Hyundai HD78 General Information - 1

General
Information
Chassis Number Nameplate ................ GI - 2
General Service Information ................ GI - 3
Precautions For Electric Welding ........ GI -10
General
CHASSIS NUMBER NAMEPLATE
Vehicle Identification Number Location
The vehicle identification number (V.I.N) is stamped on
the rear side of the right front spring bracket.
2. Manufacturer
M-Manufactured by HMC
3. Vehicle Type
B-Trailer
J-Bus
F- Truck
E- Tractor
C- Special vehicle
4. Vehicle Line
TRUCK
C-MIGHTY / Bare chassis

G-MIGHTY(Wide Cab)
J- MIGHTY / GVW 4 TON
V-MIGHTY (Narrow cab)
SUDGIA0001L
5. Body Type
TRUCK
A- Cargo / Top Truck Type
B- Full Cargo Type
E- Double Cab Type
F- Bare chassis
6. Vehicle Division
1- All vehicle
7. Brake System
7-Hydraulic Brake System
8-Pneumatic Brake System
9-Compound Brake System
8. Engine Type
A- D4DA
B- D4DB, D4BB
C-D4DC
E- D4AE
F- D4AF
H-D4GA
K-D4AK
L-D4AL
P-D4DD
9. Check Digit Other

EMTGI5002A
VEHICLE IDENTIFICATION NUMBER
P-Left Hand Driver (LHD)

R-Right Hand Driver (RHD)
10.Model year or Product Year
9: 2009
A: 2010
B:2011
C: 2012
D: 2013
E: 2014
F:2015
G:2016
11.Plant
U-Ulsan plant(in Korea)
EMTGI5101A
1. Geographic zone
K-Built in Korea by HMC (Hyundai Motor company)
C-Cheonju plant(in Korea)

A-Asan plant(in Korea)
12.Serial Number (Vehicle Production)
000001-999999
1. Inspection of parts
GENERAL SERVICE INFORMATION

PROTECTION OF THE VEHICLE
Always be sure to cover fenders, seats, and floor areas
before starting work.
Each part, when removed, should be carefully on

suspected for malfunction, deformation, damage, and
other problems.
PREPARATION OF TOOLS AND MEASURING

EQUIPMENT
Be sure that all necessary tools and measuring
equipment are available starting work.
SPECIAL TOOLS
Use special tools when they are required.
EAKE005C
2. Arrangement of parts
All disassembled parts should be carefully arranged
for effective reassembly.
Be sure to separate and correctly identify the parts to
be replaced from those that will be used again.
EAKE005A
DISASSEMBLY
If the disassembly procedure is complex, requiring many
parts to be disassembled, all parts should be
disassembled in a way that will not affect their
performance or external appearance.
EAKE005D
3. Cleaning parts for reuse
REPLACEMENT
All parts to be used again should be carefully and

thoroughly cleaned by an appropriate method.
Standard values, such as torques and certain

adjustments, must be strictly observed in the reassembly
of all parts.
If removed, the following parts should always be replaced
with new ones.
1. Oil seals
2. Gaskets
3. O-rings
4. Lock washers
5. Cotter pins (split pins)
6. Plastic nuts
EAKE005E
PARTS
When replacing parts, use HYUNDAI genuine parts.
EAKE005G
Depending on their location.

7. Sealant should be applied to gaskets.
8. Oil should be applied to the moving components of
parts.
EAKE005F
9. Specified oil or grease should be applied to the

prescribed locations (oil seals, etc) before assembly.
EAKE005I
RUBBER PARTS AND TUBES

EAKE005H
ADJUSTMENT
Always prevent gasoline or from touching rubber parts or

tubing.
Use gauges and testers to adjust correctly the parts to

standard values correctly.
ELECTRICAL SYSTEM
1. Be sure to disconnect the battery cable from the
negative (-) terminal of the battery.
2. Never pull
connectors.
on
the
wires
when
disconnecting
3. Locking connectors will click when the connector is

secure.
4. Handle sensors and relays carefully. Be careful not to
drop them against other parts.
EAKE005J
MEASURING BODY DIMENSIONS

