Hyundai HL930A Manual

WHEEL LOADER
OPERATION & MAINTENANCE
MANUAL
HL930A
HL930A XT
Serial No.

INTRODUCTION
1. EC Declaration of Conformity................ 0-1
2. Disclaimer............................................. 0-2
3. Foreword............................................... 0-3
4. Emission-related components war-
ranty (USA and CANADA only)..............0-4
5. Before servicing this machine................0-5
6. Table to enter serial no. and distributor.. 0-6
7. EC regulation approved......................... 0-7
8. Safety labels..........................................0-8
9. Machine data plate.............................. 0-18
GUIDE
1. Guide...................................................0-19
SAFETY HINTS
1. California proposition 65........................1-1
2. Safety rules............................................1-2
SPECIFICATIONS
1. Major components.................................2-1
2. Specifications........................................2-2
3. Weight................................................... 2-6
4. Specifications for major components.....2-7
CONTROL DEVICES
1. Cabin devices........................................3-1
2. Cluster...................................................3-2
3. Monitor (7 inch touch screen).............. 3-14
4. Switches..............................................3-51
5. Control devices....................................3-58
6. Air conditioner and heater................... 3-63
7. Others................................................. 3-66
OPERATION
1. Suggestion for new machine................. 4-1
2. Check before starting the engine...........4-2
3. Starting and stopping the engine...........4-3
4. Warming-up operation........................... 4-7
5. Operation of working device.................. 4-8
6. Travelling of the machine....................... 4-9
7. Efficient working method..................... 4-14
8. Adjustment of the work equipment...... 4-20
9. Operation in special work sites............4-21
10. Storage................................................4-22
11. Exhaust system cleaning.....................4-24
12. Attachment manually lowering (En-
gine stopped)...................................... 4-26
TRANSPORTATION
1. Road travelling.......................................5-1
2. Preparation for transportation................ 5-2
3. Loading the machine............................. 5-3
4. Fixing the machine................................ 5-4
5. Loading and unloading by crane............5-6
6. Towing the machine...............................5-7
MAINTENANCE
1. Instruction..............................................6-1
2. Tightening torque.................................. 6-4
3. Specification of fuel, coolant and lu-
bricants..................................................6-6
4. Maintenance checklist...........................6-8
5. Maintenance chart...............................6-11
6. Servicing instructions.......................... 6-14
7. Electrical system................................. 6-54
8. Air conditioner and heater................... 6-57
TROUBLESHOOTING GUIDE
1. Engine................................................... 7-1
2. Electrical system................................... 7-2
3. Power train system................................ 7-3
4. Hydraulic system................................... 7-4
OTHERS
1. Quick Coupler........................................8-1
INDEX..............................................9- 1
CONTENTS

1. EC DECLARATION OF CONFORMITY
This declaration of conformity is issued under the sole responsibility of manufacturer:
HYUNDAI CONSTRUCTION EQUIPMENT CO., LTD.
12th Fl., Hyundai Bldg. 75, Yulgok-ro, Jongno-gu,
Seoul 03058, Korea
Hyundai Construction Equipment Europe N.V located at Hyundailaan 4, 3980 Tessenderlo, Belgium, as authorized
representative in the European Community is authorized to compile the technical construction file and declares that the
product:
Type: *********
Model: ******
Serial number (PIN): *****************
is in conformity with the relevant provisions of the Community harmonization legislation:
2006/42/EC - Machinery directive
2014/30/EU - Electromagnetic compatibility directive
2000/14/EC - Noise emission outdoor equipment directive
2002/44/EU - Exposure of workers to vibration risks directive
their amendments, and other applicable directives.
EMC (2014/30/EU)
Certificate number: ***********
Date: DD/MM/YYYY
Notified body: ************
Noise levels (2000/14/EC)
Certificate number: *****************
Date: DD/MM/YYYY
Conformity assessment proc.: Annex VIII Full Quality Assurance
Notified body: *****************
*************
Measured sound power level: nnn.n dB(A)
Guaranteed sound power level: nnn.n dB(A)
Engine information
Manufacturer : *********
Engine model name : ********
Type-approval number : ***********
Stage (Regulation) : STAGE ** (**/**/**)
Gross Power (SAE J1995) : ***kW / ****rpm
Net Power (SAE J1349) : ***kW / ****rpm
Harmonized standards, other technical standards and specifications applied:
EN 474-1:2006+A*:**** (EMM - Safety - Part 1); EN 474-3:2006+A*:**** (EMM - Safety - Part 3); EN ISO
3471:2008 (EMM - ROPS: Lateral/Vertical/Longitudinal loads); EN ISO 3449:2008 (EMM - FOPS: Level II cabin);
ISO 2631-1:1997 & ISO 2631-1:1997/Amd1 :2010 (Whole-body vibration); EN ISO 5349-1:2001 &EN ISO 5349-2:2001
& EN ISO 5349-2:2001/A1:2015 (Hand-arm vibration)
**********
Managing Director
Place, date of issue:
(Original instruction)
Tessenderlo Belgium, DD MM YYYY
0-1

