PDF Service Manual Hyundai HL740-9S Wheel Loader - 8 MB
This is the 2023 service manual for the Hyundai HL740-9S wheel loader, providing the most up-to-date repair and maintenance information.
It contains detailed procedures for servicing all major systems, including the engine, hydraulics, and transmission.
Professional technicians rely on this manual to perform accurate diagnostics and repairs.
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--- Page 1 ---
FOREWORD
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
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
This group explains the system operational checks and troubleshooting charts correlating problem to
remedy.
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
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.
0-1
--- Page 3 ---
SECTION 1 GENERAL
Group 1 Safety Hints --------------------------------------------------------------------------------------------------------1-1
Group 2 Specifications -----------------------------------------------------------------------------------------------------1-10
Group 3 Operational Checkout Record Sheet ---------------------------------------------------------------1-23
--- Page 4 ---
GROUP 2 SPECIFICATION
1. MAJOR COMPONENTS
Bucket Tire Head light Hydraulic tank Radiator
Boom Boom cylinder Main control valve Battery Counterweight
Precleaner(option)
Bell crank Bucket cylinder Cab Main pump Rain cap(std) Muffler
Air cleaner
Bucket link Front axle Steering cylinder Transmission Rear axle Engine Fuel tank
7409S2SP05
1-10
--- Page 5 ---
6. TORQUE CHART
Use following table for unspecified torque.
1) BOLT AND NUT
(1) Coarse thread
8T 10T
Bolt size
kg·m lb·ft kg·m lb·ft
M 6×1.0 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6
M 8×1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.73 ~ 4.12 19.5 ~ 29.8
M10×1.5 4.0 ~ 6.0 28.9 ~ 43.4 5.5 ~ 8.3 39.8 ~ 60
M12×1.75 7.4 ~ 11.2 53.5 ~ 79.5 9.8 ~ 15.8 71 ~ 114
M14×2.0 12.2 ~ 16.6 88.2 ~ 120 16.7 ~ 22.5 121 ~ 167
M16×2.0 18.6 ~ 25.2 135 ~ 182 25.2 ~ 34.2 182 ~ 247
M18×2.5 25.8 ~ 35.0 187 ~ 253 35.1 ~ 47.5 254 ~ 343
M20×2.5 36.2 ~ 49.0 262 ~ 354 49.2 ~ 66.6 356 ~ 482
M22×2.5 48.3 ~ 63.3 350 ~ 457 65.8 ~ 98.0 476 ~ 709
M24×3.0 62.5 ~ 84.5 452 ~ 611 85.0 ~ 115 615 ~ 832
M30×3.0 124 ~ 168 898 ~ 1214 169 ~ 229 1223 ~ 1655
M36×4.0 174 ~ 236 1261 ~ 1703 250 ~ 310 1808 ~ 2242
(2) Fine thread
8T 10T
Bolt size
kg·m lb·ft kg·m lb·ft
M 8×1.0 2.17 ~ 3.37 15.7 ~ 24.3 3.04 ~ 4.44 22.0 ~ 32.0
M10×1.25 4.46 ~ 6.66 32.3 ~ 48.2 5.93 ~ 8.93 42.9 ~ 64.6
M12×1.25 7.78 ~ 11.58 76.3 ~ 83.7 10.6 ~ 16.0 76.6 ~ 115
M14×1.5 13.3 ~ 18.1 96.2 ~ 130 17.9 ~ 24.1 130 ~ 174
M16×1.5 19.9 ~ 26.9 144 ~ 194 26.6 ~ 36.0 193 ~ 260
M18×1.5 28.6 ~ 43.6 207 ~ 315 38.4 ~ 52.0 278 ~ 376
M20×1.5 40.0 ~ 54.0 289 ~ 390 53.4 ~ 72.2 386 ~ 522
M22×1.5 52.7 ~ 71.3 381 ~ 515 70.7 ~ 95.7 512 ~ 692
M24×2.0 67.9 ~ 91.9 491 ~ 664 90.9 ~ 123 658 ~ 890
M30×2.0 137 ~ 185 990 ~ 1338 182 ~ 248 1314 ~ 1795
M36×3.0 192 ~ 260 1389 ~ 1879 262 ~ 354 1893 ~ 2561
1-20
--- Page 6 ---
3) COOLING SYSTEM
7607B2EG09
※ Never operate the engine without a thermostat. Without a thermostat, the coolant will not
flow to the radiator and the engine will overheat.
