VEHICLE MAINTENANCE REQUIREMENTSD6CA D6CB D6CC D6DA D6AB, D6AC, D6AV D6CA, D6CB D6CC SEVERE DRIVING CONDITIONS A - Repeated short distance driving B - Extensive idling C - Driving

VEHICLE MAINTENANCE REQUIREMENTS

6-1

Scheduled maintenance .......................................... 6-2Maintenance under severe usage conditions ......... 6-6Lubrication ................................................................ 6-7Rubbers & switches .................................................. 6-10Explanation of scheduled maintenance items ......... 6-11Paper element type air cleaner maintenance .......... 6-13Oil filter ...................................................................... 6-14Centrifugal type by pass filter inspection (if equipped) ............................................................ 6-16Oil cleaner filter (if equipped) ................................... 6-17CCV(closed crankcase ventilation) filter (if equipped) ............................................................ 6-17Fuel filter ................................................................... 6-18Water separator ........................................................ 6-18Bleed of fuel filter ...................................................... 6-19Check radiator and radiator hose ............................ 6-23V-belt looseness and damage ................................. 6-23

Removal of condensate water from air tank ............ 6-24Steering wheel free play .......................................... 6-24Checking brake pedal free play ............................... 6-25Clutch pedal play ...................................................... 6-25Clutch fluid ................................................................ 6-25Checking the brakes ................................................ 6-26Coolant level and leaks in cooling system ............... 6-26Adjustment of brake shoe clearance ........................ 6-29Windshield washer fluid level .................................. 6-30Turbocharger ............................................................ 6-31How to check the vehicle equipped with EGR (exhaust gas recirculation) system ......................... 6-32Battery ....................................................................... 6-33Replacement of fuse ................................................ 6-34Replacing light bulbs ................................................ 6-36Centralized lubrication system (if equipped) ........... 6-37Auto grease lubrication system (if equipped) .......... 6-38

6


6-2

G377A027D-GAT

SCHEDULED MAINTENANCEThe following maintenance services must be performed to assure good vehicle control and performance. Keep receipts for all vehicle services to protectyour warranty. Where both kilometers and time are shown, the frequency of service is determined by whichever occurs first. Even though a certainsystem is in the same maintenance period, the distance of inspection or replacement can be different from each other due to the characteristics of system.

R : Replace I : Inspect and after inspection, clean adjust, repair or replace if necessary

NO.

1

2

3

4

Interval (Kilometers) X 1000Interval (Miles) X 1000

ItemEngine control system maintenanceAir, fuel oil coolant for leakage

Oil filter

Engine oil

Air cleaner element *

10060

I

R

R

9557

9054

I

R

R

8551

8048

I

R

R

7545

6539

6036

I

R

R

5533

5030

I

R

R

4527

4024

I

R

R

3521

3018

I

R

R

2515

2012

I

R

R

159

106

I

R

R

53

10.6

RR

RR

7042

I

R

R

D6DAD6AB, D6AC, D6AVD6CA, D6CBD6CCD6DAD6AB, D6AC, D6AV

D6CA

D6CB

D6CC

D6AVD6CB, D6AC, D6CA, D6AB

D6CC

Replace every 16,000 km (every 8,000 km in severe driving condition)Replace every 20,000 km

Replace initial 1,000 km and every 30,000 km

Replace every 16,000 km (every 8,000 km in severe driving condition)With oil cleaner : Replace initial 1,000 km and every 60,000 kmWithout oil cleaner : Replace initial 1,000 km and every 20,000 kmWith oil cleaner : Replace initial 1,000 km and every 60,000 kmWithout oil cleaner : Replace initial 1,000 km and every 40,000 kmWith oil cleaner : Replace initial 1,000 km and every 80,000 kmWithout oil cleaner : Replace initial 1,000 km and every 60,000 km

Replace every 20,000 km (inspect every 5,000 km)Replace every 6 month or 60,000 km

Inspect every 10,000 km and replace every 120,000 kmor when the dust warning lamp on meter set light.

* Clean the air cleaner filter when dust indicator lamp is on.


6-3

NO.

567891011

12

13

14

1516171819

1

23


ItemEngine control system maintenanceInterior of rotor in centrifugal type filterV-belt tension and damageV-ribbed beltInjector tighteningInjection pressure and injection condition of the nozzleInjection timingFuel feed pump filter

Fuel filter

Mass air flow (MAF) sensor

Closed crankcase ventilation (CCV) filter

Air compressorRemoval of foreign matter in the fuel tankValve clearance, EUI prestrokeEngine operation condition (Starting,Idling speed, Max. speed, Acceleration)Engine coolantPower line

Transmission oil

Clutch/brake pedal free play and operation conditionClutch fluid

10060

I

II

I

I

I

I

9557

I

I

9054

I

I

I

I

I

8551

I

I

8048

I

IIII

II

I

I

7545

I

I

6539

I

I

6036

I

II

I

I

I

I

5533

I

I

5030

I

I

I

I

I

4527

I

I

4024

I

IIII

II

I

I

3521

I

I

3018

I

I

I

I

I

2515

I

I

2012

I

II

I

I

I

I

159

I

I

106

I

I

I

I

I

53

I

I

I

10.6

I

I

7042

I

I

I

I

I

Replace every 20,000kmReplace every 25,000 km

Replace initial 20,000 km and every 40,000 kmClean every 6 months or 60,000 km

Replace every 60,000 km or when the engine check warning light is on.And indicator at the top of the CCV spring out upward.

Adjust the valve clearance every 40,000 km after first adjustment of 5,000 km

Inspect initial 100,000 km and every 10,000 km

Remove sediment when replacing the engine oil filter

Inspect every 20,000km. Replace every 2 years or 40,000 km

DYMOSZF

Replace initial 5,000 km and every 40,000 km (inspect every 10,000 km)Replace initial 5,000 km and every 1 year or 60,000 km

Replace every 1 year or if necessary

D6AB, D6AC, D6AVD6CA, D6CBD6CC


6-4

NO.

123456

12345

12345678


ItemDriving systemRear axle oilPropeller shaft universal joint, slip joint & center bearingFront, rear wheel hub bearing damage & free playWheel stud bolts and nutsTire pressure and damageTire rotationSteering systemPower steering gear oilSteering system oil leakageOverall axle alignment (side slip)Steer angle and stopper bolt retighteningSteering free play & linkage for looseness (in driving the engine)Service brakesBrake fluidBrake system for fluid leakageBrake lining clearanceBrake lining for wearBrake drum for wearBrake pedal free playAir dryerAir dryer heater plug

10060

II

RI

RI

I

I

9557

I

II

I

I

8551

I

II

I

I

8048

II

IIII

RI

III

7545

I

II

I

I

6539

I

II

I

I

6036

I

RI

I

I

5533

I

II

I

I

5030

II

RI

II

I

I

4527

I

II

I

I

4024

II

IIII

RI

I

I

3521

I

II

I

I

3018

II

I

II

I

I

2515

I

II

I

I

159

I

II

I

I

106

II

I

II

I

I

53

RI

II

I

I

10.6

I

I

7042

II

I

II

I

I

Inspect before drivingReplace every 15,000 km

Inspect and replace if necessary

9054

II

I

II

I

I

2012

II

I

RI

I

I

Inspect every 20,000 km. Replace initial 8,000 km and replace every 1 year or 40,000 km.

