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 cluster.
(2) Shorten the interval of inspect and service
depending on site condition. (Such as dusty
area, quarry, sea shore and etc.)
(3) Practice the entire related details at the same
time when the service interval is doubled.
For example, in case of 100hours, carry out all Service meter
the maintenanceÖEach 100hours, each 50
hours and daily service× at the same time. 555C96MA01

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.
ö Be sure to start the maintenance after fully
understand the chapter 1, safety hints.

6-2
4) RELIEVING THE PRESSURE IN THE HYDRAULIC SYSTEM
ö Spouting of oil can cause the accident when
loosening the cap or hose right after the operating
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.

555C96MA02

(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.
ö This does not completely release the
p r e s s u r e , s o w h e n s e r v i n g hy d r a u l i c
component, loosen the connections slowly
and do not stand in the direction where the oil
spurt out.

5596MA02

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

Cap
tank by pushing the top of the air breather.
Pushing

Air breather

R5576MA04

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 Every
Pump delivery hose
circuit 2 years
Hydraulic Swing hose
system Boom cylinder line hose
Working Every
Arm cylinder line hose
device 2 years
Bucket cylinder line hose
ö1. 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
kgÂm lbÂft kgÂm lbÂft
M 6Ý1.0 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6
M 8Ý1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.7 ~ 4.1 19.5 ~ 29.7
M10Ý1.5 4.0 ~ 6.0 28.9 ~ 43.4 5.5 ~ 8.3 39.8 ~ 60
M12Ý1.75 7.4 ~ 11.2 53.5 ~ 81.0 9.8 ~ 15.8 70.9 ~ 114
M14Ý2.0 12.2 ~ 16.6 88.2 ~ 120 16.7 ~ 22.5 121 ~ 163
M16Ý2.0 18.6 ~ 25.2 135 ~ 182 25.2 ~ 34.2 182 ~ 247
M18Ý2.5 25.8 ~ 35.0 187 ~ 253 35.1 ~ 47.5 254 ~ 344
M20Ý2.5 36.2 ~ 49.0 262 ~ 354 49.2 ~ 66.6 356 ~ 482
M22Ý2.5 48.3 ~ 63.3 349 ~ 458 65.8 ~ 98.0 476 ~ 709
M24Ý3.0 62.5 ~ 84.5 452 ~ 611 85.0 ~ 115 615 ~ 832
M30Ý3.0 124 ~ 168 898 ~ 1214 169 ~ 229 1223 ~ 1656
M36Ý4.0 174 ~ 236 1261 ~ 1704 250 ~ 310 1808 ~ 2242

(2) Fine thread

8T 10T
Bolt size
kgÂm lbÂft kgÂm lbÂft
M 8Ý1.0 2.2 ~ 3.4 15.9 ~ 24.6 3.0 ~ 4.4 21.7 ~ 31.8
M10Ý1.2 4.5 ~ 6.7 32.5 ~ 48.5 5.9 ~ 8.9 42.7 ~ 64.4
M12Ý1.25 7.8 ~ 11.6 56.4 ~ 83.9 10.6 ~ 16.0 76.7 ~ 116
M14Ý1.5 13.3 ~ 18.1 96.2 ~ 131 17.9 ~ 24.1 130 ~ 174
M16Ý1.5 19.9 ~ 26.9 144 ~ 195 26.6 ~ 36.0 192 ~ 260
M18Ý1.5 28.6 ~ 43.6 207 ~ 315 38.4 ~ 52.0 278 ~ 376
M20Ý1.5 40.0 ~ 54.0 289 ~ 391 53.4 ~ 72.2 386 ~ 522
M22Ý1.5 52.7 ~ 71.3 381 ~ 516 70.7 ~ 95.7 511 ~ 692
M24Ý2.0 67.9 ~ 91.9 491 ~ 665 90.9 ~ 123 658 ~ 890
M30Ý2.0 137 ~ 185 990 ~ 1339 182 ~ 248 1314 ~ 1796
M36Ý3.0 192 ~ 260 1390 ~ 1880 262 ~ 354 1894 ~ 2562

6-6
2) PIPE AND HOSE (FLARE type)
Thread size (PF) Width across flat (mm) kgfÂm lbfÂft

1/4" 19 4 28.9
3/8" 22 5 36.2
1/2" 27 9.5 68.7
3/4" 36 18 130
1" 41 21 152
1-1/4" 50 35 253

