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Hyundai HL975A CVT Service Manual
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Hyundai HL975A CVT Service Manual

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HL975A CVT
WHEELED LOADER
SERVICE MANUAL

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Summary of Contents for Hyundai HL975A CVT

  • Page 1 HL975A CVT WHEELED LOADER SERVICE MANUAL...

  • Page 2: Table Of Contents

    TABLE OF CONTENT CONTENTS FOREWORD SECTION 1 GENERAL Group 1 Safety Hints Group 2 Specifications 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 Group 4 Disassembly And Assembly...

  • 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 --------------------------------------------------------------- 1-23 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 Monitoring System ------------------------------------------------------------------------------------------ 7-22 Group 4 Electrical Component Specification --------------------------------------------------------------- 7-72 Group 5 Connectors ------------------------------------------------------------------------------------------------------- 7-79 Group 6 Troubleshooting ------------------------------------------------------------------------------------------------ 7-101 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 HD Hyundai Construction Equipment distributor for the latest information.
  • Page 6 Revised edition mark Revised edition mark (①②③…) Any additions, amendments or other changes When a manual is revised, an edition mark is will be sent to HD Hyundai Construction recorded on the bottom outside corner of the Equipment distributors. 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 ---------------------------------------------------------------1-23...

  • 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 wor k 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 Radiator Bucket Tire Head light Boom Boom cylinder Main control valve Battery Counterweight Main pump Engine Bell crank Bucket cylinder Air cleaner Bucket link Front axle Steering cylinder Transmission Rear axle...
  • Page 24 2. SPECIFICATIONS 2. SPECIFICATIONS 1) 1) WITH BOLT-ON CUTTING EDGE TYPE BUCKET WITH BOLT-ON CUTTING EDGE TYPE BUCKET (HL975A CVT) 975CVT2SE03 Description Unit Specification Operating weight kg (lb) 26500 (58430) Struck 4.1 (5.4) Bucket capacity Heaped 4.8 (6.3) Overall length 9205 (30' 2")
  • Page 25 WITH BOLT-ON CUTTING EDGE TYPE BUCKET WITH BOLT-ON CUTTING EDGE TYPE BUCKET (HL975A CVT XT) 975CVT2SE03-1 Description Unit Specification Operating weight kg (lb) 27295 (60180) Struck 4.1 (5.4) Bucket capacity Heaped 4.8 (6.3) Overall length 9640 (31' 8") Overall width 3250 (10' 8")
  • Page 26 2) 2) WITH 1-PIECE TOOTH TYPE BUCKET WITH 1-PIECE TOOTH TYPE BUCKET (HL975A CVT) 975CVT2SE04 Description Unit Specification Operating weight kg (lb) 26395 (58190) Struck 4.0 (5.2) Bucket capacity Heaped 4.6 (6.0) Overall length 9355 (30' 8") Overall width 3300 (10' 10") Overall height 3590 (11' 9")
  • Page 27 WITH 1-PIECE TOOTH TYPE BUCKET WITH 1-PIECE TOOTH TYPE BUCKET (HL975A CVT XT) 975CVT2SE04-1 Description Unit Specification Operating weight kg (lb) 27190 (59950) Struck 4.0 (5.2) Bucket capacity Heaped 4.6 (6.0) Overall length 9790 (32' 1") Overall width 3300 (10' 10") Overall height 3590 (11' 9")
  • Page 28 Item Front frame assembly 2245 4949 Rear frame assembly 2587 5703 Front fender (LH & RH) Counterweight (HL975A CVT) 1950 4300 Counterweight (HL975A CVT XT) 2450 5400 Cab assembly 1045 2304 Engine assembly 1896 Transmission assembly 1766 Drive shaft (front)
  • Page 29 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 30 3) 3) FAN + BRAKE PUMP FAN + BRAKE PUMP Item Specification Type Variable piston pump Capacity 28 cc/rev Maximum operating pressure 250 kgf/cm (3560 psi) Rated oil quantity 50ℓ/min (13.2 U.S.gpm) Maximum speed 1800 rpm 4) 4) MAIN CONTROL VALVE MAIN CONTROL VALVE Item Specification...
  • Page 31 Specification Boom cylinder Bore dia×Rod dia×Stroke Ø170×Ø100×795 mm Bucket cylinder (HL975A CVT) Bore dia×Rod dia×Stroke Ø190×Ø100×565 mm Bucket cylinder (HL975A CVT XT) Bore dia×Rod dia×Stroke Ø190×Ø100×585 mm Steering cylinder Bore dia×Rod dia×Stroke Ø100×Ø55×467 mm 9) 9) DYNAMIC POWER TRANSMISSION DEVICES...
  • Page 32 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 M 6 × 1.0 0.8 ~ 1.2 5.8 ~ 8.6 1.2 ~ 1.8...
  • Page 33 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 34 TIGHTENING TORQUE OF MAJOR COMPONENT TIGHTENING TORQUE OF MAJOR COMPONENT Torque Descriptions Bolt size kgf・m lbf・ft Engine mounting bolt, nut (rubber, 2EA) M24×3.0 76.5 ± 7.7 553 ± 55.7 Engine mounting bolt (bracket, 8EA) M12×1.75 11.7 84.6 Engine mounting bolt (T/C housing, 11EA) 6.63 ±...
  • Page 35 DEF compatible with AdBlue® ★4 If the machine is equipped with axle oil cooler, ★1 Ultra low sulfur diesel refer to page 6-43 in operator's manual. - sulfur content  15 ppm ★5 HD Hyundai Construction Equipment Bio Hydraulic Oil 1-22...

  • Page 36: 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 37: 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 38 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 39 9752EG4-1 Lubricating oil flow from lubricating oil filter head to engine block main oil rifle Main oil rifle Flow to main bearings Flow to cylinder head Flow to piston cooling nozzle Flow to air compressor Flow to fuel pump Flow to camshaft idler gear Flow to crankshaft idler gear 10 Flow to REPTO idler gear (if applicable) 11 Block oil rifle pressure sensing channel...
  • Page 40 9752EG4-2 Flow from cylinder block to cylinder head Flow to camshaft bushings Flow to rocker lever shafts Rocker lever shaft Flow from rocker lever shaft to intake rocker levers Flow from rocker lever shaft to exhaust rocker levers. 9752EG4-3 Main bearing flow from oil rifle Flow to crankshaft connecting rod bearing Piston pin Flow from oil rifle to piston cooling nozzle...
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