PDF Operator's Manual Hyundai HL757TM-7 Wheel Loader - 1 MB
This is the official operator's manual for the Hyundai Ceres HL757TM-7 Wheel Loader.
It provides essential guidance on proper machine operation, safety protocols, and routine maintenance checks.
Understanding the information in this manual is key to maximizing productivity and ensuring the long-term reliability of your equipment.
It is a must-read for all operators.
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--- Page 1 ---
CONTENTS
Foreword - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 0-1 5. TRANSPORATION
Before servicing this machine - - - - - - - - - - - - - - - - - - - - - - - - - - - 0-2 1. Road traveling - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1
Table to enter S/No and distribution - - - - - - - - - - - - - - - - - - - - - - 0-3 2. Preparation for transportation - - - - - - - - - - - - - - - - - - - - 5-2
EC regulation approved - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 0-4 3. Loading the machine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-3
Safety labels - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 0-5 4. Fixing the machine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-4
Guide(Direction, S/No, Symbol) - - - - - - - - - - - - - - - - - - - - - - - - 0-12 5. Loading and unloading by crane - - - - - - - - - - - - - - - - 5-6
6. Towing the machine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-7
1. SAFETY HINTS
1. Before operating the machine - - - - - - - - - - - - - - - - - - - - 1-1 6. MAINTENANCE
2. During operating the machine - - - - - - - - - - - - - - - - - - - - 1-5 1. Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1
3. During maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-14 2. Tightening torque - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-5
4. Parking - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-18 3. Specification of fuel, coolant
and lubricants - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-8
2. SPECIFICATIONS 4. Maintenance check list - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-10
1. Major components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1 5. Maintenance chart - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-13
2. Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2 6. Service instruction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-15
3. Weight - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-4 7. Electrical system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-44
4. Specification for major components - - - - - - - - - - - 2-5 8. Air conditioner and heater - - - - - - - - - - - - - - - - - - - - - - - - - - 6-47
3. CONTROL DEVICES 7. TROUBLESHOOTING GUIDE
1. Cab devices - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1 1. Engine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1
2. Cluster - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-2 2. Electrical system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-2
3. Switches - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-13 3. Power train system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
4. Control device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-19 4. Hydraulic system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-4
5. Air conditioner and heater - - - - - - - - - - - - - - - - - - - - - - - - - - 3-21
6. Others - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-24 8. INDEX 8-1
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 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-6
5. Operation of the working device - - - - - - - - - - - - - - - - - 4-7
6. Traveling of the machine - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-8
7. Efficient working method - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-13
8. Adjustment of the work equipment - - - - - - - - - - - - - 4-20
9. Operation in the special work sites - - - - - - - - - - - - - 4-22
10. Storage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-24
--- Page 3 ---
15) BATTERY(Item 25)
This warning label is positioned on the
battery box.
Electrolyte containing sulfuric acid cause
severe burns. Avoid being in contact
with skin, eyes or clothes. In the event of
accident flush with sufficient water, call a
physician immediately. 21070FW05
※ Maintain the electrolyte at the
recommended 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
accmulated in the battery.
16) HYDRAULIC OIL LUB(Item 26)
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
internal pressure completely. 21070FW04
17) STAY FIX(Item 29)
The warning label is positioned on the
engine side door.
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.
21070FW14
--- Page 4 ---
Avoid parking and stopping on a slope.
Lower the bucket to the ground and block the
tire when parking.
73031SH24
Avoid traveling in a cross direction on a slope as
it can cause the danger of rolling over and
sliding.
73031SH25
Traveling on the slope is dangerous.
Be sure to operate slowly when driving down a
slope and maintain the bucket at a height of
20~30cm(1ft) above the ground so that it can be
used as brake in an emergency.
20~30
cm
73031SH26
Steering of the machine while traveling on a
slope is dangerous.
When an inevitable turning of direction is
required, turn on the flat and solid ground.
73031SH27
--- Page 5 ---
4. PARKING
When leaving the machine lower the bucket to
the ground completely and put the safety lever
at parking position then remove the key.
Lock the cab door.
73031SH58
Park the machine in the flat and safe place.
P
73031SH59
Hope you can work easily and safely observing
safety rules.
For safe operation, observe all safety rules.
73031SH60
--- Page 6 ---
2) FUEL GAUGE
(1) This gauge indicates the amount of fuel in the fuel tank.
(2) Fill the fuel when the indicator moves E point, refuel as soon as
possible to avoid running out of fuel.
※ If the gauge indicates below E point even though the
machine is on the normal condition, check the electric device
77073CD04 as that can be caused by the poor connection of electricity or
sensor.
3) ENGINE COOLANT TEMPERATURE GAUGE
(1) This indicates the temperature of coolant.
Red
·Red range : Above 104。C (219。F )
(2) Keep idling engine at low speed until the indicator is in the
operating range.
Operating
(3) If the indicator is in the red range, turn OFF the engine, check the
range 77073CD05 radiator and engine.
4) TRANSMISSION OIL TEMPERATURE GAUGE
(1) This range indicates the temperature of transmission oil.
