, 4
刱 check all connections immediately.
In case of leakage and if adjustment does not 1
刲 correct the trouble, replace necessary parts or
2
O-ring.

1 Inner cup assy

2 Outer cup assy
3 Body assy
4 Removable element
5 Marking
6 O-ring 480S6MA35

(2) Oil cup

刮 Service the inner oil cup (1) and outer oil cup
(2) daily or when 1/2" of dirt has collected in
bottom of either cup.
侍 Severe operating conditions may require sever-
al inspections daily.
刯 Loosen the side clamps and removing bottom
of unit and lift the removable element assembly
(4) from the oil cup.
到 Pour out the oil and remove inner cup (1) from
out cup (2) and remove sludge and wipe clean. Side clamp
刱 Reassembled inner cup (1) in outer cup (2) and
480S6MA36
refill both cups to indicated oil level.
刲 The same oil specified for the engine crank-
case is generally acceptable.
侍 Do not over fill or under fill the cup.
Overfilling means loss of capacity and under
filling means lack of efficiency.

6-26-1
(3) Removable element
① First step in servicing removable element
assembly is hold up to a strong light. An even,
bright pattern of light through the wire element
means if is clean.
② If removable element is even partially plugged
with dirt, lint or chaff, wash thoroughly with sol-
vent.
Then blowout with compressed air.
③ Inspect lower portion of body assembly and
center tube each time oil cup is serviced. See
back side for service details.
④ Reassemble removable element assembly to
serviced oil cups and to air cleaner body.
Be sure the oil cup is tight to body assembly.

Pressurized air
480S6MA37

(4) Body assembly

The lower portion of the body assembly should
be inspected each time the air cleaner is ser-
viced. If there is any sign of build-up or plugging,
the body assembly should be removed and
cleaned. At least once a year, remove the body
assembly and perform the following service
steps.
① Remove oil cup and removable element
assembly.
② Check and clean center tube.

480S6MA38

③ Pump solvent through the air outlet with suffi-

cient force and volume to produce a hard, even
stream out the bottom of the body assembly.
Reverse flush until all foreign material is
removed.

480S6MA39

6-26-2
11) FUEL TANK
(1) Fill fuel fully when system the operation to mini-
mize water condensation, and check it with fuel
gauge before starting the machine.
(2) Drain the water and sediment in the fuel tank by
opening the drain cock. Fuel gauge
※ Be sure to LOCK the cap of fuel tank.
※ Remove the strainer of the fuel tank and
clean it if contaminated.
Stop the engine when refueling.
All lights and flames shall be kept at a safe
Drain cock
distance while refueling. 3009SH6MA05

12) REPLACEMENT OF FUEL FILTER

(1) Clean around the filter head, remove the filter
and clean the gasket surface.
(2) Replace the O-ring.
(3) Fully fill fuel in the new filter.
(4) Apply engine oil on the gasket of filter when
mounting, and tighten 1/2 to 3/4 turn more after
the gasket touches the filter head. 45076MA09

(5) Relieve the air after mounting.

※ Check for fuel leakage after the engine starts.
※ If air is in the fuel system, the engine will not
start. Start engine after bleeding the air
according to the method of bleeding air.

13) FUEL WATER SEPARATOR

- Drain the water and sediment from the separa-
tor daily.
- Shut off the engine.
- Use your hand to open the drain valve.
- Turn the valve counterclockwise 3-1/2 complete
turns until the valve drops down 1".
- Drain the filter sump of water until clear fuel is
visible.
※ Do not overtighten the valve.
Overtightening can damage the threads.
- Push the valve up and turn the valve clockwise
to close the drain valve.

45076MA10

6-27
14) PREFILTER
※ Inspect or drain the collection bowl of water daily
and replace the element every 500hours.

(1) Drain water

① Open bowl drain valve to evacuate water.
② Close drain valve.
Hyd tank
Bowl
Drain valve
Open Close

48096MI12

(2) Replace
eplace element
① Drain the unit of fuel. Follow "Drain water"
instructions above.
② Remove element / bowl from filter head. Hyd tank
※ The bowl is reusable, do not damage or dis- Open
Bowl
card.
③ Separate element from bowl. Clean bowl and
seal gland.

