Hyundai Hl930a User manual

CONTENTS

EC declaration of conformity

-----------------------------

0-1

Foreword

-----------------------------------------------------------

0-2

Emission-related components warranty

(USA and CANADA only)

--------------------------------

0-2-1

Before servicing this machine

---------------------------

0-3

Table to enter S/No and distribution

---------------------

0-4

EC regulation approved

------------------------------------

0-5

Safety labels

------------------------------------------------------

0-6

Machine data plate

--------------------------------------------

0-16

Guide (direction, S/No, symbol)

------------------------

0-17

1. SAFETY HINTS

1. California proposition 65

----------------------------

1-1

2. Safety rules

------------------------------------------------

1-2

2. SPECIFICATIONS

1. Major components

--------------------------------------

2-1

2. Specifications

----------------------------------------------

2-2

3. Weight

---------------------------------------------------------

2-6

4. Specification for major components

-----------

2-7

3. CONTROL DEVICES

1. Cab devices

------------------------------------------------

3-1

2. Cluster

--------------------------------------------------------

3-2

3. Monitors

------------------------------------------------------

3-13

4. Switches

-----------------------------------------------------

3-44

5. Control device

---------------------------------------------

3-49

6. Air conditioner and heater

--------------------------

3-53

7. Others

---------------------------------------------------------

3-56

4. OPERATION

1. Suggestion for new machine

----------------------

4-1

2. Check before starting the engine

---------------

4-2

3. Starting and stop the engine

----------------------

4-3

4. Warming-up operation

--------------------------------

4-8

5. Operation of the working device

-----------------

4-9

6. Traveling of the machine

-----------------------------

4-10

7. Efficient working method

----------------------------

4-15

8. Adjustment of the work equipment

-------------

4-22

9. Operation in the special work sites

-------------

4-23

10. Storage

--------------------------------------------------------

4-25

11. Exhaust system cleaning

-----------------------------

4-27

12. Attachment manually lowering

----------------------

4-28

5.

TRANSPORTATION

1. Road traveling

--------------------------------------------

5-1

2. Preparation for transportation

--------------------

5-2

3. Loading the machine

---------------------------------

5-3

4. Fixing the machine

-------------------------------------

5-4

5. Loading and unloading by crane

----------------

5-6

6.Towing the machine

-------------------------------------

5-7

6. MAINTENANCE

1. Instructions

-------------------------------------------------

6-1

2. Tightening torque

---------------------------------------

6-5

3. Spec of fuel, coolant and lubricants

-----------

6-8

4. Maintenance check list

-------------------------------

6-10

5. Maintenance chart

-------------------------------------

6-13

6. Service instruction

-------------------------------------

6-15

7. Electrical system

----------------------------------------

6-54

8. Air conditioner and heater

--------------------------

6-57

7. TROUBLESHOOTING GUIDE

1. Engine

--------------------------------------------------------

7-1

2. Electrical system

----------------------------------------

7-2

3. Power train system

---------------------------------------

7-3

4. Hydraulic system

----------------------------------------

7-4

8. OTHERS

1. Quick coupler

---------------------------------------------

8-1

INDEX

-------------------------------------------------------------

9-1

0-1

This declaration of conformity is issued under the sole responsibility of manufacturer:

HYUNDAI CONSTRUCTION EQUIPMENT CO., LTD.

12th Fl., Hyundai Bldg. 75, Yulgok-ro, Jongno-gu,

Seoul 03058, Korea

Hyundai Construction Equipment Europe N.V located at Hyundailaan 4, 3980 Tessenderlo, Belgium, as

authorized repre sentative in the European Community is authorized to compile the technical construction

file and declares that the product:

Type: *********

Model: ******

Serial number (PIN): *****************

is in conformity with the relevant provisions of the Community harmonization legislation:

2006/42/EC - Machinery directive

2014/30/EU - Electromagnetic compatibility directive

2000/14/EC - Noise emission outdoor equipment directive

2002/44/EU - Exposure of workers to vibration risks directive

their amendments, and other applicable directives.

