![Hyundai HL770A Repair Manual [Wheel Loader]](https://youfixthis.com/wp-content/uploads/2016/02/2016-02-16_11-07-01-1-300x300.jpg)
Part of the Hyundai Repair Manuals.
Need the factory numbers for your HL770 wheel loader? This 485-page Hyundai HL770 service manual PDF walks the whole machine: torque converter and transmission teardown, brake and steering hydraulics, work equipment, and the full electrical system. You get hydraulic schematics tracing the main pump, flow amplifier, and control valves, plus wiring diagrams and a troubleshooting section keyed to cluster warning lamps (coolant overheat, low oil pressure, parking solenoid faults). Inside: pressure and flow tests, cylinder drift and leakage checks, and step-by-step disassembly for the main pump, boom cylinders, and transmission. Torque the front axle mounting bolts to 120 ± 15 kg·m, fill the engine with 39L of oil, and set the main pump at 210 kg/cm2. Your loader is parked and the clock is running. Bookmarked with a live text layer; search any spec, jump to any system, and get wrenching.
What's Inside This Hyundai HL770 Manual
| System | Pages | Key Topics |
|---|---|---|
| Conversion Table | 3-8 | Method of Using the Conversion Table, Example, Millimeters to Inches, Kilogram to Pound, Liter to U.S. Gallon, Liter to U.K. Gallon, Kgm to Lb Ft, Kg/Cm2 to Lb/In2 |
| General | 9-32 | Safety Hints, Specification (Major Components, Specifications, Weight, Tightening Torque), Operational Checkout Record Sheet |
| Engine | 33-43 | Structure, Cooling System, Fuel System, Lubrication System, Intake and Exhaust System |
| Power Train System | 44-183 | Structure and Function (Power Train Component Overview, Torque Converter, Transmission, Axle), Operational Checks and Troubleshooting (Power Train Operational Checks) |
| Brake System | 184-233 | Structure and Function (Outline, Brake Pump, Brake Valve, Cut-Off Valve, Parking Brake Cylinder, Brake Accumulator, Pressure Switches, Parking Brake) |
| Steering System | 234-327 | Structure and Function (Outline, Flow Amplifier, Steering Unit, Steering Cylinder), Operational Checks and Troubleshooting |
| Work Equipment | 328-410 | Structure and Function (Hydraulic System Outline, Main Pump Operation, Remote Control Valve, Main Control Valve, Main Relief Valve, Overload Relief Valve, Pilot Oil Supply Unit, Safety Valve Unit, Boom and Bucket Cylinder, Hydraulic Oil Tank, Accumulator) |
| Electrical System | 411-485 | Component Location |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Tightening torque for M24 x 3.0 (10T) metric bolt | 85.0 - 115 kg·m | p. 26 |
| Tightening torque for Front axle mounting bolt (M30 x 2.0) | 120 ± 15 kg·m | p. 28 |
| Tightening torque for steering valve end cover screws (M10) | 3.1 ± 0.6 kg·m | p. 317 |
| Engine Oil Quantity | 39 L | p. 23 |
| Maximum Operating Pressure (Main Pump) | 210 kg/cm2 | p. 23 |
| Transmission Oil Capacity | 43 L | p. 29 |
| Clutch Cut-off Pressure Switch Rated Pressure | 25 kgf/cm2 | p. 84 |
| Main Relief Valve Pressure | 200 kg/cm2 | p. 24 |
| Parking Brake Cylinder Operating Pressure | 150 kgf/cm2 | p. 203 |
Hyundai HL770 Common Problems This Manual Covers
Hyundai HL770 transmission warning lamp on, no 3rd or 4th gear, error codes on LCD
Stop the machine before diagnosing anything. Check transmission oil level cold and hot; total capacity is 43 L, listed on page 29. Work through the transmission troubleshooting charts starting on page 77, testing shift solenoid connectors for corrosion. Verify the clutch cut-off pressure switch operates at its rated 25 kgf/cm2 (page 84) before condemning clutch packs.
Manual Section: Transmission Troubleshooting p. 29Engine oil pressure warning lamp stays on after start or flickers at low idle
Shut down immediately and check the dipstick; the engine holds 39 L, per the spec on page 23. Inspect the filter housing, drain plug, and front seal for leakage, and replace the oil filter if pressure drops once oil warms up. If level and filter check good, test the pressure switch wiring before suspecting the pump.
Manual Section: Electrical Troubleshooting: Air Cleaner/Engine Oil/Hydraulic Oil p. 23Steering wheel shock or harsh kickback when turning, abnormal play felt through the steering
Check the steering valve mounting hardware first; retorque the end cover screws to 3.1 ± 0.6 kg·m as shown on page 317. Inspect center pivot pins and bearings for wear, and grease them if they run dry. If the shock persists, follow the flow amplifier and steering unit checks in the Steering System section, page 234.
Manual Section: Steering System p. 317Boom lifts slowly, bucket breakout feels weak, hydraulic oil runs hot under load
Test main relief valve pressure at the pump outlet; it should hold 200 kg/cm2 per the spec on page 24, and never exceed the pump's 210 kg/cm2 maximum. Check hydraulic tank level and swap clogged return filters. If pressure still tests low, run the pump and main control valve checks in the Work Equipment section, page 328.
Manual Section: Work Equipment p. 24Frequently Asked Questions
What is the engine oil capacity for the Cummins M11-C engine?
The engine oil quantity for the Cummins M11-C engine is 39 liters (10.3 U.S. gal). p. 23
What is the tightening torque for the main pump housing mounting bolts?
The tightening torque for the main pump housing mounting bolts (M14 x 2.0) is 19.6 ± 2.9 kg·m (142 ± 21 lb·ft). p. 28
What is the recommended oil for the hydraulic tank?
The recommended hydraulic oil depends on the ambient temperature. For temperatures between -20°C and 40°C, ISO VG 32, ISO VG 46, or ISO VG 68 are recommended, as shown in the lubrication chart on page 29. p. 29
Is this Hyundai HL770 Service Manual a digital download?
One searchable PDF covering 485 pages, delivered instantly. No disc, no shipping, no waiting on the post.
Can I print just the pages I need from this Hyundai HL770 manual?
Printing is allowed without restriction. Pull the pages you need for the job and bin them when they get greasy.
Does this Hyundai HL770 manual show the machine's wiring?
Yes, this Hyundai HL770 Service Manual includes complete electrical wiring diagrams, wire routing, and connector pinouts. You can see one on page 413.
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