Replace every 1 year or 50,000 kmReplace every 2 year or 100,000 km

Inspect every 5,000 km. Retighten after driving 50-100 km from replacing a tire.


6-5

NO.

123

1234

1234

12345


ItemParking brakeParking brake functionDrum for wearLining for wearSuspensionSuspension for damageU-bolt*Leaf spring for damageShock absorbers for oil leakage or damageChassisBolts and nuts on chassis and bodyOil for cab tiltTractor coupler function pin and kingpin bearing for damage and loosenessPintle hook and lunette-eyeElectric systemBattery fluid specific gravityStarter motor functionAlternator (with tester)Electric harness and connection for damage and loosenessGauges, warning and indicator lamps

10060

II

I

I

I

9557

I

I

I

9054

II

I

I

I

8551

I

I

I

8048

II

I

II

IIII

7545

I

I

I

6539

I

I

I

6036

II

I

I

I

5533

I

I

I

5030

II

I

I

I

4527

I

I

I

4024

II

I

II

IIII

3521

I

I

I

3018

II

I

I

I

2515

I

I

I

2012

II

I

I

I

159

I

I

I

106

II

I

I

I

53

I

II

I

I

10.6

I

7042

II

I

I

I

Inspect every 5,000 km or if necessaryInspect every 10,000 km or if necessary

Inspect every 5,000 km or if necessaryInspect every 1 year, replace every 2 year

Replace initial 1,000 km and Inspect before driving

* Retighten initial 1,000km after replacing a spring and the U-bolt of the suspension.

Inspect every 5,000 km and every 2,000 km in severe driving condition

At first, retighten every 5,000 km. After that, retighten every 20,000 km


6-6

MaintenanceIntervalsMaintenance item Maintenance

OperationDriving

Condition

LB397D-FOT

MAINTENANCE UNDER SEVERE USAGE CONDITIONSThe following items must be serviced more frequently on vehicles normally used under severe driving conditions. Refer to the chart below for theappropriate maintenance intervals.

I : Inspect, correct or replace if necessary R: Replace

Engine oil

Oil filter

Air cleaner filterMass air flow (MAF) sensorBrake liningBrake drumsSteering gear rack, linkage & boots

R

R

RIIII

Every 5,000 kmEvery 8,000 kmWith oil cleaner : Initial 1,000 km and every 20,000 kmWithout oil cleaner : Initial 1,000 km and every 10,000 kmInitial 1,000 km and every 20,000 kmWith oil cleaner : Initial 1,000 km and every 40,000 kmWithout oil cleaner : Initial 1,000 km and every 30,000 kmEvery 5,000 kmEvery 8,000 kmEvery 10,000 kmReplace initial 10,000 km and every 15,000 kmMore frequentlyClean every 6 months or 60,000 kmMore frequentlyEvery 20,000 kmMore frequently

A, B, C, F, H

C, EA, B, C, F, HC, D, G, HC, D, G, HC, D, E, F

D6DAD6AB, D6AC, D6AV

D6CA

D6CB

D6CC

D6DAD6AB, D6AC, D6AVD6CA, D6CBD6CC

SEVERE DRIVING CONDITIONSA - Repeated short distance drivingB - Extensive idlingC - Driving in dusty conditions

D - Driving in areas with salt or other corrosive materials or in very cold weatherE - Driving in sandy areasF - More than 50% driving in heavy city traffic during hot above 90°F (32°C)G - Driving in mountainous areasH - Driving under overload


6-7

4,5 11 2 2 2 31

3284,5667109 8

NO

1

2

3

4

5

6

PARTPROPELLAR SHAFT CENTER BEARINGASSEMBLYPROPELLAR SHAFT UNIVERSAL JOINTAND SLIDING SLEEVE

REAR WHEEL HUB BEARING

KING PIN-LOWER, LH/RH

KING PIN-UPPER, LH/RH

DRAG LINK

GREASE SPEC.

NLGI #2

NLGI EP#2

NLGI #2

NLGI #2

NLGI #2

NLGI #2

INTERVAL

Every 50,000km

Every 15,000kmor 1 month

Every 30,000km

Every 10,000kmor 3 months



NO

7

8

9

10

11

PART

STEERING, UNIVERSAL JOINT

FRT SPRING, RR SPRING

CAB HINGE BRACKET LH/RH

CAB SUSPENTION CONNECTING ARMLH/RH

LATCH CTR

GREASE SPEC.

NLGI #2

NLGI #2

NLGI #2

NLGI #2

NLGI #2

INTERVALEvery 10,000km

or 3 monthsEvery 10,000km




or 3 months

HD160

G377C017D-GAT

LUBRICATION (HD160)

8 TON CARGO


6-8

4,5 11 2 2 31212

3284,5667109 8

HD250

G377D017D-GAT

LUBRICATION (HD250)

11.5 TON CARGO

NO

1

2

3

4

5

6





DRAG LINK

GREASE SPEC.

NLGI #2

NLGI EP#2

NLGI #2

NLGI #2

NLGI #2

NLGI #2

INTERVAL

Every 50,000km


Every 30,000km




NO

7

8

9

10

11

PART





LATCH CTR

GREASE SPEC.

NLGI #2

NLGI #2

NLGI #2

NLGI #2

NLGI #2






or 3 months


6-9

4,511 2 2 322

3884,567109 8

HD320

G377E017D-GAT

LUBRICATION (HD320)

19 TON CARGO

NO

1

2

3

4

5

6





DRAG LINK

GREASE SPEC.

NLGI #2

NLGI EP#2

NLGI #2

NLGI #2

NLGI #2

NLGI #2

INTERVAL

Every 50,000km


Every 30,000km




NO

7

8

9

10

11

PART





LATCH CTR

GREASE SPEC.

NLGI #2

NLGI #2

NLGI #2

NLGI #2

NLGI #2






or 3 months


6-10

G377F017D-GAT

RUBBERS & SWITCHES

Parts

Brake valve packing & rubber parts

Wheel cylinder piston cup & dust seal

Valve packing & rubber parts

Pressure governor diaphragm & rubber parts

Brake hose

Load sensing valve cup & other rubber parts

Brake system(Brake chamber relay valve, Quick release valve etc.)

rubber parts

Trailer brake system (Tractor)

Heater hose

Vacuum hose

Air spring diaphragm

Power steering system rubber parts & hose

Fuel hose

Air compressor & pressure gauge hose

Air master & power cylinder packing (Except full air brake vehicle)

Air conditioner hose

Brake lamp switch

Remarks

Except full air brake vehicle

Except full air brake vehicle

Vacuum sub hydraulic brake vehicle

Every 3 yearEvery 1 year

••••••

•

••

Every 2 year

••••••••


6-11

G0001407D-FOT

EXPLANATION OF SCHEDULED MAIN-TENANCE ITEMS

o Engine oil and filterThe engine oil and filter should be changed atthose intervals specified in the maintenanceschedule. If the vehicle is being driven in severeconditions, more frequent oil and filter changesare required.

G0001437D-FOT

o Fuel filterA clogged filter can limit the speed at which thevehicle may be driven, damage the emissionsystem and cause hard starting. If an exces-sive amount of foreign matter accumulates inthe fuel tank, the filter may require replacementmore frequently.After installing a new filter, run the engine forseveral minutes, and check for leaks at theconnections.

