PDF Service Manual Hyundai HL780-9S Wheel Loader - 6 MB
This comprehensive service manual is the ultimate resource for maintaining and repairing the Hyundai HL780-9S Wheel Loader.
It provides technicians with detailed diagnostic procedures, step-by-step repair instructions, and complete system schematics.
From the engine to the hydraulics, this manual covers every aspect of the machine.
It is essential for performing professional, factory-quality service.
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--- Page 1 ---
CONTENTS
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
Group 1 Structure and Function -------------------------------------------------------------------------------------- 2-1
Group 2 Engine speed and Stall rpm ----------------------------------------------------------------------------- 2-14
Group 3 Fuel warmer system ------------------------------------------------------------------------------------------ 2-15
SECTION 3 POWER TRAIN SYSTEM
Group 1 Structure and Function -------------------------------------------------------------------------------------- 3-1
Group 2 Operational Checks and Troubleshooting ------------------------------------------------------- 3-58
Group 3 Test and Adjustments ---------------------------------------------------------------------------------------- 3-69
Group 4 Disassembly and Assembly ----------------------------------------------------------------------------- 3-71
SECTION 4 BRAKE SYSTEM
Group 1 Structure and Function -------------------------------------------------------------------------------------- 4-1
Group 2 Operational Checks and Troubleshooting ------------------------------------------------------- 4-29
Group 3 Tests and Adjustments -------------------------------------------------------------------------------------- 4-36
Group 4 Disassembly and assembly ------------------------------------------------------------------------------ 4-38
SECTION 5 STEERING SYSTEM
Group 1 Structure and Function -------------------------------------------------------------------------------------- 5-1
Group 2 Operational Checks and Troubleshooting ------------------------------------------------------- 5-18
Group 3 Tests and Adjustments -------------------------------------------------------------------------------------- 5-26
Group 4 Disassembly and Assembly ----------------------------------------------------------------------------- 5-34
SECTION 6 WORK EQUIPMENT
Group 1 Structure and Function -------------------------------------------------------------------------------------- 6-1
Group 2 Operational Checks and Troubleshooting ------------------------------------------------------- 6-41
Group 3 Tests and Adjustments -------------------------------------------------------------------------------------- 6-52
Group 4 Disassembly and Assembly ----------------------------------------------------------------------------- 6-67
0-9
--- Page 3 ---
SECTION 1 GENERAL
Group 1 Safety Hints --------------------------------------------------------------------------------------------------------1-1
Group 2 Specifications -----------------------------------------------------------------------------------------------------1-10
Group 3 Operational Checkout Record Sheet ---------------------------------------------------------------1-25
--- Page 4 ---
GROUP 2 SPECIFICATION
1. MAJOR COMPONENT
Bucket Tire Head light Hydraulic tank Air cleaner Battery
Boom Bucket cylinder Main control valve Step Radiator Counterweight
Precleaner(option)
Bucket link Bell crank Steering cylinder Cab Rain cap(std) Muffler Engine
Front axle Boom cylinder Main pump Transmission Rear axle Fuel tank
7809S2SE01
1-10
--- Page 5 ---
5. TIGHTENING TORQUE OF MAJOR COMPONENT
