Hyundai Wheel Loader HL780-3 - Service Manual - Operators Manual - Wiring Diagrams

HYUNDAI WHEEL LOADER HL780-3 - WORKSHOP, SERVICE, REPAIR MANUAL - OPERATORS MANUAL - WIRING DIAGRAMS

- English Service Manual, Operators Manual and Wiring Diagrams, to Wheel Loader Hyundai HL780-3.
 

CONTENTS:

SERVICE MANUAL

- FOREWORD
- CONTENTS
- SECTION 1
- GENERAL
- Group 1 Safety Hints
- Group 2 Specifications
- Group 3 Operation Checkout Record Sheet
- SECTION 2
- ENGINE
- Group 1 Structure and Function
- SECTION 3
- POWER TRAIN SYSTEM
- Group 1 Structure and Function
- Group 2 Operational Checks and Troubleshooting
- Group 3 Test and Adjustments
- Group 4 Disassembly and Assembly
- SECTION 4
- BRAKE SYSTEM
- Group 1 Structure and Function
- Group 2 Operational Checks and Troubleshooting
- Group 3 Test and Adjustments
- Group 4 Disassembly and Assembly
- SECTION 5
- STEERING SYSTEM
- Group 1 Structure and Function
- Group 2 Operational Checks and Troubleshooting
- Group 3 Test and Adjustments
- Group 4 Disassembly and Assembly
- SECTION 6
- WORK EQUIPMENT
- Group 1 Structure and Function
- Group 2 Operational Checks and Troubleshooting
- Group 3 Test and Adjustments
- Group 4 Disassembly and Assembly
- SECTION 7
- ELECTRICAL SYSTEM
- Group 1 Component Location
- Group 2 Electrical Circuit
- Group 3 Monitoring System
- Group 4 Electrical Component Specification
- Group 5 Connectors
- Group 6 Troubleshooting


CUMMINS NTA 855 ENGINE

- Operating Instructions
- Prestarting Instructions 1-1
- Starting the Engine 1-3
- Engine Warm-Up  1-6
- Engine Speeds 1-6
- Engine Exhaust 1-7
- High Altitude Operation 1-7
- Engine Shutdown 1-7
- Cold Weather Protection 1-8
- Industrial Fire Pump Engines  1-11
- Maintenance Operations
- Schedule 2-2
- Check Sheet  2-3
- A Checks - Daily  2-7
- A Checks - Weekly 2-11
- B Checks  2-15
- C Checks  2-34
- D Checks  2-50
- Seasonal Maintenance Checks  2-54
- Specifications and Torque
- Lubricating Oil 3-1
- Grease 3-5
- Fuel 011 3-6
- Coolant  3-7
- Torque Speclflcatlons 3-8
- Trouble-Shooting
- Description 4-1
- Chart 4-2


