HYUNDAI HX480L, HX520L Crawler Excavator Service Repair Manual

SECTION 1 GENERAL SECTION 1 GENERAL Group 1 Safety Hints -------------------------------------------------------------------------------------------------------- 1-1 Group 2 Specifications ----------------------------------------------------------------------------------------------------- 1-10

FOLLOW SAFE PROCEDURE FOLLOW SAFE PROCEDURE Unsafe work practices are dangerous. Understand service procedure before doing work; Do not attempt shortcuts. WEAR PROTECTIVE CLOTHING WEAR PROTECTIVE CLOTHING Wear close fitting clothing and safety equipment appropriate to the job. WARN OTHERS OF SERVICE WORK WARN OTHERS OF SERVICE WORK Unexpected machine movement can cause serious injury. Before performing any work on the excavator, attach a「Do Not Operate Do Not Operate」tag on the right side control lever. USE HANDHOLDS AND STEPS USE HANDHOLDS AND STEPS Falling is one of the major causes of personal injury. When you get on and off the machine, always maintain a three point contact with the steps and handrails and face the machine. Do not use any controls as handholds. Never jump on or off the machine. Never mount or dismount a moving machine. Be careful of slippery conditions on platforms, steps, and handrails when leaving the machine. SECTION 1 GENERAL SECTION 1 GENERAL GROUP 1 SAFETY GROUP 1 SAFETY 1-1 13031GE01 13031GE02 13031GE03

PREPARE FOR EMERGENCIES PREPARE FOR EMERGENCIES Be prepared if a fire starts. Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone. PROTECT AGAINST FLYING DEBRIS PROTECT AGAINST FLYING DEBRIS Guard against injury from flying pieces of metal or debris; Wear goggles or safety glasses. PROTECT AGAINST NOISE PROTECT AGAINST NOISE Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises. AVOID POWER LINES AVOID POWER LINES Serious injury or death can result from contact with electric lines. Never move any part of the machine or load closer to electric line than 3m(10ft) plus twice the line insulator length. 1-2 13031GE04 13031GE05 13031GE06 13031GE07

KEEP RIDERS OFF EXCAVATOR KEEP RIDERS OFF EXCAVATOR Only allow the operator on the excavator. Keep riders off. Riders on excavator are subject to injury such as being struck by foreign objects and being thrown off the excavator. Riders also obstruct the operator's view resulting in the excavator being operated in an unsafe manner. MOVE AND OPERATE MACHINE SAFELY MOVE AND OPERATE MACHINE SAFELY Bystanders can be run over. Know the location of bystanders before moving, swinging, or operating the machine. Always keep the travel alarm in working condition. It warns people when the excavator starts to move. Use a signal person when moving, swinging, or operating the machine in congested areas. Coordinate hand signals before starting the excavator. OPERATE ONLY FORM OPERATOR'S SEAT OPERATE ONLY FORM OPERATOR'S SEAT Avoid possible injury machine damage. Do not start engine by shorting across starter terminals. NEVER start engine while standing on ground. Start engine only from operator's seat. PARK MACHINE SAFELY PARK MACHINE SAFELY Before working on the machine: ·Park machine on a level surface. ·Lower bucket to the ground. ·Turn auto idle switch off. ·Run engine at 1/2 speed without load for 2 minutes. ·Turn key switch to OFF to stop engine. Remove key from switch. ·Move pilot control shutoff lever to locked position. ·Allow engine to cool. 1-3 13031GE08 13031GE09 13031GE26