(1) The illustrantion identifies the significant features of the coolant system.
① Sections A and B.
Coolant is drawn from the radiator by the integrally mounted water pump. The output from
the water pump empties into the oil cooler cavity of the cylinder block.
The coolant then circulates around each cylinder and crosses the block to the fuel pump
side of the engine.
1 Coolant inlet 4 Coolant flow past cylinder head
2 Pump Impeller 5 Coolant to cylinder head
3 Coolant flow past oil cooler
② Sections C and D.
Coolant then flows up into the cylinder head, crosses over the valve bridges, and down the
exhaust manifold side of the engine to the integral thermostat housing.
As the coolant flows across the head toward the thermostat housing, it provides cooling for
the injector. When the engine is below operating temperature, the thermostat is closed, and
the coolant flow bypasses the radiator and goes to the water pump inlet through internal
drillings in the block and cylinder head.
1 Coolant flow from the cylinder head 5 Coolant bypass passage
2 Coolant to the thermostat housing 6 Coolant flow to pump inlet
3 Coolant flow past injector 7 Bypass closed
4 Thermostat 8 Coolant flow back to radiator
When operating temperature is reached, the thermostat opens, blocking the bypass
passage to the water pump and opening the outlet to the radiator.
2-4
--- Page 7 ---
2) INSTALLATION VIEW
1 2 9 10 11 12 14
15
20
3 16
19
3 13 18
4 17
7 6 5
7409S3PT02
1 Lifting lugs 12 Transmission-case cover
2 Connection to engine 13 Transmission case
3 Transmission suspension threads M20 14 Power take-off; Coaxial;
4 Output flange-converter side Engine-dependent
5 Oil drain plug with magnetic insert M38×1.5 15 Electro-hydraulic control
6 Model identification plate 16 Oil level tube with oil dipstick
7 Attachment possibility for oil level tube 17 Transmission suspension threads M20
with oil dipstick (converter side) 18 Output flange-rear
9 Cover 19 Exchange filter (fine filter)
10 Converter bell housing 20 Filter head with connection for filter
11 Breather restriction switch
3-6
--- Page 8 ---
6) ELECTRIC CONTROL UNIT
(1) Complete system
1
2
14 12
5
4 15
3
10
9
7
11
2
6
13 8
7409S3PT33
1 Transmission control unit(EST-37A)
2 Kickdown switch
3 Clutch cut off switch
4 Full automatic switch
5 Monitor
6 Gear selector(DW-3) with integrated kickdown switch
7 Power supply connection
8 Transmission
9 Cable to inductive transmitter - speed central gear train
10 Cable to inductive transmitter - speed turbine
11 Cable to inductive transmitter - speed engine
12 Cable to speed sensor output and speedometer
13 Cable to plug connection on the electro - hydraulic control unit
14 CAN-Connection
15 Wiring
(2) Description of the basic functions
The powershift transmissions is equipped is electronic transmission control unit(EST-37A), devel-
oped for it.
The system is processing the desire of the driver according to the following criteria.
·Gear determination depending on controller position, driving speed and load condition.