Torque
No. Descriptions Bolt size
kgf·m lbf·ft
1 Engine mounting bolt, nut (rubber, 4EA) M24×3.0 100 ± 15.0 723 ± 108
2 Engine mounling bolt (flywheel housing, 14EA) M10×1.5 4.6 ± 0.7 33.3 ± 5.1
3 Engine mounling bolt (coupling, 8EA) 1/2-13UNC 8.37 ± 0.41 53.3 ± 3.0
Engine
4 Engine mounting bolt (gear housing, 6EA) M10×1.5 4.6 ± 0.7 33.3 ± 5.1
5 Radiator mounting bolt M20×2.5 57.9 ± 8.7 419 ± 62.9
6 Fuel tank mounting bolt, nut M16×2.0 29.7 ± 4.5 215 ± 32.5
7 Main pump housing mounting bolt M16×2.0 29.7 ± 4.5 215 ± 32.5
8 Steering pump housing mounting bolt M16×2.0 29.7 ± 4.5 215 ± 32.5
9 Main control valve mounting bolt M12×1.75 12.8 ± 3.0 92.6 ± 21.7
10 Steering unit mounting bolt M10×1.5 6.9 ± 1.4 49.9 ± 10.1
11 Hydraulic Flow amplifier mounting bolt M10×1.5 6.9 ± 1.4 49.9 ± 10.1
12 system Brake valve mounting bolt M8×1.25 2.5 ± 0.5 18.1 ± 3.6
13 Cut-off valve mounting bolt M12×1.75 12.3 ± 2.0 89.0 ± 14
14 Remote control lever mounting bolt M6×1.0 1.1 ± 0.2 8.0 ± 1.4
15 Safety valve M8×1.25 2.5 ± 0.5 18.1 ± 3.6
16 Hydraulic oil tank mounting bolt M20×2.5 57.9 ± 8.7 419 ± 62.9
17 Transmission mounting bolt, nut (rubber, 4EA) M24×3.0 100 ± 15.0 723 ± 108
18 Transmission mounting bolt (bracket, 8EA) M20×2.5 24.0 ± 2.4 174 ± 18.1
19 Transmission bolt (bracket, converter side) M16×2.0 18.4 ± 2.0 133 ± 14.5
20 Power train Front axle mounting bolt, nut M36×3.0 270 ± 30 1950 ± 217
21 system Rear axle support mounting bolt, nut M36×3.0 270 ± 30 1950 ± 217
22 Tire mounting nut M22×1.5 79 ± 2.5 571 ± 18
23 Drive shaft joint mounting bolt (front, center, rear) 1/2-20UNF 15.5 ± 0.5 112 ± 3.6
24 Drive shaft joint mounting bolt (upper) 1/2-20UNF 10.5 ± 0.5 75.9 ± 3.6
25 Counterweight mounting bolt M30×2.0 199 ± 30 1439 ± 217
26 Counterweight mounting bolt M24×3.0 100 ± 15 723 ± 108
Others
27 Operator's seat mounting bolt M8×1.25 3.4 ± 0.8 24.6 ± 5
28 Cab mounting bolt (4EA) M20×2.5 58 ± 8.7 419 ± 63
1-19
--- Page 6 ---
5) The Oil Temperature Sensor is mounted in
the main oil rifle. It provides input to the
engine protection system.
6) The Engine Position Sensor, or EPS, is a
magnetic pick-up type device that uses the
detection of 24 specially machined
surfaces, on the back side of the camshaft
gear, to monitor engine speed.
A unique "tooth" indicates number one
cylinder at top dead center compression
stroke, for injection timing purposes.
7) The pressure sensors are a three-wire type
sensor with a 5 volt supply, a signal wire,
and a return. Although pressure sensors
use an analog signal similar to the
temperature sensors, the electronics built
into the sensor require that separate signal
and return wires be used.
8) The oil Pressure Sensor is mounted in the
main oil rifle. Like the oil temperature
sensor, it provides input information to the
engine protection system.
2-3
--- Page 7 ---
41) The primary diagnostic tool for use with the
QSM system will be the INSITE computer
based diagnostic tool.
Echek and Compulink cartridges will be
available for use with QSM.
2-13
--- Page 8 ---
3) OPERATION OF TRANSMISSION
(1) Forward
① Forward 1st
In 1st forward, forward clutch and 1st clutch are engaged.
Forward clutch and 1st clutch are actuated by the hydraulic pressure applied to the clutch piston.
INPUT
KV K1
KR K2
K4 K3
OUTPUT OUTPUT
78093PT07
3-7
--- Page 9 ---
·Protection from operating errors as far as necessary, is possible via electronic protection
(programming).
·Protection from over-speeds (On the basis of engine and turbine speed).
·Automatic reversing (Driving speed-dependent).
·Pressure cut-off possible (Disconnecting of the drive train for maximum power on the power
take-off).
·Change-over possibility for Auto-/Manual mode.
·Kick down functions possible.
