Hyundai Hb90 Hb100 Backhoe Repair Service Manual

Hyundai Hb90 Hb100 Backhoe Loader Service Repair Manual

Hyundai Hb90 Hb100 Backhoe Loader Service Repair Manual Engine: ● The wheel loader is typically equipped with a diesel engine. ● The exact specifications of the engine may vary, but it usually has a displacement of around liters.

Hyundai Hb90 Hb100 Backhoe Loader Service Repair Manual

SECTION 1 GENERAL Group 1 Safety Hints --------------------------------------------------------------------------------------------------------1-1 Group 2 Specifications -----------------------------------------------------------------------------------------------------1-10 Group 3 Operational Checkout Record Sheet ---------------------------------------------------------------1-17

SECTION 1 GENERAL GROUP 1 SAFETY HINTS FOLLOW SAFE PROCEDURE Unsafe wor k practices are dangerous.

Understand service procedure before doing work; Do not attempt shortcuts.

WEAR PROTECTIVE CLOTHING Wear close fitting clothing and safety equipment appropriate to the job.

73031GE01

WARN OTHERS OF SERVICE WORK Unexpected machine movement can cause serious injury.

Before performing any work on the wheel loader, attach a ÖDo Do Not Operate Operate× tag on the right side controller lever.

WARN DO NOT OPERATE

HB100GE01

USE HANDHOLDS AND STEPS Falling is one of the major causes of personal injury.

When you get on and off the machine, always maintain a three point contact with the steps and handrails and face the machine. Do not use any controls as handholds.

Never jump on or off the machine. Never mount or dismount a moving machine.

Be careful of slippery conditions on platforms, steps, and handrails when leaving the machine.

73032E01

1-1

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 Before starting a job : Â Clean work area and machine. Â Make sure you have all necessary tools to do your job. Â Have the right parts on hand. Â Read all instructions thoroughly; Do not attempt shortcuts.

73031GE26

PROTECT AGAINST FLYING DEBRIS Guard against injury from flying pieces of metal or debris; Wear goggles or safety glasses.

73031GE04

PROTECT AGAINST NOISE Prolonged exposure to loud noise can cause impairment or loss of hearing.

Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.

73031GE05

1-2

PARK MACHINE SAFELY Before working on the machine: Â Park machine on a level surface. Â Lower bucket to the ground. Â Turn key switch to OFF to stop engine.

Remove key from switch. Â Press down to switch off safety switch. Â Allow engine to cool.

73031GE23

SUPPORT MACHINE PROPERLY Always lower the attachment or implement to the ground before you work on the machine. If you must work on a lifted machine or attachment, securely support the machine or attachment.

Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load.

Do not work under a machine that is supported solely by a jack. Follow recommended procedures in this manual.

73031GE06

SERVICE COOLING SYSTEM SAFELY Explosive release of fluids from pressurized cooling system can cause serious burns.

Shut off engine. Only remove filler cap when cool enough to touch with bare hands.

73031GE07

HANDLE FLUIDS SAFELY-AVOID FIRES Handle fuel with care; It is highly flammable.

Do not refuel the machine while smoking or when near open flame or sparks. Always stop engine before refueling machine.

Fill fuel tank outdoors.

73031GE08

1-3

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 Prevent asphyxiation. Engine exhaust fumes can cause sickness or death.

If you must operate in a building, be positive there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area.

REMOVE PAINT BEFORE WELDING OR HEATING Avoid potentially toxic fumes and dust.

Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch.

Do all work outside or in a well ventilated area.

Dispose of paint and solvent properly.

Remove paint before welding or heating: Â If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. Â If you use solvent or paint stripper, remove stripper with soap and water before welding.

Remove solvent or paint stripper containers and other flammable material from area.

Allow fumes to disperse at least 15 minutes before welding or heating.

73031GE10

1-4

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.

73031GE11

SERVICE MACHINE SAFELY Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing or necklace when you work near machine tools or moving parts.

If these items were to get caught, severe injury could result.

Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.

73031GE12

STAY CLEAR OF MOVING PARTS Entanglements in moving parts can cause serious injury.

To prevent accidents, use care when working around rotating parts.

73031GE13

1-5

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 fluids.

73031GE14

If an accident occurs, see a doctor immediately.

Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result.

73031GE15

AVOID HEATING NEAR PRESSURIZED FLUID LINES Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials.

Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area.

Install fire resisting guards to protect hoses or other materials.

