Hyundai HL980 Service Manual
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Hyundai HL980 Service Manual

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HL980
WHEELED LOADER
SERVICE MANUAL

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Summary of Contents for Hyundai HL980

  • Page 1 HL980 WHEELED LOADER SERVICE MANUAL...

  • Page 2: Table Of Contents

    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 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 --------------------------------------------------------------- 1-21 SECTION 2 ENGINE SECTION 2 ENGINE Group 1 Structure and Function -------------------------------------------------------------------------------------- 2-1 Group 2 Engine speed and Stall rpm ----------------------------------------------------------------------------- 2-3 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 --------------------------------------------------------------- 7-67 Group 5 Connectors ------------------------------------------------------------------------------------------------------- 7-74 Group 6 Troubleshooting ------------------------------------------------------------------------------------------------ 7-95 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: General

    SECTION 1 GENERAL SECTION 1 GENERAL Group 1 Safety Hints --------------------------------------------------------------------------------------------------------1-1 Group 2 Specifications -----------------------------------------------------------------------------------------------------1-10 Group 3 Operational Checkout Record Sheet ---------------------------------------------------------------1-21...

  • Page 14: 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 Counterweight Bucket Tire Head light Battery Precleaner(option) Main control valve Step Boom Bucket cylinder Rain cap(std) Bucket link Steering cylinder Air cleaner Engine Radiator Bell crank Front axle Boom cylinder Transmission...

  • Page 24: Specifications

    2. SPECIFICATIONS WITH BOLT-ON CUTTING EDGE TYPE BUCKET (HL980) 9802SE03 Description Unit Specification Operating weight kg (lb) 31000 (68340) Struck 4.8 (6.3) Bucket capacity Heaped 5.6 (7.3) Overall length 9610 (31' 6") Overall width 3450 (11' 4") Overall height 3865 (12' 8") Ground clearance 495 (1' 7")
  • Page 25 WITH BOLT-ON CUTTING EDGE TYPE BUCKET (HL980 XT) 9802SE03-1 Description Unit Specification Operating weight kg (lb) 31700 (69890) 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 485 (1' 7")
  • Page 26 Front frame assembly 2920 6440 Rear frame assembly 3280 7230 Front fender (LH /RH) 52/52 115/115 Counterweight (HL980) 1200 2650 Counterweight (HL980 XT) 1750 3860 Cab assembly 2190 Engine assembly 1075 2370 Transmission assembly 1880 Drive shaft (front) Drive shaft (center)
  • Page 27 4. SPECIFICATION FOR MAJOR COMPONENTS 4. SPECIFICATION FOR MAJOR COMPONENTS 1) 1) ENGINE ENGINE Item Specification Model Scania DC13 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 28 3) 3) 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 101ℓ/min (26.7 U.S.gpm) Engine high rpm 2100 rpm 4) 4) MAIN CONTROL VALVE...
  • Page 29 Ø180×Ø105×885 mm Boom cylinder Bore dia×Rod dia×Stroke Ø200×Ø110×550 mm Bucket cylinder (HL980) Bore dia×Rod dia×Stroke Ø200×Ø110×545 mm Bucket cylinder (HL980 XT) Bore dia×Rod dia×Stroke Ø105×Ø55×480 mm Steering cylinder Bore dia×Rod dia×Stroke 9) 9) DYNAMIC POWER TRANSMISSION DEVICES DYNAMIC POWER TRANSMISSION DEVICES...
  • 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 76.5 ± 7.7 553 ± 55.7 Engine mounting bolt, nut (rubber, 4EA) M24×3.0 28.6 ± 4.3 207 ± 31.1 M16×1.5 Engine mounting bolt (bracket, 16EA) 9.18 ±...
  • Page 33 American Society of Testing and Material : Soft water ★3 UTTO UTTO Universal Tractor Transmission Oil City water or distilled water Diesel Exhaust Fluid ★4 : Hyundai Bio Hydraulic Oil - For more information, contact HYUNDAI dealers. DEF compatible with AdBlue® 1-20...

  • Page 34: 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 35 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 36 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 37: Engine

    SECTION 2 ENGINE SECTION 2 ENGINE Group 1 Structure and Function -------------------------------------------------------------------------------------- 2-1 Group 2 Engine speed and Stall rpm ----------------------------------------------------------------------------- 2-3...

  • Page 38: Structure And Function

    SECTION 2 ENGINE SECTION 2 ENGINE GROUP 1 STRUCTURE AND FUNCTION GROUP 1 STRUCTURE AND FUNCTION 1. STRUCTURE 1. STRUCTURE Compressed air from turbo Oil filter Crankcase ventilation Oil pressure sensor Coolant drain Flywheel housing Coolant inlet Oil centrifugal cleaner Compressed air intake Fuel filter Hand pump for fuel...
  • Page 39 2. SCR SYSTEM 2. SCR SYSTEM The following drawing provides an overview of SCR system components. 770F2EG06 Evaporator Coolant hose, return from tank and pump heating Pressure line for reductant NOx sensor with control unit Coolant hose for tank and pump heating 10 Oxidation catalytic converter Coolant valve 11 Exhaust gas temperature sensor...

  • Page 40: Engine Speed & Stall Rpm

    GROUP 2 GROUP 2 ENGINE SPEED & STALL RPM ENGINE SPEED & STALL RPM 1. T 1. TEST CONDITION EST CONDITION Normal temperature of the whole system Coolant : Approx 80˚C (176˚F) : 45 ± 5˚C (113 ± 10˚F) Hydraulic oil Transmission oil : 75 ±...

  • Page 41: Power Train System

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