Hyundai HL630VL User manual

Attention Please
Subject : Matters needing attention for maintenance and accessories
1. First welcome you to have used our product and thank you for great coordination in business.
2. In case the equipment is in faults, it should be maintained by our Company or the company appointed
by our Company using standard parts.
3. At present, In some markets there have been some forged and fake imported parts and some
unauthorized and untrained companies or persons to maintain the products of our company, causing
many problems left and seriously affecting the equipment performance and operation life.
4. In view of the above, the customers are requested to pay attention to followings:
1) The adopting of non-standard parts may not have obvious effects on the equipment in short time,
however, it will certainly have a series of harmful effects later. In order to prevent the damage to the
equipment or the performance deterioration causing severer loss, never use non-standard parts.
2) When the customer is purchasing the parts, it is necessary to purchase products from our
company or the company authorized by our company for selling the parts, and be careful for the
discrimination. Welcome to contact our company if there is doubtful phenomenon.
3) If the customer requires to maintain the equipment, it is requested to contact our company or the
company authorized by our company.
4) In case of the equipment faults arising from the maintenance with non-standard parts or by the
unauthorized company or persons, our Company do not bear the responsibilities for the warranty
service, even within the Warranty period.
5) With the improvement of products, the contents of this manual may be lagging behind. Customers in
order to obtain the latest product information, please contact our company or our authorized dealer.
5. Thank you once again for the business cooperation at normal times.
With best regards

Special Explanation
Topic: special explanation of fuel system operation and maintenance
for loader
In order to let Hyundai loader for you to create greater economic benefits, please read this article
seriously.
Fuel quality is the important factors of make the engine to obtain ne performance and prolong service life
and realize low emission.
The main function of fuel is provide the required energy for diesel engine work and provide cooling and
lubrication for fuel inside the system precision components .The market supply of most of the diesel oil
can meet Hyundai loader installed diesel engine use requirement, but it has to meet the viscosity, cetane
number, sulfur content, cloud point, water and sediment content and performance requirements. Among
them, the viscosity, cetane number, cloud point and indicators in selecting the right after the diesel brand
generally its performance does not change, but the water and sediment index will because transportation,
storage, add and maintain undeserved causes such overweight, exceed the prescribed content
requirements (less than 0.05 volume percent). So as to increase the wear and tear of diesel engine fuel
system, causing the engine starting difculty, power loss, smoke when fault.
To this end, we please the Hyundai loader users and operators must do the following points:
1) Choose conform to the requirements of the use of diesel, don’t use small smelter and other production
the inferior diesel oil;
2) In diesel oil transportation, storage, added to take appropriate measures to reduce moisture and
impurity interfuse;
3) In strict accordance with “The operation maintenance manual “provisions of the maintenance period
of fuel system for drainage, lter replacement and maintenance work, and can shorten appropriately
according to working environment drainage and lter cartridge replacement cycle.
Thank you again for you choose the Hyundai products!
With best regards

Our Company has the right to continuously improve the products so as to promote the best
products to the market as possible as we can. These improvements can be implemented at
any time; however, we will not change the materials for the products being sold at that time.
The consumers should particularly be reminded of that they should regularly contact with the
Agent to ask for the newest information of the equipment.
These information may include the auxiliary equipment and optional ones, but you equipment
does not. If you need other devices, please contact with the Agent.
The pictures use in this Manual is only to visually depict the related sections of the equipment
and they may be different from the actually installed equipment.
Operation & Maintenance Manual

Contents 1
Contents
Safety................................................................................................................1-1
Advice for Operation of a HYUNDAI Wheel Loadar.....................................................1-1
Safety Labels................................................................................................................1-5
Unauthorized Modications..........................................................................................1-7
General Hazard Information.........................................................................................1-7
Before Starting Engine ...............................................................................................1-16
Operation of Loader ...................................................................................................1-20
Maintenance...............................................................................................................1-26
Battery........................................................................................................................1-34
Towing........................................................................................................................1-36
Shipping and transportation .......................................................................................1-37
Operation Controls..........................................................................................2-2
Component Locations ..................................................................................................2-2
Operator`s Area............................................................................................................2-4
Manipulating Facility and Monitoring System...............................................................2-6
Rocker Switch ............................................................................................................2-19
Monitoring System......................................................................................................2-22
Instrument Panel ........................................................................................................2-30
A/C System ................................................................................................................2-30
Stereo.........................................................................................................................2-32
Seat Adjustment.........................................................................................................2-38
Seat Belt.....................................................................................................................2-39
Ajustment of Rear-view Mirrorr...................................................................................2-40
Operation..........................................................................................................3-1
Advice for Operation of New Loader ............................................................................3-1
Operationg Manchine...................................................................................................3-6
Operation of Loader ...................................................................................................3-14
Operation Under Abnormal Conditions ......................................................................3-23