(3) Driving and shifting
- Neutral position :
Neutral position will be selected via the controller.
After the ignition is switched on, the electronics remains in the waiting state. By the position
NEUTRAL of the controller, resp. by pressing the pushbutton NEUTRAL, the EST-37A becomes
ready for operation.
Now, a gear can be engaged.
- Starting :
The starting of the engine has always to be carried out in the NEUTRAL POSITION of the
controller.
For safety reasons it is to recommend to brake the machine securely in position with the parking
brake prior to start the engine.
After the starting of the engine and the preselection of the driving direction and the gear, the
machine can be set in motion by acceleration.
At the start off, the converter takes over the function of a master clutch.
On a level road it is possible to start off also in higher gears.
- Upshifting under load
Upshifting under load will be then realized if the machine can still accelerate by it.
- Downshifting under load
Downshifting under load will be realized if more traction force is needed.
- Upshifting in overrunning condition
In the overrunning mode, the upshifting will be suppressed by accelerator pedal idling position, if
the speed of the machine on a downgrade should not be further increased.
- Downshifting in overrunning condition
Downshiftings in overrunning mode will be then carried out if the machine should be retarded.
If the machine will be stopped and is standing with running engine and engaged transmission,
the engine cannot be stalled. On a level and horizontal roadway it is possible that the machine
begins to crawl, because the engine is creating at idling speed a slight drag torque via the
converter.
It is convenient to brake the machine at every stop securely in position with the parking brake.
At longer stops, the controller has to be shifted to the NEUTRAL POSITION.
At the start off, the parking brake has to be released. We know from experience that at a
converter transmission it might not immediately be noted to have forgotten this quite normal
operating step because a converter, due to its high ratio, can easily overcome the braking
torque of the parking brake.
3-17
--- Page 10 ---
Fault code
J1939 SPN Reason Effect (only when fault code is active)
J1939 FMI
Engine oil rifle pressure - Data erratic, None on performance. No engine protection
435
intermittent, or incorrect. An error in the engine for oil pressure.
100
oil pressure switch signal was detected by the
2
ECM.
Battery 1 voltage - Data valid but below normal Engine may stop running or be difficult to start.
441
operational range - Moderately severe level.
168
ECM supply voltage is below the minimum
18
system voltage level.
Battery 1 Voltage - Data valid but above normal Possible electrical damage to all electrical
442
operational range - Moderately severe level. components.
168
ECM supply voltage is above the maximum
16
system voltage level.
449 Injector metering rail 1 pressure - Data valid but None or possible engine noise associated with
157 above normal operational range - Most severe higher injection pressures (especially at idle or
0 level. light load). Engine power is reduced.
Injector metering rail 1 pressure sensor circuit - Power and or speed derate.
451
Voltage above normal, or shorted to high source.
157
High signal voltage detected at the rail fuel
3
pressure sensor circuit.
Injector metering rail 1 pressure sensor circuit - Power and or speed derate.
452
Voltage below normal, or shorted to low source.
157
Low signal voltage detected at the rail fuel
4
pressure sensor circuit.
Intake manifold 1 temperature - Data valid but Progressive power derate increasing in
488 above normal operational range - Moderately severity from time of alert.
157 severe level. Intake manifold air temperature
16 signal indicates intake manifold air temperature
is above the engine protection warning limit.
497 Multiple unit synchronization switch - Data
1377 erratic, intermittent, or incorrect.
2
523 Auxiliary intermediate (PTO) speed switch None on performance.
611 validation - Data erratic, intermittent, or
2 incorrect.
Auxiliary input/output 2 circuit - Voltage above None on performance.
527 normal, or shorted to high source. High signal
702 voltage or open circuit has been detected at the
3 auxiliary input/output 2 circuit.
528 Auxiliary alternate torque validation switch - None on performance.
93 Data erratic, intermittent, or incorrect.
2
Auxiliary input/output 3 circuit - Voltage above
529
normal, or shorted to high source. Low signal
703
voltage has been detected at the auxiliary input/
3
output 2 circuit.
Injector metering rail 1 pressure - Data valid but The ECM will estimate fuel pressure and
553 above normal operational range - Moderately power is reduced.