1. Basically, all measurements in this manual are taken
with a tracking gauge.
2. When a measuring tape is used, check to be sure
there is no elongation, twisting or bending.
3. For
measuring
dimensions,
both
projected
dimensions and actual - measurement dimensions
are used in this manual.
DIMENSIONS PROJECTED
MEASURING ACTUAL DIMENSIONS
1. These are the dimensions measured when the

measurement points are projected from the vehicle's
surface, and are the reference dimensions used for
body alterations.
1. These dimensions indicate the actual linear distance

between measurement points, and are used as the
reference dimensions when a tracking gauge is used
for measurement.
2. If the length of the tracking gauge probes is

adjustable, measure it by lengthening one of two
probes as long as the different value in height of the
two surface.
2. First adjust both probes to the same length (A=A')

before measurement.
NOTICE
Check the probes and gauge itself to make sure
there is no free play.
EAKE005K
EAKE005L
MEASUREMENT POINT
Measurements should be taken at the center of the hole.
EAKE005M
CHECKING CABLES AND WIRES
CHECK FUSES
1. Check the terminal for tightness.
A blade type fuse test taps provided to allow checking

the fuse itself without removing if from the fuse box. The
fuse is good if the test lamp lights up when one lead is
connected to the test taps (one at a time) and the other
lead is grounded. (Turn the ignition switch so that the
fuse circuit becomes operative)
2. Check terminals and wires for corrosion from battery

electrolyte, etc.
3. Check terminals and wires for open circuits.
4. Check wire insulation and coating for damage, cracks
and degrading.
5. Check the conductive parts of terminals for contact
with other metallic parts (vehicle body and other
parts).
6. Check grounded parts to verify that there is complete
continuity between their attaching bolt(s) and the
vehicle's body.
7. Check for incorrect wiring.
8. Check that the wiring is so clamped to the prevent
contact with sharp corners of the vehicle body, etc. or
hot parts (exhaust manifold, etc.)
9. Check that the wiring is clamped firmly to provide
enough clearance from the fan pulley, fan belt and
other rotating or moving parts.
10.Check that the wiring has a little space so that it can
vibrate between fixed and moving parts such as the
vehicle body and the engine.
EAKE005O
SERVICING THE ELECTRICAL SYSTEM

1. Prior to servicing the electrical system, be sure to
turn off the ignition switch and disconnect the battery
ground cable.
EAKE005R
EAKE005P
2. Attach the wiring harnesses with clamps so that there

is no slack. However, for any harness which passes
the engine or other vibrating parts of the vehicle,
allow some slack within a range that does not allow
the engine vibrations to cause the harness to come
into contact with any of the surrounding parts and
then secure the harness by using a clamp.
4. When installing any parts, be careful not to pinch or

damage any of the wiring harness.
EAKE005T
5. Never throw relays, sensors or electrical parts, or

expose them to strong shock.
EAKE005R
3. If any section of a wiring harness interferes with the

edge of a parts, or a corner, wrap the section of the
harness with tape or something similar in order to
protect if from damage.
EAKE005U
EAKE005S
6. The electronic parts used in the computer, relays,

etc. are readily damaged by heat. If there is a need
for service operations that may cause the
temperature to exceed 80C (176F), remove the
electronic parts before hand.
8. When disconnecting a connector, be sure to grip only

the connector, not the wires.
EAKE006C
EAKE006A
9. Disconnect connector which have catches by

pressing in the direction of the arrows shown the
illustration.
7. Loose connectors cause problems. Make sure that

the connectors are always securely fastened.
EAKE006D
EAKE006B
10.Connect connectors which have catches by inserting

the connectors until they make a clicking sound.
12.To avoid overloading the wiring, take the electrical

current load of the optional equipment into
consideration, and determine the appropriate wire
size.
Permissible current
SAE gauge
Nominal size
In engine co No.
Other areas
mpartment
0.3mm
AWG 22
5A
0.5mm
AWG 20
7A
13A
0.85mm
AWG 18
9A
17A
1.25mm
AWG 16
12A
22A
2.0mm
AWG 14
16A
30A
3.0mm
AWG 12
21A
40A
5.0mm
AWG 10
31A
54A
Precautions for electric welding