2. DISCLAIMER
THIS TRANSLATION IS BASED UPON THE ORIGINAL ENGLISH OPERATION AND MAINTE-
NANCE MANUAL.
THE ENGLISH VERSION SHALL PREVAIL OVER THE TRANSLATION IN CASE OF ANY LE-
GAL DISPUTE.
0-2

3. FOREWORD
This manual contains a number of instructions and safety recommendations regarding driving, handling,
lubrication, maintenance, inspection and adjustment of the machine.
The manual is to promote safety maintenance and enhance machine performance.
Keep this manual at hand and have all personnel read it periodically.
If you sell the machine, be sure to give this manual to the new owners.
This machine complies with the EC directive "2006/42/EC".
1) Read and understand this manual before operating the machine.
This operator's manual may contain attachments and optional equipment that are not available in
your area. Please consult your local Hyundai distributor for those items you require.
Improper operation and maintenance of this machine can be hazardous and could result in serious
injury or death.
Some actions involved in operation and maintenance of the machine can cause a serious acci-
dent, if they are not done in a manner described in this manual.
The procedures and precautions given in this manual apply only to intended uses of the machine.
If you use your machine for any unintended use that is not specifically prohibited, you must be sure
that it is safe for you and others. In no event should you or others engage in prohibited uses of
actions as described in this manual.
Some illustrations in this manual show details or attachments that can be different from your ma-
chine. Covers and guards might have been removed for illustrative purposes.
2) Inspect the job site and follow the safety recommendations in the safety hints section before op-
erating the machine.
3) Use genuine Hyundai spare parts for the replacement of parts.
We expressly point out that Hyundai will not accept any responsibility for defects resulting from
non-genuine parts or non workmanlike repair.
In such cases Hyundai cannot assume liability for any damage.
Continuing improvements in the design of this machine can lead to changes in detail which may not be
reflected in this manual. Consult Hyundai or your Hyundai distributor for the latest available information
for your machine or for questions regarding information in this manual.
0-3

4. EMISSION-RELATED COMPONENTS WARRANTY (USA and CANADA
only)
Hyundai shall have obligation under the EPA (Environmental Protection Agency) regulation of warranty
about Emission-related components. This warranty shall exist for 3,000 hours or five years, whichever
occurs first.
Naturally, this warranty does not cover to damage arising from accident, misuse or negligence, use of
non-Hyundai parts, or from alterations not authorized by Hyundai.
Emission-related components according to the EPA regulation.
1) Air-induction system.
2) Fuel system.
3) Ignition system.
4) Exhaust gas recirculation systems.
5) After treatment devices.
6) Crankcase ventilation valves.
7) Sensors.
8) Electronic control units.
0-4

5. BEFORE SERVICING THIS MACHINE
It is the responsibility of the owner and all service and maintenance personnel to avoid accidents and
serious injury by keeping this machine properly maintained.
It also is the responsibility of the owner and all service and maintenance personnel to avoid accidents
and serious injury while servicing the machine.
No one should service or attempt to repair this machine without proper training and supervision.
All service and maintenance personnel should be thoroughly familiar with the procedures and precau-
tions contained in this manual.
All personnel also must be aware of any federal, state, provincial or local laws or regulations covering
the use and service of construction equipment.
The procedures in this manual do not supersede any requirements imposed by federal, state, provincial
or local laws.
Hyundai can not anticipate every possible circumstance or environment in which this machine may be
used and serviced.
All personnel must remain alert to potential hazards.
Work within your level of training and skill.
Ask your supervisor if you are uncertain about a particular task. Do not try to do too much too fast.
Use your common sense.
How to adjust the language of monitor
User can select preferable language and all displays are changed the selected language.
Please refer to the page 3-39 for the monitor.
0-5

6. TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
Machine serial no.
Engine serial no.
Manufacturing year
Manufacturer Hyundai Construction Equipment co., Ltd.
Address 12th fl., Hyundai Bldg 75, Yulgok-ro, Jongno-Gu,
Seoul, 03058, Korea
Distributor for U.S.A Hyundai Construction Equipment U.S.A., Inc.
Address 6100 Atlantic Boulevard Norcross
GA 30071
U.S.A.
Distributor for Europe Hyundai Construction Equipment Europe N. V.
Address Hyundailaan 4
3980 Tessenderlo
Belgium
Dealer
Address
0-6

