Hyundai HL975 User manual

HL975
WHEELED LOADER
SERVICE MANUAL

CONTENTS
CONTENTS
SECTION 1 GENERAL
SECTION 1 GENERAL
Group 1 Safety Hints -------------------------------------------------------------------------------------------------------- 1-1
Group 2 Specifications ----------------------------------------------------------------------------------------------------- 1-10
Group 3 Operational Checkout Record Sheet --------------------------------------------------------------- 1-23
SECTION 2 ENGINE
SECTION 2 ENGINE
Group 1 Structure and Function -------------------------------------------------------------------------------------- 2-1
Group 2 Engine speed and Stall rpm ----------------------------------------------------------------------------- 2-9
SECTION 3 POWER TRAIN SYSTEM
SECTION 3 POWER TRAIN SYSTEM
Group 1 Structure and Function (fault codes) ---------------------------------------------------------------- 3-1
Group 2 Operational Checks and Troubleshooting ------------------------------------------------------- 3-83
Group 3 Test and Adjustments ---------------------------------------------------------------------------------------- 3-95
Group 4 Disassembly and Assembly
----------------------------------------------------------------------------- 3-99
SECTION 4 BRAKE SYSTEM
SECTION 4 BRAKE SYSTEM
Group 1 Structure and Function -------------------------------------------------------------------------------------- 4-1
Group 2 Operational Checks and Troubleshooting ------------------------------------------------------- 4-32
Group 3 Tests and Adjustments -------------------------------------------------------------------------------------- 4-39
Group 4 Disassembly and assembly
------------------------------------------------------------------------------ 4-41
SECTION 5 STEERING SYSTEM
SECTION 5 STEERING SYSTEM
Group 1 Structure and Function -------------------------------------------------------------------------------------- 5-1
Group 2 Operational Checks and Troubleshooting ------------------------------------------------------- 5-16
Group 3 Tests and Adjustments -------------------------------------------------------------------------------------- 5-24
Group 4 Disassembly and Assembly
----------------------------------------------------------------------------- 5-31
SECTION 6 WORK EQUIPMENT
SECTION 6 WORK EQUIPMENT
Group 1 Structure and Function -------------------------------------------------------------------------------------- 6-1
Group 2 Operational Checks and Troubleshooting ------------------------------------------------------- 6-40
Group 3 Tests and Adjustments -------------------------------------------------------------------------------------- 6-51
Group 4 Disassembly and Assembly
----------------------------------------------------------------------------- 6-63
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TABLE OF CONTENT
CONTENTS 1
FOREWORD 3
GENERAL 11
1. SAFETY HINTS 12
2. SPECIFICATIONS 21
3. OPERATIONAL CHECKOUT RECORD SHEET 34
ENGINE 37
1. STRUCTURE AND FUNCTION 38
2. ENGINE SPEED & STALL RPM 45
POWER TRAIN SYSTEM 46
1. STRUCTURE AND FUNCTION 47
2. OPERATIONAL CHECKS AND TROUBLESHOOTING 129
3. TESTS AND ADJUSTMENTS 141
4. DISASSEMBLY AND ASSEMBLY 145
BRAKE AND FAN SYSTEM 347
1. STRUCTURE AND FUNCTION 348
2. OPERATIONAL CHECKS AND TROUBLESHOOTING 379
3. TESTS AND ADJUSTMENTS 386
4. DISASSEMBLY AND ASSEMBLY 388
STEERING SYSTEM 408
1. STRUCTURE AND FUNCTION 409
2. OPERATIONAL CHECKS AND TROUBLESHOO 424
3. TESTS AND ADJUSTMENTS 432
4. DISASSEMBLY AND ASSEMBLY 439
WORK EQUIPMENT 502
1. STRUCTURE AND FUNCTION 503
2. OPERATIONAL CHECKS AND TROUBLESHOOTING 543
3. TESTS AND ADJUSTMENTS 554
4. DISASSEMBLY AND ASSEM 566
ELECTRICAL SYSTEM
1. COMPONENT LOCATION
2. ELECTRICAL CIRCUIT (-#0047)
2. ELECTRICAL CIRCUIT (#0048-)
3. MONITORING SYSTEM
4. ELECTRICAL COMPONENT SPECIFICATION
5. CONNECTORS
6. TROUBLESHOOTING
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SECTION 7 ELECTRICAL SYSTEM
SECTION 7 ELECTRICAL SYSTEM
Group 1 Component Location --------------------------------------------------------------------------------------- 7-1
Group 2 Electrical Circuit
----------------------------------------------------------------------------------------------- 7-3
Group 3 Monitoring System ------------------------------------------------------------------------------------------ 7-22
Group 4 Electrical Component Specification
--------------------------------------------------------------- 7-69
Group 5 Connectors ------------------------------------------------------------------------------------------------------- 7-76
Group 6 Troubleshooting ------------------------------------------------------------------------------------------------ 7-98
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0-1
FOREWORD
FOREWORD
1. STRUCTURE
1. STRUCTURE
This service manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to
perform repairs and make judgements. Make sure you understand the contents of this manual and
use it to full effect at every opportunity.