EAKE006E
11.When using a circuit tester to check continuity or

voltage on connector terminals, insert the test probe
into the harness side. If the connector is a sealed
connector, insert the test probe through the hole in
the rubber cap until contacts the terminal, being
careful not to damage the insulation of the wires.
WARNING
When electric-welding the electronic parts which are
connected directly to the battery, current in the
welding machine can flow through the grounding
circuit to these parts, thus damaging them. Follow
below procedures surely.
1. Turn off all of the electric switches in vehicle.
2. Remove the (-) Battery.
3. Disconnect all of grounding circuits earthed in
vehicle, insulate the current using rubber and etc.
NOTICE
Refer the Electrical Troubleshooting Manual in
relation position of ground terminal.
4. Disconnect all ECU and controller connector.
Engine control system : ECU or ECM
Brake control system : ABS ECU
The other system : ETACS
NOTICE
Refer the Electrical Troubleshooting Manual in
relation position of ground terminal.
5. Do not earth grounding circuit in the welding machine
to the fuel tank.
EAKE006G
6. The welding spark should not be contacted to the fuel

tank.
7. When tightening ground terminal to the body, clean

the neighborhood of body and tighten it with specified
torque.
Tightening torque
Item
Outer Diameter of bolt(mm)

Nm
kgfm
lb-ft
Battery (+) cable tightening
M8
88.3~137.3
9~14
65.1~101.3
Battery (+) terminal
M8
88.3~137.3
9~14
65.1~101.3
Battery (-) cable tightening
M10
137.3~156.9
14~16
101.3~115.7
Battery (-) terminal
M6
39.2~58.8
4~6
28.9~43.4
Starter motor
M8
98.1~117.7
10~12
72.3~86.8
Alternator "B" terminal
M8
88.3~137.3
9~14
65.1~101.3
Engine grounding strap
M10
186.3~274.6
19~28
137.4~202.5
Main Fuse box
M8
88.3~137.3
9~14
65.1~101.3
Recommended Lubrication
Item
Engine oil Except D4GA API CF-4 or above
Recommended fluid
Quantity(liter)
0~40 : SAE 30W
*Total :9.0(9.3 : When By-pass filter is installed.)

*Oil pan : 8.0
-10 above : SAE 20W-40

-20 ~ 40 dabove : SAE 10W-30
-25 ~ 40 dabove : SAE 5W-30
10 below : SAE 0W-30
D4GA
API CI-4 or above
0~40 : SAE 30W

*14(With oil filter)

*Oil pan : MAX - 13.5
MIN - 9.5

-20 ~ 40 dabove : SAE 10W-30
-25 ~ 40 dabove : SAE 5W-30
10 below : SAE 0W-30
Transmission oil
API GL-4, SAE 75W85
Transmission oil
Temperate/Frigid zone : API GL-3, SAE 80 or API GL-4 80W M2S5 : 4.0 (With PTO : 4.5)
-90
M3S5 : 3.4 (With PTO : 3.9)
Tropical zone : API GL-4 SAE 90
M035S5 : 3.2 (With PTO : 3.7)
Rear Axle oil
Temperate/Frigid zone : API GL-5, SAE 80W-90

Tropical zone : API GL-5 SAE 140 or SAE 85W/140
Steering gear box flow ra- PSF-3

te
T60S5 : 4.5(With PTO : 4.9)

T60S6 : 5.5(With PTO : 5.9)
R130HS : 6.20.25
D033H : 5.80.25
D2H/D3H : 4.50.14
7 / Min
TIGHTENING TORQUE TABLE OF STANDARD