7. EC REGULATION APPROVED
• Noise levels (EN474-1: 2006 and 2000/14/EC) are as follows:
Lwa: 102 dB (EU only)
Lpa: 70 dB
• The value of vibrations transmitted by the operator's seat are lower than the standard value of
EN474-1: 2006 and 2002/44/EC.
0-7

8. SAFETY LABELS
1) LOCATION
Always keep these labels clean. If they are lost or damage, attach them again or replace them with a
new label.
CAB INSIDE-LH CAB INSIDE-RH
ACCUMULATOR
VIEW A - A
HYDRAULIC TANK
FRONT FRAME
VIEW B - B VIEW C - C
1 Start motor
2 Turbocharger cover
3 Hyd oil level
4 Ride control (option)
5 Grease (A)
6 Grease (B)
7 Bucket stopper
8 ROPS cab
9 Steering warning-LH
10 Steering warning-RH
11 Engine start caution
12 Control ideogram
13 Air conditioner filter
14 Electric welding
15 Lift & tie
16 Air cleaner element
17 Manual lowering valve
18 Fueling
19 Battery accident
20 Hyd oil lub
21 High pressure hose
22 Bio oil
23 Engine door shearing
24 Service instruction
25 Start procedure
26 Diesel exhaust fluid
27 Specification sheet
28 Grease (center)
29 Keep clear/Reflect
30 Name plate
31 ROPS plate
32 Accumulator
33 Caution (water separator,
turbocharger)
34 Surge tank
35 Fuel shut off
36 Ultra low sulfur diesel
37 Emergency fire holes
38 No step
39 Refrigerant
40 Use handrail
41 Quick coupler
42 Engine name plate
43 Stay fix
0-8

2) DESCRIPTION
There are several specific warning labels on this machine. Please familiarise yourself with all the warn-
ing labels.
Replace any safety label that is damaged or missing. If a safety label is attached to a part that is re-
placed, install a safety label on the replacement part.
(1) START MOTOR (Item 1)
This warning label is positioned on the left side of the
engine hood.
Start the engine only from the operator's
compartment. Never short across the starter
terminals or across the batteries. Shorting
could bypass the engine neutral start sys-
tem. Shorting could also damage the electri-
cal system.
(2) TURBOCHARGER COVER (item 2)
This warning label is positioned on the turbocharger
cover.
Do not touch turbocharger or it may cause
severe burn. When the engine is running or
immediately after engine shut down.
(3) HYDRAULIC OIL LEVEL (Item 3)
This warning label is positioned on the left side of the
hydraulic oil tank.
Place the bucket on the ground whenever
you are servicing the hydraulic system.
Check oil level on the level gauge.
Refill the recommended hydraulic oil up to
specified level if necessary.
77070FW05
STOP
CAUTION
0-9

(4) RIDE CONTROL (Item 4)
This warning label is positioned on the front frame.
Before checking the boom operation system:
1. The bucket should be laid on the ground.
2. Turn start switch to "ON" position and press
the button on monitor to operate ride control
function.
3. Depressurize boom head by joystick. (boom
down or floating)
(5) BUCKET STOPPER (Item 7)
This warning label is positioned on the middle of the
boom.
When working under or around the bucket or
linkage, with the bucket raised, proper sup-
port must be provided for the bucket and/or
the linkage.
(6) STEERING WARNING (Item 9, 10)
The warning label is positioned on both sides of the
front frame.
No clearance for persons in this area when
machine turns.
Severe injury or death from crushing could
occur.
(7) ENGINE START CAUTION (Item 11)
This warning label is positioned on the right side win-
dow of the cab.
Study the operator's manual before starting
and operating machine.
7803AFW05
77070FW07
77070FW08
0-10

(8) CONTROL IDEOGRAM (Item 12)
This warning label is positioned on the right side win-
dow of the cab.
Confirm the operation of the control lever
and working device before operating the ma-
chine.
Refer to the page 4-8 for details.
(9) AIR CONDITIONER FILTER (Item 13)
This warning label is positioned on the airconditioner
filter.
Periodic and proper inspection, cleaning and
change of filter prolong air conditioner life
time and maintain good performance.
(10) ELECTRIC WELDING (Item 14)
This warning label is positioned on the side of the
battery box.
Before carrying out any electric welding on
this machine, follow the procedure descri-
bed below.
- Pull the connectors out of all electronic
control units.
- Connect the ground lead of the welding
equipment as close to the welding point
as possible.
See page 6-54 for details.
0-11