EMC (2014/30/EU)

Certificate number: ***********

Date: DD/MM/YYYY

Notified body: ************

Noise levels (2000/14/EC)

Certificate number: *****************

Date: DD/MM/YYYY

Conformity assessment proc.: Annex VIII Full Quality Assurance

Notified body: *****************

*************

Measured sound power level: nnn.n dB(A)

Guaranteed sound power level: nnn.n dB(A)

Engine information

Manufacturer : *********

Engine model name: ********

Type-approval number: ***********

Stage (Regulation) : STAGE ** (**/**/**)

Gross Power (SAE J1995): ***kW / ****rpm

Net Power (SAE J1349): ***kW / ****rpm

Harmonized standards, other technical standards and specifications applied:

EN 474-1:2006+A*:**** (EMM - Safety - Part 1); EN 474-3:2006+A*:**** (EMM - Safety - Part 3); EN ISO

3471:2008 (EMM - ROPS: Lateral/Vertical/Longitudinal loads); EN ISO 3449:2008 (EMM - FOPS: Level II

cabin); ISO 2631-1:1997 & ISO 2631-1:1997/Amd1 :2010 (Whole-body vibration); EN ISO 5349-1:2001

&EN ISO 5349-2:2001 & EN ISO 5349-2:2001/A1:2015 (Hand-arm vibration)

**********

Managing Director

Place, date of issue: Tessenderlo Belgium, DD MM YYYY

EC Declaration of Conformity

(Original instruction)

0-2

This manual contains a number of instructions and safety recommendations regarding driving, han-

dling, lubrication, maintenance, inspection and adjustment of the machine.

The manual is to promote safety maintenance and enhance machine performance.

Keep this manual handy and have all personnel read it periodically.

If you sell the machine, be sure to give this manual to the new owners.

This machine complies with EC directive "2006/42/EC".

1.

Read

Read and

understand

understand this manual before operating the machine.

This operator's manual may contain attachments and optional equipment that are not available in

your area. Please consult your local Hyundai distributor for those items you require.

Improper operation and maintenance of this machine can be hazardous and could result in serious

injury or death.

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 uses of the machine.

If you use your machine for any unintended uses that are not specifically prohibited, you must be

sure that it is safe for you and others. In no event should you or others engage in prohibited uses of

actions as described in this manual.

Some illustrations in this manual show details or attachments that can be different from your

machine. Covers and guards might have been removed for illustrative purposes.

2.

Inspect

Inspect the jobsite and

follow

follow the safety recommendations in the

safety hints

safety hints section before oper-

ating the machine.

3. Use

genuine Hyundai spare parts

genuine Hyundai spare parts for the replacement of parts.

We expressly point out that Hyundai will not accept any responsibility for defects resulting from non-

genuine parts or non workmanlike repair.

In such cases Hyundai cannot assume liability for any damage.

Continuing improvements in the design of this machine can lead to changes in detail which may not

be reflected in this manual. Consult Hyundai or your Hyundai distributor for the latest available infor-

mation for your machine or for questions regarding information in this manual.

FOREWORD

Hyundai shall have obligation under the EPA (Environmental Protection Agency) regulation of warranty

about Emission-related components. This warranty shall exist for 3,000 hours or five years, whichever

occurs first.

Naturally, this warranty does not cover to damage arising from accident, misuse or negligence, use of

non-Hyundai parts, or from alterations not authorized by Hyundai.

※Emission-related components according to the EPA regulation.

Emission-related components according to the EPA regulation.

1. Air-induction system.

2. Fuel system.

3. Ignition system.

4. Exhaust gas recirculation systems.

5. After treatment devices.

6. Crankcase ventilation valves.

7. Sensors.

8. Electronic control units.

EMISSION-RELATED COMPONENTS WARRANTY

EMISSION-RELATED COMPONENTS WARRANTY (USA AND CANADA ONLY)

0-2-1

0-3

It is the responsibility of the owner and all service and maintenance personnel to avoid accidents and

serious injury by keeping this machine properly maintained.

It also is the responsibility of the owner and all service and maintenance personnel to avoid accidents

and serious injury while servicing the machine.

No one should service or attempt to repair this machine without proper training and supervision.

All service and maintenance personnel should be thoroughly familiar with the procedures and precau-

tions contained in this manual.

All personnel also must be aware of any federal, state, provincial or local laws or regulations covering

the use and service of construction equipment.

The procedures in this manual do not supersede any requirements imposed by federal, state, provin-

cial or local laws.