Contents 2
Inspection,Maintenance and Adjustment .....................................................4-1
Preparation and Setting of the Equipment Before Maintenance ..................................4-3
Recommended Lubricants Table .................................................................................4-4
Fluid Capacity...............................................................................................................4-5
Lubrication and Service Chart......................................................................................4-6
Maintenance Interval....................................................................................................4-9
Electrical system ........................................................................................................4-11
Bucket ........................................................................................................................4-13
Add Shim to Bucket....................................................................................................4-15
Tires ...........................................................................................................................4-16
Inspection of Bolt and Nut ..........................................................................................4-20
Maintenance under Special Conditions......................................................................4-21
Storage for a Long Term ............................................................................................4-22
Transportation .................................................................................................5-1
Transportation Machine................................................................................................5-1
Transportation Dimension ............................................................................................5-3
Trouble Shooting.............................................................................................6-1
Transmission System...................................................................................................6-1
Brakes System .............................................................................................................6-2
Hydraulic System for Working Device..........................................................................6-3
Steering Hydraulic System...........................................................................................6-4
Electrical System..........................................................................................................6-5
Specication ....................................................................................................7-1
Specication.................................................................................................................7-1
Working Range and Dimensions..................................................................................7-4
Working Capacities ......................................................................................................7-5
Approximate Weight of Workload Materials .................................................................7-7
Environment Protection..................................................................................8-1

Safety 1-1
Safety
ADVICE FOR OPERATION OF
WHEEL LOADAR
Unsafe use of the wheel loader could lead to serious injury
or death. Operating procedures, maintenance and equipment
practices or traveling or shipping methods that do not follow
the safety guidelines on the following pages could cause
serious, potentially fatal injuries or extensive damage to the
machine or nearby property.
Follow national and local road regulations
The wheel loader are not designed and manufactured for
driving on the road, mainly used for closed roads and elds
work. When wheel loader need to be transferred to other
working site, it should be loaded on truck or hanging truck for
transferring. Do need to temporarily drive on the road, should
get the permission according to the provisions of local laws
and regulations.
The wheel loader was manufactured mainly implementing the
following safety standards:
1. Mandatory terms in GB 25684.1-2010 <Earthmoving Equip-
ment Safety Part 1: General Requirement>
2. Mandatory terms in GB 25684.3-2010 <Earthmoving Equip-
ment Safety Part 3: Wheel Loader Requirement>
DANGER
WARNING
For your safety and that of others, carefully check the factors
that can lead to danger to minimize the pitfalls.

1-2 Safety
Improper operation and maintenance of this machine can be
hazardous and could result in serious injury or death.
Operator and maintenance personnel should read this manual
thoroughly before beginning operation or maintenance.
Keep this manual in the storage compartment to the rear
of the operator’s seat, and have all personnel involved in
working on the machine read the manual periodically.
Some actions involved in operation and maintenance of the
machine can cause a serious accident, if they are not done in
a manner described in this manual.
The procedures and precautions given in this manual apply
only to intended use of the machine.
If you use your machine for any unintended uses that are not
specically prohibited, you must be sure that it is safe for any
others. In no event should you or others engage in prohibited
uses or actions as described in this manual.
Hyundai delivers machines that comply with all applicable
regulations and standards of the country of which it has been
sent. If this machine has been purchased in another country
or purchased from someone in another country, it may lack
certain safety devices and specications that are necessary
for use in your country. If there is any question about whether
your product complies with the applicable standards and
regulations of your
country, consult HYUNDAI or your distributor before
operating the machine.
WARNING