157 severe level. The ECM has detected that fuel
16 pressure is higher than commanded pressure.
Injector metering rail 1 pressure - Data erratic, Possibly hard to start, low power, or engine
554 Intermittent, or incorrect. The ECM has smoke.
157 detected that the fuel pressure signal is not
2 changing.
3-27
--- Page 11 ---
Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair
(Hex) possible reason for fault detection
57 EEC1 timeout OP mode : Substitute · Check EEC controller
Timeout of CAN-message EEC1 from clutch control · Check wire of CAN-Bus
EEC controller · Check cable to EEC controller
·Interference on CAN-Bus
·CAN wire/connector is broken
·CAN wire/connector is defective and
has contact to vehicle ground or battery
voltage
58 EEC3 timeout OP mode : Substitute · Check EEC controller
Timeout of CAN-message EEC3 from clutch control · Check wire of CAN-Bus
EEC controller · Check cable to EEC controller
·Interference on CAN-Bus
·CAN wire/connector is broken
·CAN wire/connector is defective an has
contact to vehicle ground or battery
voltage
5C Auto downshift signal No reaction · Check cluster controller
CAN signal for automatic downshift is · Check wire of CAN-Bus
defective · Check cable to cluster controller
·Cluster controller is defective
·Interference on CAN-Bus
5D Manual downshift signal No reaction · Check cluster controller
CAN signal for manual downshift is · Check wire of CAN-Bus
defective · Check cable to controller
·Cluster controller is defective
·Interference on CAN-Bus
5E CCO request signal No reaction · Check cluster controller
CAN signal for CCO request is defective · Check wire of CAN-Bus
·Cluster controller is defective · Check cable to controller
·Interference on CAN-Bus
61 AEB request signal No reaction · Check I/O controller, Omron master
CAN signal for AEB request is defective OP mode : Normal · Check wire of CAN-Bus
·I/O controller is defective · Check cable to I/O controller,
·Interference on CAN-Bus Omron master
64 Sarting gear signal No reaction. · Check I/O controller
CAN signal for starting gear is defective TCU uses default starting · Check wire of CAN-Bus
·I/O controller is defective gear · Check cable to I/O controller
(illegal starting gear) OP mode : Normal
·Interference on CAN-Bus
65 Engine torque signal OP mode : Substitute · Check engine controller
CAN signal for engine torque is defective clutch control · Check wire of CAN-Bus
·Engine controller is defective · Check cable to engine controller
·Interference on CAN-Bus
69 Reference engine torque signal OP mode : Substitute · Check engine controller
CAN signal for reference of engine torque clutch control · Check wire of CAN-Bus
is defective · Check cable to engine controller
·Engine controller is defective
·Interference on CAN-Bus
6A Actual engine torque signal OP mode : Substitute · Check engine controller
CAN signal for actual engine torque is clutch control · Check wire of CAN-Bus
defective · Check cable to engine controller
·Engine controller is defective
·Interference on CAN-Bus
※ Some fault codes are not applied to this machine.