SUPPORT MACHINE PROPERLY SUPPORT MACHINE PROPERLY Always lower the attachment or implement to the ground before you work on the machine. If you must work on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack. Follow recommended procedures in this manual. SERVICE COOLING SYSTEM SAFELY SERVICE COOLING SYSTEM SAFELY Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off engine. Only remove filler cap when cool enough to touch with bare hands. HANDLE FLUIDS SAFELY-AVOID FIRES HANDLE FLUIDS SAFELY-AVOID FIRES Handle fuel with care; It is highly flammable. Do not refuel the machine while smoking or when near open flame or sparks. Always stop engine before refueling machine. Fill fuel tank outdoors. Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers. Make sure machine is clean of trash, grease, and debris. Do not store oily rags; They can ignite and burn spontaneously. 1-4 13031GE10 13031GE11 13031GE12 13031GE13

BEWARE OF EXHAUST FUMES BEWARE OF EXHAUST FUMES Prevent asphyxiation. Engine exhaust fumes can cause sickness or death. If you must operate in a building, be positive there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area. REMOVE PAINT BEFORE WELDING OR REMOVE PAINT BEFORE WELDING OR HEATING HEATING Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. Do all work outside or in a well ventilated area. Dispose of paint and solvent properly. Remove paint before welding or heating: · If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. ·If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating. ILLUMINATE WORK AREA SAFELY ILLUMINATE WORK AREA SAFELY Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil. 1-5 13031GE14 13031GE15

SERVICE MACHINE SAFELY SERVICE MACHINE SAFELY Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result. Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts. STAY CLEAR OF MOVING PARTS STAY CLEAR OF MOVING PARTS Entanglements in moving parts can cause serious injury. To prevent accidents, use care when working around rotating parts. AVOID HIGH PRESSURE FLUIDS AVOID HIGH PRESSURE FLUIDS Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. 1-6 13031GE16 13031GE17 13031GE18 13031GE19

AVOID HEATING NEAR PRESSURIZED AVOID HEATING NEAR PRESSURIZED FLUID LINES FLUID LINES Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. Install fire resisting guards to protect hoses or other materials. PREVENT BATTERY EXPLOSIONS PREVENT BATTERY EXPLOSIONS Keep sparks, lighted matches, and flame away from the top of battery. Battery gas can explode. Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer. Do not charge a frozen battery; It may explode. Warm battery to 16˚C (60˚F ). 1-7 13031GE20 13031GE21

1-8 PREVENT ACID BURNS PREVENT ACID BURNS Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. Avoid the hazard by: 1. Filling batteries in a well-ventilated area. 2. Wearing eye protection and rubber gloves. 3. Avoiding breathing fumes when electrolyte is added. 4. Avoiding spilling of dripping electrolyte. 5. Use proper jump start procedure. If you spill acid on yourself: 1. Flush your skin with water. 2. Apply baking soda or lime to help neutralize the acid. 3. Flush your eyes with water for 10-15 minutes. Get medical attention immediately. If acid is swallowed: 1. Drink large amounts of water or milk. 2. Then drink milk of magnesia, beaten eggs, or vegetable oil. 3. Get medical attention immediately. 13031GE22 USE TOOLS PROPERLY USE TOOLS PROPERLY Use tools appropriate to the work. Makeshift tools, parts, and procedures can create safety hazards. Use power tools only to loosen threaded tools and fasteners. For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches. Use only recommended replacement parts. (See Parts catalogue.) 13031GE23

1-9 DISPOSE OF FLUIDS PROPERLY DISPOSE OF FLUIDS PROPERLY Improperly disposing of fluids can harm the environment and ecology. Before draining any fluids, find out the proper way to dispose of waste from your local environmental agency. Use proper containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them. DO NOT pour oil into the ground, down a drain, or into a stream, pond, or lake. Observe relevant environmental protection regulations when disposing of oil, fuel, coolant, brake fluid, filters, batteries, and other harmful waste. REPLACE SAFETY SIGNS REPLACE SAFETY SIGNS Replace missing or damaged safety signs. See the machine operator's manual for correct safety sign placement. LIVE WITH SAFETY LIVE WITH SAFETY Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields. 13031GE24 13031GE25

HYUNDAI HX480L, HX520L Crawler Excavator Service Repair Manual

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