Hyundai can not anticipate every possible circumstance or environment in which this machine may be

used and serviced.

All personnel must remain alert to potential hazards.

Work within your level of training and skill.

Ask your supervisor if you are uncertain about a particular task. Do not try to do too much too fast.

Use your common sense.

BEFORE SERVICING THIS MACHINE

How to adjust the language of monitor

User can select preferable language and all displays are changed the selected language.

Press

※

Please refer to the page 3-34 for the monitor.

※

Press Press Press

0-4

TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR

Machine Serial No.

Engine Serial No.

Manufacturing year

Manufacturer

Address

Distributor for U.S.A

Address

Distributor for Europe

Address

Dealer

Address

Hyundai Construction Equipment co., Ltd.

12th, Fl., Hyundai Bldg. 75, Yulgok-ro, Jongno-Gu,

Seoul, 03058, Korea

Hyundai Construction Equipment U.S.A, Inc

6100 Atlantic Boulevard Norcross

GA 30071

U.S.A

Hyundai Construction Equipment Europe N. V.

Hyundailaan 4

3980 Tessenderlo

Belgium

0-5

·

Noise level (EN474-1 : 2006 and 2000/14/EC) are as followings.

LWA : 102

dB

(EU only)

LPA : 70

dB

·

The value of vibrations transmitted by the operator's seat are lower than standard value of (EN474-1

: 2006 and 2002/44/EC)

EC REGULATION APPROVED

0-6

1 Start motor

2 Turbocharger cover

3 Hyd oil level

4 Ride control (option)

5 Grease (A)

6 Grease (B)

7 Bucket stopper

10 ROPS cab

11 Steering warning-LH

12 Steering warning-RH

13 Engine start caution

14 Control ideogram

15 Air conditioner filter

16 Electric welding

18 Lift & tie

19 Air cleaner element

20 Manual lowering valve

21 Fueling

22 Battery accident

23 Hyd oil lub

24 High pressure hose

25 Bio oil

27 Engine door shearing

30 Service instruction

32 Start procedure

33 Diesel exhaust fluid

34 Specification sheet

35 Grease (center)

36 Keep clear/Reflect

37 Name plate

38 ROPS plate

39 Accumulator

41 Caution (water separator,

turbocharger)

42 Surge tank

43 Fuel shut off

44 Ultra low sulfur diesel

45 Emergency fire holes

46 No step

47 Refrigerant

48 Use handrail

49 Quick coupler

50 Engine name plate

51 Stay fix

1. LOCATION

Always keep these labels clean. If they are lost or damage, attach them again or replace them with a

new label.

CAB INSIDE-LH CAB INSIDE-RH

32

1

ACCUMULATOR

4

16

22

18

19

7

5

23

3

43

18

39

35

50

38

14

2

6

46

45

VIEW A - A

91LM-02120

18

49 30

11,12(RH) 24

20

37

27

10

36 36

13 34 41

42

2

HYDRAULIC TANK

18

FRONT FRAME

45

A

B

VIEW B - B

15(RH)

21

25(RH)

33(RH)

48

47

C

VIEW C - C

51

SAFETY LABELS

930A0FW03

0-7

2. DESCRIPTION

START MOTOR

START MOTOR (item 1)

This warning label is positioned on the left

side of the engine hood.

Start the engine only from the operator’s

compartment. Never short across the

starter terminals or across the batteries.

Shorting could bypass the engine neutral

start system. Shorting could also dam-

age the electrical system.

1)

77070FW05

HYDRAULIC OIL LEVEL

HYDRAULIC OIL LEVEL (item 3)

This warning label is positioned on the left

side of hydraulic oil tank.

Place the bucket on the ground whenever

servicing the hydraulic system.

Check oil level on the level gauge.

Refill the recommended hydraulic oil up

to specified level if necessary.

3)

※

21070FW02

STOP

7609A0FW06

RIDE CONTROL

RIDE CONTROL (item 4)

This warning label is positioned on the front

frame.

Before checking the boom operation sys-

tem,

1. Bucket should be laid on the ground.

2. Turn start switch to "ON" position and

press the button on monitor to operate

ride control function.

