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Hyundai HL940A Service Manual
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Hyundai HL940A Service Manual

Wheeled loader
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HL940A
WHEELED LOADER
SERVICE MANUAL

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Summary of Contents for Hyundai HL940A

  • Page 1 HL940A WHEELED LOADER SERVICE MANUAL...

  • Page 2: Table Of Contents

    Group 3 Tests And Adjustments Group 4 Disassembly And Assembly SECTION 6 WORK EQUIPMENT Group 1 Structure And Function 2. Hydraulic Circuit (hl940a, Hl940a Xt) Hydraulic Circuit (hl940a Tm) Group 2 Operational Checks And Troubleshooting Group 3 Tests And Adjustments...

  • 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 -------------------------------------------------------------- 1-27 SECTION 2 ENGINE SECTION 2 ENGINE Group 1 Structure and Function ------------------------------------------------------------------------------------ 2-1 Group 2 Engine speed and Stall rpm ---------------------------------------------------------------------------- 2-11 Group 3 Fuel Warmer System --------------------------------------------------------------------------------------- 2-12 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 ---------------------------------------------------------------- 7-72 Group 5 Connectors -------------------------------------------------------------------------------------------------------- 7-79 Group 6 Troubleshooting ------------------------------------------------------------------------------------------------- 7-100 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 HD Hyundai Construction Equipment distributor for the latest information.
  • Page 6 Revised edition mark Revised edition mark (①②③…) Any additions, amendments or other changes When a manual is revised, an edition mark is will be sent to HD Hyundai Construction recorded on the bottom outside corner of the Equipment distributors. 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 ---------------------------------------------------------------1-27...

  • 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 (HL940A, HL940A XT) Hydraulic tank Radiator Bucket Tire Head light Main control valve Battery Boom Boom cylinder Counterweight Engine Main pump Bell crank Bucket cylinder Air cleaner Bucket link...
  • Page 24 MAJOR COMPONENT MAJOR COMPONENT (HL940A TM) Bucket Tire Head light Hydraulic tank Radiator Main control valve Quick coupler Battery Counterweight Engine Link Bucket cylinder Main pump Air cleaner Boom Front axle Steering cylinder Rear axle Transmission Fuel tank 940ATM2SE01 1-11...
  • Page 25 2. SPECIFICATIONS 2. SPECIFICATIONS 1) 1) WITH BOLT-ON CUTTING EDGE TYPE BUCKET WITH BOLT-ON CUTTING EDGE TYPE BUCKET (HL940A) 940A2SE03 Description Unit Specification Operating weight kg (lb) 13400 (29540) Struck 2.0 (2.6) Bucket capacity Heaped 2.3 (3.0) Overall length 7600 (24' 11") Overall width 2600 (8' 6")
  • Page 26 WITH BOLT-ON CUTTING EDGE TYPE BUCKET WITH BOLT-ON CUTTING EDGE TYPE BUCKET (HL940A XT) 940A2SE03-2 Description Unit Specification Operating weight kg (lb) 13860 (30560) Struck 2.0 (2.6) Bucket capacity Heaped 2.3 (3.0) Overall length 8190 (26' 10") Overall width 2600 (8' 6") Overall height 3300 (10' 10")
  • Page 27 WITH BOLT-ON CUTTING EDGE TYPE NARROW BUCKET WITH BOLT-ON CUTTING EDGE TYPE NARROW BUCKET (HL940A) 940A2SE02 Description Unit Specification Operating weight kg (lb) 13360 (29450) Struck 1.8 (2.4) Bucket capacity Heaped 2.1 (2.7) Overall length 7560 (24' 10") Overall width 2550 (8' 4")
  • Page 28 WITH BOLT-ON CUTTING EDGE TYPE WITH BOLT-ON CUTTING EDGE TYPE NARROW NARROW BUCKET BUCKET (HL940A XT) 940A2SE02-1 Description Unit Specification Operating weight kg (lb) 13820 (30470) Struck 1.8 (2.4) Bucket capacity Heaped 2.1 (2.7) Overall length 8150 (26' 9") Overall width 2550 (8' 4")
  • Page 29 2) 2) WITH BOLT-ON CUTTING EDGE TYPE BUCKET WITH BOLT-ON CUTTING EDGE TYPE BUCKET (HL940A TM) 940ATM2SP01 Description Unit Specification Operating weight kg (lb) 13800 (30420) Struck 2.0 (2.6) Bucket capacity Heaped 2.3 (3.0) Overall length 7805 (25' 7") Overall width 2550 (8' 4")
  • Page 30 3. WEIGHT 3. WEIGHT 1) 1) HL940A, HL940A XT Item Front frame assembly 1007 2220 Rear frame assembly 1326 2923 Front fender (LH & RH) HL940A Counterweight HL940A XT 1115 Cab assembly 1856 Engine assembly 1150 Transmission assembly Drive shaft (front)
  • Page 31 2) 2) HL940A TM Item Front frame assembly 1088 2398 Rear frame assembly 1333 2938 Front fender (LH & RH) Counterweight (LH / RH) 250/250 551/551 Cab assembly 1856 Engine assembly 1146 Transmission assembly Drive shaft (front) Drive shaft (center)
  • Page 32 4. SPECIFICATION FOR MAJOR COMPONENTS 4. SPECIFICATION FOR MAJOR COMPONENTS 1) 1) ENGINE ENGINE Item Specification Model Cummins B6.7 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 33 280 kgf/cm (3980 psi) ★ Overload relief valve set pressure 340 kgf/cm (4840 psi) / 150 kgf/cm (2130 psi) ★ : Bucket dump (HL940A TM) 5) 5) REMOTE CONTROL VALVE REMOTE CONTROL VALVE Item Specification Type Joystick (or with aux lever) Minimum 3.7 kgf/cm...
  • Page 34 CYLINDER Item Specification Bore dia×Rod dia×Stroke Ø110×Ø65×738 mm Boom cylinder Bore dia×Rod dia×Stroke Ø125×Ø70×560 mm Bucket cylinder (HL940A, HL940A XT) Bore dia×Rod dia×Stroke Ø 95×Ø50×745 mm Bucket cylinder (HL940A TM) Bore dia×Rod dia×Stroke Ø 65×Ø40×429 mm Steering cylinder 7) 7)
  • 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 11.7 ± 1.8 84.6 ± 13 Engine mounting bolt (bracket, 8EA) M12×1.75 6.9 ±...
  • 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 ※ Do not mix HD Hyundai Construction Equipment genuine oil with any other lubricating oil as it may result in Do not mix HD Hyundai Construction Equipment genuine oil with any other lubricating oil as it may result in damage to the systems of major components.
  • Page 39 Cold region : Russia, CIS, Mongolia Diesel Exhaust Fluid ★3 Soft water : City water or distilled water DEF compatible with AdBlue® ★4 HD Hyundai Construction Equipment Bio Hydraulic Oil ★1 Ultra low sulfur diesel - sulfur content  15 ppm 1-26...

  • Page 40: 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.
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