3) PIPE AND HOSE (ORFS type)

Thread size (UNF) Width across flat (mm) kgfÂm lbfÂft

9/16-18 19 4 28.9
11/16-16 22 5 36.2
13/16-16 27 9.5 68.7
1-3/16-12 36 18 130
1-7/16-12 41 21 152
1-11/16-12 50 35 253

4) FITTING

Thread size Width across flat (mm) kgfÂm lbfÂft

1/4" 19 4 28.9
3/8" 22 5 36.2
1/2" 27 9.5 68.7
3/4" 36 18 130
1" 41 21 152
1-1/4" 50 35 253

6-7
 4) TIGHTENING TORQUE OF MAJOR COMPONENT
Torque
No. Descriptions Bolt size
kgfÂm lbfÂft
1 Engine mounting bolt(Engine-Bracket) M10 Ý 1.5 7.0Ü1.0 50.6Ü7.2
2 Engine mounting bolt(Bracket-Frame) M16 Ý 2.0 25Ü2.5 181Ü18.1
3 Engine Radiator mounting bolt, nut M10 Ý 1.5 6.9Ü1.4 50Ü10.0
Coupling mounting socket bolt M14 Ý 2.0 14Ü1.0 101Ü7.2
4
Coupling mounting clamp bolt M16 Ý 2.0 11Ü1.0 79.6Ü7.2
5 Main pump mounting bolt M12 Ý 1.75 12.3Ü3.0 92Ü22.0
6 Main control valve mounting bolt M 8 Ý 1.25 2.5Ü0.5 18Ü3.6
Hydraulic
7 Fuel tank mounting bolt M16 Ý 2.0 29.7Ü4.5 215Ü33
system
8 Hydraulic oil tank mounting bolt M16 Ý 2.0 29.7Ü4.5 215Ü33
9 Turning joint mounting bolt, nut M12 Ý 1.75 12.8Ü3.0 92Ü22.0
10 Swing motor mounting bolt M16 Ý 2.0 29.7Ü4.5 215Ü33.0
11 Swing bearing upper mounting bolt M16 Ý 2.0 29.7Ü4.5 215Ü33.0
Power
12 train Swing bearing lower mounting bolt M16 Ý 2.0 29.7Ü4.5 215Ü33.0
system
13 Travel motor mounting bolt M14 Ý 2.0 20Ü2.0 145Ü14.0
14 Sprocket mounting bolt M14 Ý 2.0 19.6Ü2.9 142Ü21.0
15 Carrier roller mounting bolt, nut M16 Ý 2.0 29.6Ü3.2 214Ü23.1
16 Track roller mounting bolt M18 Ý 2.0 41Ü5.0 297Ü36.0
Under
17 Track tension cylinder mounting bolt M12 Ý 1.75 12.8Ü3.0 92Ü22.0
carriage
18 Track shoe mounting bolt, nut 1/2-20UNF 19.5Ü2.0 141Ü14.5
19 Track guard mounting bolt M16 Ý 2.0 29.6Ü3.2 214Ü23.0
20 Counter weight mounting bolt M20 Ý 2.5 57.8Ü6.4 418Ü46.3
21 Others Cab mounting bolt, nut M12 Ý 1.75 12.8Ü3.0 92Ü22.0
22 Operator's seat mounting bolt M 8 Ý 1.25 1.17Ü0.1 8.5Ü0.7

ö For tightening torque of engine and hydraulic components, see engine maintenance guide and ser-
vice 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)
Hyundai genuine long life hydraulic oil (ISO VG46, VG68)
Hydraulic oil
Conventional hydraulic oil (ISO VG15)
Swing and travel reduction gear SAE 80W-90 (API GL-5)
Grease Lithium base grease NLGI No. 2
Fuel ASTM D975-No. 2 (low sulfur fuel or ultra low sulfur fuel)
Coolant Mixture of 50% ethylene glycol base antifreeze and 50% water.
SAE  Society of Automotive Engineers
API  American Petroleum Institute
ISO  International Organization for Standardization
NLGI  National Lubricating Grease Institute
ASTM  American Society of Testing and Material
Â
Low sulfur fuel : sulfur content à500 ppm
Â
Ultra low sulfur fuel : sulfur content à15 ppm