48096MI13

④ Lubricate new bowl seal with clean fuel or

motor oil and place in bowl gland. Filter head
⑤ Attach bowl to new element firmly by hand.
⑥ Lubricate new element seal and place in ele- Element
Hyd tank
ment top gland. Close
⑦ Attach the element and bowl to the head.
Bowl
Close

48096MI14

6-28
15) C O R R O S I O N R E S I S T O R ( C O O L A N T
FILTER)
Do not remove the radiator
rad iator cap from a hot
engine. Wait until the coolant temperature is CLUSTER CLUSTER
TYPE 1 TYPE 2
below 50
50˚C
C (120
(120˚C)
C) before removing the radi-
ator cap. Heated coolant spray or steam can
OK Remote
cause personal injury coolant
filter
(1) Remove the radiator cap.
4809S6MA18

(2) Turn the valve to the OFF position.

(3) Remove and discard the filter.
Clean the coolant filter head gasket's surface.
A small amount of coolant can leak when ser- OFF OFF
vicing the filter with the shutoff valve in the
OFF position. To avoid personal injury, avoid
contact with hot coolant.
4809S6MA19

(4) Apply a thin film of clean engine oil to the gasket

sealing surface before installing the new filter.
※ If the filter canister is damaged in any way, do
not use it. Dents or scrapes can lead to a rup-
ture or premature failure of the filter.

7803AMI25

(5) Install a new filter on the filter head.

Tighten the filter until the gasket contacts the fil-
ter head surface.
(6) Tighten the filter an additional 1/2 to 3/4 of a
turn.
※ Mechanical over tightening can distort the fil-
ter threads or damage the filter head.

4809S6MA20

6-29
 (7) Turn the valve to the ON position, and install the
radiator cap.
ON
(8) Operate the engine and check for leaks.
ON
侍 The valve must be in the ON position to pre-
vent engine damage.

4809S6MA21

16) LEAKAGE OF FUEL

FIRE
Be careful and clean the fuel hose, injection
pump, fuel filter and other connections as the
leakage from these part can cause fire.

48096MI19

17) HYDRAULIC OIL CHECK (R480, 520LC-9S)

Red line
(1) Stop the engine after retract the arm and bucket
cylinders, then lower the boom and set the buck-
et on the ground at a flat location as in the illus-
Level gauge
tration.
(2) Check the oil level at the level gauge of hydrau-
lic oil tank.
(3) The oil level is normal if between the red lines. 38096MA04

17-1) HYDRAULIC OIL CHECK (R520LC-9S FS)

Fully retracted Center line
(1) Park the machine on a hard, level surface. 10mm
Lower the hydraulic shear to the plank with stick Oil line

in the vertical position, as shown the illustration.

Make sure that the machine is stabilized as the
above position.
(2) Stop the engine.
Touch the ground
(3) Open the access door on the right side of the 5209SFS6MA01

machine in order to access the sight gauge.

6-30
18) FILLING HYDRAULIC OIL
Air breather
(1) Stop the engine to the position of level check.
(2) Relieve the pressure in the tank by pushing the
top of the air breather.
(3) Remove the breather on the top of oil tank and
fill the oil to the specified level.
(4) Start engine after filling and operate the work
equipment several times. 38096MA02

(5) Check the oil level at the level check position

after engine stops.

6-30-1
19) CHANGE HYDRAULIC OIL
(1) Lower the bucket on the ground pulling the arm
and bucket cylinder to the maximum. Air breather
Cover
(2) Relieve the pressure in the tank by pushing the O-ring
top of the air breather.
(3) Remove the cover.
ÂTightening torque : 6.9Ü1.4 kgfÂm
(50Ü10 lbfÂft)
(4) Prepare a suitable container.
(5) To drain the oil loosen the drain plug at the bot-
tom of the oil tank.
(6) Fill proper amount of recommended oil.
(7) Put the breather in the right position.
(8) Bleed air hydraulic pump loosen the air
breather at top of hydraulic pump assembly.
Drain valve
(9) Start engine and run continually. Release the
air by full stroke of each control lever. 3309A6MI21

20) CLEAN SUCTION STRAINER

Clean suction strainer as follows paying attention Air breather
to the cause to be kept during oil filling.
Cover
(1) Remove the cover on the top of the oil tank.
ÂTightening torque : 6.9Ü1.4 kgfÂm
(50Ü10 lbfÂft)
(2) Pull out the strainer in the tank.
(3) Wash the foreign material on the suction strainer
with gasoline or cleaning oil.
Strainer
(4) Replace the suction strainer if it is damaged.
(5) Assemble with reverse order of disassembly.
Be sure to install a new O-ring and reinsert in
the oil tank.
ö Loosen the bolt slowly at the cover can be
spring out by the spring when removing it.
38096MI11

6-31
21) REPLACEMENT OF RETURN FILTER
Replace as follows paying attention to the cause
Cover
to be kept during the replacement.
O-ring
(1) Remove the cover. Spring
ÂTightening torque : 6.9Ü1.4 kgfÂm Bypass valve
(50Ü10 lbfÂft)
(2) Remove the spring, by-pass valve, and return fil-
ter in the tank. Return filter

(3) Replace the element with new one.