G0001447D-FOT

o Vacuum and crankcaseventilation hoses

Inspect the surface of hoses for evidence ofheat and/or mechanical damage. Hard andbrittle rubber, cracking, tears, cuts, abrasions,and excessive swelling indicate deterioration.Particular attention should be paid to examiningthose hose surfaces nearest to high heatsources, such as the exhaust manifold.Inspect the hose routing to assure that thehoses do not come in contact with any heatsource, sharp edges or moving componentwhich might cause heat damage or mechanicalwear. Inspect all hose connections, such asclamps and couplings, to make sure they aresecure, and that no leaks are present. Hosesshould be replaced immediately if there is anyevidence of deterioration or damage.

G0001457D-FOT

o Fuel hose, vapor hose and fuelfiller cap

The fuel hose, vapor hose and fuel filler capshould be inspected at those intervals speci-fied in the maintenance schedule. Make surethat a new fuel hose, vapor hose or fuel filler capis correctly replaced. Consult your Hyundaidealer if you have any questions.

G0001467D-FOT

o Air cleaner filterA genuine Hyundai part is recommended forreplacement of the air cleaner filter.

G0001477D-FOT

o Drive beltsInspect all drive belts (water pump and alterna-tor) for evidence of cuts, cracks, excessivewear or oiliness, and replace if necessary.Drive belts should be checked periodically forproper tension and adjusted as necessary.

G0001427D-FOT

o Fuel lines and connectionsCheck the fuel lines and connections for leak-age and damage. Replace any damaged orleaking parts immediately.

G0001487D-FOT

o Engine coolantThe coolant should be changed at those inter-vals specified in the Vehicle Maintenance Re-quirements Section.


6-12

G0001497D-FOT

o Manual transmission oilCheck manual transmission oil according tothe maintenance schedule.

NOTE:If the oil level is low, check for possibleleaks before adding oil. Do not overfill.

G0001507D-FOT

o Brake hoses and linesVisually check for proper installation, chafing,cracks, deterioration and any leakage. Re-place any deteriorated or damaged parts im-mediately.

G0001517D-FOT

o Brake fluidCheck brake fluid level in the brake fluid reser-voir. The level should be between “L” and “H”marks on the side of the reservoir. Use onlyhydraulic brake fluid conforming SAE J706.

G0001527D-FOT

o Brake drums and liningsCheck for scoring, burning, leaking fluid, bro-ken parts, and excessive wear.

G0001537D-FOT

o Brake pads, calipers and rotorsCheck the pads for excessive wear, discs forrun out and wear, and calipers for leaking fluidleakage.

G0001547D-FOT

o Parking brakeInspect the parking brake system such asparking brake lever, cables, and so on. Fordetailed service procedures, refer to the Shopmanual.

G0001557D-FOT

o Exhaust pipe connections,muffler and suspension bolts

Check the exhaust pipe, muffler, and suspen-sion connections for looseness or damage.

G0001567D-FOT

o Steering gear box, linkage and bootsWith the vehicle stopped and engine off, checkfor excessive free-play in the steering wheel.check the linkage for bends or damage. Checkthe dust boots and ball joints for deterioration,cracks, or damage. Replace any damagedparts.

G0001577D-FOT

o Wheel bearing greaseCheck the wheel bearings and grease accord-ing to the maintenance schedule. For inspec-tion procedures, see Shop Manual.


6-13

G280037D-FOT

PAPER ELEMENT TYPE AIR CLEANERMAINTENANCEThe air cleaner element should be cleaned orreplaced when the dust indicator light in thecluster comes on.

G280047D-FOT

Removal and installation of element

1. Loosen the wing nut (1) and remove thecover (2) straight and withdraw the ele-ment (3).

2. Check the element for contamination. Thecleaning procedure varies with the degreeof contamination.

3. After cleaning, install by reversing the re-moval procedure.

NOTE:The inner element should be replaced whenthe outer element is replaced.Note that the inner element is not wash-able.

CAUTION:Make sure that the element and cover aresecurely installed. If they are loose, thecleaner will absorb dust and will fail tofunction properly.

G280067D-FOT

Cleaning of elementDry dust buildup

Blow clean compressed air evenly up anddown from inside the element to loosen andremove the dust.

(1)(2)

(3)

HEG5007

(1)

G280077D-FOT

Checks to make after drying

HR60050A

Check the filter paper for damage, pinholes andthin portions. If a defective portion or brokenpacking is evident, replace the element with anew one.

HEG5002

NOTE:Do not strike the element or hit it againstother object. Make sure that the pressure ofthe compressed air used for cleaning doesnot exceed 2 kgf/cm².


6-14

G2607D-FOT

OIL FILTER

o The engine oil and filter should be changedat those intervals specified in the mainte-nance schedule. If the vehicle is beingdriven in severe conditions, more frequentoil and filter changes are required.

o If the filter is blocked the warning light is onand if the oil pressure is low the buzzersounds at the same time. Replace it inde-pendent of the mileage.

o An element assembly cannot be reused.

FARE004

G260137D-FOT

To check the oil filter

FPVOM080

1

3

2

Position the vehicle on a level surface. The besttime to check the oil level is before operating theengine or about 30 minutes after stop of engine.The checking procedure is as follows :

1. Wipe the level gauge (1) well with a cloth,insert it into the level gauge guide (2) andremove the gauge to check the oil level.The oil level should be between "FULL"and "LOW" inscribed lines.

CAUTION :If the oil level is checked when the engineis stopped before sufficient rise of oil tem-perature, the detected level will be lowerthan the actual level, because some oilaccumulation in the engine does not flowback into the oil pan.

2. If the level is low, add engine oil through thefiller cap (3).After addition of engine oil, allow more thanfifteen minutes and then recheck the oillevel.

3. If badly contaminated engine oil is obviouswhen checking the oil level, replace theengine oil irrespective of the service inter-vals.


6-15

Replacement of filter typeD6AB, D6AC, D6AV Engine1. Put an empty container below the oil filter

drain hose. Remove the air bleeding plugand drain the engine oil out.

2. Disassemble the case by pulling the cen-ter bolt on the oil filter out and remove theelement.

3. Use the genuine parts when you assemble.Replace the element and rub packing ofthe case simultaneous. Apply engine oil onthe rub packing before assembling. Tightenthe center bolt with specified torque5.5±0.5kg.m.

4. When you replace only the oil filter replen-ish the engine oil.

5. Crank the engine and check the oil leak-age and the oil level later.

CAUTION:Be very careful when draining the engineoil as it may be hot enough to burn you.Dropped oil may cause a fire. Wipe andclean each part in the engine room.

D6CB, D6CC Engine

1. Put an empty container below the oil filterdrain hose. Remove the air bleeding plugand drain the engine oil out.

2. Disassemble the case by pulling the centerbolt on the oil filter out and remove theelement.

3. Use the genuine parts when you assemble.Replace the element and rub packing of thecase simultaneous. Apply engine oil on therub packing before assembling. Tighten thecenter bolt with specified torque 6~7kg.m.

4. When you replace only the oil filter replenishthe engine oil.

5. Crank the engine and check the oil leakageand the oil level later.

OGV026073A

CAUTION:Be very careful when draining the engineoil as it may be hot enough to burn you.Dropped oil may cause a fire. Wipe andclean each part in the engine room.

NOTE:Always dispose of used engine oil in anenvironmentally acceptable manner. It issuggested that it be placed in a sealedcontainer and taken to a service station forreclamation. Do not pour the oil on theground or put it into the household trash.