73031GE16

PREVENT BATTERY EXPLOSIONS Keep sparks, lighted matches, and flame away from the top of battery. Battery gas can explode.

Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer.

Do not charge a frozen battery; It may explode.

Warm battery to 16˚C (60˚F).

73031GE17

1-6

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.

1. Avoid the hazard by: 2. Filling batteries in a well-ventilated area.

3. Wearing eye protection and rubber gloves.

Avoiding breathing fumes when electrolyte is added.

4. Avoiding spilling of dripping electrolyte.

5. Use proper jump start procedure.

1. If you spill acid on yourself: 2. Flush your skin with water.

Apply baking soda or lime to help neutralize the acid.

3. Flush your eyes with water for 10-15 minutes.

Get medical attention immediately.

1. If acid is swallowed: 2. Drink large amounts of water or milk.

Then drink milk of magnesia, beaten eggs, or vegetable oil.

3. Get medical attention immediately.

73031GE18

USE TOOLS PROPERLY Use tools appropriate to the work. Makeshift tools, parts, and procedures can create safety hazards.

Use power tools only to loosen threaded tools and fasteners.

For loosening and tightening hardware, use the correct size tools. Avoid bodily injury caused by slipping wrenches.

73031GE19

Use only recommended replacement parts.

(See Parts catalogue.)

1-7

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.

Never weld or heat a wheel and tire assembly.

The heat can cause an increase in air pressure resulting in a tire explosion.

Welding can structurally weaken or deform the wheel.

When inflating tires, use a clip-on chuck and extension hose long enough to allow you to stand to one side and not in front of or over the tire assembly. Use a safety cage if available.

Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts.

73031GE24

USE PROPER LIFTING EQUIPMENT Lifting heavy components incorrectly can cause severe injury or machine damage.

Follow recommended procedure for removal and installation of components in the manual.

73031GE25

DISPOSE OF FLUIDS PROPERLY Improperly disposing of fluids can harm the environment and ecology. Before draining any fluids, find out the proper way to dispose of waste from your local environmental agency.

Use proper containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.

73031GE20

DO NOT pour oil into the ground, down a drain, or into a stream, pond, or lake. Observe relevant environmental protection regulations when disposing of oil, fuel, coolant, brake fluid, filters, batteries, and other harmful waste.

1-8

REPLACE SAFETY SIGNS Replace missing or damaged safety signs.

See the machine operator's manual for correct safety sign placement.

73031GE21

LIVE WITH SAFETY Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields.

KEEP ROPS INSTALLED PROPERLY Make certain all parts are reinstalled correctly if the roll-over protective structure (ROPS) is loosened or removed for any reason. Tighten mounting bolts to proper torque.

The protection offered by ROPS will be impaired if ROPS is subjected to structural damage, is involved in an overturn incident, or is in any way altered by welding, bending, drilling, or cutting. A damaged ROPS should be replaced, not reused.

73031GE22

1-9

GROUP 2 SPECIFICATION 1. MAJOR COMPONENT

Tire

Engine assy

Bucket

Radiator

Tilt cylinder

Engine hood

Fuel tank

ROPS/FOPS Cabin

Transmission Hydraulic oil tank

Stabilizer

Exhaust tail pipe

Attachment Front axle

Tool box

Rear axle

Boom

Extendable dipper

Bucket Swing post carriage Control linkage

Lift cylinder

HB1002SP01

1-10

2. SPECIFICATIONS

K M

E

45

H H'

1) HB100/HB90

L

L'

B

C

D

F

J N

J'

P

G G'

A

HB1002SP02

Operating weight Transport length Transport height Transport width

Description

Unit

Standard dipper and GP bucket Extendible dipper and MP bucket

Specification HB100

HB 90

kg (lb)

7900 (17420)

7830 (17260)

kg (lb)

8500 (18740)

8440 (18610)

GP bucket

5800 (19' 0")

5800 (19' 0")

MP bucket

5850 (19' 2")

5850 (19' 2")

Standard dipper

3650 (12' 0")

3450 (11' 4")

Extendible dipper

3700 (12' 2")

3500 (11' 6")

2350 (7' 9")

2350 (7' 9")

GP bucket MP bucket

Overall length

A

7350 (24' 1")

7350 (24' 1")

Dump clearance

B

2735 (9' 0")

2735 (9' 0")

Hinge pin height

C

3530 (11' 7")

3530 (11' 7")

Dump reach

D

785 (2' 7")

785 (2' 7")