38096MI12

22) REPLACEMENT OF ELEMENT IN HYDRAULIC

TANK BREATHER Snap ring

(1) Relieve the pressure in the tank by pushing the Element

top of the air breather.
Cover
(2) Remove the cover.
(3) Remove the snap ring and pull out the filter
element.
(4) Replace the filter element new one.
(5) Reassemble by reverse order of disassembly.
 Tightening torque : 0.2~0.3 kgfÂm
(1.4~2.1 lbfÂft)

38096MI13

23) REPLACE OF DRAIN FILTER CARTRIDGE

Clean the dust around filter and replace with new
one after removing the cartridge. Drain
filter
ö Tighten about 2/3 turn more after the gasket of
cartridge contacts seal side of filter body for
mounting.
ö Change cartridge after initial 250 hours of
operation. Thereafter, change cartridge every
Hydraulic
1000 hours. oil tank
38096MI14

6-32
24) REPLACE OF PILOT LINE FILTER
Solenoid
(1) Loosen the nut positioned on the filter body. valve

A
5
P1
(2) Pull out the filter element and clean filter hous-

A
4
ing. P4

P
A1

2
A2
(3) Install the new element and tighten using speci- A3

fied torque.
※ Change cartridge after initial 250 hours of
operation. Thereafter, change cartridge every
1000 hours. 21096MA25

25) CHECK THE SWING REDUCTION GEAR OIL

(1) Pull out the dipstick and clean it.
(2) Insert it again.
(3) Pull out one more time to check the oil level and
fill the oil if the level is not sufficient.

21096MA30

26) CHANGE SWING REDUCTION GEAR OIL

(1) Raise the temperature of oil by swinging the
machine before replace the oil and park the Filling port
plug
machine on the flat ground. Cap

(2) Prepare a proper container.

(3) Open the cap and loosen the drain valve.
(4) Clean around the valve and close the drain Drain valve
valve and cap.
Fill proper amount of recommended oil.
48096MI20
·Amount of oil : 5.0ℓ(1.3 U.S.gal, TYPE 1)
·Amount of oil : 7.0ℓ(1.8 U.S.gal, TYPE 2)

27) LUBRICATE BEARING OF OUTPUT SHAFT IN

REDUCTION GEAR
(1) Remove air vent plug.
(2) Lubricate NLGI No.2 with grease gun until Air vent
port plug
comes out new grease from air vent port.
·Amount of oil : 1.2ℓ(0.3 U.S.gal) Grease filling
nipple

48096MI21

6-33
28) LUBRICATE SWING BEARING
(1) Grease at 2 fitting.
ö Lubricate every 250 hours.

3309A6MI18

29) SWING GEAR AND PINION

(1) Drain old grease
Η Remove under cover of lower frame.
Θ Remove drain cover of lower frame.
Ι Remove filler cover of upper frame. Filler cover
Κ Operate full turn (360Á) of swing several times.
FRONT
Filler hole

2507A6MA28

(2) Refill new grease

Η Install drain cover.
FRONT
Θ Fill with new grease.
Ι Install filler cover.
ÂCapacity : 14.0 kg (31 lb)
Top of
lower frame
Drain cover
REAR

2507A6MA29

30) CHECK THE TRAVEL REDUCTION GEAR OIL

(1) Operate the machine to the position of drain
plug down to the flat ground.
(2) Loosen the level plug and check the oil level.
If the level is at the hole of the plug, it is normal.
Fill the oil if it is not sufficient.
ÂAmount of oil : 7.5˶(1.98 U.S.gal, TYPE 1, 2)
ÂAmount of oil : 12.0˶(3.2 U.S.gal, TYPE 3, 4)
45076MA25

6-34
31) CHANGE OF THE TRAVEL REDUCTION GEAR OIL
(1) Raise the temperature of the oil by traveling
machine first.
(2) Stop when the position of the drain plug is down.
(3) Loosen the level plug and then the drain plug.
(4) Drain the oil to adequate container.
(5) Tighten the drain plug and fill specified amount
of oil at filling port.
(6) Tighten the level plug and travel slowly to check
45076MA26
if there is any leakage of oil.