WARNING:Used motor oil may cause irritation orcancer of the skin if left in contact with theskin for prolonged periods of time. Al-though this will probably not be a concernunless you handle used oil on a regularbasis, you should wash your hands withsoap and warm water as soon as possibleafter handling used oil.


6-16

If the filter is blocked, the warning light is onwhen the RPM is high.Replace it independent of the mileage.If the oil pressure decreases the warning lightalso is on ant the buzzer sounds simultaneous.But the parking brake is applied on it does notsound.

Replacement of cartridge typeD6DA Engine

JJWOM168

1. Put an empty container below the oil filterand remove the drain plug. Drain the en-gine oil out.

2. When the draining is finished pull the oilfilter out with a wrench.

3. Use the genuine parts when you assemble.Assemble the rub packing on top of thefilter after applying the engine oil on.

4. When you replace the oil filter replenish theengine oil.

5. Start your engine. Check whether the oilleaks. The checking should be done be-fore driving and after.

CAUTION:Split oil may cause a fire. Wipe and cleaneach part in the engine room. Never reusethe filter assembly.

CENTRIFUGAL TYPE BY PASS FILTERINSPECTION (IF EQUIPPED)

1. Remove accumulated sediment inside thecover of centrifugal type when replacing theengine oil filter.

2. Using the proper cleaning solution, cleanthe rotor components.

WARNING:o There is the danger of a fire if the

vehicle is driven with oil spread overengine compartment.Be sure to wipe it clean.

CAUTION:o Be sure to replace the oil filter with

genuine Hyundai parts when replacingit.

o Improper oil filter installation maycause damage to engine oil leaks.

OGV026074


6-17

CCV(CLOSED CRANKCASEVENTILATION) FILTER (IF EQUIPPED)

This is the device for re-circulating the blow-bygas generated from the engine to the intakeside.After oil warning lamp is turned on, check theindicator located upper side of the CCV. If theindicator is protruded upside, replace the CCVfilter.

CAUTION:o When oil pressure is lack, warning lamp

and buzzer will work simultaneously.o After replacing filter element, press the

indicator to reset.

OGD058056

WARNING:o Be careful not to burn yourself due to

hot oil and wear the safety goggle andglove.

o There is the danger of a fire if thevehicle is driven with oil spread overengine compartment. Be sure to wipeit off.

o Use only genuine oil filter. Using un-authorized oil filter may cause dam-ages to engine.

OIL CLEANER FILTER (IF EQUIPPED)

OPY077135L

1. Turn the T bolt of T-R oil cleaner counter-clockwise to open it.

2. Remove the cap of T bolt and lift up theelement after taking the element band.

3. Replace it with a new element.4. Tighten the T bolt to the 5.5 ± 0.5 kg.m.5. Add the oil 2.5 liter.6. Start the engine and check for oil leaks.

NOTE:Do not reuse the element. Refer to the labelfor maintenance interval.


6-18

C620601A

G300A02O-GAT

WATER SEPARATORRemoval of water from the water separator(D6AB,D6AC,D6AV,D6CA,D6CB Engine)

Loosen the drain plug and remove the conden-sate before the float reaches the redline (1).

CAUTION:If the water accumulated in the water sepa-rator is not drained at proper times, dam-ages to the major parts such as pumppriming plunger can be caused by waterpermeation in the fuel filter.

To remove, proceed as follows:

1. Loosen the air vent plug (2) at the upperpart of the water separator.

2. Loosen the drain plug (3) at the bottom ofthe water separator.

3. Drain the water.4. After the float has come down, tighten the

drain plug at the bottom of the water sepa-rator.

5. Tighten the air vent plug.6. Wipe the water separator and surrounding

parts clean.7. Check for fuel leaks.

NOTE:It is recommended that water accumulatedin the water separator should be removedby an authorized Hyundai dealer.

WARNING:Be sure to carefully wipe away any waterdrained out in this manner, because thefuel mixed in the water might be ignitedand result in a fire.

OPY058102

Do not reuse the fuel filter element after clean-ing it.1. Separate the fuel filter cartridge by turning

it counterclockwise. Use a filter wrench toloosen it.

2. Apply engine oil to the bowl slightly whenassembling it and tighten it to 3/4~1 turn(4.2~4.6kgf.m).

3. Perform air bleeding.4. Check fuel for leaks or not after starting

the engine.

CAUTION:o Wipe off fuel to protect the danger of

a fire in case fuel overflows.o When replacing the fuel filter, do not

spill off the fuel on the floor for theprotection of environment.

FUEL FILTERReplacement


6-19

Replacement (D6CC Engine)

OPY028083A

Do not reuse the water separator after cleaningit. Be sure to follow the prescribed maintenanceinterval of fuel filter. If you don't follow it, theremay cause damage to engine.Replace the water separator at initial 20,000kmand replace it at every 40,000km. Even if it iswithin maintenance interval, be sure to replacethe fuel filter element when the engine checklamp blinks since the element may be contami-nated earlier than maintenance interval ac-cording to the conditions or circumstances ofvehicle. The engine power is limited to protectthe engine fuel system when the vehicle isoperated with the warning lamp blinked for fivehours or more.

G311107D-FOT

BLEED OF FUEL FILTERD6AB, D6AC, D6AV engine

If the engine stops by being used up fuel,cleaning the fuel system or changing the fuelfilter the engine does not start through fuel isreplenished due to be come air into the fuelsystem.Air should be removed from the fuel system tomake it start your engine.

Bleed air by the following procedure.1. Loosen the air bent cock on the top of the

fuel filter.

FRVOM153A

Priming Pump

OPY028082A

1. Separate the bowl by turning it counter-clockwise. Use a filter wrench to loosen it.

2. Apply new oil to the bowl slightly whenassembling it and install the gasket on sealsurface of head and tighten it to 3/4~1 turn(1.68~1.86kgf.m).

3. Perform air bleeding.4. Check fuel for leaks or not after starting the

engine.

CAUTION:o Wipe off the fuel to protect the danger

of a fire in case fuel overflows.o Be sure to follow the maintenance in-

terval of fuel filter.


6-20

G311058A-FOT

D6CA, D6CB engineIf the engine stops by being used up fuel

1. Do the above instruction 1 to 3 of thebleeding air from the fuel system.

2. Rock the air bent cock on the top of the fuelfilter.

3. Open the air bent cock front of the cylinderhead and have the priming pump worked.Rock the air bent cock of the cylinder headside if air is removed completely.

4. Crank the engine. Do the cranking severaltimes for an enough time 10-15 seconds tillthe engine is running.

CAUTION:As it cause the starter motor to overstrain todo cranking for a long time, do not exceed15 seconds in the sequence cranking. No-tice that there is a surplus time about 30seconds from cranking to cranking in ordernot to overheat the starter motor.

5. After running the engine waits for the en-gine to be stable by keeping the revolutionof the engine about 1,000 rpm.

MA263000

C620602A

D6CB Engine

D6CA Engine

HR60090A

2. Turn the priming pump counterclockwisewith pressing down and then the pumppiston is pushed out by a spring.

3. Operate the priming pump until the fuelwithout air bubble flow out.

4. Tighten the air bent cock and fix the pumppiston by turning clockwise with pressingdown.

5. Start the engine and check for fuel leaks.


6-21

MA263001

Air bent cock

If you replace a cartridge of the fuel filter

Do not necessary to bleed air from the cylinderhead in replacing the fuel filter.Usually the engine starts by once of cranking.

