PDF Service Manual Hyundai H930C H940C Backhoe Loader - 6 MB
This comprehensive service manual covers the Hyundai H930C and H940C Backhoe Loaders.
It provides detailed, step-by-step instructions for repair and maintenance procedures, from the engine to the hydraulic system.
The manual includes troubleshooting guides, technical specifications, and wiring diagrams to assist technicians in performing accurate and efficient repairs.
It's the ultimate resource for keeping your Hyundai backhoe in prime working condition.
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--- Page 1 ---
CONTENTS
SECTION 1 GENERAL
Group 1 Safety Hints -------------------------------------------------------------------------------------------------------- 1-1
Group 2 Specifications ----------------------------------------------------------------------------------------------------- 1-10
Group 3 Operational Checkout Record Sheet --------------------------------------------------------------- 1-17
SECTION 2 ENGINE
Group 1 Structure and Function -------------------------------------------------------------------------------------- 2-1
Group 2 Engine Speed and Stall rpm ----------------------------------------------------------------------------- 2-8
SECTION 3 POWER TRAIN SYSTEM
Group 1 Structure and Function -------------------------------------------------------------------------------------- 3-1
Group 2 Operational Checks and Troubleshooting ------------------------------------------------------- 3-17
Group 3 Test and Adjustments ---------------------------------------------------------------------------------------- 3-25
Group 4 Disassembly and Assembly ------------------------------------------------------------------------------ 3-27
SECTION 4 BRAKE SYSTEM
Group 1 Structure and Function -------------------------------------------------------------------------------------- 4-1
Group 2 Operational Checks and Troubleshooting ------------------------------------------------------- 4-7
Group 3 Tests and Adjustments -------------------------------------------------------------------------------------- 4-11
SECTION 5 STEERING SYSTEM
Group 1 Structure and Function -------------------------------------------------------------------------------------- 5-1
Group 2 Operational Checks and Troubleshooting ------------------------------------------------------- 5-9
Group 3 Tests and Adjustments -------------------------------------------------------------------------------------- 5-16
Group 4 Disassembly and Assembly ----------------------------------------------------------------------------- 5-23
SECTION 6 WORK EQUIPMENT
Group 1 Structure and Function -------------------------------------------------------------------------------------- 6-1
Group 2 Operational Checks and Troubleshooting ------------------------------------------------------- 6-71
Group 3 Tests and Adjustments -------------------------------------------------------------------------------------- 6-84
Group 4 Disassembly and Assembly ----------------------------------------------------------------------------- 6-96
0-9
--- Page 3 ---
SECTION 1 GENERAL
Group 1 Safety Hints --------------------------------------------------------------------------------------------------------1-1
Group 2 Specifications -----------------------------------------------------------------------------------------------------1-10
Group 3 Operational Checkout Record Sheet ---------------------------------------------------------------1-17
--- Page 4 ---
GROUP 2 SPECIFICATION
1. MAJOR COMPONENT
Tire Engine assy Fuel tank ROPS Cabin
Bucket Radiator Transmission Hydraulic oil tank Stabilizer
Tilt cylinder Engine hood Exhaust tail pipe Boom Dipper
Attachment Front axle Tool box Rear axle Bucket
Lift cylinder Swing post Control linkage
H940C2SP01
1-10
--- Page 5 ---
7. Steering system checks
·Steering unit check □ □
·Steering system leakage check □ □
8. Accessory checks
·Operating lights check □ □
·Work light check □ □
·Brake light check □ □
·Cab light check □ □
·Horn circuit check □ □
·Windshield washer and wiper check □ □
·Defroster blower check □ □
·Heater/Air conditioner blower check □ □
·Heater functional check □ □
·Air conditioner functional check □ □
·Start aid system check □ □
9. Cab components and vandal protection checks
·Cab door latch check □ □
·Cab door hold open latch check □ □
·Cab door release button check □ □
·Cab door lock check □ □
·Cab door window check □ □
·Cab window latch check □ □
·Steering column adjustment check □ □
·Seat and seat belt check □ □
·Air intake filter door check □ □
·Engine side panels check □ □
·Radiator cap access door check □ □
·Boom lock check □ □
·Service decal check □ □
1-19
--- Page 6 ---
STRUCTURE (2/2)
1
2
8
3
4
5
7 6
H940S2EG02
1 Oil filler cap 4 Turbocharger 7 Flywheel
2 Exhaust manifold 5 Start motor 8 Air intake
3 Alternator 6 Flywheel housing
2-9
--- Page 7 ---
SECTION 3 POWER TRAIN SYSTEM
Group 1 Structure and Function -------------------------------------------------------------------------------------- 3-1
Group 2 Operational Checks and Troubleshooting ------------------------------------------------------- 3-17
Group 3 Test and Adjustments ---------------------------------------------------------------------------------------- 3-25
Group 4 Disassembly and Assembly ------------------------------------------------------------------------------ 3-27
--- Page 8 ---
② Forward
In forward, forward clutch and K1, K2, K3, K4 clutch are engaged.