3. Depressurize boom head by joystick.

(boom down or floating)

Before checking the boom operation system,

the button on monitor to operate

CAUTION

1.Bucket should be laid on the ground.

3.Depressurize boom head by joystick

(Boom down or Floating)

2.Turn starter switch to “ON” position and press

ride control function.

970A0FW90

4)

There are several specific warning labels on this machine please become familiarized with all warn-

ing labels. Replace any safety label that is damaged, or missing. If a safety label is attached to a part

that is replaced, install a safety label on the replacement part.

TURBOCHARGER COVER

TURBOCHARGER COVER (item 2)

This warning label is positioned on the tur-

bocharger cover.

Do not touch turbocharger or it may

cause severe burn. When the engine is

running or immediately after engine shut

down.

2)

0-8

STEERING WARNING

STEERING WARNING (item 11, 12)

The warning label is positioned on the both

side of the front frame.

No clearance for person in this area

when machine turns.

Severe injury or death from crushing

could occur.

6)

77070FW07

ENGINE START CAUTION

ENGINE START CAUTION (item 13)

This warning label is positioned on the right

side window of the cab.

Study the operator's manual before start-

ing and operating machine.

7)

CONTROL IDEOGRAM

CONTROL IDEOGRAM (item 14)

This warning label is positioned on the right

side window of the cab.

Confirm the operation of control lever

and working device before operating the

machine.

Refer to the page 4-9 for details.

※

74090FW04

77070FW08

BUCKET STOPPER

BUCKET STOPPER (item 7)

This warning label is positioned on the mid-

dle of the boom.

When working under or around the buck-

et or linkage, with bucket raised, proper

support must be provided for the bucket

and/or the linkage.

5)

7803AFW05

8)

0-9

AIR CONDITIONER FILTER

AIR CONDITIONER FILTER (item 15)

This warning label is positioned on the air-

conditioner filter.

Periodic and proper inspection, cleaning

and change of filter prolong air condition-

er life time and maintain good perfor-

mance.

9)

※

760F0FW10

ELECTRIC WELDING

ELECTRIC WELDING (item 16)

This warning label is positioned on the

side of the battery box.

Before carrying out any electric welding

on this machine

- Pull the connectors out of all electronic

control units.

- Connect the ground lead of the welding

equipment as close to the welding point

as possible.

Refer to the page 6-56 for details.

10)

※

7803AFW20

·Before carrying out any electric welding on this

machine

- Pull the connectors out of all electronic control

units.

- Connect the ground lead of the welding equipment

as close to the welding point as possible.

·Read the instructions in operator's manual for

details.

W A R N I N G

LIFT & TIE

LIFT & TIE (item 18)

This label is positioned on the both side of

the front and rear frame.

- Lifting point

In order to lift the machine, attach the

lifting devices to the lifting points.

- Tying point

In order to tie down the machine, attach

the tie-downs to the tying points.

Lifting

Tying

11)

75790FW04

0-10

FUELING

FUELING (item 21)

This warning label is positioned on the left

side of fuel filler neck.

Stop the engine when refueling. All

lights or flames shall be kept at a safe

distance while refueling.

14)

21070FW04

HYDRAULIC OIL LUB

HYDRAULIC OIL LUB (item 23)

This warning label is positioned on the top

of the hydraulic oil tank.

Do not mix with different brand oils.

Never open the filler cap while engine

running or at high coolant temperature.

Loosen the cap slowly and release inter-

nal pressure completely.

15)

※

14070FW08

MANUAL LOWERING VALVE

MANUAL LOWERING VALVE (item 20)

The warning label is positioned on the left

side of the front frame.

Be sure no one is under or near the

attachment before lowering the boom.

Refer to the page 4-28.

13)

※

760F0FW12

AIR CLEANER

AIR CLEANER ELEMENT (item 19)

The warning label is positioned on the air

cleaner.

Periodic and proper inspection, cleaning

and change of elements prolong engine

life time and maintain the good perfor-

mance of engine.

12)

21070FW01

0-11

BATTERY ACCIDENT

BATTERY ACCIDENT (item 22)

This warning label is positioned on the bat-

tery box.

Electrolyte containing sulfuric acid cause

severe burns. Avoid being in contact with

skin, eyes or clothes. In the event of acci-

dent flush with sufficient water, call a

physician immediately.