NOTE:In replacing the cartridge if you install thefuel filter with the fuel filled up.You can shorten the pumping time.

CAUTION:o As the new EUI system is applied to

D6CA engine and the injector is in-stalled inside of the cylinder head, thereis remaining air in the injector afterbleeding air from the fuel filter. Thus toremove remaining air, it is necessary todo enough the cranking after the bleed-ing.

o If the bleeding is finished normallythere is no problem to start the engineby enough the cranking.

o Leakage of fuel could cause a fire.Wipe and clean leaked fuel.

D6CC EngineIn case fuel in fuel line is exhausted and theengine stalls, the engine may not start eventhough fuel is refilled up after servicing fuel lineor replacing fuel filter. In this case, since thereis the air in fuel system, be sure to bleed air asfollows.

CAUTION:o Keep sparks or open flames away when

servicing.o Before performing the air bleeding,

clean out the air vent and around it.o After air bleeding, start the engine and

check if the fuel is leaked.o After completing the air bleeding, per-

form the engine cranking 3~5 times atevery 10~15 seconds. (Wait 30 secondsfrom one cranking to the next crankingto prevent the start motor from beingoverheated.)


6-22

OEG068056

1. Loosen the air vent bolt a little.2. Place a proper vessel under the rubber

tube installed at the air bleeding plug.3. Operate the priming pump repeatedly until

air is not bleeding from the fuel.4. After air is completely removed from the

fuel, tighten the air vent bolt.

CAUTION:o Check if any fuel is leaked from the air

bleeding plug or the fuel filter.o Wipe any fuel spread over around off.o Keep sparks or open flames away when

servicing.

Air bleeding from the fuel filter

OPY028081A

1. Loosen the plug for air bleeding of fuel filterwith a hexagonal wrench.(One turn or so)

2. Cover the shop towel around the plug forair bleeding and repeat to operate primingpump until the air bubble in the fuel doesnot come out.

3. Tighten the plug for air bleeding securely.

❈ When replacing the fuel filter cartridge withnew one, it is not required to perform theair bleeding from water separator.

Air bleeding from the water separator CAUTION:o Check if there is any fuel leak around

the plug for air bleeding or the fuelfilter.

o Wipe any fuel spread over around off.o Keep sparks or open flames away when

servicing.


6-23

OGV026083A

1. Loosen the air vent cock a little.2. Place a proper vessel under the rubber

tube installed at the air bleeding plug.3. Operate the priming pump installed at the

fuel filter head repeatedly until air is notbleeding from the fuel.

4. After air is completely removed from thefuel, tighten the air vent bolt.

❈ When replacing the fuel filter cartridgeonly, it is not required to perform the airbleeding from the cylinder head.

CAUTION:o Check if any fuel is leaked from the air

bleeding plug or the fuel filter.o Wipe any fuel spread over around off.o Keep sparks or open flames away when

servicing.

Air bleeding from the cylinder head G251157D-FOT

CHECK RADIATOR AND RADIATORHOSE

HR60110A

(2)

(3)

(3)

Check the radiator (2), radiator hose (3), etc.for water leaks.Check for the traces of water leaks on theground where the vehicle has been parked. Ifthere are water leaks in the cooling system,take the vehicle to the nearest service shop forservice.

G255037D-FOT

V-BELT LOOSENESS AND DAMAGE

HR60120A

10 to 15 mm

When the V-belt is pressed down at the middlewith a force of about 10 kgf (98 N).

To adjust tension, refer to the table.

Adjust tension 55 kgf for D6CA in case of newand readjust 40 kgf.

D6DA

D6AB, D6AC,

D6CA

5-15 mm

20-25 mm (New)

25-30 mm (Readjust)


6-24

G563057D-FOT

STEERING WHEEL FREE PLAY

JJRT049

Lightly rock steering wheel at the center posi-tion to check for free play. If the free playexceeds 15 to 35 mm, have the steering wheeladjusted by an authorized Hyundai dealer.

G0001587D-FOT

REMOVAL OF CONDENSATE WATERFROM AIR TANK

EGHOM523

Open all drain cocks to remove the watercollected in the air tank.

Slightly loosen the generator attaching boltsand adjust by moving the whole generator.

CAUTION:o After adjustment, tighten the bolts and

nuts firmly. Over tension will causedamage to the V-belt and bearing.

o Make sure that the V-belt is not fouledwith oil or grease. Oil or grease willcause the belt to slip and will shortenits life.

o When a V-belt is defective, make surethat the two V-belts are replaced as aset.

G371247D-FOT

Adjustable Generator Freeplay

SOLA018A


6-25

G580137D-FOT

CHECKING BRAKE PEDAL FREE PLAY

TR60660A

10 ~ 22 mm(0.39 ~ 0.87 in.)

Check the pedal free play by depressing thepedal with finger.The pedal free play is the stroke made by thepedal moves until you feel a change in resis-tance.This is the brake pedal free play. The freeplayshould be within the limits specified in theillustration below. If it is not, have it inspected byan authorized Hyundai dealer and adjusted orrepaired if necessary.

With the engine off, press lightly on the clutchpedal until you feel a change in resistance. Thisis the clutch pedal free-play. The play should be3 ~ 8 mm. If it is not, have it inspected by anauthorized Hyundai dealer and adjusted orrepaired if necessary.

CAUTION:A special care must be taken because thevehicle can be started suddenly if the clear-ance is too small.

FRVOM189-2

G414067D-FOT

CLUTCH PEDAL PLAY

Freeplay

HV60340B

G414067E-FOT

CLUTCH FLUID

1. Open reservoir tank cap and check thatthe level on the reservoir is between MAXand MIN.

2. Add clutch fluid if necessary.


6-26

G251147D-FOT

COOLANT LEVEL AND LEAKS INCOOLING SYSTEM

FJRG011A

Surgetank Good

If lamp is illuminated add the coolant afterremoving the surge tank cap at first.

G580147D-FOT

CHECKING THE BRAKES

CAUTION:Because brakes are essential to the safeoperation of the vehicle, it is suggestedthat they be checked and inspected by anauthorized Hyundai dealer. The brakesshould be checked and inspected for wearat those intervals specified in the vehiclemaintenance schedule in Section 6.

CAUTION:o Do not add clutch fluid to bring it up

to the upper position (MAX position).o Be careful that dust etc. does not get

into the reservoir tank when adding.o Do not pour the clutch fluid around

when adding. If the clutch fluid ispoured around, it may cause damageto other parts. Wipe it off thoroughlywith dry and clean cloth.

o Have the clutch system checked byHyundai dealer for clutch fluid leaks ifthe level of clutch fluid is excessivelylow.

o Observe proper safety regulation whenhandling clutch fluid as clutch fluid isharmful to human body.

o When filling the clutch fluid, do notmix the clutch fluid with the othercompany’s one.


6-27

HV60100A

(1)

Check reservoir tank for the coolant level.The coolant level should be with in the range (1)shown in the illustration. If the level is low, addcoolant by reference to "Replacement of cool-ant".

CAUTION :o Check the coolant level before vehicle

operation while the engine is cold.o After checking the coolant level, be

sure to reinstall the cap positively.o Be sure to add the coolant containing

anti-rust or anti-freeze of the sameconcentration as the coolant in thecooling system.

o Do not check the coolant level after theengine has been stopped. Be sure tocheck the level when the coolant tem-perature is low.