32) LUBRICATE RCV LEVER A B

Remove the bellows and with a grease gun
grease the joint part (A) and sliding parts (B).

36076MA25

6-35
33) ADJUSTMENT OF TRACK TENSION
ö It is important to adjust the tension of track
properly to extend the lifetime of track and
90 ~ 110
traveling device.
ö The wear of pins and bushings on the under-
carriage will vary with the working conditions
and soil properties.
It is thus necessary to continually inspect the Bottom of track frame Track frame
track tension so as to maintain the standard
tension on it.
(1) Raise the chassis with the boom and arm. L
(2) Measure the distance between bottom of track
frame on track center and track of shoe.
ö Remove mud with rotating the track before Back of shoe Track shoe
measuring. 21076MA27

(3) If the tension is tight, drain the grease in the Working condition Length (L)
grease nipple and if the tension is loose, charge General 390~420 mm 15.4~16.5"
the grease. Swamp 420~460 mm 16.5~18.1"
Personal injury or death can result from Sand, Mud, pebbes About 460 mm About 18.1"
grease under pressure.
When loosening the grease nipple, do not
loosen more than one turn as there is a dan-
ger of a spring coming out of the nipple
because of the high pressure inside.
ö When the grease is drained, move the track
to the forward and backward slightly.
If the track tension is loose even after the
grease is charged to the maximum, change
the pins and bushings as there are worn seri-
ously.

6-36
34) REPLACEMENT OF BUCKET
When knocking the pin in with a hammer,
metal particles may fly and cause serious
injury, particularly if they get into your eyes.
When carrying out this operation, always
wear goggles, helmet, gloves, and other pro-
tective equipment.
ö When the bucket is removed, place it in a sta-
ble condition.
38094OP21
ö When performing joint work, make sure sig-
nals to each other and work carefully for safe-
ty's sake.
(1) Lower the bucket on the ground as the picture
shown in the right.
1
(2) Lock the safety lever to the LOCK position and 3
stop the engine. 2
1
(3) Remove the stopper bolts (1) and nuts (2), then
remove pins (3, 4) and remove the bucket. 4
ö When removing the pins, place the bucket so 2
that it is in light contact with the ground.
36076MA26
ö If the bucket is lowered strongly to the
ground, the resistance will be increased and it
will be difficult to remove the pins.
ö After remove the pins, make sure that they do
not become contaminated with sand or mud
and that the seals of bushing on both sides
do not become damaged. B
(4) Align the arm with holes (A) and the link with A
holes (B), then coat with grease and install
pins(3, 4)
ö When installing the bucket, the O-rings are 13036MI15

easily damaged, so fit the O-rings on the

boss of the bucket as shown in the picture.
After knocking the pin, move the O-ring down
to the regular groove.
Pin O-ring
(5) Install the stopper bolt (1) and nuts (2) for each
Nut
pin, then grease the pin.

Bolt
Bushing Arm boss Bucket

45076MA29A

6-37
35) REPLACEMENT OF BUCKET TOOTH
(1) Timing of replacement
Η Check wearing condition as shown in the illus-
tration and replace tooth tip before adapter Tooth adapter
starts to wear. Tooth tip
Θ If excessive use, tooth adapter has worn out,
replacement may become impossible.

13036MI20

(2) Instructions for replacement

Η Pull out pin by striking pin with punch or ham-
mer, avoiding damage to locking washer.
Θ Remove dust and mud from surface of tooth
adapter by using knife.
Ι Place locking washer in its proper place, and fit Tooth pin Tooth adapter
tooth tip to adapter.
Κ Insert pin until locking washer is positioned at Tooth tip Locking washer
tooth pin groove.
Personal injury can result from bucket falling.
13036MI21
Block the bucket before changing tooth tips
or side cutters.

