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Hyundai HL940 Service Manual
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Hyundai HL940 Service Manual

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HL940, HL940 TM
WHEELED LOADER
SERVICE MANUAL

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Summary of Contents for Hyundai HL940

  • Page 1 HL940, HL940 TM WHEELED LOADER SERVICE MANUAL...

  • Page 2: Table Of Contents

    TABLE OF CONTENT CONTENTS FOREWORD SECTION 1 GENERAL Group 1 Safety Hints Group 2 Specification Group 3 Operational Checkout Record Sheet SECTION 2 ENGINE Group 1 Structure And Function Group 2 Engine Speed & Stall Rpm Group 3 Fuel Warmer System SECTION 3 POWER TRAIN SYSTEM Group 1 Structure And Function Group 2 Operational Checks And Troubleshooting...

  • Page 3: Contents

    CONTENTS CONTENTS SECTION 1 GENERAL SECTION 1 GENERAL Group 1 Safety Hints ------------------------------------------------------------------------------------------------------- 1-1 Group 2 Specifications ---------------------------------------------------------------------------------------------------- 1-10 Group 3 Operational Checkout Record Sheet -------------------------------------------------------------- 1-26 SECTION 2 ENGINE SECTION 2 ENGINE Group 1 Structure and Function ------------------------------------------------------------------------------------ 2-1 Group 2 Engine speed and Stall rpm ---------------------------------------------------------------------------- 2-12 Group 3 Fuel Warmer System --------------------------------------------------------------------------------------- 2-13 SECTION 3 POWER TRAIN SYSTEM...
  • Page 4 SECTION 7 ELECTRICAL SYSTEM SECTION 7 ELECTRICAL SYSTEM Group 1 Component Location --------------------------------------------------------------------------------------- 7-1 Group 2 Electrical Circuit ------------------------------------------------------------------------------------------------ 7-3 Group 3 Monitoring System ------------------------------------------------------------------------------------------- 7-22 Group 4 Electrical Component Specification ---------------------------------------------------------------- 7-69 Group 5 Connectors -------------------------------------------------------------------------------------------------------- 7-76 Group 6 Troubleshooting ------------------------------------------------------------------------------------------------- 7-97 Find manuals at https://best-manuals.com...

  • Page 5: Foreword

    The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact your Hyundai distributor for the latest information. Find manuals at https://best-manuals.com...
  • Page 6 Revised edition mark (①②③…) Any additions, amendments or other changes When a manual is revised, an edition mark is will be sent to HYUNDAI distributors. recorded on the bottom outside corner of the Get the most up-to-date information before you pages.
  • Page 7 3. CONVERSION TABLE 3. CONVERSION TABLE Method of using the Conversion Table The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. Example Example Method of using the Conversion Table to convert from millimeters to inches...
  • Page 8 Millimeters to inches Millimeters to inches 1mm = 0.03937in 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142 1.181 1.220 1.260 1.299 1.339...
  • Page 9 Liter to U.S. Gallon Liter to U.S. Gallon 1ℓ = 0.2642 U.S.Gal 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019 5.283 5.548 5.812 6.6076 6.340 6.604 6.869 7.133 7.397 7.661 7.925 8.189...
  • Page 10 kgf·m to to lbf lbf·ft ft 1kgf·m = 7.233lbf·ft 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8 217.0 224.2 231.5 238.7 245.9 253.2...
  • Page 11 kgf/cm kgf/cm to to lbf/in lbf/in 1kgf / cm = 14.2233lbf / in 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5 426.7...
  • Page 12 TEMPERATURE TEMPERATURE Fahrenheit-Centigrade Conversion. A simple way to convert a fahrenheit temperature reading into a centigrade temperature reading or vice verse is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.

  • Page 13: Section 1 General

    SECTION 1 GENERAL SECTION 1 GENERAL Group 1 Safety Hints --------------------------------------------------------------------------------------------------------1-1 Group 2 Specifications -----------------------------------------------------------------------------------------------------1-10 Group 3 Operational Checkout Record Sheet ---------------------------------------------------------------1-26...