3-37
--- Page 12 ---
Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair
(Hex) possible reason for fault detection
C6 O.C. at joystick status indicator No reaction · Check the cable from TCU to
TCU detected a wrong voltage at the OP mode : Normal joystick status indicator
output pin, that looks like a O.C. for this · Check the connectors from joystick
output pin status indicator to TCU
·C a b l e i s d e fe c t i ve a n d h a s n o · Check the resistance* of joystick
connection to TCU status indicator
·Joystick status indicator has an internal * See page 3-49
defect
·Connector pin has no connection to
TCU
D1 S.C. to battery voltage at power supply See fault codes No.21 to · Check cables and connectors to
for sensors 2C sensors, which are supplied from
TCU measures more than 6V at the pin AU1
AU1 (5V sensor supply) · Check the power supply at the pin
AU1(Should be appx. 5V)
· Fault codes No.21 to No.2C may be
reaction of this fault
D2 S.C. to ground at power supply for See fault codes No.21 to · Check cables and connectors to
sensors 2C sensors, which are supplied from
TCU measures less than 4V at the pin AU1
AU1 (5V sensor supply) · Check the power supply at the pin
AU1(Should be appx. 5V)
· Fault codes No.21 to No.2C may be
reaction of this fault
D3 Low voltage at battery Shift to neutral · Check power supply battery
Measured voltage at power supply is lower OP mode : TCU shutdown · Check cables from batteries to TCU
than 18V(24V device) · Check connectors from batteries to
TCU
D4 High voltage at battery Shift to neutral · Check power supply battery
Measured voltage at power supply is OP mode : TCU shutdown · Check cables from batteries to TCU
higher than 32.5V(24V device) · Check connectors from batteries to
TCU
D5 Error at valve power supply VPS1 Shift to neutral · Check fuse
TCU switched on VPS1 and measured OP mode : TCU shutdown · Check cables from gearbox to TCU
VPS1 is off or TCU switched off VPS1 and · Check connectors from gearbox to
measured VPS1 is still on TCU
·Cable or connectors are defect and are · Replace TCU
contacted to battery voltage
·Cable or connectors are defect and are
contacted to vehicle ground
·Permanent power supply KL30 missing
·TCU has an internal defect
D6 Error at valve power supply VPS2 Shift to neutral · Check fuse
TCU switched on VPS2 and measured OP mode : TCU shutdown · Check cables from gearbox to TCU
VPS2 is off or TCU switched off VPS2 and · Check connectors from gearbox to
measured VPS2 is still on TCU
·Cable or connectors are defect and are · Replace TCU
contacted to battery voltage
·Cable or connectors are defect and are
contacted to vehicle ground
·Permanent power supply KL30 missing
·TCU has an internal defect
※ Some fault codes are not applied to this machine.
3-47
--- Page 13 ---
2. TROUBLESHOOTING
1) TRANSMISSION
※ Diagnose malfunction charts are arranged from most probable and simplest to verify, to least likely,
more difficult to verify. Remember the following steps when troubleshooting a problem :
Step 1. Operational check out procedure (See group 3 in section 1.)
Step 2. Operational checks (In this group.)
Step 3. Troubleshooting
Step 4. Tests and/or adjustments (See group 3.)
Problem Cause Remedy
Transmission slippage Low oil level. Add oil.
Wrong oil grade. Change oil.
Restricted transmission pump Remove and clean screen.
suction screen.
Leak in transmission control valve Remove valve and inspect gaskets.
or gasket.
Low transmission pump flow due Do transmission pump flow test.
to worn pump.
W e a k o r b r o k e n p r e s s u r e Do transmission system pressure test.
regulating valve spring.
Error code on display Something wrong in transmission. Go to transmission error code group at page
3-32~3-48.
3-57
--- Page 14 ---
(5) Remove the retaining clamp
Figure 1005
(6) Loosen the cap screws and take off the
cover.
Remove the opposite cover.
※ Special tool
Socket spanner TX-27 5873 042 002
Figure 1006
(7) Remove the wiring harness.
Figure 1007
(8) Loosen the cap screws, remove the fixing
plates and the pressure controllers.
※ Special tool
Socket spanner TX-27 5873 042 002
Figure 1008
3-67
--- Page 15 ---
(2) Loosen the bolt connection and by means
of the forcing screws (3EA) separate the
cover from the converter bell.
※ Special tool
Forcing screws 5870 204 005
Figure 5
(3) By means of the extractor pull the oil
supply flange out of the converter bell.
※ Special tool
Extractor 5870 000 089
Figure 6
(4) Remove the converter safety valve (arrow
1), if required.
※ Converter safety valve is fixed by means
of slotted pin (arrow 2).
2
Figure 7
(5) Loosen the bolt connection (M8 and M12)
and by means of lifting tackle and pry bar
set separate the coverter bell from the
transmission housing.
※ Special tool
Eyebolts assortment 5870 204 002
Pry bar set 5870 345 036
Lifting chain 5870 281 047
Figure 8
3-77
--- Page 16 ---
(5) Expel the output shaft from the output
gear.
Figure 50
(6) Loosen the hexagon screws and remove
the oil baffle.