Max loading height

E

4380 (14' 4")

4380 (14' 4")

Depth of bucket down

F

105 (0' 4")

105 (0' 4")

Max digging depth (STD)

G

4455 (14' 7")

4250 (13' 11")

Max digging depth (EXT)

G'

5665 (18' 7")

5470 (17' 11")

Max digging height (STD)

H

5570 (18' 3")

5370 (17' 7")

Max digging height (EXT)

H'

6390 (20' 12")

6190 (20' 4")

Backhoe Max digging reach (STD) data Max digging reach (EXT)

J

5550 (18' 3")

5350 (17' 7")

J'

6665 (21' 10")

6480 (21' 3")

Max loading height

K

3720 (12' 2")

3520 (11' 6")

Minimum ground clearance

L

350 (1' 2")

350 (1' 2")

Height of outrigger

L'

363 (1' 3")

363 (1' 3")

Dumping height

M

3860 (12' 8")

3660 (12' 0")

Loader data

mm (ft-in)

1-11

3. SPECIFICATION FOR MAJOR COMPONENTS 1) ENGINE Specification

Item

HB100

HB90

Manufacture

FPT (IVECO)

Model

F4GE9484F*J

F4GE9454J*J

Type

4-stroke, turbocharged and charge air-cooled

4-stroke, turbocharged

Non-road emission standards

Certified to EPA Tier 3 / EU stage III-A 4.5 ℓ (1.2 U.S.gal)

Piston displacement Fuel

Diesel

Rated horse power (Gross)

99 hp (74 kW) at 2200 rpm 89 hp (66 kW) at 2200 rpm

Maximum torque at 1250 rpm (Net)

44 kgfÂm (318 lbfÂft)

41 kgfÂm (297 lbfÂft)

Alternator

90 amp

Battery

12V

2) MAIN PUMP Specification

Item

HB100

Type

HB90

Fixed displacement double gear pump

Capacity

Steering

40 cc/rev

35 cc/rev

Attachment

35 cc/rev

35 cc/rev

Maximum operating pressure Rated oil quantity

250 kgf/cm2 (3560 psi) Steering

88˶ min (23.3 U.S.gpm)

77˶/min (20.3 U.S.gpm)

Attachment

77˶/min (20.3 U.S.gpm)

77˶/min (20.3 U.S.gpm)

Rated speed

2200 rpm

3) MAIN CONTROL VALVE FOR LOADER Item

Specification

Type

2 spool (OPT : 3 spool)

Operating method

Manual control

Main relief valve pressure

250 kgf/cm2 (3560 psi)

Unloading relief valve pressure

220 kgf/cm2 (3130 psi)

Overload relief valve pressure

Bucket out

175 kgf/cm2 (2490 psi)

Bucket in

300 kgf/cm2 (4270 psi)

1-12

4) MAIN CONTROL VALVE FOR BACKHOE Item

Specification

Type

6 spool (OPT : 7 spool)

Operating method

Hydraulic pilot control

Main relief valve pressure

250 kgf/cm2 (3560 psi)

Overload relief valve pressure

Boom up

300 kgf/cm2 (4270 psi)

Boom down

300 kgf/cm2 (3980 psi)

Swing LH, RH

240 kgf/cm2 (3410 psi)

Bucket in

300 kgf/cm2 (4270 psi)

Bucket out

300 kgf/cm2 (4270 psi)

Dipper in

300 kgf/cm2 (4270 psi)

Dipper out

300 kgf/cm2 (4270 psi)

5) STEERING UNIT Item

Specification

Type

Dual displacement load sensing, dynamic signal, non reaction

Displacement

156 cc/rev + 59 cc/rev

Relief valve pressure

248 kgf/cm2 (3530 psi)

Overload relief valve pressure

303 kgf/cm2 (4310 psi)

6) PILOT SUPPLY UNIT Item

Specification

Reducing & relief valve pressure Safety solenoid valve

30 kgf/cm2 (430 psi) Voltage

DC 12V

Ampere

1.8 A

7) ACCUMULATOR Specification

Item

Ride control (OPT)

Type

Pilot supply Nitrogen

Capacity

1.5ℓ

0.35ℓ

Precharge pressure

30 kgf/cm2 (430 psi)

15 kgf/cm2 (215 psi)

Max working pressure

350 kgf/cm2 (4980 psi)

170 kgf/cm2 (2420 psi)