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

SAE 30

SAE 10W
Engine oil pan Engine oil 11.6 (3.1)
SAE 10W-30

SAE 15W-40

NLGI NO.1
Grease 0.2 (0.05)
Swing drive NLGI NO.2

Gear oil 1.5 (0.4)

SAE 80W-90
Final drive Gear oil 1.2Ý2
(0.3Ý2)

ISO VG 32
## Tank:
70 (18.5)
Hydraulic tank# Hydraulic oil ISO VG 46
System:
120 (31.7)######
ISO VG 68

ASTM D975 NO.1

Fuel tank# Diesel fuel 120 (31.7)
ASTM D975 NO.2

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

Mixture of
Radiator antifreeze
9.5 (2.5) Ethylene glycol base permanent type
(Reservoir tank)# and water
50 : 50侏1

SAE : Society of Automotive Engineers 侏1#=#Soft water

API : American Petroleum Institute City water or distilled water

ISO : International Organization for Standardization
NLGI : National Lubricating Grease Institute
ASTM : American Society of Testing and Material

6-10
 4. MAINTENANCE CHECK LIST

1) DAILY SERVICE BEFORE STARTING

Check items Service Page
Visual check
Fuel tank Check, Refill 6-25
Hydraulic oil level Check, Add 6-27
Engine oil level Check, Add 6-18
Coolant level Check, Add 6-20
Control panel & pilot lamp Check, Clean 6-36
Prefilter (water, element) Check, Clean 6-25
Fan belt tension & damage Check, Adjust 6-23
ø
Attachment pin and bushing Lubricate 6-35
ÂBoom cylinder tube end
ÂBoom foot
ÂBoom cylinder rod end
ÂArm cylinder tube end
ÂArm cylinder rod end
ÂBoom + Arm connecting
ÂBucket cylinder tube end
ÂBoom swing post pin
ÂBoom swing cylinder
ø Lubricate every 10 hours or daily for initial 100 hours.

2) EVERY 50 HOURS SERVICE

Check items Service Page
Fuel tank (water, sediment) Drain 6-25
Track tension Check, Adjust 6-32
Swing reduction gear oil Check, Add 6-30
Bucket linkage & blade pins Lubricate 6-41
ÂBucket cylinder rod end
ÂBucket + Arm connecting
ÂBucket control link + Arm
ÂBucket control rod
ÂBoom swing post + Upper frame connecting
ÂBoom swing cylinder head and rod
ÂDozer blade + Lower frame connecting
ÂDozer blade cylinder head and rod

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
★ Hydraulic oil return filter Replace 6-28
★ Pilot line filter element Replace 6-29
★ Replace 2 filters for continuous hydraulic breaker operation only.

5) INITIAL
NITIAL 250 HOURS SERVICE
Check items Service Page
Engine oil Change 6-18, 19
Engine oil filter Replace 6-18, 19
Prefilter (water, element) Replace 6-25
Fuel filter element Replace 6-26
Hydraulic oil return filter Replace 6-28
Pilot line filter element Replace 6-29
Swing reduction gear oil Change 6-30
Swing reduction gear grease Check, Add 6-30
Travel reduction gear oil Change 6-31

6-12
 6) EVERY 250 HOURS SERVICE
Check items Service Page
Battery (voltage) Check, Clean 6-36
Aircon & heater fresh air filter Check 6-39
Swing bearing grease Lubricate 6-30
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
Attachment pin and bushing Lubricate 6-35
·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
·Boom swing post pin
·Boom swing cylinder

6-13
 7) EVERY 500 HOURS SERVICE
Check items Service Page

★Engine oil Change 6-18, 19

★Engine oil filter Replace 6-18, 19
Radiator, cooler fin and charge air cooler Check, Clean 6-23
☆Air cleaner element (primary) Check, Clean 6-24
Fuel filter element Replace 6-26
Prefilter Replace 6-25
★ If you use high sulfur containing fuel above than 0.5% or use low grade of engine oil reduce change
interval.
☆ 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.