PARTS
Thick bolt
Bolt nominal diameter
(mm)
SDFGI8022D
Torque N.m(kgf.m , lb-ft)
Pitch(mm)
Head mark 4
SDFGI8023D
Head mark 8
SDFGI8024D
SDFGI8026D
M5
1.5
17.6~26.5
(1.8~2.7 , 13~19.5)
42.1~58.8
(4.3~6 , 31.1~43.4)
M6
1.75
30.4~46.1
(3.1~4.7 , 22.4~34)
73.5~98
(7.5~10 , 54.2~72.3)
M8
53.9~73.5
(5.5~7.5 , 39.8~54.2)
117.6~166.6
(12~17 , 86.8~122.9)
M10
88.2~117.6
(9~12 , 65.1~86.8)
186.2~254.8
(19~26 , 137.4~188)
M12
2.5
117.6~156.8
(12~16 , 86.8~115.7)
254.8~343
(26~35 , 188~253)
M14
2.5
166.6~225.4
(17~23 , 122.9~166.3)
362.6~490
(37~50 , 267.5~361.5)
M16
2.5
225.4~303.8
(23~31 , 166.3~224.1)
490~666.4
(50~68 , 361.5~491.6)
M18
284.2~392
(29~40 , 209.7~289.2)
627.2~842.8
(64~86 , 462.7~621.8)
NOTICE
1. The torques shown in the table are standard values
under the following conditions :
3. If you reduce the torques in the table to the

percentage indicated below, under the following
conditions, it will be the standard value.
Nuts and bolts are made of galvanized steel bar.
If spring washers are used : 85%
Galvanized plain steel washers are inserted.
All nuts, bolts and plain washers are dry.
If threads and bearing surfaces are stained with

oil : 85%
2. The torques shown in the table are not applicable :
When spring washers, toothed washers and the

like are inserted.
If plastic parts are fastened.
If self-tapping screws or self-locking nuts are

used.
If threads and surfaces are coated with oil.

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General

C-MIGHTY / Bare chassis

A- Cargo / Top Truck Type

B- Full Cargo Type

E- Double Cab Type

9. Check Digit Other

VEHICLE IDENTIFICATION NUMBER

P-Left Hand Driver (LHD)

C-Cheonju plant(in Korea)

GENERAL SERVICE INFORMATION

Each part, when removed, should be carefully on

PREPARATION OF TOOLS AND MEASURING

3. Cleaning parts for reuse

All parts to be used again should be carefully and

Standard values, such as torques and certain

Depending on their location.

9. Specified oil or grease should be applied to the

RUBBER PARTS AND TUBES

Always prevent gasoline or from touching rubber parts or

Use gauges and testers to adjust correctly the parts to

3. Locking connectors will click when the connector is

MEASURING BODY DIMENSIONS

MEASURING ACTUAL DIMENSIONS

1. These are the dimensions measured when the

1. These dimensions indicate the actual linear distance

2. If the length of the tracking gauge probes is

2. First adjust both probes to the same length (A=A')

CHECKING CABLES AND WIRES

1. Check the terminal for tightness.

A blade type fuse test taps provided to allow checking

2. Check terminals and wires for corrosion from battery

SERVICING THE ELECTRICAL SYSTEM

2. Attach the wiring harnesses with clamps so that there

4. When installing any parts, be careful not to pinch or

5. Never throw relays, sensors or electrical parts, or

3. If any section of a wiring harness interferes with the

6. The electronic parts used in the computer, relays,

8. When disconnecting a connector, be sure to grip only

9. Disconnect connector which have catches by

7. Loose connectors cause problems. Make sure that

10.Connect connectors which have catches by inserting

12.To avoid overloading the wiring, take the electrical

Precautions for electric welding

11.When using a circuit tester to check continuity or

6. The welding spark should not be contacted to the fuel

7. When tightening ground terminal to the body, clean

Outer Diameter of bolt(mm)

Battery (+) cable tightening

Battery (+) terminal

Battery (-) cable tightening

Battery (-) terminal

Alternator "B" terminal

Engine grounding strap

Main Fuse box

0~40 : SAE 30W

*Total :9.0(9.3 : When By-pass filter is installed.)

-10 above : SAE 20W-40

API CI-4 or above

0~40 : SAE 30W