1-13

8) REMOTE CONTROL VALVE Specification

Item

For backhoe

Type

For stabilizer

Pressure reducing type

Operating

Minimum

6.5 kgf/cm2 (93 psi)

5.5 kgf/cm2 (78 psi)

Maximum

25 kgf/cm2 (356 psi)

26 kgf/cm2 (370 psi)

19 degree

23.5 degree

Single operation angle

9) LINE FILTER Item

Specification

Filtration rating

10 μm

Max working pressure

280 kgf/cm2 (3980 psi)

Bypass cracking pressure

7 kgf/cm2 (100 psi)

10) DOUBLE PILOT CHECK VALVE FOR STABILZER Item

Specification

Max working pressure

350 kgf/cm2 (4980 psi)

Cracking pressure

4.5 kgf/cm2 (64 psi)

Pilot ratio

1 : 5.5

11) TIRES Item Front

Specification 4WD-12.5/80-18 4WD-18.4-26 (STD)

Rear

4WD-16.9-28 (OPT) 4WD-21L-24 (OPT)

1-14

12) POWERTRAIN Item

Specification 4-Speed helical-cut gears, full powershift with hydraulic control standard, electric clutch cutoff on loader lever

Transmission

Maximum travel speed with standard (18.4-26 tire) Gear

1st

2nd

3rd

4th

Forward (km/hr)

5.9

10.9

22.0

37.5

Reverse (km/hr)

7.5

13.7

21.7

N/A

Torque converter (ratio) 1 : 2.526 Differential lock

Front : Conventional Rear : Hydraulic lock (push-button activation)

Steering

Hydrostatic power and emergency steering

Brake

Service

Hydraulic wet disc, mounted inboard, self-adjusting and self-equalizing

Parking

Spring applied, hydraulically releases, wet, multi disc independent of service brakes with electric switch control

13) BUCKET Item

Capacity (liters)

Width (mm)

Weight (kg)

Loader GP

1000

2350

425

Loader MP

1000

2350

790

Trenching

170

630

140

Trenching

200

720

150

1-15

14) RECOMMENDED LUBRICANTS Use only oils listed below or equivalent.

Do not mix different brand oil.

Service point

Kind of fluid

Capacity ˶ (U.S. gal)

Ambient temperatureĦC (ĦF) -20 (-4)

-10 (14)

0 (32)

10 (50)

20 (68)

30 (86)

SAE 30 SAE 10W Engine oil pan

Engine oil

12 (3.2) SAE 10W-30 SAE 15W-40

SAE 10W-30

Torque converter Transmission

Engine oil

Axle

UTTO

Front : 8 (2.1) Rear : 16 (4.2)

Hydraulic oil

Tank: 60 (15.9) System: HB100 : 115 (30.4) HB90 : 110 (29.1)

Hydraulic tank

18 (4.6) SAE 15W-40

UTTO

ISO VG 32 ISO VG 46 ISO VG 68

ASTM D975 NO.1 Fuel tank

Diesel fuel

160 (42.3) ASTM D975 NO.2 NLGI NO.1

Fitting (grease nipple)

Grease

Radiator

Mixture of antifreeze and water 50 : 50

As required NLGI NO.2

Ethylene glycol base permanent type

19 (5.0)

·SAE Society of Automotive Engineers ·API American Petroleum Institute ·ISO International Organization for Standardization ·NLGI National Lubricating Grease Institute ·ASTM American Society of Testing and Material ·UTTO Universal Tractor Transmission Oil

1-16

40 (104)

GROUP 3 OPERATIONAL CHECKOUT RECORD SHEET

ÂOwner

ÂDate

ÂHours ÂSerial No. ÂTechnician ö Use this sheet to record operational checkout results.

Perform the operational check before installing any test equipment.