3-16
--- Page 9 ---
Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair
(Hex) possible reason for fault detection
34 S.C. to battery voltage or O.C. at turbine OP mode : Substitute clutch · Check the cable from TCU to the
speed input control sensor
TCU measures a voltage higher than If a failure is existing at · Check the connectors
7.00V at speed input pin output speed, · Check the speed sensor
·Cable is defective and is contacted to TCU shifts to neutral
vehicle battery voltage OP mode : Limp home
·Cable has no connection to TCU
·Speed sensor has an internal defect
·Connector pin is contacted to battery
voltage or has no contact
35 S.C. to ground at turbine speed input OP mode : Substitute clutch · Check the cable from TCU to the
TCU measures a voltage less than 0.45V control sensor
at speed input pin If a failure is existing at · Check the connectors
·Cable/connector is defective and is output speed, · Check the speed sensor
contacted to vehicle ground TCU shifts to neutral ※ This fault is reset after power up of
·Speed sensor has an internal defect OP mode : Limp home TCU
36 Logical error at turbine speed input OP mode : Substitute clutch · Check the cable from TCU to the
TCU measures a turbine speed over a control sensor
threshold and at the next moment the If a failure is existing at · Check the connectors
measured speed is zero output speed, · Check the speed sensor
·Cable/connector is defective and has TCU shifts to neutral · Check the sensor gap
bad contact OP mode : Limp home
·Speed sensor has an internal defect
·Sensor gap has the wrong size
37 S.C. to battery voltage or O.C. at internal OP mode : Substitute clutch · Check the cable from TCU to the
speed input control sensor
TCU measures a voltage higher than · Check the connectors
7.00V at speed input pin · Check the speed sensor
·Cable is defective and is contacted to
vehicle battery voltage
·Cable has no connection to TCU
·Speed sensor has an internal defect
·Connector pin is contacted to battery
voltage or has no contact
38 S.C. to ground at turbine speed input OP mode : Substitute clutch · Check the cable from TCU to the
TCU measures a voltage less than 0.45V control sensor
at speed input pin · Check the connectors
·Cable/connector is defective and is · Check the speed sensor
contacted to vehicle ground
·Speed sensor has an internal defect
39 Logical error at internal speed input OP mode : Substitute clutch · Check the cable from TCU to the
TCU measures a internal speed over a control sensor
threshold and at the next moment the · Check the connectors
measured speed is zero · Check the speed sensor
·Cable/connector is defective and has · Check the sensor gap
bad contact ※ This fault is reset after power up of
·Speed sensor has an internal defect TCU
·Sensor gap has the wrong size
3A S.C. to battery voltage or O.C. at output Special mode for gear · Check the cable from TCU to the
speed input selection sensor
TCU measures a voltage higher than OP mode : S u b s t i t u t e · Check the connectors
12.5V at speed input pin clutch control · Check the speed sensor
·Cable is defective and is contacted to If a failure is existing at
battery voltage turbine speed,
·Cable has no connection to TCU TCU shifts to neutral
·Speed sensor has an internal defect OP mode : Limp home
·Connector pin is contacted to battery
voltage or has no contact
※ Some fault codes are not applied to this machine.
3-26
--- Page 10 ---
Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair
(Hex) possible reason for fault detection
B3 Slippage at clutch K3 TCU shifts to neutral · Check pressure at clutch K3
TCU calculates a differential speed at OP mode : Limp home · Check main pressure in the system
closed clutch K3. If this calculated value If failure at another clutch · Check sensor gap at internal speed
is out of range, TCU interprets this as is pending sensor
slipping clutch TCU shifts to neutral · Check sensor gap at output speed
·Low pressure at clutch K3 OP mode : TCU shutdown sensor
·Low main pressure · Check signal at internal speed
·Wrong signal at internal speed sensor sensor
·Wrong signal at output speed sensor · Check signal at output speed
·Wrong size of the sensor gap sensor
·Clutch is defective Replace clutch
B4 Slippage at clutch K4 TCU shifts to neutral · Check pressure at clutch K4
TCU calculates a differential speed at OP mode : Limp home Check main pressure in the system
closed clutch K4. If this calculated value If failure at another clutch · Check sensor gap at internal speed
is out of range, TCU interprets this as is pending sensor
slipping clutch TCU shifts to neutral · Check sensor gap at turbine speed
·Low pressure at clutch K4 OP mode : TCU shutdown sensor