CUMMINS N14 ENGINE

-Main Menu
-Cover Page
-Foreword
-Table Of Contents
-Introduction
- Manual Organization
- General Repair Instructions
- General Safety Instructions
- Symbols Used In This Manual
- Simbolos Usados En Este Manual
- Symboles Utilises Dans Ce Manuel
- Symbole
- Illustrations
- Glossary Of Terms
- Engine Identification
- Engine Diagrams
- General Cleaning Instructions
-Group 0 - Engine Disassembly And Assembly
- Coolant - Drainage
- Engine Disassembly And Assembly - Service Tools
- Engine Disassembly And Assembly - General Information
- Engine - Preparation For Cleaning
- Coolant Filter - Removal
- Lubricating Oil Filter - Removal
- Crankcase Breather - Removal
- Turbocharger - Removal
- Exhaust Manifold - Removal
- Starting Motor - Removal
- Fan And Fan Spacer - Removal
- Alternator Belts - Removal
- Alternator - Removal
- Alternator Mounting Bracket - Removal
- Lubricating Oil Cooler Assembly - Removal
- Coolant Inlet Transfer Connection - Removal
- Dipstick Tube And Housing - Removal
- Piston Cooling Nozzles - Removal
- Water Header Covers - Removal
- Engine - Installation On The Rebuild Stand
- Flywheel - Removal
- Flywheel Housing - Removal
- Rear Cover - Removal
- Crankshaft Seal, Rear - Removal
- Fan Belts - Removal
- Fan Hub And Fan Hub Support Bracket - Removal
- Water Pump Belt - Removal
- Celect™ Coolant Temperature Sensor - Removal
- Thermostat Housing - Removal
- Air Compressor Coolant Inlet And Outlet Tubes - Removal
- Water Pump - Removal
- Accessory Drive Pulley - Removal
- Vibration Damper - Removal
- Engine Support Bracket, Front - Removal
- Stc External Oil Plumbing - Removal
- Stc Oil Control Valve - Removal
- Celect™ Actuator Harness - Removal
- Celect™ Sensor Harness - Removal
- Celect™ Electronic Control Module (Ecm) - Removal
- Celect™ Ambient Air Pressure Sensor -Removal
- Celect™ Lubricating Oil Pressure Sensor - Removal
- Celect™ Ecm Cooling Plate - Removal
- Fuel Pump - Removal
- Air Compressor - Removal
- Accessory Drive - Removal
- Fuel Tubing - Removal
- Celect™ Engine Position Sensor (Eps) - Removal
- Lubricating Oil Tranfer Tube - Removal
- Lubricating Oil Pump Signal Line - Removal
- Lubricating Oil Pump - Removal
- Viscosity Sensor - Removal
- Celect™ Boost Pressure Sensor - Removal
- Celect™ Intake Air Temperature Sensor - Removal
- Intake Manifold - Removal
- Rocker Housing Covers - Removal
- Engine Brakes - Removal
- Rocker Lever Shaft Assemblies - Removal
- Valve Crossheads - Removal
- Push Tubes - Removal
- Injectors - Removal
- Rocker Lever Housing - Removal
- Fuel Crossovers - Removal
- Cylinder Heads - Removal
- Cam Follower Assemblies - Removal
- Camshaft Bearing Support - Removal
- Lubricating Oil Pan - Removal
- Gear Cover - Removal
- Crankshaft Seal, Front - Removal
- Accessory Drive Seal - Removal
- Camshaft - Removal
- Piston And Connecting Rod Assemblies - Removal
- Cylinder Liners - Removal
- Crankshaft - Removal
- Cylinder Block - Removal From The Rebuild Stand
- Cylinder Block - Installation On The Rebuild Stand
- Crankshaft - Installation
- Cylinders Liners - Installation
- Piston And Connecting Rod Assemblies - Assembly And Installation
- Rear Cover - Installation
- Crankshaft Seal, Rear - Installation
- Flywheel Housing - Installation
- Flywheel - Installation
- Cylinder Heads - Installation
- Camshaft Installation
- Cam Follower Assemblies - Installation
- Injection Timing - General Information
- Accessory Drive - Installation
- Celect™ Engine Position Sensor (Eps) - Installation
- Lubricating Oil Pump - Installation
- Gear Cover - Installation
- Crankshaft Seal, Front - Installation
- Camshaft Bearing Support - Installation
- Accessory Drive Seal - Installation
- Accessory Drive Pulley - Installation
- Lubricating Oil Pan - Installation
- Fuel Crossovers - Installation
- Rocker Lever Housing - Installation
- Injectors - Installation
- Push Tubes - Installation
- Valve Crossheads - Installation
- Rocker Lever Shaft Assemblies - Installation
- Injector And Valve Adjustment
- Engine Brake - Installation
- Engine Brake Adjustment
- Rocker Housing Covers - Installation
- Intake Manifold - Installation
- Celect™ Intake Air Temperature Sensor - Installation
- Celect™ Boost Pressure Sensor - Installation
- Viscosity Sensor - Installation
- Lubricating Oil Pump Signal - Installation
- Lubricating Oil Transfer Tube - Installation
- Fuel Tubing - Installation
- Air Compressor - Installation
- Fuel Pump - Installation
- Celect™ Ecm Cooling Plate - Installation
- Celect™ Lubricating Oil Pressure Sensor - Installation
- Celect™ Ambient Air Pressure Sensor - Installation
- Celect™ Electronic Control Module (Ecm) - Installation