Safety 1-3
This word indicates a potentially dangerous situation as a
safety message and security labels. if not avoided could
cause slight or moderate injury.
It can also be used to remind general unsafe operations.
CAUTION
Be prepared-Get to Know All Operating and Safety
Instructions. This is the Safety Alert Symbol. Wherever it
appears in this manual or on safety signs on the machine you
must be alert to the potential for personal injury or accidents.
Always observe safety precautions and follow recommended
procedures.
Learn Signal Words Used with Safety Alert
Symbol
The words “CAUTION”, “WARNING”, and “DANGER” used
throughout this manual and on decals on the machine indicate
degree of risk of hazards or unsafe practices.
All three degrees of risk indicate that safety is involved.
Observe precautions indicated whenever you see the Safety
Alert “Triangle”, no matter which signal word appears next to
“Exclamation Point” symbol.
SAFETY ALERT SYMBOL
This word indicates a potentially dangerous situation as a
safety message and security labels,
if not avoided, could cause serious injury or death. It can also
be used to alert against highly unsafe practice.
This word indicates a directly dangerous situation as a safety
message and security labels, if not avoided, could cause
death or extremely serious injury. It may also be used to alert
against equipment that may detonate or explode if handled or
treated carelessly.
WARNING
DANGER

1-4 Safety
SAFETY DECALS
Fig 1
The safety decals are attached to the machine. In this Chapter,
the locations and descriptions of these decals will be reviewed
in the following section. Please become familiarized with all
safety decals and their messages.
Make sure that all the decals are in correct locations and legible.
Clean or replace the safety deals if the decals are missing or
damaged, or the texts and pictorials are not legible. Use cloth,
water and soap to clean the labels. Do not use solvent, gasoline
or other harsh chemicals to clean the decals because they may
lead the adhesive that secures the labels to the machine, thus
causing the labels to come off.
Replace the damaged or lost labels. Remember, if a safety
decal is attached to a part that is replaced, install a new safety
deal on the replacement part.

Safety 1-5
3. Severe injury and death from crushing could occur
in articulation position when machine turns.
2. Never stand under the bucket.
1. Never stand under the moving arm.
Sudden or accidental movement of boom may cause injury
or death.
Securely brace boom before working or walking under
raised boom.
Make sure people are clear of machine before starting en-
gine or moving steering wheel.
Fig 2
Fig 3
Fig 4

1-6 Safety
4. Keep Away C/W
Standing here is strictly prohibited while the machine
is moving. Otherwise, it will cause serious injury or
death accidents.
Fig 5
6. Lifting Point
Identies lift point point location
7. Tie Down
Identies tie down point location
Fig 7
Fig 8
5. Hot Pressurized Fluid

HOT PRESSURIZED FLUID CAN CAUSE SERIOUS BURNS
• Do not loosen or open cap when hot.
• Before opening:
1) Turn engine off
2) Allow machine to cool.
3) Tip cap and open slowly to relieve pressure.
WARNING
Fig 6

Safety 1-7
9. Important Reminder about Hydraulic Oil
Fig 10
8. Rotating Parts - Fan

CONTACT WITH ROTATING
FAN CAN CAUSE DEATH OR SERIOUS INJURY
• Keep away from fan and rotating parts.
• Stop engine before servicing.
WARNING
Fig 9
Fig 11
10. Important Reminder about Air Tank.

1-8 Safety
UNAUTHORIZED
MODIFICATIONS
In case of the safety accidents arising from any modification
without authorization by Hyundai, the Owner shall bear the respon-
sibilities.
As a safety precaution, all OEM parts must be replaced with the
correct authorized or genuine parts. If the fasteners, bolts
or nuts are not regularly replaced with correct spare parts, it
may cause these parts to exceed the safety limit of operation.
GENERAL HAZARD INFORMA-
TION
Safety Regulation
Operation and maintenance of the loader should only be carried
out by authorized professionals with the requisite training.
Strictly follow all safety regulations, warnings and requirements
when performing operation and maintenance.
When feeling ill or tired for taking medication or not adapt to the
environment,you should not operate the machine. These prob-
lems will interfere with your sense of judgment in emergencies
and may cause accidents.
When working together with another operator or with a person
on work site trafc duty, it is necessary to ensure that all per-
sons know the nature of the work and understand all hands sig-
nals that are to be use.
Always observe strictly any other rules related to safety.
Safety Features
Ensure all the guards and covers are installed in proper posi-
tion. Repair immediately if damaged.
Be sure that you understand the methods of all safety features
such as seat belt, and perform the correct operation.
Never remove the safety features, and keep them in good oper-
ating condition.
Incorrect operation of the safety features may also cause seri-
ous bodily injury.