  • Page 14: Group 1 Safety Hints

    SECTION 1 GENERAL SECTION 1 GENERAL GROUP 1 SAFETY HINTS GROUP 1 SAFETY HINTS FOLLOW SAFE PROCEDURE FOLLOW SAFE PROCEDURE Unsafe wor k practices are dangerous. Understand service procedure before doing work; Do not attempt shortcuts. WEAR PROTECTIVE CLOTHING WEAR PROTECTIVE CLOTHING Wear close fitting clothing and safety equipment appropriate to the job.
  • Page 15 PREPARE FOR EMERGENCIES 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 WORK IN CLEAN AREA Before starting a job : ·...
  • Page 16 PARK MACHINE SAFELY PARK MACHINE SAFELY Before working on the machine: · Park machine on a level surface. · Lower bucket to the ground. · Turn key switch to OFF to stop engine. Remove key from switch. · Move pilot cut off switch to locked position. ·...
  • Page 17 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 BEWARE OF EXHAUST FUMES Prevent asphyxiation.
  • Page 18 ILLUMINATE WORK AREA SAFELY 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.
  • Page 19 AVOID HIGH PRESSURE FLUIDS 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 73031GE14 fluids.
  • Page 20 PREVENT ACID BURNS 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. Avoid the hazard by: Filling batteries in a well-ventilated area. Wearing eye protection and rubber gloves.
  • Page 21 SERVICE TIRES SAFELY 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.
  • Page 22 REPLACE SAFETY SIGNS REPLACE SAFETY SIGNS Replace missing or damaged safety signs. See the machine operator's manual for correct safety sign placement. 73031GE21 LIVE WITH SAFETY LIVE WITH SAFETY Before returning machine to customer, make sure machine is functioning properly, especially the safety systems.