·Low main pressure · Check signal at internal speed
·Wrong signal at internal speed sensor sensor
·Wrong signal at turbine speed sensor · Check signal at turbine speed
·Wrong size of the sensor gap sensor
·Clutch is defective Replace clutch
B5 Slippage at clutch KV TCU shifts to neutral · Check pressure at clutch KV
TCU calculates a differential speed at OP mode : Limp home · Check main pressure in the system
closed clutch KV. If this calculated value If failure at another clutch · Check sensor gap at internal speed
is out of range, TCU interprets this as is pending sensor
slipping clutch TCU shifts to neutral · Check sensor gap at turbine speed
·Low pressure at clutch KV OP mode : TCU shutdown sensor
·Low main pressure · Check signal at internal speed
·Wrong signal at internal speed sensor sensor
·Wrong signal at turbine speed sensor · Check signal at turbine speed
·Wrong size of the sensor gap sensor
·Clutch is defective · Replace clutch
B6 Slippage at clutch KR TCU shifts to neutral · Check pressure at clutch KR
TCU calculates a differential speed at OP mode : Limp home Check main pressure in the system
closed clutch KR. If this calculated value If failure at another clutch · Check sensor gap at internal speed
is out of range, TCU interprets this as is pending sensor
slipping clutch TCU shifts to neutral · Check sensor gap at turbine speed
·Low pressure at clutch KR OP mode : TCU shutdown sensor
·Low main pressure · Check signal at internal speed
·Wrong signal at internal speed sensor sensor
·Wrong signal at turbine speed sensor · Check signal at turbine speed
·Wrong size of the sensor gap sensor
·Clutch is defective · Replace clutch
B7 Overtemp sump No reaction · Cool down machine
TCU measured a temperature in the oil OP mode : Normal · Check oil level
sump that is over the allowed threshold. · Check temperature sensor
B9 Overspend engine Retarder applies
-
OP mode : Normal
BA Differential pressure oil filter No reaction · Check oil filter
TCU measured a voltage at differential OP mode : Normal · Check wiring from TCU to
pressure switch out of the allowed range differential pressure switch
·Oil filter is polluted · C h e ck d i f fe r e n t i a l p r e s s u r e
·Cable/connector is broken or cable/ switch(Measure resistance)
connector is contacted to battery voltage
or vehicle ground
·Differential pressure switch is defective
※ Some fault codes are not applied to this machine.
3-36
--- Page 11 ---
6. TIRE AND WHEEL
2
5
4
3
6
1
7407APT10
1 Wheel rim 3 O-ring 5 Side ring
2 Tire 4 Lock ring 6 Valve assembly
1) The tire acts to absorb the shock from the ground surface to the machine, and at the same time
they must rotate in contact with the ground to gain the power which drives the machine.
2) Various types of tires are available to suit the purpose. Therefore it is very important to select the
correct tires for the type of work and bucket capacity.
3-46
--- Page 12 ---
Problem Cause Remedy
Torque conver ter stall Low engine power. Do engine power test.
RPM too low
Mechanical malfunction. Remove and inspect torque converter.
Transmission pressure Low oil level. Add oil.
light comes ON when
Cold oil. Warm oil to specification.
shifting from forward to
reverse (all other gears Leak in reverse pack. Do transmission pressure, pump flow, and
OK) leakage check.
Transmission pressure Cold oil. Warm oil to specification.
light comes ON for each
No time delay in monitor. Do monitor check.
shift
Restriction in modulation orifice. Remove orifice and inspect for restriction and/or
plugging.
Stuck PPC valve. Remove and inspect.
Low transmission pressure circuit. Do transmission system pressure test.
Leak in transmission pressure Do converter out pressure test.
circuit.
Failed transmission pump. Do transmission pump flow test.
Clogged filter. Inspect filter. Replace.
3-56
--- Page 13 ---
(10) Introduce female connector against
shoulder, with the groove facing the guide
nose of the cover.
Install gasket (arrow) and fasten cover by
means of socket head screws.
·Torque limit : 0.56 kgf·m (4.06 lbf·ft)
Box spanner 5873 042 002
73073CV026
(11) Fix female connector by means of
retaining clamp, see figure.
Install opposite cover.
73073CV027
(12) Install two adjusting screws and mount
gasket Ⅰ.
※ Pay attention to the different gaskets, see
on the right figure and (15).
Adjusting screws 5870 204 063
73073CV028
Intermediate plate-Version with screens
(13) Insert screws (6EA) flush mounted into
the bore of the intermediate plate, see
arrow.
※ Pay attention to the installation position-
screws are showing upward (facing the
duct plate).
73073CV029
3-66
--- Page 14 ---
⑥ On the right figure shows the installation
position of the single clutches as well as
of the input and output.