Forward clutch and K1, K2, K3, K4 clutch are actuated by the hydraulic pressure applied to the
clutch piston.
KV KV
K4 K4
AN/KR AN/KR
K1 K1
K2/AB K2/AB
K3 K3
VA VA
1st gear forward 2nd gear forward
KV KV
K4 K4
AN/KR AN/KR
K1 K1
K2/AB K2/AB
K3 K3
VA VA
3rd gear forward 4th gear forward
HB100PT13
KR/AN = Clutch reverse/input K2/AB = Clutch 2nd speed/output K4 = Clutch 4th speed
KV = Clutch forward K3 = Clutch 3rd speed VA = Front wheel drive
K1 = Clutch 1st speed (4 wheel drive only) (4 wheel drive only)
3-10
--- Page 9 ---
2. TROUBLESHOOTING
1) TRANSMISSION
※ Diagnose malfunction charts are arranged from most probable and simplest to verify, to least likely,
more difficult to verify. Remember the following steps when troubleshooting a problem :
Step 1. Operational check out procedure (See group 3 in section 1.)
Step 2. Operational checks (In this group.)
Step 3. Troubleshooting
Step 4. Tests and/or adjustments (See group 3.)
Problem Cause Remedy
Transmission slippage Low oil level. Add oil.
Wrong oil grade. Change oil.
Leak in transmission control valve Remove valve and inspect gaskets.
or gasket.
Low transmission pump flow due Do transmission pump flow test.
to worn pump.
Weak or broken pressure regulat- Do transmission system pressure test.
ing valve spring.
Machine will not move Low oil level. Add oil.
Applied park brake. Check parking brake fuse.
Check continuity to parking brake switch.
Malfunctioning parking brake Remove and inspect parking brake solenoid
solenoid valve. valve.
Check for power to solenoid valve.
Excessive leakage in Do transmission element leakage test using
transmission element. system pressure.
Worn clutch disks. Repair transmission.
Low or no transmission See transmission pressure is low in this group.
pressure.
Service brake will not release. Do brake pedal operational check.
Do service and park system drag checks.
Failed torque converter. Do torque converter stall test.
If engine pull down in normal, torque converter
is good.
Broken shafts or gears. Drain transmission to determine if large pieces
of metal contamination are present.
Broken drive shafts. Inspect drive shafts and universal joints for
external damage. Repair.
Machine does not Malfunctioning transmission Check solenoid valve.
engage in low gear control solenoid valve.
Stuck spool in transmission Remove and inspect transmission control valve
control valve. spools.
3-20
--- Page 10 ---
(2) Main pressure valve and conver ter
safety valve
① Loosen screw plug (1) and remove main
pressure valve (control pressure valve) :
Main pressure valve consists of:
1 = Screw plug
2 = O-ring
3 = Piston
4 = Spacer ring HB108TM017
5 = Compression spring
※ Functional check of converter safety
valve (1).
