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Hyundai HL975 Service Manual
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Hyundai HL975 Service Manual

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HL975
WHEELED LOADER
SERVICE MANUAL

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Summary of Contents for Hyundai HL975

  • Page 1 HL975 WHEELED LOADER SERVICE MANUAL...
  • Page 2 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...
  • Page 3 TABLE OF CONTENT CONTENTS FOREWORD GENERAL 1. SAFETY HINTS 2. SPECIFICATIONS 3. OPERATIONAL CHECKOUT RECORD SHEET ENGINE 1. STRUCTURE AND FUNCTION 2. ENGINE SPEED & STALL RPM POWER TRAIN SYSTEM 1. STRUCTURE AND FUNCTION 2. OPERATIONAL CHECKS AND TROUBLESHOOTING 3. TESTS AND ADJUSTMENTS 4.
  • 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 --------------------------------------------------------------- 7-69 Group 5 Connectors ------------------------------------------------------------------------------------------------------- 7-76 Group 6 Troubleshooting ------------------------------------------------------------------------------------------------ 7-98 Find manuals at https://best-manuals.com...
  • Page 5 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 Group 1 Safety Hints --------------------------------------------------------------------------------------------------------1-1 Group 2 Specifications -----------------------------------------------------------------------------------------------------1-10 Group 3 Operational Checkout Record Sheet ---------------------------------------------------------------1-23...
  • Page 14 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 1. MAJOR COMPONENT 1. MAJOR COMPONENT Hydraulic tank Radiator Bucket Tire Head light Main control valve Battery Boom Boom cylinder Counterweight Engine Main pump Air cleaner Bell crank Bucket cylinder 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 (HL975) 9752SE03 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") Overall width 3250 (10' 8")
  • Page 25 WITH BOLT-ON CUTTING EDGE TYPE BUCKET WITH BOLT-ON CUTTING EDGE TYPE BUCKET (HL975 XT) 9752SE03-1 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") Overall height 3590 (11' 9")
  • Page 26 2) 2) WITH 1-PIECE TOOTH TYPE BUCKET WITH 1-PIECE TOOTH TYPE BUCKET (HL975) 9752SE04 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 (HL975 XT) 9752SE04-1 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 2222 4900 Rear frame assembly 2504 5520 Front fender (LH & RH) Counterweight (HL975) 1950 4300 Counterweight (HL975 XT) 2450 5400 Cab assembly 1070 2360 Engine assembly 1896 Transmission assembly (4-speed/5-speed) 760/810 1680/1790 Drive shaft (front)
  • Page 29 4. SPECIFICATION FOR MAJOR COMPONENTS 4. SPECIFICATION FOR MAJOR COMPONENTS 1) 1) ENGINE ENGINE Item Specification Model Cummins QSG12 Type 4-cycle turbocharged, charge air cooled diesel engine Control type Electronic control Cooling method Water cooling Number of cylinders and arrangement 6 cylinders, in-line Firing order 1-5-3-6-2-4...
  • 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 80ℓ/min (21.1 U.S.gpm) Maximum speed 2100 rpm 4) 4) MAIN CONTROL VALVE MAIN CONTROL VALVE Item Specification...
  • Page 31 CYLINDER CYLINDER Item Specification Ø170×Ø100×795 mm Boom cylinder Bore dia×Rod dia×Stroke Ø190×Ø100×565 mm Bucket cylinder (HL975) Bore dia×Rod dia×Stroke Ø190×Ø100×585 mm Bucket cylinder (HL975XT) Bore dia×Rod dia×Stroke Ø100×Ø55×480 mm Steering cylinder Bore dia×Rod dia×Stroke 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 76.5 ± 7.7 553 ± 55.7 Engine mounting bolt, nut (rubber, 2EA) M24×3.0 18.4 ± 1.8 133 ± 13.0 Engine mounting bolt (bracket, 8EA) M14×2.0 6.9 ±...
  • Page 35 : If the machine is equipped with axle oil cooler, Ultra low sulfur diesel - sulfur content  15 ppm refer to page 6-38 of operator's manual. ★5 : Hyundai Bio Hydraulic Oil - For more information, contact HYUNDAI dealers. 1-22...
  • Page 36 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 37 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 38 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 39 SECTION 2 ENGINE SECTION 2 ENGINE Group 1 Structure and Function -------------------------------------------------------------------------------------- 2-1 Group 2 Engine speed and Stall rpm ----------------------------------------------------------------------------- 2-8...
  • Page 40 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...
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