8) EVERY 1000 HOURS SERVICE

Check items Service Page
Air breather element Replace 6-29
Travel reduction gear oil Change 6-31
Swing reduction gear oil Change 6-30
Swing reduction gear grease Change 6-30
Hydraulic oil return filter Replace 6-28
Pilot line filter element Replace 6-29

9) EVERY 2000 HOURS SERVICE

Check items Service Page
Coolant Change 6-20, 21, 22, 23
Hydraulic tank suction strainer Check, Clean 6-28
★Hydraulic oil ★1 Change 6-27
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 6-27

★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
Fuel system
·Fuel tank Drain or Clean 6-25
·Prefilter Clean or Replace 6-25
·Fuel filter element Replace 6-26
Engine lubrication system
·Engine oil Change 6-18, 19
·Engine oil filter Replace 6-18, 19
Engine cooling system
·Coolant Add or Change 6-20, 21, 22, 23
·Radiator Clean or Flush 6-20, 21, 22, 23
·Charge air cooler Check 6-23
Engine air system
·Air cleaner element Replace 6-24
Hydraulic system
·Hydraulic oil Add or Change 6-27
·Hydraulic oil return filter Replace 6-28
·Pilot line filter element Replace 6-29
·Element of breather Replace 6-29
·Suction strainer Clean 6-28
Under carriage
·Track tension Check, Adjust 6-32
Bucket
·Tooth Replace 6-34
·Side cutter Replace 6-33
·Linkage Adjust 6-33
·Bucket assy Replace 6-33
Air conditioner and heater
·Fresh air filter Clean, Replace 6-39
·Recirculation filter Clean 6-40

6-15
 5. MAINTENANCE CHART

9 11 12 25 14 8 1 16 17 15 22 4

6
2
20
3
5
21

25 19 10 18

26

7 24 13 23

559S6MA03

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.
4. For other details, refer to the service manual.

6-16
 Service Service Oil Capacity Service
No. Description
interval action symbol ˶(U.S.gal) points No.
1 Hydraulic oil level Check, Add HO 70 (18.5) 1
2 Engine oil level Check, Add EO 11.6 (3.1) 1
10 Hours
4 Radiator coolant Check, Add C 9.5 (2.5) 1
or daily
5 Prefilter (water, element) Check, Clean - - 1
6 Fan belt tension and damage Check, Adjust - - 1
8 Fuel tank (water, sediment) Check, Clean - - 1
10 Swing drive gear case (gear oil) Check, Add GO 1.5 (0.4) 1
50 Hours
12 Swing gear and pinion Check, Add PGL - 1
or weekly
13 Track tension Check, Adjust PGL - 2
24 Bucket linkage & blade pin Lubricate PGL - 7
7 Attachment pin Lubricate PGL - 9
9 Swing bearing Lubricate PGL - 3
14 Battery (voltage) Check, Clean - - 1
250 Hours
19 Air conditioner filter (outer) Clean - - 1
25 Boom swing cylinder Lubricate PGL - 1
26 Boom swing post pin Lubricate - - 3
2 Engine oil Change EO 11.6 (3.1) 1
3 Engine oil filter Replace - - 1
5 Prefilter (water, element) Replace - - 1
500 Hours
20 Air cleaner element (primary) Clean - - 1
21 Fuel filter element Replace - - 1
22 Radiator, cooler fin and charge air cooler Check, Clean - - 3
10 Swing drive gear case (gear oil) Change GO 1.5 (0.4) 1
11 Swing drive gear case (grease) Change PGL 0.2 (0.05) 1

1000 15 Hydraulic oil return filter Replace - - 1

Hours 16 Air breather element Replace - - 1
18 Line filter element Replace - - 1
23 Final drive gear case Change GO 1.2 (0.3) 2
1 Hydraulic oil*1 Change HO 70 (18.5) 1
4 Radiator coolant Change C 9.5 (2.5) 1
2000
Hours 17 Hydraulic oil suction strainer Check, Clean - - 1
Hoses, fittings, clamps Check, Retighten,
- - - -
(fuel, coolant, hydraulic) Replace
5000 Hours 1 Hydraulic oil*2 Change HO 70 (18.5) 1

As 19 Air conditioner filters Check, Replace - - 2

required 20 Air cleaner element (safety / primary) Check, Replace - - 2
*1 : Conventional hydraulic oil *2 : 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

Filler port
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.
ö If the oil is contaminated or diluted, change
the oil regardless of the regular change
Dipstick Dipstick
interval.
ö Check oil level after engine has been stopped
for 15 minutes.
Upper limit
Do not operate unless the oil level is in the Lower limit
normal range.
R5576MA06

2) REPLACEMENT OF ENGINE OIL AND OIL

FILTER
Oil pan
(1) Warm up the engine.
(2) Remove the cover of drain plug and connect the Drain plug
quick coupler hose. Quick coupler hose
ö A drain pan with a capacity of 20 liters (5 U.S.
gallons) will be adequate.