Safety 1-9
Matters needing attention in cabin
When entering the operator’s cabin, always remove all mud and
oil from the soles of your shoes. If you operate the accelerator
and brake pedals with mud or oil stuck to your shoes, your foot
may slip and this may cause a serious accident.
Clean grease and dirt from pedals and controls. This contrib-
utes to safe operation. Cleaning also provides an opportunity to
inspect equipment. Minor damage can be repaired or corrected
before major problems result.
Keep cabin oor and consoles free of tools and personal items.
Do not stick suction pads to the window glass. Suction pads act
as a lens and may cause re.
Do not leave lighters laying around the operator’s cabin. If the
temperature inside the operator’s cabin becomes high, there is
a danger that lighter may explode.
Do not use cellular telephones inside the operator’s cabin when
driving or operating the machine. There is a danger that this
may lead to an unexpected accident.
Do not use cellular telephones inside the operator’s cabin when
driving or operating the machine. There is a danger that this
may lead to an unexpected accident.
To ensure safety, do not use the radio or music headphones
when operating the machine. There is a danger that this may
lead to a serious accident.
When operating the machine, do not put your hands or head out
of the window.
When standing up from the operator’s seat, always place trans-
mission neutral lock lever in the “LOCK” position and set pilot
cutoff switch to “O” (OFF) position. If you accidentally touch the
work equipment levers when they are not locked, the machine
may suddenly move and cause serious injury or damage.
When leaving the machine, completely lower the work equip-
ment to the ground, set transmission neutral lock lever in the
“LOCK” position, set pilot cutoff switch to “O” (OFF) position,
“APPLY” parking brake, and shut down engine. Use the key to
lock all the equipment. Always remove key and take it with you.

1-10 Safety
Clothing and Personal Protective Items
Secure long hair, and avoid loose clothing and jewelry. These
items have the tendency to catch on controls or protrude into
parts and cause serious injury or death.
Do not wear oily clothes. They are highly ammable.
Full eye protection, a hard hat, safety shoes and gloves may be
required at the work site.
While working on the machine, never use inadequate tools.
They could break or slip, causing injury, or they may not ade-
quately perform intended functions.
Breathing masks & Ear Protection
Do not neglect the factors which do not have direct hazardous
impact on the health. The waste gas and noise pollutions are
invisible, but they can cause disability or permanent injury.
Mounting and Dismounting
Before getting on or off machine, if there is any oil, grease, or
mud on handrails or steps, wipe it off immediately. Always keep
these parts clean. Repair any damage and tighten any loose
bolts.
Never jump on or off machine. In particular, never get on or off
a moving machine. These actions can result in death or serious
injury.
When getting on or off machine, always face machine. Maintain
a three-point contact (both feet and one hand or one foot and
both hands) with handrails and steps to ensure that you support
yourself securely.
Never hold onto any control levers when getting on or off ma-
chine.
Securely latch door. If you grip handrail inside door when mov-
ing on platform outside of door, and door latch is not securely
engaged, door may move and cause you to fall resulting in
death or serious injury.
Use points marked by arrows in diagram when getting on or off
machine.
Do not carry tools or supplies when you mount or dismount the
machine.
Fig 13
Fig 12

Safety 1-11
Fire Hazards for Fuel, Oil and Hydraulic
Oil
If fuel, oil and anti-freeze uid are put close to the re source, it
is easy to cause re. In particular, the fuel may cause extreme
danger.
Pay strictly attention to the following conditions:
Make sure the premises are well ventilated when the fuel, oil,
anti-freeze-fluid and hydraulic oil are filled in. Switch off the
lamp, control lever and the starter switch after the machine
is shut off. Shut off the engine. The equipment should be far
away from the ame and heating element. The auxiliary heating
element or the equipment which may cause sparks must be
quenched, switched off and move away from the loader.
Static can produce electric sparks at the oil ller. When it is cold
or dry, or in other conditions which easily cause the static, it is
necessary to make the oil ller always contact with the oil-lling
pipe, so as to guarantee a good grounding.
The covers for fuel tank and other liquid tanks shall be
tightened. Strictly prohibit from starting the equipment before
tightening.
Fig 14
Fig 15
Fig 16
Precautions When Fluids at High
Temperature
When the operation has just been stopped, the temperature of
coolant, engine oil and hydraulic oil is very high, and there is still
pressure in Radiator and hydraulic tank. In this case, opening
the cover to drain the oil or the coolant, or replacing the ltration
element will cause burns. It is necessary to wait for the tem-
perature to go down and perform the operation according to the
specied procedures.
In order to prevent the splashing of HT coolant and oil, it is
necessary to shut off the engine, and wait for cooling of coolant
oil, then slowly loosen the cover to release the pressure.