Lift the output gear out of the transmission
housing (figure).
※ Special tool
Stop washer 5870 100 054
Eyebolts assortment 5870 204 002
Figure 51
(7) Remove the bearing inner ring from the
output gear.
※ Special tool
Three-armed puller 5870 971 003
Figure 52
(8) Take the roller bearing out of the housing
bore and remove the oil baffle (arrow).
Figure 53
3-87
--- Page 17 ---
Figure 94
(8) Squeeze out the snap ring.
Remove end shim and disc set K1.
Figure 95
(9) Rotate disc carrier by 90˚.
Loosen the slotted nut.
※ Special tool
Slotted nut wrench 5870 401 118
Slotted nut wrench 5870 401 115
Figure 96
(10) Pull off the taper roller bearing from the
disc carrier.
※ Special tool
Gripping insert 5873 001 034
Basic tool 5873 001 000
Figure 97
3-97
--- Page 18 ---
Disc Components K4
※ Below sketch or table shows the standard version as to the installation position of the single
components. Obligatory is the respective spare parts list.
Figure 136
Position Description Quantity s (mm) Remarks
1 Disc carrier 1
2 Piston 1
3 Outer clutch disc 2 1.85 Coated on one side
4 Outer clutch disc 5 2.5 Coated on both sides
5 Inner clutch disc 3 3.5
6 Inner clutch disc 1 4.0
7 Inner clutch disc 2 2.5~4.0 Optional
8 Snap ring 1 2.10~3.10 Optional
9 End shim 1
Number of friction surfaces : 12
Disc clearance : 2.2 ~ 2.4 mm
※ Install the outer clutch discs position 3 with uncoated side showing to the piston and end shim
respectively. The respective clutch side can be seen on the length of the disc carrier, see sketch.
K4 Dimension X (short disc carrier side)
K3 Dimension Y (long disc carrier side)
3-107
--- Page 19 ---
(1) Lift the disc carrier with the KR-side
showing downwards into the clamping
ring and fasten it.
Then rotate disc carrier by 180˚.
To install new disc carriers the finished
bores have to be sealed with plugs.
Installation position, see arrow, figure
160~161.
※ Special tool
Figure 160
Clamping ring 5870 654 033
Hand mounting tool 5870 320 014
Ratchet 5870 320 018
Figure 161
(2) Flush-mount the drain valve (arrow) with
the chamfer showing downwards.
※ Special tool
Inserting tool 5870 320 019
Figure 162
(3) Put both O-rings scroll-free into the
annular grooves of the piston, see arrows.
Figure 163
3-117
--- Page 20 ---
(8) Lift the disc carrier into the clamping ring
and fasten it.
Rotate disc carrier by 90˚.
K2-side :
Install the slotted nut.
※ Observe installation position of the slotted
nut. Chamfer must show to the bearing
inner ring, also see sketch (Figure 159).
Oil the thread.
Figure 189
·Torque limit : 56.1 kgf·m (406 lbf·ft)
※ Special tool
Clamping ring 5870 654 033
Slotted nut wrench 5870 401 099
KR-side :
Install the slotted nut.
※ Observe installation position of the slotted
nut. Collar (Ø76 mm) must show to the
bearing inner ring, also see sketch/page
3-113. Oil the thread.
·Torque limit : 56.1 kgf·m (406 lbf·ft)
※ Special tool
Slotted nut wrench 5870 401 099 Figure 190
(9) Check function of the clutches K3 and K4
by means of compressed air (figure 191).
※ Closing or opening of the clutches is
clearly audible when the single parts have
been installed adequately.
Snap-in and lock the rectangular rings
(3EA, see arrows).
Figure 191
3-127
--- Page 21 ---
Preassemble and install spur gear K1
(figure 215~222) :
1
(1) Opposite figure shows the single
components of spur gear K1.
1 Ball bearing (assy)
2 Snap ring
3 Spur gear 3
2
※ Prior to installation of the single com-
ponents, align the disc set by means of Figure 215
the spur gear radially and center it, see
figure 216.
Figure 216
(2) Install the ring.