Hyundai HL980T3 Service Manual
  1. Manuals
  2. Brands
  3. Hyundai Manuals
  4. Front End Loaders
  5. HL980T3
  6. Service manual

Hyundai HL980T3 Service Manual

Wheeled loader
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
HL980T3
WHEELED LOADER
SERVICE MANUAL

Advertisement

Table of Contents
loading

Related Manuals for Hyundai HL980T3

Summary of Contents for Hyundai HL980T3

  • Page 1 HL980T3 WHEELED LOADER SERVICE MANUAL...

  • Page 2: Table Of Contents

    TABLE OF CONTENT CONTENTS FOREWORD SECTION 1 GENERAL Group 1 Safety Hints Group 2 Specifications Group 3 Operational Checkout Record Sheet SECTION 2 ENGINE Group 1 Structure And Function Group 2 Engine Speed & Stall Rpm SECTION 3 POWER TRAIN SYSTEM Group 1 Structure And Function Group 2 Operational Checks And Troubleshooting Group 3 Tests And Adjustments...

  • Page 3: Contents

    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 --------------------------------------------------------------- 1-22 SECTION 2 ENGINE SECTION 2 ENGINE Group 1 Structure and Function -------------------------------------------------------------------------------------- 2-1 Group 2 Engine speed and Stall rpm ----------------------------------------------------------------------------- 2-8 SECTION 3 POWER TRAIN SYSTEM SECTION 3 POWER TRAIN SYSTEM...
  • Page 4 SECTION 7 ELECTRICAL SYSTEM SECTION 7 ELECTRICAL SYSTEM Group 1 Component Location --------------------------------------------------------------------------------------- 7-1 Group 2 Electrical Circuit ----------------------------------------------------------------------------------------------- 7-3 Group 3 Electrical Component Specification ---------------------------------------------- ---------------- 7-22 Group 4 Connector -------------------------------------------------------------------------------------------------------- 7-29 Group 5 Troubleshooting ----------------------------------------------------------------------------------------------- 7-52 Find manuals at https://best-manuals.com...

  • Page 5: Foreword

    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. Find manuals at https://best-manuals.com...
  • Page 6 Revised edition mark (①②③…) Any additions, amendments or other changes When a manual is revised, an edition mark is will be sent to HYUNDAI distributors. recorded on the bottom outside corner of the Get the most up-to-date information before you pages.
  • Page 7 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...
  • Page 8 Millimeters to inches Millimeters to inches 1mm = 0.03937in 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142 1.181 1.220 1.260 1.299 1.339...
  • Page 9 Liter to U.S. Gallon Liter to U.S. Gallon 1ℓ = 0.2642 U.S.Gal 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019 5.283 5.548 5.812 6.6076 6.340 6.604 6.869 7.133 7.397 7.661 7.925 8.189...
  • Page 10 kgf・m to to lbf lbf・ft ft 1kgf・m = 7.233lbf・ft 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8 217.0 224.2 231.5 238.7 245.9 253.2...
  • Page 11 kgf/cm kgf/cm to to lbf/in lbf/in 1kgf / cm = 14.2233lbf / in 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5 426.7...
  • Page 12 TEMPERATURE TEMPERATURE Fahrenheit-Centigrade Conversion. A simple way to convert a fahrenheit temperature reading into a centigrade temperature reading or vice verse is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.

  • Page 13: Section 1 General

    SECTION 1 GENERAL SECTION 1 GENERAL Group 1 Safety Hints --------------------------------------------------------------------------------------------------------1-1 Group 2 Specifications -----------------------------------------------------------------------------------------------------1-10 Group 3 Operational Checkout Record Sheet ---------------------------------------------------------------1-22...