R5576MA07

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

with a filter wrench and clean the gasket surface.
e
os
Cl Engine oil filter
Open

R5576MA08

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

R5576MA50

(5) Install the filter to the filter head.

Remove the quick coupler hose.
e
ö Mechanical over-tightening may distort the Cl
os Engine oil filter

Open
threads or damage the filter element seal.
Â
Install the filter as specified by the filter manu-
facturer.

R5576MA08

(6) Fill the engine with clean oil to the proper level. Filler port
ÂQuantity : 11.6˶(3.1 U.S.gallons)

Oil

R5576MA10

(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.

R5576MA09

6-19
3) CHECK COOLANT
(1) Check if the level of coolant in reservoir tank is
between FULL and LOW.
LL
(2) Add the mixture of antifreeze and water after FU

removing the cap of the reservoir tank if coolant

is not sufficient. LO
W

(3) Be sure to add the coolant by opening the cap of

radiator when coolant level is below LOW. 555C96MA11

(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
OK NOT OK
cap after the engine has cooled down.

555C96MA14

4) FLUSHING AND REFILLING OF RADIATOR

(1) Change coolant OK
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. 555C96MA15

ö Protect the environment : Handling and

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

6-20
 Wait until the temperature is below 50 50˚C
(122˚F
F ) before removing the coolant system
pressure cap.
Water drain plug
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 20 liters (5 U.S.gallons
U.S.gallons)) will be
R5576MA16
adequate in most applications.

(2) Flushing of cooling system

OK
Η Fill the system with a mixture of sodium
carbonate and water(or a commercially
available equivalent).
ö Use 0.5 kg (1.0 pound) of sodium carbonate
for every 23 liters (6.0 U.S. gallons)
gallons) of water.
ö Do not install the radiator cap. The engine is
to be operated without the cap for this
process.
18036MI17

Θ Operate the engine for 5 minutes with the

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

START

ON
OFF
555C96MA17

Ι Fill the cooling system with clean water.

ö Be sure to vent the engine and aftercooler
for complete filling.
ö Do not install the radiator cap or the new
coolant filter.

18036MI20

6-21
 Κ Operate the engine for 5 minutes with the
coolant temperature above 80˚C (176˚F) .
Shut the engine off, and drain the cooling
system.
ö If the water being drained is still dirty, the
system must be flushed again until the water
is clean.
START

ON
OFF 555C96MA17

(3) Cooling system filling

Η Use a mixture of 50 percent water and 50
percent ethylene glycol antifreeze to fill the
cooling system.
Coolant capacity (engine only) : 10˶(2.6 U.S.
gallons)
DCA

18036MI22

Θ The system has a maximum fill rate of 14 liters

(3.5 U.S. gallons) per minute.
Do not exceed this fill rate.
ö The system must be filled slowly to prevent
air locks.
During filling, air must be vented from the
engine coolant passage.

21076MA57

Ι Install the pressure cap. Operate the engine NOT OK

until it reaches a temperature 80˚C (176˚F),
and check for coolant leaks.
Check the coolant level again to make sure the
system is full of coolant.

555C96MA19

6-22
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 550kPa
and debris from the fins. (80psi)
13036MI01
Blow the air in the opposite direction of the fan
air flow.
(3) Visually inspect the radiator for bent or broken
fins.
ö 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.
13036MI01

6) FAN BELT TENSION

Radiator fan Set bolt
(1) Measure the belt deflection at the longest span B

of the belt. Alternator

ÂDeflection
Deflection
A B C C A
V-belt
Used belt 10~14 7~10 9~13
New belt 8~12 5~8 7~11 Crankshaft Press with thumb
V-pulley
R5576MA19

(2) Inspect the drive for damage.

OK

NOT OK
13036MI03

6-23
7) INSPECTION OF COOLING FAN
Personal injury can result from a fan blade fail-
ure. Never pull or pry on the fan. This can
damage the fan blade and cause fan failure.
ö Rotate the crankshaft by using the engine bar-
ring gear.
ö 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.