Use a screwdriver to check the movability
of the ball in the valve.
※ If the valve is o.k., it does not need to be
removed.
※ Valve assy is installed in the housing-not
visible.
HB108TM018
3) REMOVAL OF CLUTCHES, CENTRAL SHAFT AND DISASSEMBLY OF TRANSMISSION
PUMP
(1) Removal of clutches
① Force out cylindrical pins (1).
Loosen bolted connection (2) of housing
front and rear part.
HB108TM019
3-30
--- Page 11 ---
③ Remove bearing inner ring (1), axial
bearing assy (2) and inner disk carrier
(3).
HB108TM053
④ Remove needle cage (1).
HB108TM054
⑤ Remove axial bearing assy (1).
HB108TM055
⑥ Remove snap ring (1).
HB108TM056
3-40
--- Page 12 ---
⑬ Snap out rectangular rings (1).
HB108TM093
⑭ Pull tapered roller bearing (inner ring)
off the shaft.
(S) Grab sleeve 5873 001 026
(S) Basic tool 5873 001 000
HB108TM094
※ The clutch (1) cannot be disassembl-ed.
It is supplied by the spare parts service
only as a complete assy which consists
of:
1A = Ball
1B = Helical gear
1C = Shaft
1D = Disk carrier
HB108TM095
(5) K3 clutch
① Snap out rectangular ring (1).
HB108TM096
3-50
--- Page 13 ---
⑨ By means of compressed air (see arrow),
press piston (1) off the shaft/disk carrier
and remove it.
HB108TM133
⑩ Pull tapered roller bearing (inner ring) off
the shaft.
(S) Grab sleeve 5873 001 026
(S) Basic tool 5873 001 000
HB108TM134
※ The clutch (1) cannot be disassembled.
It is supplied by the spare parts service
only as a complete assy which consists
of:
1A = Shaft
1B = Disk carrier
HB108TM135
3-60
--- Page 14 ---
⑮ Snap retaining ring 40×1.75 (1) into the
groove.
※ Contact for axial bearing - see the next
figure 16 .
HB108TM172
16 Mount running disk 40×60×3.5 (1),
axial needle cage 40×60×3 (2) and
axial washer 40×60×1 (3) and oil them.
※ Mount running disk (1), with the chamfer
showing towards the retaining ring.
HB108TM173
17 Mount needle cage 40×45×17 (1) and
oil it.
HB108TM174
18 Mount inner disk carrier until contact is
obtained.
19 Install inner disks by short ccw/cw
rotations of the inner disk carrier (1).
HB108TM175
3-70
--- Page 15 ---
⑪ Install cup spring (1) according to the
sketch.
Legend:
1 = Cup spring 122.7×87×2.55 (convex
side showing towards the piston)
2 = Compression spring with spring cup
and retaining ring
3 = Piston with O-rings
4 = Clutch assy HB108TM212
⑫ Install outer and inner disks alternately
into the disk carrier (3) as shown in
figure, starting with an outer disk and
ending with an inner disk.
Legend:
1 = Outer disks (13 pcs)
2 = Inner disks (13 pcs)
3 = Clutch assy
HB108TM213
⑬ Mount end plate (1) with the flat side
showing towards the disk package and
fix it by means of snap ring (2) (e.g.
thickness = 2.5 mm / recommended
value).
※ Pay attention to the installation position of
the end plate.
HB108TM214
⑭ Equally press on end plate with F
(approx. 1.8 kg to 2.0 kg) and set dial
indicator to "zero".
HB108TM215
3-80
--- Page 16 ---
⑦ Mount compression spring (1) and spring
cup (2).
HB108TM252
⑧ By means of the assembly aid, preload
compression spring under a hand-
operated press until the retaining ring
40×1.75 (1) can be snapped in.