KVForward clutch
KR Reverse clutch
K11st speed clutch
K22nd speed clutch
K33rd speed clutch
K44th speed clutch
AN Input
ABOutput 73073TM040
※ The following figures describe the
common removal of all clutches.
For this purpose, the housing cover,
combined with special tool is necessary.
The removal of single clutches without
help of the housing cover and the
handles is extremely difficult because of
the installation condition.
Besides, there is the danger of injuries.
※ Prior to the common removal of the
clutches, the output shaft must be
removed, see the below figure.
⑦ Loosen socket head screws and remove
output shaft as well as both oil baffle
plates.
73073TM042
3-76
--- Page 15 ---
(11) Disassemble input shaft
① If necessary, press turbine shaft out of
the input shaft.
※ The turbine shaft is axially fixed by
means of a snap ring which will be
destroyed at the pressing out.
73073TM78
② Squeeze rectangular ring out and pull off
the tapered roller bearing.
Pull off the opposite tapered roller
bearing.
※ The separation of input shaft 1 and gear
2 is not possible (shrink fit).
※ Special tool
Grab sleeve 5873 001 058
Basic set 5873 001 000
73073TM79
3-86
--- Page 16 ---
③ Check function of the drain valve.
※ Ball may not seize, if necessary clean by
means of compressed air.
Insert both O-rings (arrows) scroll free
into the piston recesses and oil them.
73073TM127
④ Introduce piston until contact is obtained.
※ Pay attention to the installation position,
see on the right figure.
73073TM128
⑤ Introduce compression spring along with
spring cup (2EA).
73073TM129
⑥ Preload compression spring and fix it by
means of circlip.
※ Special tool
Assembly aid(K2 and K3) 5870 345 085
Assembly aid(K1) 5870 345 086
73073TM130
3-96
--- Page 17 ---
(4) Pre-assemble input shaft
① Undercool the input shaft (about -80°C),
heat gear (about +120°C) and assemble
it until contact is obtained.
73073TM174
② Fix gear axially by means of circlip.
73073TM175
③ Squeeze snap ring into the recess of the
turbine shaft.
73073TM176
④ Introduce turbine shaft until the snap ring
snaps into the recess of the input shaft-
turbine shaft is axially fixed.
73073TM177
3-106
--- Page 18 ---
③ Install two adjusting screws and
introduce stator shaft until contact is
obtained.
※ Pay attention to the overlapping of the
bores.
※ Special tool
Adjusting screws 5870 204 007
73073TM225
④ Install O-ring (arrow) and oil it.
73073TM226
⑤ Introduce transmission pump until
contact is obtained.
※ Pay attention to the overlapping of the
bores.
73073TM227
⑥ Equip socket head screws with new
O-rings (arrow).
※ Grease O-rings.
73073TM228
3-116
--- Page 19 ---
(3) Using two screwdrivers or two levers
inserted in the slots provided, disjoin the
planetary cover (3) away from the wheel
hub (16).
3
7409FAX004
(4) Remove the cover (3). Use an eye-bolt to lift
3
7409FAX005
(5) Remove the sun gear (6).
6
7409FAX006
(6) Remove the safety spring rings (4) of the
4
planetary gears (5).
5
7409FAX007
3-126
--- Page 20 ---
3) DISASSEMBLY SERVICE BRAKE
2
3
1
4
7
8
9
10 15
11 12 14
13
5
6
2
3
16
17
18
7409FAX040
(1) If axle is positioned on an overhaul bench,
place a safety anti-tilting stand “B” under
the arm that remains connected and block
wheels, if any.
7409FAX041
(2) Sling the arm to be removed and connect
it to a hoist.
Remove the retainer screws (3) and
relative washers (2).
7409FAX042
3-136
--- Page 21 ---
※ If axle is positioned on an overhaul bench,
place a safety antitilting stand “B” under
the arm that remains connected and
block wheels, if any.
7409FAX078
(11) Sling the arm to be removed and connect
it to a hoist.
Remove the retainer screws and relative
washers.
7409FAX079
(12) Remove arm together with brakes and
axle shafts; lay down the arm vertically.
Release pressure.
7409FAX080