  • Page 23: Group 2 Specification

    GROUP 2 SPECIFICATION GROUP 2 SPECIFICATION 1. MAJOR COMPONENT 1. MAJOR COMPONENT (HL940, HL940XT) Hydraulic tank Radiator Bucket Tire Head light Main control valve Battery Boom Boom cylinder Counterweight Engine Bell crank Bucket cylinder Main pump Air cleaner Bucket link...
  • Page 24 MAJOR COMPONENT MAJOR COMPONENT (HL940TM) Hydraulic tank Radiator Bucket Tire Head light Main control valve Battery Quick coupler Counterweight Engine Link Bucket cylinder Main pump Air cleaner Boom Front axle Steering cylinder Rear axle Transmission Fuel tank 940TM2SE01 1-11...
  • Page 25 2. SPECIFICATIONS WITH BOLT-ON CUTTING EDGE TYPE BUCKET (HL940) 740F2SE03 Description Unit Specification Operating weight kg (lb) 13100 (28880) Struck 2.0 (2.6) Bucket capacity Heaped 2.3 (3.0) Overall length 7430 (24' 5") Overall width 2600 (8' 6") Overall height 3300 (10' 10") Ground clearance 417 (1' 4")
  • Page 26 WITH BOLT-ON CUTTING EDGE TYPE BUCKET (HL940 XT) 740F2SE03-1 Description Unit Specification Operating weight kg (lb) 13400 (29540) Struck 2.0 (2.6) Bucket capacity Heaped 2.3 (3.0) Overall length 7895 (25' 11") Overall width 2600 (8' 6") Overall height 3300 (10' 10") Ground clearance 417 (1' 4")
  • Page 27 WITH BOLT-ON CUTTING EDGE TYPE BUCKET (HL940TM) 940TM2SP01 Description Unit Specification Operating weight kg (lb) 13600 (29980) Struck 2.0 (2.6) Bucket capacity Heaped 2.3 (3.0) Overall length 7715 (25' 3") Overall width 2550 (8' 4") Overall height 3300 (10' 9") Ground clearance 417 (1' 4") Wheelbase...
  • Page 28 WITH TOOTH TYPE BUCKET (HL940) 740F2SE02 Description Unit Specification Operating weight kg (lb) 13030 (28725) Struck 1.9 (2.5) Bucket capacity Heaped 2.2 (2.9) Overall length 7530 (24' 8") Overall width 2650 (8' 8") Overall height 3300 (10' 10") Ground clearance 417 (1' 4")
  • Page 29 WITH TOOTH TYPE BUCKET (HL940 XT) 740F2SE02-1 Description Unit Specification Operating weight kg (lb) 13330 (29390) Struck 1.9 (2.5) Bucket capacity Heaped 2.2 (2.9) Overall length 8200 (26' 11") Overall width 2650 (8' 8") Overall height 3300 (10' 10") Ground clearance 417 (1' 4")
  • Page 30 3. WEIGHT (HL940, HL940XT) 3. WEIGHT (HL940, HL940XT) Item Front frame assembly 2090 Rear frame assembly 1267 2790 Front fender (LH & RH) HL940 (LH/RH) 150/150 331/331 Counterweight HL940XT (LH/RH) 250/250 551/551 Cab assembly 2160 Engine assembly 1150 Transmission assembly...
  • Page 31 WEIGHT (HL940TM) WEIGHT (HL940TM) Item Front frame assembly 1010 2230 Rear frame assembly 1259 2780 Front fender (LH & RH) Counterweight (LH / RH) 250/250 551/551 Cab assembly 2160 Engine assembly 1150 Transmission assembly Drive shaft (front) Drive shaft (center) Drive shaft (rear) Drive shaft (upper) Front axle (include differential)
  • Page 32 4. SPECIFICATION FOR MAJOR COMPONENTS 4. SPECIFICATION FOR MAJOR COMPONENTS 1) 1) ENGINE ENGINE Item Specification Model Cummins QSB6.7 Type 4-cycle turbocharged and charge air-cooled diesel engine Cooling method Water cooling Number of cylinders and arrangement 6 cylinders, in-line Firing order 1-5-3-6-2-4 Combustion chamber type Direct injection type...
  • Page 33 (427 psi) 6) 6) CYLINDER CYLINDER Item Specification Bore dia×Rod dia×Stroke Ø110×Ø65×738 mm Boom cylinder Bore dia×Rod dia×Stroke Ø125×Ø70×505 mm (HL940, HL940XT) Bucket cylinder Bore dia×Rod dia×Stroke Ø 95×Ø50×745 mm (HL940TM) Bore dia×Rod dia×Stroke Ø 65×Ø40×429 mm Steering cylinder 1-20...
  • Page 34 7) 7) DYNAMIC POWER TRANSMISSION DEVICES DYNAMIC POWER TRANSMISSION DEVICES Item Specification Model ZF 4WG160 Torque converter Type Single-stage, single-phase Ratio 2.30 : 1 Type Full-automatic power shift Gear shift Forward fourth gear, reverse third gear Transmission Control Electrical single lever type, kick-down system Pump rated fl...
  • Page 35 5. TIGHTENING TORQUE OF MAJOR COMPONENT 5. TIGHTENING TORQUE OF MAJOR COMPONENT Torque Descriptions Bolt size kgf·m lbf·ft 57.9 ± 8.7 419 ± 63 Engine mounting bolt, nut (rubber, 2EA) M20×2.5 10.7 ± 1.6 77.4 ± 11.6 Engine mounting bolt (bracket, 8EA) M12×1.75 4.5 ±...
  • Page 36 6. TORQUE CHART 6. TORQUE CHART Use following table for unspecified torque. 1) 1) BOLT AND NUT BOLT AND NUT (1) (1) Coarse thread Coarse thread 8.8T 10.9T 12.9T Bolt size kgf·m lbf·ft kgf·m lbf·ft kgf·m lbf·ft M 6 × 1.0 0.8 ~ 1.2 5.8 ~ 8.6 1.2 ~ 1.8...
  • Page 37 2) 2) PIPE AND HOSE PIPE AND HOSE (FLARE type) Thread size Width across flat (mm) kgf·m lbf·ft 1/4" 28.9 3/8" 36.2 1/2" 68.7 3/4" 1" 1-1/4" 3) 3) PIPE AND HOSE PIPE AND HOSE (ORFS type) Thread size Width across flat (mm) kgf·m lbf·ft 9/16-18...
  • Page 38 DEF compatible with Russia, CIS, Mongolia AdBlue® : Soft water ★3 ★1 Ultra low sulfur diesel - sulfur content  15 ppm City water or distilled water : Hyundai Bio Hydraulic Oil ★4 - For more information, contact HYUNDAI dealers. 1-25...

  • Page 39: Group 3 Operational Checkout Record Sheet

    GROUP 3 OPERATIONAL CHECKOUT RECORD SHEET GROUP 3 OPERATIONAL CHECKOUT RECORD SHEET ·Owner ·Date ·Hours ·Serial No. ·Technician ※ Use this sheet to record operational Use this sheet to record operational checkout results. checkout results. Perform the operational check before Perform the operational check before installing any test equipment.

  • Page 40: Section 2 Engine

    4. Brake system and clutch cut off checks 4. Brake system and clutch cut off checks □ □ · Park brake capacity check □ □ · Park brake transmission lockout check □ □ · Service brake pump flow check □ □...
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