G251167D-FOT

Checking and changing the enginecoolant

WARNING:Do not remove the surge tank cap when theengine is hot. When the engine is hot, thecoolant is under pressure and may eruptthrough the opening if the cap is removed.You could be seriously burned if you donot observe this precaution.Do not remove the surge tank cap until theradiator is cool to the touch.

G251078A-FOT

Handling of cooling systemEngine overheating is caused by the low cool-ant level or rust and scale accumulations in thecooling system. If the radiator clogs very badlyor coolant is very dirty, perform cleaning andcoolant replacement as described below. If thecoolant level is low, add coolant as necessary.

G251088A-FOT

Replacement of coolantIf the radiator clogs badly or coolant becomesdirty, replace coolant immediately regardlessof the specified replacement intervals. In mak-ing this kind of replacement, be sure to clean thecooling system by the procedure shown in"Cleaning method".


6-28

G251178A-FOT

AntifreezeSelect proper concentration between 30 and53% by reference to the table shown below.

Atmospheretemperature (°C)

-10

-15

-20

-25

-30

-35

Antifreezefluid (%)

30

36

42

45

50

53

Coolant(%)

70

64

58

55

50

47

CAUTION :o Be sure to use anti-freeze at the con-

centration most appropriate for theatmospheric temperature within a rangefrom 30 to 53%. If the concentration isbelow 30%, the anti-corrosion prop-erty will be adversely affected. If theconcentration is above 53%, the anti-freeze property will decrease and en-gine overheating will also be caused.Use anti-freeze at the specified con-centration.

o If winter is over, be sure to drain thecoolant containing antifreeze and putin genuine anti-rust "RADIPET 9".

G251058A-FOT

Addition of coolantIf the warning lamp lights when the starterswitch is set to "ON", the coolant level is low.Note that the procedure for adding coolantvaries according to the type of the enginecooling system on vehicle.Use city water as coolant and add anti-rust oranti-freeze to have a specified concentrationfor prevention of engine or cooling systemcorrosion.Do not use hard water from well river etc..

G251098A-FOT

Cleaning methodRun the engine at idle to heat the coolant to 90°Cor higher. Then clean by the following proce-dure.

1. Open the radiator and engine drain cocksto drain the coolant.

2. After complete draining, close each draincock and fill the system with city water.

3. Close the drain cocks and fill the systemwith city water. Run the engine for a whileand drain the system.Repeat this operation until a colorless, trans-parent water flows out from the drain cock.

4. Fill the radiator with city water containinggenuine anti-rust "RADIPET 9" or genuineanti-freeze at a specified concentration.Run the engine until the coolant is heatedto the temperature (90°C) at which thethermostat opens, and bleed air thoroughlyfrom the cooling system.

5. Stop the engine and make sure that thecoolant is at the proper level. If the coolantlevel is low, add city water.

CAUTION:When the cooling system is cleaned, thecoolant or cleaning solution is drained atelevated temperature. Therefore, be care-ful not to get scalded.


6-29

G580187D-FOT

ADJUSTMENT OF BRAKE SHOECLEARANCE

G580197D-FOT

If the brake linings are worn and the clearancebetween the brake drum and linings (brakeshoe clearance) increases, it can be danger-ous because the brake performance deterio-rates. Check and adjust the brake shoe clear-ance at regular intervals.

o The brake shoe clearance should be de-termined on the basis of the stroke of thebrake chamber push rod. If the push rodstroke exceeds 40 mm (1.57 in.) on thefront wheels or 50 mm (1.97 in.) on the rearwheels when the brake pedal is depressedall the way, adjust the clearance.

1. Apply chocks to the tires before the wheelto be adjusted is jacked up.

2. Strongly push the outer periphery of tire tocheck for wheel looseness. If the wheel isloose, it cannot be correctly adjusted. Takethe vehicle to your nearest service shopfor correction.

3. Start the engine to increase the com-pressed air pressure to more than 6.4 kgf/cm² (625 kPa). Leave the engine runningat idle.

4. Release the parking brake. HR60300A

Servicelimit

5. Remove the dust cap from the wheelbrake inspection hole and check the liningthickness.If the lining is worn down to the notchshown in illustration, it is worn beyond theservice limit. Have your nearest serviceshop replace the linings. Make sure thatthe dust cap is reinstalled after inspection.

6. Turn the worm shaft of the slack adjusterin the direction that the push rod extendsuntil the worm shaft touches the stopper.

7. Back off the worm shaft 3 or 4 notches onthe front wheels or 4 or 5 notches on therear wheels.The notches are indicated by the clocksthe worm shaft makes when turned.


6-30

G981057D-FOT

WINDSHIELD WASHER FLUID LEVEL

HV60370A

Check to ensure that windshield washer fluid isat a proper level.

9. Turn the wheel in the forward direction byhand and depress the brake pedal to stoprotation of the wheel. Turn the wheel tocheck for dragging. With slight foot pres-sure on the brake pedal, turn each wheelby hand to check that the front wheels areslightly lighter to turn than the rear wheelsor there is not great difference and thatright and left wheels are about equal.

10.As a final step, install the dust plug. Operatethe vehicle at a slow speed and performbrake tests to check for brake perfor-mance, uneven braking and other troubles.

HR60310A

8. Measure the stroke made by the push rodof the brake chamber when the brakepedal is depressed all the way. Verify thatthe stroke is up to specifications given inthe following table if it is out of specification,adjust with the worm shaft.

Standard stroke of brake chamber push rod

Front wheel 25 mm (0.98 in.)

Rear wheel 30 mm (1.18 in.)


6-31

o Push the knob to check that the windshieldwasher fluid is sprayed at the correctposition.

o Turn the lever and check the wipers forproper operation.

NOTE:Be sure to operate the windshield washerbefore the wipers are operated.Do not operate the wipers on dry glass.This can result in more rapid wear of thewiper blades and may scratch the glass.

G981067D-FOT

Operation of wipers

HV20090A

C2827D-FOT

TURBOCHARGERPrinciple of turbo charger operation

Compressed air

Compressor

Engine Cylinder

Turbine

Exhaustgas out

Air intake throughair cleaner

Turbo engine is a device that produces morepower by supplying sufficient air into the com-bustion chamber by using the energy of ex-haust gas is usually wasted in the generalengine.The exhaust gases are accelerated in theturbine housing and directed onto the turbinewheel to turn it.This spins the compressor wheel, which re-sults in the intake air being forced into theengine cylinders.As the intercooler is installed that improves thefuel economy and power of the engine, whilereducing harmful exhaust gases to a minimum.

FARG100

Engine, exhaust gas

C2728D-FOT

Intercooler

FARG101

The intake air compressed by the turbochargerincreases to 170°C and as a result, power of theengine is limited by engine overheated.The intercooler cools the heat. This improvesthe combustion efficiency and as a result, itincreases that the fuel economy and power ofthe engine, while reducing harmful exhaust.

Air duct

Air cleaner

Intercooler

Turbo charger

Intake manifold(front)

Intake manifold(rear)


6-32

Precautions while operating

1. Check the oil level and oil pressureBefore starting the engine, measure thecrankcase oil level. As soon as the enginestarts, check oil pressure indicator fornormal rise.

2. Warm the engine upAfter the engine starts, avoid sudden ac-celeration or sudden start.Enough RPM is needed before startingengine until the engine is warm for 3 to 10minutes.