(S) Assembly aid 5870 345 114
HB108TM253
⑨ Mount plate assy with cup springs (1),
with the open side showing towards the
piston.
※ Installation position of plate see also the
next figure ⑩.
HB108TM254
⑩ Fit plate (1) according to sketch (see
arrow).
Legend:
1 = Plate assy with cup springs
2 = Compression spring with spring cup
and retaining ring
3 = Piston with O-rings
4 = Input shaft assy
HB108TM255
3-90
--- Page 17 ---
④ Fit stator hollow shaft (1).
HB108TM288
⑤ Fix stator hollow shaft radially with two
cylindrical screws (1).
※ Do not tighten the cylindrical screws –
just turn them in until contact is obtained
and then turn them back by approx. 1/2
rotation.
Place O-ring (2) 135×3 into the annular
groove and grease it.
HB108TM289
(2) Oil suction tube and oil filter tube
① Mount O-ring 30×3 (1) onto the suction
tube (2) and grease it.
HB108TM290
② Fix suction tube (1) with cylindrical
screws M8×16 (2).
·Tightening torque M8/8.8×16 ;
2.35 kgf·m (17.0 lbf·ft)
※ When reusing the cylindrical screws
these must be secured with loctite #243.
※ New cylindrical screws are already
provided with adhesive (microcapsule).
The microcapsule bursts when the screw HB108TM291
is turned in, wets screw and nut thread
and hardens.
3-100
--- Page 18 ---
② Use the driver tool (S) to install screen
sheet (2) onto the VA clutch shaft (3) until
contact position (see figure TM321 of
previous page).
(S) Driver tool 5870 048 310
HB108TM322
(3) Reassembly of screw plug at measuring
point "63"
① Fit screw plug M14×1.5 (1) with new
O-ring 11×2 (2).
·Tightening torque ;
2.55 kgf·m (18.4 lbf·ft)
※ Refer to page 3-23 for measuring point
63.
HB108TM325
3-110
--- Page 19 ---
4) AXLE BEAM GROUP DISASSEMBLY
※ Some of the following pictures may not
show exactly your axle, but the process is
the same.
(1) Remove the upper bushings and the ball
bearing cups from king pin seats with a
suitable extractor only if replacement is
required.
H940CFA011
(2) Remove the rear and front seals from the
pivot using a suitable tool.
※ This is a destructive operation for the seal
rings.
Remove the rear and front bushings from
the axle beam pivot only if replacement is
necessary.
※ This is a destructive operation for the
bushings. Pay attention not to damage the H940CFA012
bushing seats.
3-120
--- Page 20 ---
(5) Disengage the retaining ring.
HB108FA105
(6) Pull off the planetary gear with the
cylindrical roller bearing.
HB108FA106
(7) Loosen the locking screws.
HB108FA107
(8) Pull the ring gear with a three-armed
puller from the knuckle housing/from the
bushes.
(S) Pressure piece 5870 100 080
HB108FA108
3-130
--- Page 21 ---
(5) Loosen the hexagon nut and remove the
shim lying behind.
(S) Clamping fork 5870 240 025
HB108FA305
(6) Pull the yoke from the input pinion.
HB108FA306
(7) Press the screen sheet with the cut-off
device (S) from the yoke.
(S) Cut-off device 5870 300 024
HB108FA307
(8) Force the input pinion out of the axle
housing.
※ If the pinion bearing should not be
replaced, special care must be taken that
the outer bearing inner ring is always in
contact position with the bearing outer
ring when forcing the input pinion out.
HB108FA308
3-140
--- Page 22 ---
⑤ Heat the roller bearing and mount until
contact is obtained.
※ Adjust the bearing after cooling down.
HB108FA607
Setting of the rolling torque of the input
pinion bearing 0.1~0.31 kgfkgf·m (without
shaft seal ring)
① Mount bush (1) and spacer (2), e.g. s =
6.40 mm.
※ Experience has shown that the required
rolling torque is reached when reusing
the shims being removed dur ing
disassembly ( e.g. s = 6.40 mm).