HB100OC01

OK

NOT OK

 Hourmeter and gauge check  Battery check

□ □

□ □

 Monitor indicator circuit check

□

□

 Cluster turn signals and warning indicator check

□

□

 Transmission control lever and neutral

□

□

 Neutral start and reverse warning

□

□

 Alarm circuit checks

□

□

 Monitor display and alternator output checks

□

□

 Monitor bypass circuit and seat belt indicator check

□

□

 Monitor primary and secondary level check

□

□

 Transmission oil warm up procedure

□

□

 Transmission temperature lamp check

□

□

Item

1. Monitor indicator and gauge checks (engine OFF)

2. Transmission, axle and engine, neutral start switch and reverse warning alarm switch checks

3. Monitor indicator and gauge checks (engine running)

1-17

Comments

4. Brake system and clutch cut off checks  Park brake capacity check

□

□

 Park brake transmission lockout check

□

□

 Service brake pump flow check

□

□

 Service brake capacity check

□

□

 Brake accumulator precharge check

□

□

 Brake system leakage check

□

□

 Service brake pedal check

□

□

 Service and park brake system drag check

□

□

 Clutch cut off check

□

□

ÂTransmission oil warm up procedure

□

□

ÂTransmission noise check

□

□

ÂSpeedometer check

□

□

ÂTransmission kick down system check

□

□

Â1st, 2nd, 3rd and 4th speed clutch pack drag check

□

□

ÂTransmission pressure, pump flow and leakage check

□

□

ÂTransmission shift modulation check

□

□

ÂTorque converter check

□

□

ÂEngine power check

□

□

ÂHydraulic system warm up procedure

□

□

ÂHydraulic pump performance check

□

□

ÂPilot control valve boom float check

□

□

ÂBoom down solenoid valve check

□

□

ÂControl valve lift check

□

□

ÂBucket rollback circuit relief valve check

□

□

Low pressure check

□

□

High pressure check

□

□

ÂBoom and bucket cylinder drift check

□

□

ÂBoom down solenoid valve leakage check

□

□

ÂPilot controller check

□

□

ÂReturn to dig check

□

□

ÂBoom height kickout check-if equipped

□

□

5. Driving checks

6. Hydraulic system checks

ÂBucket dump circuit relief

1-18

7. Steering system checks ÂSteering unit check

□

□

ÂSteering system leakage check

□

□

ÂOperating lights check

□

□

ÂWork light check

□

□

ÂBrake light check

□

□

ÂCab light check

□

□

ÂHorn circuit check

□

□

ÂWindshield washer and wiper check

□

□

ÂDefroster blower check

□

□

ÂHeater/Air conditioner blower check

□

□

ÂHeater functional check

□

□

ÂAir conditioner functional check

□

□

ÂStart aid system check

□

□

ÂCab door latch check

□

□

ÂCab door hold open latch check

□

□

ÂCab door release button check

□

□

ÂCab door lock check

□

□

ÂCab door window check

□

□

ÂCab window latch check

□

□

ÂSteering column adjustment check

□

□

ÂSeat and seat belt check

□

□

ÂAir intake filter door check

□

□

ÂEngine side panels check

□

□

ÂRadiator cap access door check

□

□

ÂBoom lock check

□

□

ÂService decal check

□

□

8. Accessory checks

9. Cab components and vandal protection checks

1-19

SECTION 2 ENGINE Group 1 Structure and Function -------------------------------------------------------------------------------------- 2-1 Group 2 Engine Speed and Stall rpm ----------------------------------------------------------------------------- 2-8

SECTION 2 ENGINE GROUP 1 STRUCTURE AND FUNCTION 1. STRUCTURE 13

12

1

11

3

2 10

4 9 8 5

7

6

HB100EG01

1 2 3 4 5

Starter Water temperature sensor Oil filter Alternator Resistance for cold start up

6 7 8 9 10

Oil pan Oil pressure sensor Oil filler Fuel filter Injection pump

2-1

11 12 13

Timing gear housing Breather valve Turbocharger

2. SYSTEM DIAGRAMS The following drawings show the flow through the engine systems.

1) LUBRICATION Lubrication by forced circulation is achieved through oil rotary expansion pump, placed in the front part of the basement, driven by the straight-tooth gear splined to the shaft's bar hold.

From the pan, the lubrication oil flows to the driving shaft, to the camshaft and to the valve drive.

Lubrication involves the oil cooler and the turboblower.

All these components may often vary according to the specific duty.

1

2

Routing of oil under pressure Routing of oil return by gravity to sump Introduction of oil

3

4

HB100EG02

1 2

Lubrication oil pipe to supercharger Oil cooler body

3 4

2-2

Oil rotary expansion pump Oil filter

2) OIL VAPOUR RECIRCULATING SYSTEM On the tappet cap (3) there is a valve (1) whose duty is to condense oil vapour inducing these to fall down because of gravity, to the tappet cap underneath.

The remaining non-condersed vapours shall be properly conveyed through the breather pipe (2), by suction as an example.