Maintain the electrolyte at the recomm-

ended level. Add distilled water to the

battery only when starting up, never

when shutting down.

With electrolyte at proper level, less

space may cause the gases to be accu-

mulated in the battery.

Extinguish all smoking materials and

open flames before checking the battery.

Do not use matches, lighters or torches

as a light source near the battery for the

probable presence of explosive gas.

Do not allow unauthorized personnel to

change the battery or to use booster

cables.

For safety from electric shock, do not

battery terminal with a wet hand.

16)

※

7579A0FW30

14070FW29

HIGH PRESSURE HOSE

HIGH PRESSURE HOSE (item 24)

This warning label is positioned on the left

side of the front frame.

Escaping fluid under pressure can pene-

trate the skin causing serious injury.

Avoid the hazard by relieving pressure

before disconnecting hydraulic lines or

other lines.

See the maintenance section for details.

17)

※

0-12

ENGINE DOOR SHEARING

ENGINE DOOR SHEARING (item 27)

This warning label is positioned on the left

side of the engine side door.

Don't open the engine door during the

engine's running. Stay clear of rotating

parts.

Don't touch exhaust pipe or it may cause

severe burn.

19)

21070FW15

BIO OIL

BIO OIL (item 25)

This warning label is positioned on the right

side of the engine hood.

Do not mix with other bio-oil.

18)

960A0FW11

DIESEL EXHAUST FLUID

DIESEL EXHAUST FLUID (item 33)

This warning label is positioned on the right

side of the rear frame.

Fill only the DEF/AdBlue

Fill only the DEF/AdBlue®

(Diesel

Exhaust Fluid, standardised as ISO

22241).

Aqueous urea solution made with 32.5%

high-purity urea and 67.5% deionized

water.

Do not fill the diesel fuel.

21)

※

760F0FW13

START PROCEDURE

START PROCEDURE (item 32)

This warning label is positioned on the right

side window of the cab.

Start Procedure

1. Start ignition on.

2. Wait up to 4 seconds for grid heater operation in summer.

(45 seconds in winter)

3. Start cranking.

4. If engine still does not start, turn the Keyswitch to OFF position.

5. Loosen fuel supply line at the outlet of pre-filter.

6. Do hand-priming repeatedly until air bubbles comes out from

fuel supply line completely.

7. Tighten fuel supply line to its origin position.

8. Recranking.

9. If the engine still would not start,

please contact the nearest HYUNDAI or Cummins dealers.

20)

7609A0FW07

0-13

ACCUMULATOR

ACCUMULATOR (item 39)

This warning label is positioned on the

accumulator of the solenoid valve.

The accumulator is filled with high-pres-

sure nitrogen gas, and it is extremely

dangerous if it is handled in the wrong

way. Always observe the following pre-

cautions.

Never make any hole in the accumulator

expose it to flame or fire.

Do not weld anything to the accumulator.

When carrying out disassembly or main-

tenance of the accumulator, or when dis-

posing of the accumulator, it is neces-

sary to release the gas from the accu-

mulator. A special air bleed valve is nec-

essary for this operation, so please con-

tact your Hyundai distributor.

22)

※

1107A0FW46

This warning label is positioned on the right

side window of the cab.

In order to protect high pressure fuel sys-

tem, please drain water in water separa-

tor before starting the engine.

In order to prevent turbocharger failure,

please allow more than 5 minutes' cool

down period (no load low idle operation)

before shutting the engine off.

- In order to protect high pressure fuel system, please drain

water in water separator before starting the engine.

- In order to prevent turbocharger failure, please allow more

then 5 minutes cool down period(no load low idle operation)

before shutting the engine off.

120090SL02

CAUTION (WATER SEPARATOR, TURBOCHARGER)

CAUTION (WATER SEPARATOR, TURBOCHARGER) (item 41)

23)

FUEL SHUT OFF

FUEL SHUT OFF (item 43)

This warning label is positioned on the

hydraulic tank.

Fill only the hydraulic oil.

Do not fill the diesel fuel.

Relieve tank pressure with the engine off

by removing the cap slowly to prevent

burns from hot oil.

24)

※

140WH90FW51

0-14

ULTRA LOW SULFUR DIESEL

(item 44)

This warning label is positioned on the left

side of fuel filler neck.