8) CLEANING OF AIR CLEANER Cover

(1) Primary element

Η Open cover and remove the element.
Θ Clean the inside of the body.
Ι Clean the element with pressurized air.
ÂRemove the dust inside of the element by the
pressurized air (below 3 kgf/cm 2, 40 psi)
forward and backward equally. Pressurized air
3kgf/cm2 below
Κ Inspect for cracks or damage of element by
putting a light bulb inside of the element.
Λ Insert element and close cover.
ö Replace the primary element after 4 times
cleanings.
(2) Safety element
ö Replace the safety element only when the
primary element is cleaned for the 4 times. 5596MA04
ö Always replace the safety element. Never
attempt to reuse the safety element by
cleaning the element.

21076MA11A

6-24
9) FUEL TANK
(1) Fill fuel fully when system the operation to
minimize water condensation, and check it with
fuel gauge before starting the machine.
(2) Drain the water and sediment in the fuel tank by
Fuel gauge
opening the drain cock.
ö Be sure to LOCK the cap of fuel tank.
ö Remove the strainer of the fuel tank and
clean it if contaminated.
Stop the engine when refueling.
All lights and flames shall be kept at a safe
distance while refueling.
Drain cock R5576MA21

10) Prefilter
(1) Prepare a waste oil container.
(2) Close the fuel cock.
(3) Loosen the drain cock at bottom of the water
Close Fuel cock
seperator and drain off any water collected
Open Element
inside.
Float ring
(4) Be sure to bleed air in the fuel system.
ö Wash the element and inside cup with clean Drain cock 55W9S6MA22
fuel oil.
ö Replace the element with a new one if any
damaged.

6-25
11) REPLACEMENT OF FUEL FILTER
(1) Clean around the filter head, remove the filter
with a filter wrench and clean the gasket surface.
(2) Apply a small amount of fuel to the O-ring of
new cartridge.
(3) Install new cartridge by hand. Cartridge
ö Do not add fuel to the new cartridge. Invisible
particles of dirt which might get inside the 95W36MI05
injection pump can damage its finely finished
parts.
(4) Relieve the air after mounting.
ö Check for fuel leakage after the engine starts.
ö 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.

95W36MI06

12) BLEEDING THE FUEL SYSTEM

(1) Turn the start switch to the ON position and hold it
in the position for 10~15 seconds to operate the
fuel feed pump.
START

ON
OFF

R5576MA23

6-26
13) LEAKAGE OF FUEL
Be careful and clean the fuel hose, injection FIRE
pump, fuel filter and other connections as the
leakage from these part can cause fire.

R5576MA24

14) HYDRAULIC OIL CHECK

(1) Stop the engine after retract the arm and bucket Red line
cylinders, then lower the boom and set the
bucket on the ground at a flat location as in the
Level gauge
illustration.
(2) Check the oil level at the level gauge of hydraulic
oil tank.
(3) The oil level is normal if between the red lines. 555C96MA16

15) FILLING HYDRAULIC OIL Cap

(1) Stop the engine to the position of level check.
Pushing
(2) Loosen the cap and 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.
 Tightening torque : 1.44Ü0.3 kgfÂm
Air breather
(10.4Ü2.1 lbfÂft)
(4) Start engine after filling and operate the work
equipment several times.
(5) Check the oil level at the level check position
after engine stops. R5576MA04

6-27
16) CHANGE HYDRAULIC OIL
(1) Lower the bucket on the ground pulling the arm
and bucket cylinder to the maximum.
(2) Loosen the cap and relieve the pressure in the
tank by pushing the top of the air breather.
(3) Remove the cover.
 Tightening torque : 6.9Ü1.4 kgfÂm
(50Ü10 lbfÂft)
(4) Prepare a suitable container.
(5) To drain the oil loosen the drain plug at the
bottom 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.
(9) Start engine and run continually. Release the
air by full stroke of each control lever. R5576MA26

17) CLEAN SUCTION STRAINER

Clean suction strainer as follows paying attention
to the cause to be kept during oil filling.
Air breather
(1) Remove the cover on the top of the oil tank.
Cover
· Tightening torque : 6.9Ü1.4 kgfÂm O-ring
(50Ü10 lbfÂft)
(2) Pull out the strainer in the tank.
(3) Wash the foreign material on the suction strainer Strainer
with gasoline or cleaning oil.
(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.