FARG102

Intake air outlet

BearingHousing

Intakeair inlet

Compressorwheel

CompressorCover Exhaust gas inlet

Shaft andturbine wheel

Exhaust gasoutlet

Piston ring

Turbine housing

Bearing

Oil inlet

HOW TO CHECK THE VEHICLEEQUIPPED WITH EGR (EXHAUST GASRECIRCULATION) SYSTEMEGR(Exhaust Gas Recirculation) system isthe device that re-circulates the exhaust gasexhausted from the engine after combustion tothe combustion chamber. The exhaust gas willbe cooled by passing through the water-cooledtype EGR cooler and it will be mixed with theintake air. It can remarkably reduce the amountof the nitrogen oxide emission comparing withgeneral engines.o How to handle the vehicle equipped with

EGR system.- Failures of the EGR system are mainly

caused by lack of coolant, severe incom-pliant from outside or service incompliantto instruction for changing parts.

- If the vehicle is driven under lacking ofcoolant or with the engine overheat warn-ing lamp on, the inside of the EGR cooleror all engine may lead to damages.

- When coolant is lack or engine is over-heated, please contact the authorizedHyundai dealer to check and remedy.

o How to check the vehicle equipped withEGR system.- When checking, be careful not to step on

the EGR valve or EGR cooler.

3. No staring suddenly and No accelerat-ing heavilyIf you accelerate heavily, start suddenly orwhen you turn off the engine suddenly itmay damage to the engine and turbo-charger parts.

CAUTION:o If running a vehicle without air cleaner

filter, foreign material drawn can de-stroy engine and turbo charger.

o When you turn off an engine suddenlymay damage bearing, hi-speed rota-tion part of turbo charger inside, so letthe engine run at idle for sufficienttime.


6-33

CAUTION:During driving a car, from the below rea-sons, Engine check indicator ( ) or En-gine overheat warning indicator ( ) ap-pears on the cluster with low power, imme-diately check or repair your car at nearservice center managed by Hyundai orservice cooperator.o High temperature of water from engine

overheat.o The defect of EGR regarding equip-

ment.o Problem with fuel support pressure.

G210A01A-AAT

BATTERY

WARNING:Batteries can be dangerous! When work-ing with batteries, carefully observe thefollowing precautions to avoid seriousinjuries.

The fluid in the battery contains a strong solu-tion of sulfuric acid, which is poisonous andhighly corrosive. Be careful not to spill it onyourself or the vehicle. If you do spill batteryfluid on yourself, immediately do the following:

o If battery fluid is on your skin, flush theaffected areas with water for at least 15minutes and then seek medical assis-tance.

o If battery fluid is in your eyes, rinse outyour eyes with water and get medicalassistance as soon as possible. While youare being driven to get medical assistance,continue to rinse your eyes by using asponge or soft cloth saturated with water.

o If you swallow battery fluid, drink a largequantity of water or milk followed by milk ofmagnesia, eat a raw egg or drink veg-etable oil. Get medical assistance as soonas possible.

While batteries are being charged (either by abattery charger or by the vehicle's alternator),they produce explosive gases. Always ob-serve these warnings to prevent injuries fromoccurring:

o Charge batteries only in a well ventilatedarea.

o Do not permit flames, sparks or smokingin the area.

o Keep children away from the area.


6-34

If the electrical system is out of order, open thecover and check for a blown fuse in the follow-ing sequence.

1. Open the cover.2. Remove the circuit checker from the re-

verse side of the cover.3. Insert the female terminal of the circuit

checker into "CHECKER" ground terminaland touch the male terminal to the fuse topsurface.

4. If the lamp lights, the fuse is good.The headlamp circuit should be checkedwith the head light switch at lightingposition.

5. Replace the defective fuse.

G911047D-FOT

REPLACEMENT OF FUSE

EGHOM414

If any electrolyte gets into youreyes, flush your eyes with cleanwater for at least 15 minutes andget immediate medical attention.If possible, continue to apply waterwith a sponge or cloth until medi-cal attention is received.If electrolyte gets on your skin,thoroughly wash the contactedarea.If you feel a pain or a burningsensation, get medical attentionimmediately.Wear eye protection when charg-ing or working near a battery.Always provide ventilation whenworking in an enclosed space.

o Never attempt to charge the batterywhen the battery cables are connected.

o The electrical ignition system workswith high voltage.Never touch these components withthe engine running or the ignitionswitched on.

G210B01Y-GAT

Checking the batteryKeep the battery clean. Any evidence of corro-sion around the battery posts or terminalsshould be removed using a solution of house-hold baking soda and warm water. After thebattery terminals are dry, cover them with alight coating of grease.

WARNING:Always read the following instruc-tions carefully when handling abattery.Keep lighted cigarettes and allother flames or sparks away fromthe battery.Hydrogen, which is a highly com-bustible gas, is always present inbattery cells and may explode ifignited.Keep batteries out of the reach ofchildren because batteries con-tain highly corrosive SULFURICACID. Do not allow battery acid tocontact your skin, eyes, clothingor paint finish.


6-35

CAUTION:o Use of a fuse out of specification or

wire could be dangerous. Be sure notto use a substitute fuse. Make sure thata blown fuse is replaced with a genu-ine fuse.

o If a defective point cannot be located,have inspection made at your nearestservice shop.

o Do not pour water over the relay andfuse box. Do not put your foot on thebox or kick it. When the inside of thecab was cleaned with water, removethe water completely through the drainhole in the floor and then tilt the cab.

NOTE:Inside the cover, you can find the fuse labeldescribing fuse name and capacity.


6-36

G941837D-FOT

REPLACING LIGHT BULBSBefore attempting to replace a light bulb, besure the switch is turned to the "OFF" positionand place the ignition switch in the "LOCK"position. Be sure to replace the burned-out bulbwith one of the same number and wattagerating.

G0001587D-FOT

Outside the vehicle

Wattage

70/70

70

21

21

21

5/21

21

5

Lamp Name

1. Head lamp

2. Fog lamp

3. Turn signal lamp

4. Side turn signal lamp

5. Turnsignal lamp

6. Tail/Stop lamp

7. Backup lamp

8. License lamp

OEGHOM087-2

67MX924 HR6044A

2 1 4 6 57

5

6 7

8

5 6 7 8

3


6-37

CLS Inspection1. Pour grease into the reservoir tank. Turn

the ignition key to the ON position andpush the manual button.

2. Check the operating condition of the pump.If it is normal open a plug on the end of thefractionators. The pump should be oper-ated continuously until the grease is flowed.

3. Turn the main switch off after bleeding aircompletely from the main pipe and thenlock the plug.

4. Turn the battery switch on for 15 secondsand off for 5 repeatedly and then checkwhether the grease lubricates.

5. Check the indicator lamp is off when thepump is operated.

CAUTION:Do this procedure once a day before driv-ing.

F3920055-FOT

CENTRALIZED LUBRICATION SYSTEM(If equipped)C.L.S(Centralized Lubrication System) is thedevice to lubricate a proper quantity of greaseinto all major chassis parts(except propellershaft) automatically at regular interval of timethrough an exclusive lubrication pipe with acontrol unit during driving.

Inspecting & Replenishing GreasePour grease to the MAX remarked on thereservoir tank.o Inspect or add grease every 2 monthso Recommended grease : NGL 100,000

CAUTION:o When the grease is poured into the

reservoir tank it must be a pure thing.o Replenish grease through the exclu-

sive lubrication inlet to avoid enteringforeign material.