Use ultra low sulfur fuel only.

Ultra low sulfur fuel

sulfur content

≤15

15

ppm

If ultra low sulfur diesel is not used, the

aftertreatment diesel particulate filter can

be damaged.

25)

※

2609A0SL03

EMERGENCY FIRE HOLES

EMERGENCY FIRE HOLES (item 45)

This warning label is positioned inside of

the engine hood inlet cover.

It is possible to fight the fire manually

through two holes on the screen.

Holes for manual firefighting can be

accessed by opening the inlet covers on

the right and left side.

Firefighting can take place using the

holes on the screen, which provide

access to the engine compartment with,

e.g., handheld fire extinguisher.

The extinguishing agent contains glycol

which may cause injuries in case of con-

tact. Avoid contact. In case of contact

with the eyes, rinse with water. In case of

skin contact, wash with soap and rinse

with water. Always contact a doctor after

contact with the extinguishing agent.

26)

※

955TM0FW20

Inlet cover

Label is positioned for holes

inside of the inlet covers

930A4OP55

0-15

757TM9A0FW30

QUICK COUPLER

QUICK COUPLER (item 49)

This warning label is positioned on the mid-

dle of the boom.

Serious injury or death can result from

dropping bucket.

Operating the machine with attachment

switch unlocked or without safety pin of

moving hook can cause the bucket to

drop off.

29)

※

STAY FIX

STAY FIX (item 51)

This warning label is positioned on the side

cover of the LH and RH cowl.

Be sure to support the stay when the

door needs to be opened.

Be careful that the opened door may be

closed by the external or natural force

like strong wind.

30)

NO STEP

NO STEP (item 46)

This warning label is positioned on the

engine hood.

Don't step on the engine hood.

27)

9800FW08

REFRIGERANT

REFRIGERANT (item 47)

This warning label is positioned on the right

side of engine hood.

Inhaling air conditioner refrigerant gas

through a lit cigarette or other smoking

method or inhaling fumes released from

a flame contacting air conditioner refrig-

erant gas, can cause bodily harm or

death.

Refer to the page 6-58.

28)

※

HFC-134a GWP : 1430

Total mass : 0.75kg Total eq(CO2) : 1.07t

91K9-07242

0-16

MACHINE DATA PLATE

1

2

ROPS

FOR EU ONLY

3

4

1

2

3

45

1

2

6

76090FW06A

The product identification number assigned to this particular machine and should be used when

requesting information or ordering service parts for this machine from your authorized HYUNDAI

dealer. The product identification number is also stamped on the frame.

※

1 Machine type / model

4 Operating mass

2 Product identification number

5 Manufacturing year

3 Engine power

6 Maximum certified weight

0-17

GUIDE

1.

DIRECTION

The direction of this manual indicate forward,

backward, right and left, when machine is on

the traveling direction.

Backward

Forward

RightLeft

2.

SERIAL NUMBER

Inform following when you order parts or the

machine is out of order.

MACHINE SERIAL NUMBER

The numbers are located on the left side of

the front frame.

Machine serial No.

1)

ENGINE SERIAL NUMBER

The numbers are located on the engine

name plate.

It is also located on the left side frame of the

cab inside.

Engine serial No.

Cab inside(LH)

2)

940A0FW05

930A0FW06

930A0FW20

4. SYMBOLS

Important safety hint.

It indicates matters which can cause the great loss on the machine or the surroundings.

It indicates the useful information for operator.

※

3.

INTENDED USE

This machine is designed to be used mainly for the following work.

- Excavating work - Leveling work

- Loading work - Transporting work

Please refer to the section 4 (efficient working method) further details.

※

1-1

CALIFORNIA PROPOSITION 65

Breathing diesel engine exhaust exposes you to chemicals known

to the State of California to cause cancer and birth defects or

other reproductive harm.

Always start and operate the engine in a well-ventilated area.

.

If in an enclosed area, vent the exhaust to the outside.

Do not modify or tamper with the exhaust system.

Do not idle the engine except as necessary.

.

For more information go to www.P65warnings.ca.gov/diesel.

1. CALIFORANIA PROPOSTION 65

1. SAFETY HINTS

Hyundai HL930A User manual

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