This document is a service manual for the Hyundai HL955A and HL955ATM Wheeled Loaders. It provides comprehensive technical information for performing repairs and maintenance on these construction equipment models.
Function Description:
The Hyundai HL955A and HL955ATM are wheeled loaders, which are heavy equipment machines used in construction, mining, and other industries for scooping, lifting, and loading materials such as dirt, sand, gravel, and demolition debris. They feature a large front-mounted bucket for material handling and are designed for mobility and efficiency on various terrains. The manual covers the structure and function of all major components, operational checks, troubleshooting, tests and adjustments, and disassembly and assembly procedures.
Important Technical Specifications:
General Specifications (HL955A with Bolt-On Cutting Edge Type Bucket):
- Operating Weight: 15800 kg (34830 lb)
- Bucket Capacity:
- Struck: 2.4 m³ (3.1 yd³)
- Heaped: 2.8 m³ (3.7 yd³)
- Overall Length (A): 7715 mm (25' 4")
- Overall Width (B): 2740 mm (9' 0")
- Overall Height (C): 3390 mm (11' 1")
- Ground Clearance (D): 410 mm (1' 4")
- Wheelbase (E): 3050 mm (10' 0")
- Tread (F): 2010 mm (6' 7")
- Dump Clearance at 45° (G): 2785 mm (9' 2")
- Dump Reach (full lift) (H): 1180 mm (3' 10")
- Width over tires (I): 2530 mm (8' 4")
- Dump Angle (J): 48°
- Roll Back Angle (carry position) (K): 46°
- Cycle Time:
- Lift (with load): 5.5 sec
- Dump (with load): 1.8 sec
- Lower (empty): 3.9 sec
- Maximum Travel Speed: 39.2 km/hr (24.4 mph)
- Braking Distance: 13.3 m (43' 8")
- Minimum Turning Radius (center of outside tire): 5.3 m (17' 5")
- Gradeability: 30°
- Breakout Force: 14370 kg (31680 lb)
Travel Speed (HL955A with Bolt-On Cutting Edge Type Bucket):
- Forward:
- First gear: 7.1 km/hr (4.4 mph)
- Second gear: 11.7 km/hr (7.3 mph)
- Third gear: 23.6 km/hr (14.7 mph)
- Fourth gear: 39.2 km/hr (24.4 mph)
- Reverse:
- First gear: 7.4 km/hr (4.6 mph)
- Second gear: 12.3 km/hr (7.6 mph)
- Third gear: 24.9 km/hr (15.5 mph)
Engine Specifications:
- Model: Cummins B6.7
- Type: 4-cycle turbocharged and 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
- Combustion Chamber Type: Direct injection type
- Cylinder Bore x Stroke: 107 × 124 mm (4.2" × 4.9")
- Piston Displacement: 6700 cc (408 cu in)
- Compression Ratio: 17.3:1
- Rated Horse Power (Gross): 200 hp at 2200 rpm
- Maximum Torque at 1300 rpm: 101 kgf·m (730 lbf·ft)
- Engine Oil Quantity: 18 ℓ (4.8 U.S. gal)
- Wet Weight: 538 kg (1285 lb)
- High Idling Speed: 2230 ± 50 rpm
- Low Idling Speed: 800 ± 25 rpm
- Rated Fuel Consumption: 208 g/kW·hr
- Starting Motor: Melco 90P, 24V-5.5kW
- Alternator: Denso, 24V-95A
- Battery: 2 × 12V × 160Ah
Hydraulic System Specifications:
- Main Pump:
- Type: Variable piston pump
- Capacity: 100 cc/rev
- Maximum Operating Pressure: 280 kgf/cm² (3980 psi)
- Rated Oil Quantity (at 2200 rpm): 220 ℓ/min (58.1 U.S. gpm / 48.4 U.K. gpm)
- Maximum Speed: 2230 rpm
- Fan and Brake Pump:
- Type: Variable piston pump
- Capacity: 28 cc/rev
- Maximum Operating Pressure: 250 kgf/cm² (3560 psi)
- Rated Oil Quantity (at 2200 rpm): 62 ℓ/min (16.3 U.S. gpm)
- Maximum Speed: 2230 rpm
- Main Control Valve:
- Type: 2 spool & 3 spool
- Operating Method: Hydraulic pilot assist
- System Pressure: 280 kgf/cm² (3980 psi)
- Overload Relief Valve Pressure: 340 kgf/cm² (4840 psi)
- Remote Control Valve (EH Type):
- Type: Fingertip
- Axle: Single axle for boom, bucket, auxiliary
- Operating Voltage: 4.5~5.5 V
- Output Signal: 0.5~4.5 V (neutral 2.5 V)
Cylinder Specifications:
- Boom Cylinder: Bore dia × Rod dia × Stroke: Ø125 × Ø70 × 745 mm
- Bucket Cylinder (HL955A): Bore dia × Rod dia × Stroke: Ø140 × Ø75 × 560 mm
- Steering Cylinder: Bore dia × Rod dia × Stroke: Ø70 × Ø45 × 418 mm
Dynamic Power Transmission Devices:
- 4-speed Transmission (std):
- Model: ZF 4WG 190
- Type: Converter (Single-stage, single-phase), Transmission (Full-automatic power shift)
- Gear Shift: Forward fourth gear, reverse third gear
- Control: Electrical single lever type, kick-down system
- 5-speed Transmission (opt):
- Model: ZF 5WG210
- Type: Converter (Single-stage, double-phase with lock up clutch), Transmission (Full-automatic power shift)