NOTE:o Lubricate manually with pressing the

manual lubrication switch beside thetimer as required especially in rainytime or after washing a vehicle.

o Lubricating interval has specified 6hour when the vehicle is delivered. Donot necessary to adjust again.

NOTE:o The auto grease indicator light is turned

on at the same time with operation ofthe pump, and after 3 seconds the lightis off. The pump is operated for 154seconds at one time.

o If the auto grease indicator light isilluminated continuously even after 3seconds there is a malfunction in theCSL. Have the CLS inspected and re-paired by an authorized Hyundai dealer.

CAUTION:o Turn the main switch off after having

the pump worked for 154 seconds al-though the lamp is off after 3 secondsnormally.

o Inspect the tightening condition of leak-age of the conjunction part and greaseline.


6-38

1 2 3

456789

TK20400

Lubrication time adjustment switch

Manual motor switch

Motor operation time adjustment switch

Lubrication time indication lamp

Motor revolution indication lamp

Power supply confirmation lamp (turned

off in case of low voltage (DC 15V and

less))

G3920055-FOT

AUTO GREASE LUBRICATION SYSTEM(If equipped)Liquid grease (kumho)Proper lubrication is automatically provided bythe electric gear pump and control unit of thepiston fractionator. If lubrication quantity issmall or excessive, check time of the controlunit and adjust as required.

6

LS indicator lamp

Illuminated while motor is operating.

Pressure sensing lamp

Adjusting lubrication time(Maintain the established value when avehicle is delivered)

o Adjust time of pouring greaseo Lubrication time : 0.5-1.0-1.5 ~ 9.0-9.5-10

~ 24 (In case of 10 or less, it consists of34 sections by 30 minutes)

o When pressing down the lubrication timeadjustment method switch once, 4lamp shows lubrication time and 5 lampshows motor operation.Whenever pressing down, 4 lamp showsthe established period in ascending pow-ers. (When pressing down in succession,it shows three times per a second automati-cally in ascending powers.)

Motor operation time is established 2.5minutes when a vehicle is delivered.

(None can't control except the manufacturer.)

Manual function:When pressing down this switch, lubrication isoccurred. (When the motor stops, accumu-lated time returns to first, After it works, motoroperation time is accumulated.)

7

8

9

Management of CLSo Check that there is the grease lubricated

at a necessary part around the refuelinghole and leaking grease at connecting partof the lubricator and fractionators, periodi-cally.

o Wash the grease container with benzeneor mineral oil. Never use trichloroethyleneor equivalent solvent.

o Maintain the main switch is OFF when thevehicle is not working for a long time.

o If you work the CLS when the tank isempty, it may be damaged. Inspect fre-quently.


6-39

TK20406

EGHOM722

G3920255-FOT

Liquid grease (Lincoln)

1. Manual switch2. Rotary switch3. Jumper switch

CAUTION:o Check the grease container often and

maintain the grease quantity not to beunder the "MIN" position of it.

o When pouring the grease, be carefulwater, dust, foreign material and soonnot to enter the container and pump.

o Check that there is the grease lubri-cated at a necessary part around therefueling hole and leaking grease atconnecting part of the lubricator andfractionator, periodically.

o Wash the grease container with ben-zene or mineral oil. Never use trichlo-roethylene or equivalent solvent.

o When it raining or after washing, lubri-cate manually as required.

o If any problem is occurs in the systemof a lamp and instrument lamp, they areilluminated continuously. In this case,check or ask the designated agency.

G3920155-FOT

Replenishing grease & bleeding air

o Pour grease to the "MAX" position of thestorage container using a specified tool.

o When bleeding air, perform following pro-cedures.1. After replenishing grease, turn on the

main switch.2. Press down the manual control switch

and operate the pump.3. Open the plug of the fractionator end

part and bleed air from the main pipeuntil the grease is flowed.

4. Turn the main switch off and then lockplug of it.

OPY077002A

(1) (2)(3)


6-40

o Proper lubrication is automatically providedby the electric gear pump and control unitof the piston fractionator. If lubricationquantity is short or excessive, check timeof the control unit and adjust it as required.

o Lubrication period is optionally adjustedfrom thirty minutes to eleven hours ac-cording to selection of the control timer inthe pump.

Adjusting time : 15 minutes ~ 3 hours 45minutes(15 steps) 30 minutes~7 hours(15steps)/hour ~ 15 hours(15 steps) optionaladjustment.

o If you want to know position of the built-incontrol unit, disconnect the cover andprotection cap of the unit.

o When the location of jumper is "1h" thelubrication period of timer is set 6 hour.

hour

minute

hour

minute

hour

3

30

7

-

14

3

45

7

30

15

15m

30m

1h

3

15

6

30

13

3

-

6

-

12

2

45

5

30

11

2

30

5

-

10

2

15

4

30

9

2

-

4

-

8

1

45

3

30

7

1

30

3

-

6

1

15

2

30

5

1

-

2

-

4

-

45

1

30

3

-

30

-

-

2

-

15

-

30

1

G3920355-FOT

G3920455-FOT

Replenishing grease & bleeding air

o Pour grease to the "MAX" position of thestorage container using a specified tool.1. After replenishing grease, turn on the

main switch.2. Press down the manual control switch

and operate the pump.3. Open the plug of the fractionator end

part and bleed air from the main pipeuntil the grease is flowed.

4. Turn the main switch off and then lockplug of it.

o Lubrication period is optionally adjustedaccording to selection of the control timerin the pump. When adjusting, open the capof the grease container and then you willfind the device.

TK20402A


6-41

Hard grease (Lincoln)Automatic lubrication system is grease fillingsystem which supplies all lubrication points ofvehicle by using digital controller (Time) de-pending on adjusted time & suitable quantity ofgrease. You can adjust lubrication time de-pending on vehicle model, even if it is adjustedas factory default.

1. Control PCB cap2. Grease refill nipple3. Pause timer4. Operation timer + B225. Manual switch

How to operate the pumpFactory default pause time : Blue switch (66hours) : See above illustrations (3)Operation time : Red switch (24 minutes) :See above illustrations (4)

Pause time is adjusted as 15 steps upon bluerotation timer

Operation time is adjusted as 15 steps upon redrotation timer

OPY077007

OPY077008

It can be adjusted from 1 hour to 14 hours uponinput timer of lubrication pump.

Switch location 1 2 3 4 5 6 7 8 9

Time 1 2 3 4 5 6 7 8 9

Switch location A B C D F

Time 10 11 12 13 14

Switch location 1 2 3 4 5 6 7 8 9

Minute 2 4 6 8 10 12 14 16 18

Switch location A B C D F

Minute 20 22 24 26 28


6-42

Owner’s settingPause time (Blue timer) = 6 Operation time (Redswitch) =2

Grease pump operates for 4 min. every 6hours.

Manual refillWhile the main switch of vehicle is on, bypushing manual switch on pump then pump isoperated and grease is filled through all greasepoints. (But operation time is based on minutessetted by red timer.)

Grease refillFill the grease before grease indicates MIN lineof grease pump. When filling the grease, fill thegrease by the MAX line.

NOTE:Use NLGI 1,2 grade grease which can beused under -25°C.

Documents

VEHICLE MAINTENANCE REQUIREMENTSD6CA D6CB D6CC D6DA D6AB, D6AC, D6AV D6CA, D6CB D6CC SEVERE DRIVING CONDITIONS A - Repeated short distance driving B - Extensive idling C - Driving