R5576MA27

6-28
 18) 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

 Tightening torque : 6.9Ü1.4 kgfÂm Bypass valve
(50Ü10 lbfÂft)
Return filter
(2) Remove the spring, by-pass valve, and return
filter in the tank.
(3) Replace the element with new one.

R5576MA28

19) REPLACEMENT OF ELEMENT IN HYDRAULIC

TANK BREATHER Cap
Nut
(1) Loosen the cap and relieve the pressure in the
Cover
tank by pushing the top of the air breather.
Element
(2) Loosen the lock nut and remove the cover.
(3) 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)
R5576MA29

20) REPLACE OF PILOT LINE FILTER

(1) Loosen the nut positioned on the filter body.
(2) Pull out the filter element and clean filter
housing.
(3) Install the new element and tighten using
specified torque.
ö Change cartridge after initial 250 hours of
operation. Thereafter, change cartridge every
1000 hours. R5576MA30

6-29
21) 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.

R5576MA60

22) CHANGE SWING REDUCTION GEAR OIL

(1) Raise the temperature of oil by swinging the
Filling port plug
machine before replace the oil and park the
machine on the flat ground.
(2) Loosen the plug.
(3) Drain into a proper container.
(4) Wash the drain plug and reinstall it with sealing Drain plug
tape.
Fill proper amount of recommended oil.
·Amount of oil : 1.5ℓ(0.4 U.S.gal)
65A6MA61A

23) LUBRICATE BEARING OF OUTPUT SHAFT

IN REDUCTION GEAR
(1) Grease at fitting.
※ Lubricate every 50 hours.

R5576MA52

24) MANIFOLD
(1) Swing bearing
Grease at 2 fitting.
※ Lubricate every 250 hours.

R5576MA51

6-30
 (2) Boom swing cylinder
Grease at fitting.
ö Lubricate every 250 hours.

R5576MA53

25) 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. LE FIL
VE L

If the level is at the hole of the plug, it is normal. L

Fill the oil if it is not sufficient. DR

AIN

Amount of oil : 1.2˶
(0.3 U.S.gal)

R5576MA32

26) 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.
LE FIL
VE L
L

(3) Loosen the level plug and then the drain plug.
DR

(4) Drain the oil to adequate container. AIN

(5) Tighten the drain plug and fill specified amount

of oil at filling port.
R5576MA33
(6) Tighten the level plug and travel slowly to check
if there is any leakage of oil.

27) LUBRICATE RCV LEVER

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

555C96MA25

6-31
28) ADJUSTMENT OF TRACK TENSION
ö It is important to adjust the tension of track
properly to extend the lifetime of track and
traveling device. 90 ~ 110
ö The wear of pins and bushings on the
undercarriage 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. 5596MA05

Steel track
Length (L)
(3) If the tension is tight, drain the grease in the 130~150 mm 5.1~5.9"
grease nipple and if the tension is loose, charge
the grease.
Personal injury or death can result from
grease under pressure.
Unscrew the grease nipple after release the
tension by pushing the poppet only when Bottom of track frame Track frame
necessarily required.
Grease leaking hole is not existing. So, while
unscrew the grease nipple, grease is not L
leaking until the grease nipple is completely
coming out. If the tension is not released in
advance, the grease nipple can be suddenly
Back of shoe Rubber track shoe
popped out by pressurized grease.
R5576MA34A
ö When the grease is drained, move the track
to the forward and backward slightly. Rubber track
If the track tension is loose even after the Length (L)
grease is charged to the maximum, change 39~44 mm 1.5~1.7"
the pins and bushings as there are worn
seriously.

6-32
29) 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.
555C96MA18
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
1
stop the engine. 2
4
(3) Remove the stopper bolts (1) and nuts (2), then 2

remove pins (3, 4) and remove the bucket.

ö When removing the pins, place the bucket so
that it is in light contact with the ground.
R5576MA70
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.
(4) Align the arm with holes (A) and the link with
holes (B), then coat with grease and install pins
(3, 4)
ö When installing the bucket, the O-rings are R5576MA71

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.
(5) Install the stopper bolt (1) and nuts (2) for each O-ring
Nut
pin, then grease the pin.

