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Hyundai HL960 Service Manual
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Hyundai HL960 Service Manual

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HL960
WHEELED LOADER
SERVICE MANUAL

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Summary of Contents for Hyundai HL960

  • Page 1 HL960 WHEELED LOADER SERVICE MANUAL...

  • Page 2: Table Of Contents

    TABLE OF CONTENT CONTENTS FOREWORD SECTION 1 GENERAL Group 1 Safety Hints Group 2 Specifications 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 --------------------------------------------------------------- 1-23 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 ---------------------------------------------------------------1-23...

  • 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 control shutoff lever 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 Specifications

    GROUP 2 SPECIFICATIONS GROUP 2 SPECIFICATIONS 1. MAJOR COMPONENT 1. MAJOR COMPONENT 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 Front axle Steering cylinder Rear axle Transmission...
  • Page 24 2. SPECIFICATIONS WITH BOLT-ON CUTTING EDGE TYPE BUCKET (HL960) 760F2SE03 Description Unit Specification Operating weight kg (lb) 18800 (41450) Struck 2.9 (3.8) Bucket capacity Heaped 3.3 (4.3) Overall length 8140 (26' 8") Overall width 2900 (9' 6") Overall height 3450 (11' 4") Ground clearance 410 (1' 4")
  • Page 25 WITH BOLT-ON CUTTING EDGE TYPE BUCKET (HL960 XT) 760F2SE03-1 Description Unit Specification Operating weight kg (lb) 19600 (43210) Struck 2.8 (3.7) Bucket capacity Heaped 3.3 (4.3) Overall length 8695 (28' 6") Overall width 2900 (9' 6") Overall height 3450 (11' 4") Ground clearance 420 (1' 5")
  • Page 26 WITH TOOTH TYPE BUCKET (HL960) 760F2SE02 Description Unit Specification Operating weight kg (lb) 18700 (41230) Struck 2.7 (3.5) Bucket capacity Heaped 3.2 (4.2) Overall length 8270 (27' 2") Overall width 2950 (9' 8") Overall height 3450 (11' 4") Ground clearance 420 (1' 5")
  • Page 27 WITH TOOTH TYPE BUCKET (HL960 XT) 760F2SE02-1 Description Unit Specification Operating weight kg (lb) 19500 (42990) Struck 2.7 (3.5) Bucket capacity Heaped 3.2 (4.2) Overall length 8825 (28' 11") Overall width 2950 (9' 8") Overall height 3450 (11' 4") Ground clearance 420 (1' 5")
  • Page 28 Bell crank assembly Bucket link 1830 4030 3.3 m bucket, with bolt on cutting edge 1750 3860 3.2 m bucket, with tooth Boom cylinder assembly Bucket cylinder assembly (HL960) Bucket cylinder assembly (HL960 XT) Steering cylinder assembly Seat Battery 1-15...
  • Page 29 4. SPECIFICATION FOR MAJOR COMPONENTS 4. SPECIFICATION FOR MAJOR COMPONENTS 1) 1) ENGINE ENGINE Item Specification Model Cummins QSB6.7 Type 4-cycle turbocharged, charge air cooled diesel engine Control type Electronic control Cooling method Water cooling Number of cylinders and arrangement 6 cylinders, in-line Firing order 1-5-3-6-2-4...
  • Page 30 2) 2) MAIN PUMP MAIN PUMP Specification Item Steering Loader Type Variable piston pump Capacity 60 cc/rev 63 cc/rev Maximum operating pressure 280 kgf/cm (3980 psi) Rated oil quantity 120ℓ/min (31.7 U.S.gpm) 126ℓ/min (33.3 U.S.gpm) Maximum speed 2230 rpm 3) 3) FAN AND FAN AND BRAKE PUMP BRAKE PUMP...
  • Page 31 7) 7) REMOTE CONTROL VALVE REMOTE CONTROL VALVE (FNR TYPE) Item Specification Type Joystick Axle Two axle for boom, bucket, roller for auxiliary Operating type CAN J1939 Baud rate 500 Kbps 8) 8) CYLINDER CYLINDER Item Specification Bore dia×Rod dia×Stroke Ø140×Ø80×757 mm Boom cylinder Bore dia×Rod dia×Stroke Ø160×Ø85×530 mm Bucket cylinder...
  • Page 32 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 4.6 ±...
  • Page 33 6. TIGHTENING TORQUE 6. TIGHTENING TORQUE 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 34 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 35 DEF compatible with Russia, CIS, Mongolia AdBlue® ★3 ★1 : Soft water Ultra low sulfur diesel - sulfur content  15 ppm City water or distilled water ★4 : Hyundai Bio Hydraulic Oil - For more information, contact HYUNDAI dealers. 1-22...

  • Page 36: 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 37 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 □ □...
  • Page 38 7. Steering system checks 7. Steering system checks □ □ ·Steering unit check □ □ ·Steering system leakage check ·Steering valve (EHPS) □ □ Low check pressure □ □ High check pressure 8. Accessory checks 8. Accessory checks □ □ ·Operating lights check □...

  • Page 39: Section 2 Engine

    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...

  • Page 40: Group 1 Structure And Function

    SECTION 2 ENGINE SECTION 2 ENGINE GROUP 1 STRUCTURE AND FUNCTION GROUP 1 STRUCTURE AND FUNCTION 1. STRUCTURE 1. STRUCTURE Exhaust outlet connection Crankcase breather Lifting bracket Flywheel housing Lubricating oil filter cooler Lubricating oil filter Starting motor Water inlet connection Vibration damper Oil pan Air intake connection...
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