  • Page 14: Group 1 Safety Hints

    SECTION 1 GENERAL SECTION 1 GENERAL GROUP 1 SAFETY HINTS GROUP 1 SAFETY HINTS FOLLOW SAFE PROCEDURE FOLLOW SAFE PROCEDURE Unsafe work practices are dangerous. Understand service procedure before doing work; Do not attempt shortcuts. WEAR PROTECTIVE CLOTHING WEAR PROTECTIVE CLOTHING Wear close fitting clothing and safety equipment appropriate to the job.
  • Page 15 PREPARE FOR EMERGENCIES PREPARE FOR EMERGENCIES Be prepared if a fire starts. Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambulance ser vice, hospital, and fire department near your telephone. 73031GE03 WORK IN CLEAN AREA WORK IN CLEAN AREA Before starting a job : ・...
  • Page 16 PARK MACHINE SAFELY PARK MACHINE SAFELY Before working on the machine: ・ Park machine on a level surface. ・ Lower bucket to the ground. ・ Turn key switch to OFF to stop engine. Remove key from switch. ・ Move pilot control shutoff lever to locked position.
  • Page 17 Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers. Make sure machine is clean of trash, grease, and debris. Do not store oily rags ; They can ignite and burn spontaneously. 73031GE09 BEWARE OF EXHAUST FUMES BEWARE OF EXHAUST FUMES Prevent asphyxiation.
  • Page 18 ILLUMINATE WORK AREA SAFELY ILLUMINATE WORK AREA SAFELY Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil.
  • Page 19 AVOID HIGH PRESSURE FLUIDS AVOID HIGH PRESSURE FLUIDS Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure 73031GE14 fluids.
  • Page 20 PREVENT ACID BURNS PREVENT ACID BURNS Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. Avoid the hazard by: Filling batteries in a well-ventilated area. Wearing eye protection and rubber gloves.
  • Page 21 SERVICE TIRES SAFELY SERVICE TIRES SAFELY Explosive separation of a tire and rim parts can cause serious injury or death. Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job. Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure.
  • Page 22 REPLACE SAFETY SIGNS REPLACE SAFETY SIGNS Replace missing or damaged safety signs. See the machine operator's manual for correct safety sign placement. 73031GE21 LIVE WITH SAFETY LIVE WITH SAFETY Before returning machine to customer, make sure machine is functioning properly, especially the safety systems.

  • Page 23: Group 2 Specifications

    GROUP 2 SPECIFICATIONS GROUP 2 SPECIFICATIONS 1. MAJOR COMPONENT 1. MAJOR COMPONENT Hydraulic tank Counterweight Bucket Tire Head light Battery Precleaner(option) Main control valve Step Boom Bucket cylinder Rain cap(std) Bucket link Bell crank Steering cylinder Air cleaner Engine Radiator Front axle Boom cylinder Main pump...
  • Page 24 2. SPECIFICATIONS 2. SPECIFICATIONS 1) 1) WITH BOLT-ON CUTTING EDGE TYPE BUCKET WITH BOLT-ON CUTTING EDGE TYPE BUCKET (HL980 T3) 980A2SE03 Description Unit Specification Operating weight kg (lb) 30550 (67355) Struck 4.8 (6.3) Bucket capacity Heaped 5.6 (7.3) Overall length 9610 (31' 6") Overall width 3450 (11' 4")
  • Page 25 WITH BOLT-ON CUTTING EDGE TYPE BUCKET WITH BOLT-ON CUTTING EDGE TYPE BUCKET (HL980XT T3) 980A2SE03-1 Description Unit Specification Operating weight kg (lb) 31250 (68895) Struck 4.8 (6.3) Bucket capacity Heaped 5.6 (7.3) Overall length 9930 (32' 7") Overall width 3450 (11' 4") Overall height 3865 (12' 8") Ground clearance...
  • Page 26 3. WEIGHT 3. WEIGHT Item Front frame assembly 3,005 6,625 Rear frame assembly 3,365 7,420 Front fender (LH /RH) 58 / 50 130 / 115 Rear fender (LH /RH) 100 / 96 225 / 215 Counterweight (HL980 T3) 1,200 2,650 Counterweight (HL980XT T3) 1,750 3,860...
  • Page 27 4. SPECIFICATION FOR MAJOR COMPONENTS 4. SPECIFICATION FOR MAJOR COMPONENTS 1) 1) ENGINE ENGINE Item Specification Model Cummins X12 4-cycle turbocharged, charge air cooled Type electronic controlled diesel engine Cooling method Water cooled Number of cylinders and arrangement 6 cylinders, in-line Firing order 1-5-3-6-2-4 Combustion chamber type...
  • Page 28 4) 4) FAN + BRAKE PUMP FAN + BRAKE PUMP Specification Item Fan pump Brake pump Type Piston pump Capacity 45 cc/rev Maximum operating pressure 250 kgf/cm (3980 psi) 150 kgf/cm (2130 psi) Rated oil quantity (at 2200rpm) 99ℓ/min (26.1 U.S.gpm) Engine high rpm 2100 rpm 5) 5)
  • Page 29 9) 9) CYLINDER CYLINDER Item Specification Boom cylinder Bore dia×Rod dia×Stroke Ø180×Ø105×885 mm Bucket cylinder (HL980 T3) Bore dia×Rod dia×Stroke Ø200×Ø110×550 mm Bucket cylinder (HL980XT T3) Bore dia×Rod dia×Stroke Ø200×Ø110×545 mm Steering cylinder Bore dia×Rod dia×Stroke Ø105×Ø55×460 mm DYNAMIC POWER TRANSMISSION DEVICES DYNAMIC POWER TRANSMISSION DEVICES Item Specification...
  • Page 30 5. TIGHTENING TORQUE 5. TIGHTENING TORQUE Use following table for unspecified torque. 1) 1) BOLT AND NUT BOLT AND NUT (1) (1) Coarse thread Coarse thread 8.8T 10.9T 12.9T Bolt size kgf·m lbf·ft kgf·m lbf·ft kgf·m lbf·ft 0.8 ~ 1.2 5.8 ~ 8.6 1.2 ~ 1.8 8.7 ~ 13.0...
  • Page 31 2) 2) PIPE AND HOSE PIPE AND HOSE (FLARE type) Thread size Width across flat (mm) kgf・m lbf・ft 1/4" 28.9 3/8" 36.2 1/2" 68.7 3/4" 1" 1-1/4" 3) 3) PIPE AND HOSE PIPE AND HOSE (ORFS type) Thread size Width across flat (mm) kgf・m lbf・ft 9/16-18...
  • Page 32 TIGHTENING TORQUE OF MAJOR COMPONENT TIGHTENING TORQUE OF MAJOR COMPONENT Torque Descriptions Bolt size kgf・m lbf・ft Engine mounting bolt, nut (rubber, 4EA) M24×3.0 76.5 ± 7.7 553 ± 55.7 Engine mounting bolt (bracket, 16EA) M14×2.0 18.4 ± 2.8 133 ± 20.3 Engine Fan motor mounting bolt 12.8 ±...
  • Page 33 ※ Do not mix HYUNDAI genuine oil with any other lubricating oil as it may result in damage to the systems of Do not mix HYUNDAI genuine oil with any other lubricating oil as it may result in damage to the systems of major components.
  • Page 34 Ambient temperature ˚C (˚F) Capacity Service point Kind of fluid ℓ (U.S. gal) (-58) (-22) (-4) (14) (32) (50) (68) (86) (104) SAE 15W-40 Engine ★ Engine oil 34 (9.0) SAE 5W-40 oil pan SAE 0W-40 SAE 10W-30 Transmission Engine oil 50.8 (13.4) SAE 15W-40 FR : 64 (16.9)