Red
·Red range : Above 107。C (225。F )
(2) Keep idling engine at low speed until the indicator is in the
operating range.
Operating
(3) If the indicator is in the red range, it means the transmission is
range 77073CD06 overheated. Be careful that the indicator does not move into the
red range.
5) BATTERY VOLT METER
(1) This gauge indicates the voltage in the charging system when
the engine is running.
(2) If the indicator is below 24V(Yellow range), it means that the
electricity is being discharged. If the indicator is above 30V(Red
range), an unusually high voltage may damage the alternator.
Check the charging system in both cases.
77073CD07
--- Page 7 ---
3. SWITCHES
Beacon switch(option)
Buzzer stop switch
Starting switch Parking brake switch
Rear wiper/washer switch Main light switch
Front
Ride control switch(option) Work lamp switch
LH SIDE
Auto select switch
Clutch cut off switch
Kick down switch
A
Horn button
Multi function switch
Hazard switch
Kick down switch
Attachment
unlock switch
Attachment
lock switch
757TM7CD29
1) STARTING SWITCH
(1) There are three positions, OFF, ON and START.
· (OFF) : None of electrical circuits activate.
· (ON) : All the systems of machine operate.
· (START) : Use when starting the engine.
Release key immediately after starting.
※ Key must be in the ON position with engine running maintain
77073CD41
electrical and hydraulic function and prevent serious machine
damage.
--- Page 8 ---
5) OUTLET CHANGE OVER SWITCH
(1) There are four steps of air flow.
77073CD35
(2) When defroster switch operating, INLET switch turns to FRESH
mode and air conditioner switch turns ON.
(3) In case of heating range(5~Max warm), air conditioner won't turns
ON.
6) INLET CHANGE OVER SWITCH
(1) It is possible to change the air-inlet method.
① Fresh
Fresh
Inhaling air from the outside to pressurize cab inside.
※ Check out the fresh air filter periodically to keep a good
Recirculation
efficiency.
② Recirculation
21073CD49
It recycles the heated or cooled air to increase the energy
efficiency.
※ Change air occasionally when using recirculation for a long
time.
※ Check out the recirculation filter periodically to keep a good
efficiency.
(2) Recirculation function operates when the system is OFF but it can
be changed whenever needed.
--- Page 9 ---
■CD PLAYER
(1) Winding / Rewinding button
① CD playback
BAND
AST
This CD player is suitable only for 12cm disc, do not use irregular
shaped CD.
SOURCE
RDS
· Slide the disc into the slot with label facing upwards. Playback
7807A3CD13
starts.
· If a disc is already inserted :
Press SOURCE to select CD as the source.
Playback starts.
② Previous / Next track( or )
· Short press the or button to select the desired track.
· Playback resume with the chosen track.
③ Fast rewind / Fast forward( or )
· Long press the or button for more than 2 seconds to quickly
move rewind or forward through the disc.
· Normal play back resumes when you release the button.
④ Random track playback
RND 1 · Press RND to activate / deactivate random track playback.
⑤ Repeat track
RPT 2 · Press RPT to activate / deactivate repeat current track.
⑥ Scan track
SCN 3 The scan function enables you to listen to the first few seconds of
each track.
· Press SCN to activate / deactivate scan track.
⑦ Disc eject
· Press to eject the disc.
3-33
--- Page 11 ---
5. OPERATION OF THE WORKING DEVICE
※ Confirm the operation of control lever and
working device.
1) Control lever operates the boom and the bucket. 5
1 4
2) When you release the control lever, control lever
returns to neutral position automatically. 3 2
3) When the control lever operates to the position of
boom float, boom kick out and bucket leveler ;
these function is completed, then the control lever
returns to the neutral position.
※ Control lever
Boom lower(1)
Push the control lever forward in 5
order to lower the boom.
Boom raise(2)
Pull the control lever backward in 1
3
order to raise the boom. 4
2
Bucket roll back(3)
Move the control lever toward the
left in order to tilt the bucket
backward.
Bucket dump(4)
Move the control lever toward the
3 2
right in order to dump a load from
the bucket.
4
1
Boom float(5)
Push the control lever forward into
the detent.
The boom will lower to the ground. 757TM7OP09
The boom will float along the
contour of the ground.
--- Page 12 ---
6) LOADING
Maximum efficiency can be attained by carrying
out work in such a way that the swinging angle
and the traveling distance are kept as small and
short as possible in accordance with the terrain.
(1) I method
① After digging out the soil, move backward and
position the dump truck between the heap of
soil and the machine to load the soil into the
truck.
② This is the fastest and most efficient way to load
material.
※ The ground of the jobsite should be always
level and do not swing or step on a brake
pedal abruptly with the boom raised.
73034OP12
(2) V method
① Park the truck at an angle of 60 degrees toward
the machine. After digging out, drive backward
and position the machine at a right angle with
the truck and load the truck with the soil.
② Position the machine so that the soil can be
dumped in the center of the truck.
If the length of the truck is more than double the
width of the bucket, perform the dumping work
from forward to backward.