This service manual mainly contains the necessary technical information for operations performed in
a service workshop.
For ease of understanding, the manual is divided into the following sections.
Structure and function
Structure and function
This group explains the structure and function of each component. It serves not only to give an
understanding of the structure, but also serves as reference material for troubleshooting.
Operational checks and troubleshooting
Operational checks and troubleshooting
This group explains the system operational checks and troubleshooting charts correlating problem to
remedy.
Tests and adjustments
Tests and adjustments
This group explains checks to be amide before and after performing repairs, as well as adjustments
to be made at completion of the checks and repairs.
Disassembly and assembly
Disassembly and assembly
This section explains the order to be followed when removing, installing, disassembling or
assembling each component, as well as precautions to be taken for these operations.
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Contact your Hyundai distributor for the latest information.
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0-2
Revised edition mark
Revised edition mark (①②③…)
When a manual is revised, an edition mark is
recorded on the bottom outside corner of the
pages.
Revisions
Revisions
Revised pages are shown at the list of revised
pages on the between the contents page and
section 1 page.
Symbols
Symbols
So that the shop manual can be of ample
practical use, important places for safety and
quality are marked with the following symbols.
2. HOW TO READ THE SERVICE MANUAL
2. HOW TO READ THE SERVICE MANUAL
Distribution and updating
Distribution and updating
Any additions, amendments or other changes
will be sent to HYUNDAI distributors.
Get the most up-to-date information before you
start any work.
Filing method
Filing method
See the page number on the bottom of the
page.
File the pages in correct order.
Following examples shows how to read the
page number.
Example 1
3 - 3
Section number (3. Power train
system)
Consecutive page number for
each section.
Additional pages : Additional pages are
indicated by a hyphen(-) and number after the
page number. File as in the example.
1.
2.
3.
Symbol Item Remarks
Special safety precautions are
necessary when performing the
work.
Extra special safety precautions
are necessary when performing
the work because it is under
internal pressure.
Special technical precautions or
other precautions for preserving
standards are necessary when
performing the work.
Safety
Caution
※
7 - 4
7 - 4 - 1
7 - 4 - 2
7 - 5
Added pages
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0-3
3. CONVERSION TABLE
3. CONVERSION TABLE
Method of using the Conversion Table
The Conversion Table in this section is provided to enable simple conversion of figures. For details of
the method of using the Conversion Table, see the example given below.
Example
Example
Method of using the Conversion Table to convert from millimeters to inches
Convert 55
mm into inches.
Locate the number 50
in the vertical column at the left side, take this as ⓐ , then draw a horizontal
line from
ⓐ .
Locate the number 5
in the row across the top, take this as ⓑ , then draw a perpendicular line
down from
ⓑ .
Take the point where the two lines cross as
ⓒ . This point ⓒ gives the value when converting
from millimeters to inches. Therefore, 55
mm = 2.165 inches.
Convert 550
mm into inches.
The number 550 does not appear in the table, so divide by 10 (move the decimal point one place
to the left) to convert it to 55
mm .
Carry out the same procedure as above to convert 55 mm to 2.165 inches.
The original value (550
mm ) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value.
This gives 550
mm = 21.65 inches.
1.
2.
(1)
(2)
(3)
(1)
(2)
(3)
Millimeters to inches
Millimeters to inches 1
mm = 0.03937 in
ⓑ
ⓐ
0 1 2 3 4 5 6 7 8 9
0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
ⓒ
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0-4
Millimeters to inches
Millimeters to inches 1
mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
Kilogram to Pound 1
kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.5. 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
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0-5
Liter to U.S. Gallon
Liter to U.S. Gallon 1ℓ= 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.6076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.631 25.625 25.889 26.153
Liter to U.K. Gallon
Liter to U.K. Gallon 1ℓ= 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
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0-6
kgf
kgf
·m to
to
lbf
lbf
·ft
ft
1 kgf·m = 7.233 lbf·ft
0 1 2 3 4 5 6 7 8 9
7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 396.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 10005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
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