  • Page 35: Group 3 Operational Checkout Record Sheet

    GROUP 3 OPERATIONAL CHECKOUT RECORD SHEET GROUP 3 OPERATIONAL CHECKOUT RECORD SHEET ・Owner ・Date ・Hours ・Serial No. ・Technician ※ Use this sheet to record operational Use this sheet to record operational checkout results. checkout results. Perform the operational check before Perform the operational check before installing any test equipment.
  • Page 36 4. Brake system and clutch cut off checks 4. Brake system and clutch cut off checks □ □ ・ Park brake capacity check □ □ ・ Park brake transmission lockout check □ □ ・ Service brake pump flow check □ □...
  • Page 37 7. Steering system checks 7. Steering system checks □ □ ・Steering unit check □ □ ・Steering system leakage check ・Steering valve (EHPS) □ □ Low check pressure □ □ High check pressure 8. Accessory checks 8. Accessory checks □ □ ・Operating lights check □...

  • Page 38: Section 2 Engine

    SECTION 2 ENGINE SECTION 2 ENGINE Group 1 Structure and Function -------------------------------------------------------------------------------------- 2-1 Group 2 Engine speed and Stall rpm ----------------------------------------------------------------------------- 2-8...

  • Page 39: Group 1 Structure And Function

    SECTION 2 ENGINE SECTION 2 ENGINE GROUP 1 STRUCTURE AND FUNCTION GROUP 1 STRUCTURE AND FUNCTION 1. 1. FUEL SYSTEM FUEL SYSTEM 9752EG03 Fuel supply - from suction side filter Fuel rail Fuel pump gear pump inlet Fuel rail pressure sensor Fuel pump gear pump outlet Injector supply lines Pressure side fuel filter inlet...
  • Page 40 2. 2. LUBRICATING OIL SYSTEM LUBRICATING OIL SYSTEM 9752EG04 Flow from oil pan through suction tube Flow from suction tube to lubricating oil pump Lubricating oil pump Lubricating oil pressure regulator valve Lubricating oil high-pressure relief valve Lubricating oil return to oil pan Lubricating oil flow from lubricating oil pump to lubricating oil cooler module Lubricating oil thermostat Flow with lubricating oil thermostat open...
  • Page 41 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...

Table of Contents