③ Move the control lever to the right and dump the
bucket.
④ Shake the bucket to throw off the soil stuck
inside. Move the bucket control lever to the left
and right and attach the bucket to the stopper. 73034OP13
⑤ Shake the bucket before setting it to the DUMP
position so that loaded materials are evenly
distributed inside the bucket. This will prevent
materials from slipping back when the bucket is
placed in the DUMP position.
757TM7OP15
--- Page 13 ---
2. PREPARATION FOR TRANSPORTATION
1) When transporting the machine, observe the
various road rules, road transportation vehicle
laws and vehicle limit ordinances, etc.
Overall
2) Make sure the cooling system has proper width
antifreeze if moving machine to a cold climate.
3) Select proper trailer after confirming the weight
and dimension from the page 2-2, 2-3.
4) Check the whole route such as the road width, the
Overall
height of bridge and limit of weight and etc., which height
will be passed.
5) Get the permission from the related authority if Overall length
necessary.
757TM7TA01
6) Prepare gangplank for safe loading referring to the
below table and illustration.
A B
Loading plate
1.0 3.65 ~ 3.85 of trailer B
Gan
1.1 4.00 ~ 4.25 gplan
A k
1.2 4.35 ~ 4.60
1.3 4.75 ~ 5.00 Block 15 ~ 16。
1.4 5.10 ~ 5.40
1.5 5.50 ~ 5.75 73035TA01
--- Page 14 ---
3) RELIEVING THE PRESSURE IN THE HYDRAULIC SYSTEM
※ Spouting of oil can cause the accident when
loosening the cap or hose right after the
operating of the 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 the machine in parking position, and stop
the engine.
757TM7OP07
(2) Loosen the cap and relieve the pressure in the
tank by pushing the top of the air breather. Cap
Pushing
Air breather
757TM7MI17
--- Page 15 ---
5. MAINTENANCE CHART
10 10,11 24 4 2 3
20 1,18 10,11 23 22 15
8 9 19 21 27 14 1 5 28
12 16 7 10 26 6 25 17 12 7 13
757TM7MI23
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.
6-13
--- Page 16 ---
(3) Check that the bottom tensioner arm stop is in
contact with the bottom tensioner arm stop boss
on the tensioner body. If these two are not
touching, the tensioner must be replaced.
36076MI15C
(4) Inspect the tensioner for evidence of the pivoting
tensioner arm contacting the stationary circular
base. If there is evidence of thess two areas
touching, the pivot tube bushing has failed and
the tensioner must be replaced.
36076MI15D
(5) A worn tensioner that has play in it or a belt that
“walks” off its pulley possibly indicates pulley
misalignment.
※ Maximum pulley mislignment is three
degrees. This measurement can be taken
with a straightedge and an inclinometer.
(6) Install the belt.
36076MI15E
6-23
--- Page 17 ---
Do not use recycled wheel parts.
When removing lockering or inflating tire, use
safety cable or chain to ensure safety.
Be sure to bleed air before removing
lockering. Never inflate tires unless the
lockering is assembled in its place.
※ Avoid the followings when traveling.
① Rubbing tires against road bank or rack at
cargo-unloading spot.
② Tires slippage during working.
③ Abrupt starting of machine.
④ When oil, grease or gasoline smeared on tire,
clean those. Otherwise it may cause of
permanent deformation.
25) REPLACEMENT OF TIRE
Disassembly, reassembly, replacement and
repair of tire requires special skills and
equipment. Contact a tire repair shop.
(1) Tires to be replaced
① Tires with broken or bent bead wires Tread
Break
② Tires exposed more than 1/4 of carcass fly.
③ Tires whose carcass is damaged more than 1/3
of the tire width. Side wall
Carcass
④ Tires which show fly separation.
⑤ Tires which has a radial crack near the
carcass. Bead
Valve
⑥ Tires which are judged to be unsuitable for use
73036MI11
because of deformation or damage.
(2) Separation of tire
① After moving the machine to flat ground, lower
the bucket to the ground and turn the parking
brake switch ON.
77076MI28
6-33
--- Page 18 ---
32) REPLACEMENT OF BOLT ON CUTTING
EDGE
(1) Replacement time
Replace the cutting edge before it has worn out
to the end of bucket.
(2) Replacement method
Make sure the work equipment does not
move when replacing the cutting edge.
Set the work equipment in a stable position,
put the hydraulic safety lock lever in the
LOCK position and stop the engine.
① Lift the bucket to a proper height and insert
blocks so that the bucket does not fall down.
② Loosen bolts and nuts, and remove the cutting
757TM7MI38
edge.
③ Clean the contacted surface.
④ Turn the cutting edge and install on the bucket.
※ If both sides have worn out, replace it with
new ones.
※ If the contacted face of cutting edge has
worn out, repair the contacted face of it.
⑤ Tighten evenly bolts and nuts to remove the
clearance between bucket and cutting edge.
·Tightening torque : 62.8±9.4kgf·m
(454±68lbf·ft)
⑥ After a few hours of operation, retighten bolts. 757TM7MI37
6-41