A later check of the rolling torque,
however, is absolutely necessary.
HB108FA608
② Insert the preassembled input pinion into
the axle housing and mount the heated
roller bearing until contact is obtained.
HB108FA609
③ Press the screen sheet (see arrow) onto
the yoke until contact is obtained.
※ The shaft seal ring is only mounted after
acceptance of the contact pattern (see
page 3-155).
HB108FA610
3-150
--- Page 23 ---
Mount the double U-joint shaft
① Insert the double U-joint shaft into the
knuckle housing.
※ Right before the assembly wet the
cassette type seal ring with spirit.
HB108FA708
② Pull the double U-joint shaft into the
knuckle housing until contact is obtained.
(S) Internal extractor 5870 300 014
(S) Counter support 5870 300 003
※ Place the internal extractor (S) into the
groove of the double U-joint shaft.
HB108FA709
③ Fix the double U-joint shaft with a
retaining ring.
HB108FA710
④ Insert the retaining ring into the groove of
the double U-joint shaft.
HB108FA711
3-160
--- Page 24 ---
(3) Adjustment and check of track
HB108FA817
Basic track setting
Bring the piston rod into central position.
Setting of dimension X = 121.75 mm (measured between front face/steering cylinder and front
face/axial joint).
※ The axial position of the piston rod may no more be changed during track setting.
Mount the straightedges (1) in horizontal and central axis position.
Fix the measuring device (2) to the yoke.
Loosen the hexagon nut (3) and set the length of the tie rod (axial joint), until 0° (= track setting
of zero mm) can be read on the measuring device (2).
※ For a toe-in and toe-out setting, which might be required, stick to the vehicle manufacturer’s
specification.
※ Carry out setting on both output sides.
Comment on sketch:
1 = (S) Straightedges 5870 200 029
2 = (S) Measuring device 5870 200 033
3 = Hexagon nut
X = Setting dimension 121.75 mm
Check track setting (0°) :
Determine dimension A1.
Turn both outputs by 180° – Dimension A2 must be identical with dimension A1.
Dimension Y = distance between wheel center and rim flange.
Then fix both tie rods (axial joint) with hexagon nut (3).
·Tightening torque : 30.6 kgf·m (221 lbf·ft)
3-170
--- Page 25 ---
(4) Remove bearing housing.
※ Pay attention that releasing O-rings do
not drop.
HB108RA030
(5) Press off piston by means of compressed
air and remove O-ring (arrow).
HB108RA031
(6) Remove bearing outer ring and shim
(differential bearing preload).
HB108RA032
(7) Remove sealing elements (arrows) from
bearing housing.
HB108RA033
3-180
--- Page 26 ---
(8) Take disc package out of brake housing
cover.
HB108RA059
(9) Remove sealing elements-see arrows-
from the grooves of the brake housing
cover.
HB108RA060
(10) Pull off both bolts (with O-ring).
Remove O-ring (arrow).
HB108RA061
(11) If required, disassemble brake housing
(figure RA062+063) : For this purpose,
the cpl. differential must be dismounted
first-in this connection see parts of section
3) Disassembly differential of page
3-176.
Press-off input pinion using a two-armed
puller-pay attention that releasing bearing
inner ring does not drop. HB108RA062
3-190
--- Page 27 ---
(7) Position pre-assembled differential carrier
half II on differential carrier half I.
※ Ensure radial installation of both differen-
tial carrier halves – punch-marked no. ….
(see arrow) corresponds to radial position
marking.
HB108RA092
(8) Position crown wheel on slotted pins and
press onto differential carrier until contact
is obtained.
HB108RA093
(9) Fix differential by means of a press and
connect differential carrier halves with cyl-
inder screws.
·Tightening torque (M 12/12.9) :
13.8 kgf·m (99.6 lbf·ft)
HB108RA094
(10) Install both bearing inner rings.