- Celect™ Sensor Harness - Installation
- Celect™ Actuator Harness - Installation
- Stc Oil Control Valve - Installation
- Stc External Oil Plumbing - Installationing - Installa-Tion
- Engine Support Bracket, Front - Installation
- Vibration Damper - Installation
- Water Pump - Installation
- Water Pump Belt - Installation And Adjustment
- Thermostat Housing - Installation
- Celect™ Coolant Temperature Sensor - Installation
- Air Compressor Coolant Inlet And Outlet Tubes - Installation
- Fan Hub And Fan Hub Support - Installation
- Fan Belts - Installation And Adjustment
- Engine - Removal From The Rebuild Stand
- Piston Cooling Nozzles - Installation
- Dipstick Tube And Housing - Installation
- Water Header Covers - Installation
- Coolant Inlet Transfer Connection - Installation
- Lubricating Oil Cooler Assembly - Installation
- Alternator Mounting Bracket - Installation
- Alternator - Installation
- Alternator Belts - Installation And Adjustment
- Fan And Fan Spacer - Installation
- Starting Motor - Installation
- Exhaust Manifold - Installation
- Turbocharger - Installation
- Crankcase Breather Tube - Installation
- Lubricating Oil Filter - Installation
- Coolant Filter - Installation
- Engine - Covering All Openings
-Group 1 - Cylinder Block
- Cylinder Block - Service Tools
- Cylinder Block - Exploded View
- Cylinder Block - General Information
- Cylinder Block - Disassembly
- Cylinder Block - Ceaning And Inpection
- Cylinder Block - Machining
- Cylinder Block Counterbore - Inspection And Machining
- Cylinder Block - Assembly
- Cylinder Liners - Cleaning And Inspection
- Pistons - Cleaning And Inspection
- Connecting Rod Assemblies - Cleaning And Inspection
- Connecting Rods - Bend And Twist Inspection
- Connecting Rod Bearings - Cleaning And Inspection
- Crankshaft Adapter - Cleaning And Inspection
- Crankshaft Pulley - Cleaning And Inspection
- Vibration Damper - Cleaning And Inspection
- Crankshaft - Cleaning And Inspection
- Crankshaft Gear - Replacement
- Crankshaft Bearings - Cleaning And Inspection
- Camshaft - Cleaning And Inspection
- Camshaft Gear - Replacement
- Gear Cover - Cleaning And Inspection
- Rear Cover - Cleaning And Inspection
- Magnetic Crack Inspection
-Group 2 - Cylinder Head
- Cylinder Head - Service Tools
- Cylinder Hea D - Exploded View
- Cylinder Head - General Information
- Cylinder Head - Cleaning And Inspection For Reuse
- Cylinder Head - Rebuild
- Cylinder Head - Replacing The Valve Guides
- Cylinder Head - Ring Dowel Replacement
- Cylinder Head - Replacing The Valve Seat Inserts
- Cylinder Head - Grinding The Valves
- Cylinder Head - Replacing The Injector Sleeves
- Cylinder Head - Pressure Testing
- Cylinder Head - Magnetic Particle Checking
- Cylinder Head - Vacuum Testing Valve Seating For Reuse
- Cylinder Head - Valves - Magnetic Crack Inspection
- Valve Crosshead - Cleaning And Checking For Reuse
- Valve Crosshead - Magnetic Crack Inspection
-Group 3 - Rocker Lever Housing Assembly
- Rocker Lever Housing Assembly - Service Tools
- Rocker Lever Housing Cover - Exploded View
- Rocker Lever Housing Assembly - Exploded View
- Water Manifold Plumbing - Exploded View
- Rocker Lever Housing Assembly - General Information
- Rocker Lever - Cleaning And Inspection For Reuse
- Rocker Lever Bushing - Replacement
- Rocker Lever - Magnetic Crack Inspection
- Rocker Housing Covers - Cleaning And Inspection For Reuse
- Rocker Lever Housing Assembly - Cleaning And Inspection For Reuse
- Stc Oil Plumbing - Cleaning And Inspection For Reuse
- Ring And Pin Dowel - Replacement
- Metri-Pack Pass Through Connector - Replacement
-Group 4 - Cam Follower Assembly
- Cam Follower Assembly - Service Tools
- Cam Follower Assembly - Exploded View
- Cam Follower Assembly - General Information
- Cam Follower Assembly - Cleaning And Inspection For Reuse
- Cam Follower Assembly - Rebuild
- Cam Follower Lever - Roller Replacement
- Cam Follower Socket - Replacement
- Push Rod - Cleaning And Inspection For Reuse
-Group 5 - Fuel System
- Fuel Pump - General Information
- Fuel Pump - Cleaning And Inspection For Reuse
- Fuel Pump - Rebuild
- Fuel Pump - Calibration
-Group 6 - Injectors And Fuel Lines
- Injector - Pt (Type D) Step Timing Control - Exploded View
- Injector - Celect - Exploded View
- Injectors - Pt (Type D) Step Timing Control (Stc) General Information
- Injectors - Celect - General Information
- Step Timing Control (Stc) Oil Control Valve - General Information
- Injectors - Cleaning The Exterior And Inspection For Reuse
- Injectors - Rebuild
- Injectors - Calibration
- Stc Oil Control Valve - Cleaning
- Fuel Tubes, Fittings, And Mounting Parts - Cleaning And Inspection For Reuse