6-38
36) ADJUSTMENT OF BUCKET CLEARANCE
(1) Lower the bucket on the ground as the picture
shown in the right.
(2) Swing to the left and keep the arm boss to be
contact to the bucket left.
(3) Lock the safety lever to the LOCK position and
stop the engine.
(4) Measure the clearance (A) between bucket and
arm boss. This is the total clearance.
(5) Adjusting
Η Loosen bolt (2), and remove washer (3), plate
(1) and shim (4).
Θ Remove the shim equivalent value with mea-
suring value.
Ι Assemble the parts in the reverse order of 1
removal. 2
ÂTightening torque : 29.6Ü3.2 kgfÂm 3
(214.0Ü23.1 lbfÂft)
ÂNormal clearance : 0.5 ~ 1.0 mm 4
(0.02 ~ 0.04 in) Bucket Arm boss Bushing
ö If the bucket is not adjusted correctly, noise
and vibration created during operation, and
damaged O-ring, pin and bushing quickly. 45076MA28

6-39
37) LUBRICATE PIN AND BUSHING (R480,520LC-9S)

(1) Lubricate to each pin of working device

Lubricate the grease to the grease nipple
according to the lubricating interval.
No. Description Qty
4 3 1
1 Lubrication manifold at boom 5
2 Boom cylinder pin 2
3 Boom and arm connection pin 1
4 Arm cylinder pin (rod side) 1
Bucket cylinder pin (head, rod) 2 5 2 6
Bucket link (control rod) 3
5
Arm and control link connection pin 1
Arm and bucket connection pin 1
6 Boom rear bearing center 1
ö Shorten lubricating interval when working 38094OP19

in the water or dusty place.

(2) Dust seals are mounted on the rotating part of

working device to extend the lubricating interval.
ö Mount the lip to be faced outside when
replace the dust seal.

38096MA05

ö If it is assembled in wrong direction, it will

cause fast wear of pin and bushing, and cre-
ate noise and vibration during operation.
ö Assemble the seal same direction with picture
and use with plastic hammer when replace.
Outside

13036MI28

6-40
38) LUBRICATE PIN AND BUSHING (R520LCS-9S FS)

(1) Position machine as shown the illustration and

lower the front attachment on the ground and
stop the engine.
(2) Press the grease fitting and inject grease gun on
the marked point. A, B, C, D
G
(3) After injection, clean off the old grease that has I
been purged.
K
No. Description Qty E, F
H
J
A Boom foot pin 2
B Arm cylinder bore pin 1
C Boom cylinder rod pin 2
D Bucket cylinder rod pin 2
E Boom arm joint pin 2
5209SFS6MA02
F Bucket link (control rod) 2
G Arm and control link connection pin 1
H Bucket cylinder bore pin 2
I Dump cylinder rod pin 2
J Dump cylinder bore pin 2
K Front dust pan pivot pin 2
ö If the equipment has been run in water,
the front attachment should be greased
on a 10 hour(daily basis).
ö Detail pin point

ABA C D C
E F

J
G 5209SFS6MA03

6-40-1
7. ELECTRICAL SYSTEM

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

13036MI29

2) BATTERY
(1) Clean
Η Wash the terminal with hot water if it is contami-
nated, and apply grease to the terminals after
washing.
Battery gas can explode. Keep sparks and
flames away from batteries.
Always wear protective glasses when working
with batteries.
Do not stain clothes or skin with electrolyte
as it is acid.
Be careful not to get the electrolyte in eyes.
Wash with clean water and go to the doctor if
it enters the eyes. 36070FW05

(2) Recycle
Never discard a battery.
Always return used batteries to one of the
following locations.
ÂA battery supplier
ÂAn authorized battery collection facility
ÂRecycling facility

(3) Method of removing the battery cable

Remove the cable from the ground connection
first ( terminal side) and reconnect it last
when reassembling. Battery relay
Ground

13036MI32

6-41
3) STARTING THE ENGINE WITH A BOOSTER CABLE
Keep following order when you are going to start
engine using booster cable.
(1) Connection of booster cable
Connection of booster cable
ö Use the same capacity of battery for starting.
Η Make sure that the starting switches of the nor-
Red
mal machine and trouble machine are both at
the OFF position. Ι Θ Η
Θ Connect the red terminal of booster cable to
the battery (+) terminal between exhausted and
new battery.
Normal (New) Trouble (Exhausted)
Ι
Connect the black terminal of the booster cable machine machine
between new battery (-) terminal and chassis of Black
Κ
trouble machine. To chassis of trouble machine
ö Keep firmly all connection, the spark will be
caused when connecting finally. Connection order : Η
Ą
Θ
Ą
Ι
Ą
Κ
13036MI33

(2) Starting the engine

Η Starting the engine of the normal machine and
keep it to run at high idle.
Θ Start engine of the trouble machine with start-
START
ing switch.
Ι If you can not start it by one time, restart the ON
OFF
21076MA29
engine after 2 minutes.