Bolt
Bucket Arm Bush

R5576MA42

6-33
30) REPLACEMENT OF BUCKET TOOTH
(1) Timing of replacement
Tooth adapter
Η Check wearing condition as shown in the illus- Tooth tip
tration and replace tooth tip before adapter
starts to wear.
Θ If excessive use, tooth adapter has worn out,
replacement may become impossible.

R5576MA37

(2) Instructions for replacement

Η Pull out pin by striking pin with punch or ham-
Tooth pin
mer, avoiding damage to locking rubber.
Locking rubber
Θ Remove dust and mud from surface of tooth
adapter by using knife.
Ι Place locking rubber in its proper place, and fit
tooth tip to adapter. Tooth tip
Κ Insert pin until locking rubber is positioned at
tooth pin groove. Tooth adapter
Personal injury can result from bucket falling.
R5576MA36
Block the bucket before changing tooth tips
or side cutters.

6-34
31) LUBRICATE PIN AND BUSHING
(1) Lubricate to each pin of working device
Lubricate the grease to the grease nipple
according to the lubricating interval.
No. Description Qty
1 Lubrication manifold at upper frame 4 4 5 4 3 2 1
2 Boom connection pin 2
3 Boom cylinder (head and rod side) 2
4 Arm cylinder pin (head and rod side) 2
5 Boom and arm connection pin 1
Bucket cylinder pin (Head and rod) 2 6 7 8

Bucket link (Control rod) 1

6
Arm and bucket connection pin 1
Arm and control link connection pin 1
Dozer connection pin 2
7
Dozer cylinder pin 2 5594OP10

8 Boom swing post 2

ö Shorten lubricating interval when working
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.

555C96MA23

ö If it is assembled in wrong direction, it will

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

13036MI28

6-35
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 fol-
lowing 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.
Ground Battery relay
R5576MA98

6-36
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
ö Use the same capacity of battery for starting. Connection of booster cable
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
To chassis of trouble machine
trouble machine.
ö Keep firmly all connection, the spark will be
caused when connecting finally. Connection order : ΗĄΘĄΙĄΚ
R5576MA99

(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
engine after 2 minutes. 21076MA29

(3) Taking off the booster cable

Η Take off the booster cable(black). Disconnection of booster cable
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 : ΚĄΙĄΘĄΗ
ö Do not connect (+) terminal and (-) terminal
when connecting booster cable because it
R5576MA99
will be shorted.

6-37
(4) Welding repair
Before start to welding, follow the below proce-
dure.
Η Shut off the engine and remove the starting Master switch Cluster
switch.
OFF
Θ Disconnect ground cable from battery by mas-
ter switch.
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).
Κ Connect the earth (ground) lead of the welding
equipment as close to the welding point as pos-
sible. Battery
ö Do not weld or flame cut on pipes or tubes CN-56

that contain flammable fluids. Clean them

thoroughly with nonflammable solvent before
welding or flame cutting on them. CN-51 MCU
Do not attempt to welding work before carry
out the above.
If not, it will caused serious damage at elec-
tric system. 559S6MA37

6-38
8. AIR CONDITIONER AND HEATER

1) CLEAN AND REPLACE OF THE

CIRCULATION FILTER
ö Always stop the engine before servicing.
(1) Remove the screw (1) and cover (2) on the seat
base.
(2) Remove the circulation filter (3).

3
1
2
5596MA08

(4) Clean the filter using a pressurized air (Below 2

kgf/cm2, 28psi).
When using pressurized air, be sure to wear
safety glasses. Inside

(5) Inspect the filter after cleaning. If it is damaged

or badly contaminated, use a new filter.
Outside
Pressurized air
2 kgf/cm2 below
R5576MA41

2) CLEAN AND REPLACE OF THE RECIRCULA-

TION FILTER
ö Always stop the engine before servicing.
(1) Remove the screw (1), cover (2) and pad (3).
(2) Remove the recirculation filter (4).

2
3

5596MA09

6-39
(3) Clean the recirculation filter using a pressurizes
are (Below 2 kgf/cm2, 28psi) or washing with
water.
When using pressurized air, be sure to wear
safety glasses.
(4) Inspect the filter after cleaning. If it is damaged
or badly contaminated, use a new filter.
Pressurized air
2 kgf/cm2 below
555C96MA43

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
5C 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 : 950 佳#20 g
(with receiver drier)
7) COMPRESSOR LUBRICANT OIL (SYNTHET
(SYNTHETIC
IC
OIL) : 265mL

6-40