-Group 7 - Lubricating Oil System
- Lubricating Oil System - Service Tools
- Lubricating Oil System - Exploded View
- Lubricating Oil Pump Assembly - Exploded View
- Lubricating Oil Cooler - Exploded View
- Lubricating Oil System - General Information
- Lubricating Oil Pan - Cleaning And Inspection For Reuse
- Lubricating Oil Transfer Tube - Cleaning And Inspection For Reuse
- Lubricating Oil Dipstick And Dipstick Tube - Cleaning And Inspection For Reuse
- Lubricating Oil Dipstick - Calibration
- Lubricating Oil Pump - Cleaning And Inspection For Reuse
- Lubricating Oil Pump - Rebuild
- Lubricating Oil Pump Body And Cover Bushing - Replacement
- Lubricating Oil Pump Driven Gear Bushing - Replacement
- Lubricating Oil Pump Drive Gear Or Shaft - Replacement
- Lubricating Oil Pump Driven Shaft - Replacement
- Lubricating Oil Cooler Assembly Rebuild
-Group 8 - Cooling System
- Cooling System - Service Tools
- N14 Water Pump And Idler Assembly - Exploded View
- Water Pump And Idler Assembly - General Information
- Water Pump Assembly
- Water Pump Assembly - Rebuild
- Water Pump Idler Assembly - Cleaning And Inspection
- Water Pump Idler Assembly - Rebuild
- Thermostat Housing - Cleaning And Inspection
- Coolant Filter Head Insert
- Coolant Filter Shutoff Valve
- Fan - Cleaning And Inspection
- Water Transfer Tubes - Cleaning And Inspection
-Group 9 - Drive Units
- Drive Units - Service Tools
- Accessory Drive - Exploded View
- Drive Units - General Information
- Accessory Drive - Cleaning And Inspection For Reuse
- Accessory Drive - Rebuild
- Accessory Drive Gear - Replacement
- Accessory Drive Pulley - Cleaning And Inspection For Reuse
- Accessory Drive Pulley Wear Sleeve - Replacement
-Group 10 - Intake Air System
- Service Tools
- Intake Air System - Exploded View
- Intake Air System - General Information
- Turbocharger - Cleaning And Inspection
- Turbocharger Shaft Axial Clearance Checking
- Turbocharger Bearing Radial Clearance - Checking
- Intake Air Piping - Elbows
- Intake Manifold - Cleaning And Inspection
-Group 11 - Exhaust System
- Exhaust System - Exploded View
- Exhaust System - General Information
- Exhaust Manifold - Cleaning And Inspection For Reuse
- Exhaust Manifold Turbocharger Mounting Stud - Replacement (11-02)
-Group 12 - Air Equipment
- Air Equipment - General Information
- Air Compressor - Cleaning And Inspection For Reuse
-Group 13 - Electrical Equipment
- Electrical Equipment - General Information
- Alternator Bracket - Cleaning And Inspection For Reuse
- Alternator Adjusting Link - Cleaning And Inspection For Reuse
- Starting Motor - Cleaning And Inspection For Reuse
-Group 14 - Engine Testing
- General Information
- Definition Of Terms On Engine Performance Curve
- General Run-In Procedures
- General Engine Test/Run-In Specifications
- Engine Testing - Service Tools
- Engine Dynamometer - Install Engine
- Priming The Lubricating Oil And Fuel Systems
- Engine Run-In Procedure - Engine Dynamometer
- Chassis Dynamometer Operation
- General Test Procedure - Chassis Dynamometer
- Engine Run-In Procedure - Chassis Dynamometer
- Engine Run-In Procedure Without Dynamometer
- Engine Painting
- Engine Storage - Short Term
- Engine Storage - Long Term
-Group 15 - Instruments And Controls
- Instruments And Controls - General Information
-Group 16 - Mounting Adaptations
- Mounting Adaptations
- Flywheel
- Flywheel Ring Gear
- Flywheel Housing - Cleaning And Inspection For Reuse
- Front Engine Support Bracket - Cleaning And Inspection For Reuse
-Group 18 - Specifications
- General Engine Specifications
- Capscrew Markings And Torque Values
- Pipe Plug Torque Values
- Decimal And Metric Equivalents
- Specifications - General Information
- Engine Assembly
- Cylinder Block
- Cylinder Head
- Rocker Lever Housing Asembly
- Cam Follower Assembly
- Fuel Pump - Rebuild Specifications
- Injectors - Rebuild Specifications
- Lubricating Oil System
- Lubricating Oil Pump - Inspection Specifications
- Water Pump Assembly - Rebuild Specifications
- Fan Hub - Inspection Specifications
- Thermostat Housing Assembly - Rebuild Specifications
- Thermostat (Reserve Flow Cooling) - Operating Temperature
- Cooling System - Torque Values
- Fuel Pump And Compressor Drive
- Turbocharger - Inspection Specifications
- Air Compressor - Inspection Specifications
- Engine Testing - Test Specifications
- Vehicle Braking - Rebuild Specifications
-Group 20 - Vehicle Braking
- Vehicle Braking - General Information
-Components Manufacturers: Names And Addresses
-Service Literature
- Additional Service Literature
- Service Literature Ordering Location
- Service Publications Order Form
-Index
-Literature Survey Form