(3) Taking off the booster cable Disconnection of booster cable

Η Take off the booster cable (black).
Θ Take off the booster cable (red) connected to
the (+) terminal.
Red
Ι Run engine with high idle until charging the
exhausted battery by alternator, fully. Ι Θ Η
Explosive gas is generated while using the
battery or charging it. Keep away flame and
be careful not to cause the spark. Normal (New) Trouble (Exhausted)
ö Charge the battery in the well ventilated machine machine
Black
place. Κ
To chassis of trouble machine
ö Place the machine on the earth or concrete.
Avoid charging the machine on the steel
plate.
Disconnection order : Κ
Ą
Ι
Ą
Θ
ĄΗ
ö Do not connect (+) terminal and (-) terminal
when connecting booster cable because it
13036MI33
will be shorted.

6-42
(4) Welding repair
Before start to welding, follow the below proce-
dure.
Η Shut off the engine and remove the starting
Master
switch. switch
Θ Disconnect ground cable from battery by mas-
ter switch. DISCONNECT SWITCH

OFF
Ι Before carrying out any electric welding on the
machine, the battery cables should be discon-
nected and the connectors pulled out of the
electronic control units (MCU, cluster etc).
Fuel tank
Κ Connect the earth (ground) lead of the welding
equipment as close to the welding point as pos- MOD
Y
R
G

PARTEL
: R290
NO LC-9
: 21Q8
BH

sible.
-3273
0

ö Do not weld or flame cut on pipes or tubes Battery

MCU
that contain flammable fluids. Clean them
thoroughly with nonflammable solvent before
Cluster type 1 Cluster type 2
welding or flame cutting on them.
Do not attempt to welding work before carry Wo
rk
Mo
de
Pow
er
Mo
de

Tra
vel
Spe
ed

Sel
ect

de
r Mo
Use
el

out the above.

o Dec
Aut

If not, it will caused serious damage at elec-

tric system.
CN-56
CN-56

4809S6MA22

6-43
8. AIR CONDITIONER AND HEATER

1) CLEAN AND REPLACE OF FRESH AIR FILTER

※ Always stop the engine before servicing. SEEK

MUTE

V
MODE
CALL

(1) Open the LH side cover.

LH side cover

21096MA40

(2) Remove the fresh air filter. Fresh

※ When installing a filter, be careful not to air filter
change the filter direction.
CALL

MUTE

MODE

V
SEEK

Outside

Inside

21096MA41

(3) Clean the filter using a pressurized air (below 2

kgf/cm2, 28 psi).
When using pressurized air, be sure to wear Inside
safety glasses.
Outside
(4) Inspect the filter after cleaning. If it is damaged
or badly contaminated, use a new filter. Pressurized air
2 kgf/cm2 below

13036MI34

2) CLEAN AND REPLACE OF RECIRCULATION

CALL

MUTE

MODE

Recirculation
V
SEEK

VOL

FILTER filter

※ Always stop the engine before servicing.

(1) Move seat and console box to arrow direction
using the adjust lever.

Adjust lever
2209S6MA42

6-44
 (2) Remove recirculation filter.
CALL

MUTE

MODE

Recirculation
V
SEEK

VOL

filter

2209S6MA43

(3) Clean the recirculation filter using a pressurized

air (below 2 kgf/cm2, 28 psi) or washing with
water.
When using pressurized air, be sure to wear
safety glasses.
ö Dry off after washing with water.
Pressurized air
(4) Inspect the filter after cleaning. If it is damaged 2 kgf/cm2 below
or badly contaminated, use a new filter.
13036MI35

3) PRECAUTIONS FOR USING AIR CONDITIONER

(1) When using the air conditioner for a long time,
open the window once every one hour.
(2) Be careful not to overcool the cab.
(3) The cab is properly cooled if the operator feels
cool when entering there from outside (about
5˚C lower than the outside temperature).
(4) When cooling, change air occasionally.
4) CHECK DURING SEASON
Ask the service center for replenishment of
refrigerant or other maintenance service so that
the cooling performance is not damaged.
5) CHECK DURING OFF-SEASON
Operate the air conditioner 2 or 3 times a
month (each for a few minutes) to avoid loss of
oil film in the compressor.
6) REFRIGERANT (R134-a) AMOUNT : 850 佳#20 g
7) COMPRESSOR LUBRICANT OIL (SYNTHETIC
OIL) : 265mL

6-45