- Gear Shift: Forward fifth gear, reverse third gear
- Control: Electrical single lever type, kick-down system
- Travel Speed: Forward 1/2/3/4/5: 6.5/11.4/17.6/27.3/40.0 km/hr, Reverse 1/2/3: 6.9/12.0/28.8 km/hr
- Drive Devices: 4-wheel drive
- Axle: Front (Front fixed location), Rear (Oscillation ±11° of center pin-loaded)
- Wheels: Tires: 20.5 R25, **,L3
- Brakes: Travel (Four-wheel, wet-disc type, full hydraulic), Parking (Spring applied, hydraulic released brake on transmission)
- Steering: Type (Full hydraulic, articulated), Steering Angle (40° to both right and left angle, respectively), Relief Pressure (210 kgf/cm² (2990 psi))
Usage Features:
The HL955A and HL955ATM wheeled loaders are designed for efficient material handling with various bucket options, including bolt-on cutting edge and 2-tooth types. The machines offer multiple travel speeds with both 4-speed (standard) and 5-speed (optional) full-automatic power shift transmissions, providing flexibility for different operational requirements. The articulated steering allows for maneuverability in confined spaces, while the 4-wheel drive ensures traction on challenging terrains. The hydraulic pilot assist for the main control valve and fingertip remote control valve (EH type) contribute to precise and comfortable operation.
Maintenance Features:
The service manual emphasizes the importance of proper maintenance for safety and longevity. Key maintenance aspects highlighted include:
- Safety Hints: Detailed safety precautions are provided for all service procedures, including wearing protective clothing, warning others of service work, using handholds and steps, preparing for emergencies, working in clean areas, protecting against flying debris and noise, parking the machine safely, supporting the machine properly, servicing the cooling system safely, handling fluids safely to avoid fires, preventing battery explosions, preventing acid burns, using tools properly, servicing tires safely, using proper lifting equipment, disposing of fluids properly, replacing safety signs, and ensuring ROPS (Roll-Over Protective Structure) is properly installed and maintained.
- Operational Checkout Record Sheet: A dedicated sheet is provided to record results of operational checks (engine OFF and engine running) for monitoring indicators, gauges, transmission, axle, and neutral/reverse warning systems.
- Tightening Torque: Comprehensive tables are included for tightening torque specifications for bolts and nuts (coarse and fine threads), pipe and hose connections (flare and ORFS types), fittings, and major components, ensuring correct assembly and preventing damage.
- Lubrication and Fluid Specifications: Detailed specifications for fuel, coolant, and lubricants are provided for new machines, including engine oil (API CK-4, SAE 15W-40, 5W-40, 0W-40), DEF/AdBlue® (ISO 22241), hydraulic oil (ISO VG 46, VG 68, VG 15), transmission oil (SAE 15W-40, 10W-30), axle oil (UTTO), grease (NLGI No. 2), fuel (ASTM D975-No. 2), and coolant (ethylene glycol base antifreeze). Specific recommendations are given for cold regions and for using genuine HD Hyundai Construction Equipment lubricating oils to prevent performance deterioration and component damage.
- Structure and Function Descriptions: The manual explains the structure and function of each component, which is crucial for understanding how the machine works and for effective troubleshooting.
- Troubleshooting Charts: These charts correlate problems to remedies, aiding in efficient diagnosis and repair.
- Tests and Adjustments: Procedures for checks and adjustments before and after repairs are outlined to ensure optimal machine performance.
- Disassembly and Assembly: Step-by-step instructions for removing, installing, disassembling, and assembling components are provided, along with necessary precautions.
The manual emphasizes the importance of using the most up-to-date information, consulting HD Hyundai Construction Equipment distributors for the latest specifications, and adhering to all safety and technical precautions marked with specific symbols.
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