1 2

3

HB100EG03

1 2

Valve Breather pipe

3

2-3

Tappet cap

3) COOLING SYSTEM The engine cooling system, closed circuit forced circulation type, generally incorporates the following components : ① Expansion tank ; placement, shape and dimensions are subject to change according to the engine's equipment. ② Radiator, which has the duty to dissipate the heat subtracted to the engine by the cooling liquid.

Also this component will have specific peculiarities based on the equipment developed, both for what concerns the placement and the dimensions. ③ Pusher fan, having the duty to increase the heat dissipating power of the radiator. This component as well will be specifically equipped based on the engine's development. ④ Oil cooler to cool the lubrication oil : even this component is part of the engine’s specific equipment. ⑤ Centrifugal water pump, placed in the front part of the engine block. ⑥ Thermostat regulating the circulation of the cooling liquid.

To radiator

From radiator

Water coming out from thermostat Water recirculating engine Water coming into pump

HB100EG04

2-4

4) AIR INDUCTION BOOST DIAGRAM (1) Boosting version engine (HB90) The turbocharger is composed by the following main parts: one turbine, one transforming valve to regulate the boost feeding pressure , one main body and one compressor.

During engine working process, the exhaust emission flow through the body of the turbine, provoking the turbine disk wheel’s rotation.

The compressor rotor, being connected by shaft to the turbine disk wheel, rotates as long as this last one rotates, compressing the sucked air through the air filter.

The air coming out of the compressor is sent via the intake manifold directly to the pistons.

The turbocharger is equipped with a transforming valve to regulate the pressure , that is located on the exhaust collector before the turbine and connected by piping to the induction collector.

It’s duty is to choke the exhaust of the emissions, releasing part of them directly to the exhaust tube when the boost feeding pressure, over the compressor, reaches the prescribed bar value.

The cooling process and the lubrication of the turbocharger and of the bearings is made by the oil of the engine.

AIR FILTER

TURBOCHARGER

EXHAUST

HB100EG05

2-5

(2) Inter-cooled engine version (HB100) The turbocharger is composed by the following main parts : one turbine, one transforming valve to regulate the boost feeding pressure , one main body and one compressor.

During engine working process, the exhaust emission flow through the body of the turbine, provoking the turbine disk wheel’s rotation.

The compressor rotor, being connected by shaft to the turbine disk wheel, rotates as long as this last one rotates, compressing the sucked air through the air filter.

The above mentioned air is then cooled by the radiator and flown through the piston induction collector.

The turbocharger is equipped with a transforming valve to regulate the pressure , that is located on the exhaust collector before the turbine and connected by piping to the induction collector.

It’s duty is to choke the exhaust of the emissions, releasing part of them directly to the exhaust tube when the boost feeding pressure, over the compressor, reaches the prescribed bar value.

The cooling process and the lubrication of the turbocharger and of the bearings is made by the oil of the engine.

TURBOCHARGER

AIR FILTER

EXHAUST

RADIATOR

HB100EG06

2-6

5) EXHAUST GAS RE-CIRCULATION SYSTEM (EGR) In the TIER 3 version, the profile of the exhaust cam has been modified in order to allow the partial opening of the relative valve during the aspiration phase (re-circulation of EGR exhaust gas) with the subsequent re-introduction of part of the exhaust gas into the engine cylinders.

The exhaust gases can partially be re-directed into the cylinders so as to reduce the maximum combustion temperature values responsible for the production of nitric acid (NOx).

The exhaust gas re-circulation system (EGR), reducing the combustion temperature by means of the diminishing of the concentration of oxygen in the combustion chamber, represents therefore an efficient control system of the emission of NOx .

The internal EGR system is not equipped with any electronically controlled elements: the system is always active.

Its configuration does not need additional elements i.e. checking valves, piping or oil coolers.

The exhaust cam (B) has another lobe apart from the major lobe (see Section A-A fig.) with respects to the configuration without EGR. The additional lobe, during the aspiration phase in the cylinder in question, allows a brief opening of the exhaust valve generating re-circulation due to the intake of the exhaust gases caused by depression which is created in the aspiration phase inside the cylinder.

A : Aspiration valve control B : Exhaust valve control A B

A-A

A

A

HB100EG07

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Hyundai Hb90 Hb100 Backhoe Loader Service Repair Manual

Hyundai Hb90 Hb100 Backhoe Loader Service Repair Manual Engine: ● The wheel loader is typically equipped with a diesel engine. ● The exact specifications of the engine may vary, but it usually has a displacement of around liters.

Hyundai Hb90 Hb100 Backhoe Loader Service Repair Manual