※ Use suitable support (arrow) – differential
must not be supported on bearing cage.
HB108RA095
3-200
--- Page 29 ---
(9) Press down cup spring preload using a
press, and snap in retaining ring (8).
HB108RA128
(10) Insert preassembled ring and fix with cyl-
inder screws.
※ Install cylinder screws with locking com-
pound (loctite #262).
·Tightening torque (M8/8.8) :
2.35 kgf·m (17 lbf·ft)
HB108RA129
(11) 1 = Outer discs
2 = Inner discs (lined discs)
HB108RA130
(12) Locate disc package – taking the disc
arrangement into consideration (see
sketch above).
※ Fix outside disc with grease – assembly
aid.
HB108RA131
3-210
--- Page 30 ---
(3) Insert both bolts (arrows) with O-ring into
the brake housing cover – observing the
installation position, see sketch RA161.
HB108RA163
(4) 1 = Outer discs (steel discs)
2 = Inner discs (lined discs)
HB108RA164
(5) Insert disc package into the brake hous-
ing cover – observing the disc arrange-
ment (see sketch above) starting with an
outer disc.
HB108RA165
(6) Oil sealing surface of piston and of brake
housing cover and press piston into the
brake housing cover to contact position.
※ Press in piston without tilting – risk of
damage to grooved rings and piston.
HB108RA166
3-220
--- Page 31 ---
SECTION 4 BRAKE SYSTEM
GROUP 1 STRUCTURE AND FUNCTION
1. OUTLINE
1) MASTER CYLINDER TYPE
1
2
3
B
Brake pipe C
A
A
D
Rear axle
Port Port name Port size
A To service brake 9/16-18UNF
B To parking brake 7/8-14UNF
C To differential lock 7/16-20UNF
Hand operated release for
D -
parking brake
Transmisson H940C4BS01
1 Brake pedal & bracket assembly 2 Reservoir tank assembly
3 Brake master cylinder
OPERATION
Compensating master cylinders overcome the problem of unequal wear between the right and left
brake. The units incorporate both master cylinder and compensating valve.
Each brake has its own master cylinder, brake pedals, servo units and associated pipework. Both
master cylinders have one common reservoir.
4-1
--- Page 32 ---
(3) One pedal applied
11 12 13 14 15
10 16
9 17
8 18
7 19
6 20
5 21
4 22
3 23
2 24
1 26 25
Right pedal contact
Left pedal contact
Modulated pressure
Unrestricted flow
Brake system pressure
Atmospheric pressure
H940CB4SM04
When only one pedal is applied, the opposite side brake remains at reservoir pressure. This
system works the same as described in page 4-10 except piston (13) moves full stroke then stops
and brake pressure is developed by the same means as described in page 4-10. The effort
required on one pedal is one half that of the effort when applying both pedals to obtain the same
brake pressure.
4-11
--- Page 33 ---
4. STEERING UNIT LEAKAGE TEST
· SPECIFICATION
Oil temperature 45±5˚C (113±9˚F)
Engine speed High idle
Maximum leakage 10ℓ/min
· GAUGE AND TOOL
Temperature reader
Measuring container (approx. 20ℓ)
Stop watch
1) Install temperature reader.
(see temperature reader installation proce-
dure in this group).
2) Heat hydraulic oil to specifications.
Cap fitting
(see hydraulic oil warm up procedure at
page 6-87).
3) Disconnect return hose from fitting.
Install cap fitting. Steering unit
4) Run engine at specifications. Rotate
steering wheel against locking bar using
approximately 1.2 kgf·m of force.
Measure oil flow from return hose for 1
minute.
5) Leakage is greater than specifications,
repair or replace steering unit. HB100SE20
5-20
--- Page 34 ---
SECTION 5 STEERING SYSTEM
Group 1 Structure and Function ---------------------------------------------------------------------------------- 5-1
Group 2 Operational Checks and Troubleshooting ---------------------------------------------------- 5-9