OPERATORS MANUAL

- FOREWORD
- SECTION 1
- SAFETY HINT
- Group 1 Before operating the machine
- Group 2 During operating the machine
- Group 3 During maintenance
- Group 4 Parking
- SECTION 2
- SPECIFICATIONS
- Group 1 Major components
- Group 2 Specifications
- Group 3 Weight
- Group 4 Specification for major components
- SECTION 3
- CONTROL DEVICE
- Group 1 Cab device
- Group 2 Cluster
- Group 3 Switches
- Group 4 Control device
- Group 5 Air conditioner and heater
- Group 6 Others
- SECTION 4
- OPERATION
- Group 1 Suggestion for new machine
- Group 2 Check before starting the engine
- Group 3 Starting and stopping the engine
- Group 4 Warming-up operation
- Group 5 Operation of the working device
- Group 6 Travaling of the machine
- Group 7 Efficient working method
- Group 8 Adjustment of the work equipment
- Group 9 Operation in the special work sites
- Group 10 Storage
- SECTION 5
- TRANSPORTATION
- Group 1 Road traveling
- Group 2 Preparation for transportation
- Group 3 Loading the machine
- Group 4 Fixing the machine
- Group 5 Loading and unloading by crane
- Group 6 Towing the machine
- SECTION 6
- MAINTENANCE
- Group 1 Instructions
- Group 2 Tightening torque
- Group 3 Specification of fuel, coolant and lubricants
- Group 4 Maintenance check list
- Group 5 Maintenance chart
- Group 6 Service instruction
- Group 7 Electrical system
- Group 8 Air conditioner and heater
- SECTION 7
- TROUBLESHOOTING GUIDE
- Group 1 Engine
- Group 2 Electrical system
- Group 3 Power train System
- Group 4 Hydraulic system
- INDEX