(11) LIFT & TIE (item 15)
This label is positioned on the both side of the front
and rear frame.
-Lifting point
In order to lift the machine, attach the lifting de-
vices to the lifting points.
-Tying point
In order to tie down the machine, attach the tie-
downs to the tying points.
(12) AIR CLEANER ELEMENT (item 16)
The warning label is positioned on the air cleaner.
Periodic and proper inspection, cleaning and
change of elements prolong engine life time
and maintain the good performance of en-
gine.
(13) MANUAL LOWERING VALVE (Item 17)
The warning label is positioned on the left side of the
front frame.
Be sure no one is under or near the attach-
ment before lowering the boom.
Refer to the page 4-26.
Lifting
Tying
0-12

(14) FUELLING (Item 18)
This warning label is positioned on the left side of the
fuel filler neck.
Stop the engine when refuelling. All lights or
flames shall be kept at a safe distance while
refuelling.
(15) HYDRAULIC OIL LUBRICATION (Item 20)
This warning label is positioned on the top of the hy-
draulic oil tank.
Do not mix different brands of oil.
Never open the filler cap while the engine is
running or at high coolant temperature.
Loosen the cap slowly and release the inter-
nal pressure completely.
(16) BATTERY ACCIDENT (item 19)
This warning label is positioned on the battery box.
Electrolyte containing sulfuric acid cause
severe burns. Avoid being in contact with
skin, eyes or clothes. In the event of acci-
dent flush with sufficient water, call a physi-
cian immediately.
Maintain the electrolyte at the recommended
level. Add distilled water to the battery only
when starting up, never when shutting
down.
With electrolyte at proper level, less space
may cause the gases to be accumulated in
the battery.
Extinguish all smoking materials and open
flames before checking the battery.
Do not use matches, lighters or torches as a
light source near the battery for the proba-
ble presence of explosive gas.
Do not allow unauthorized personnel to
change the battery or to use booster cables.
For safety from an electric shock, do not op-
erate the battery terminal with a wet hand.
0-13

(17) HIGH PRESSURE HOSE (item 21)
This warning label is positioned on the left side of the
front frame.
Escaping fluid under pressure can penetrate
the skin causing serious injury.
Avoid the hazard by relieving pressure be-
fore disconnecting hydraulic lines or other
lines.
See the maintenance section for details.
(18) BIO OIL (Item 22)
This warning label is positioned on the right side of
the engine hood.
Do not mix with other bio-oil.
(19) ENGINE DOOR SHEARING (Item 23)
This warning label is positioned on the left side of the
engine side door.
Do not open the engine door during the en-
gine's running. Stay clear of rotating parts.
Do not touch exhaust pipe or it may cause
severe burn.
(20) START PROCEDURE (Item 25)
This warning label is positioned on the right side win-
dow of the cab.
Start Procedure
1. Start ignition on.
2. Wait up to 4 seconds for grid heater operation in summer.
(45 seconds in winter)
3. Start cranking.
4. If engine still does not start, turn the Keyswitch to OFF position.
5. Loosen fuel supply line at the outlet of pre-filter.
6. Do hand-priming repeatedly until air bubbles comes out from
fuel supply line completely.
7. Tighten fuel supply line to its origin position.
8. Recranking.
9. If the engine still would not start,
please contact the nearest HYUNDAI or Cummins dealers.
0-14

(21) DIESEL EXHAUST FLUID (item 26)
This warning label is positioned on the right side of
the rear frame.
Fill only the DEF/AdBlue® (Diesel Exhaust
Fluid, standardised as ISO 22241).
Aqueous urea solution made with 32.5%
high-purity urea and 67.5% deionized water.
Do not fill the diesel fuel.
(22) ACCUMULATOR (Item 32)
This warning label is positioned on the accumulator
of the solenoid valve.
The accumulator is filled with high-pressure
nitrogen gas and is extremely dangerous if
handled in the wrong way. Always observe
the following precautions.
Never make a hole in the accumulator or ex-
pose it to flame or fire.
Do not weld anything to the accumulator.
When carrying out disassembly or maintenance of the accumulator, or when disposing of
the accumulator, it is necessary to release the gas from the accumulator. A special air
bleed valve is required for this operation, so please contact your Hyundai distributor.
(23) CAUTION (WATER SEPARATOR, TURBO-
CHARGER) (Item 33)
This warning label is positioned on the right side win-
dow of the cab.
In order to protect high pressure fuel sys-
tem, please drain water in water separator
before starting the engine.
In order to prevent a turbocharger failure,
please allow more than 5 minutes' cool down
period (no load low idle operation) before
shutting the engine off.
(24) FUEL SHUT OFF (item 35)
This warning label is positioned on the hydraulic
tank.
Fill only the hydraulic oil.
Do not fill the diesel fuel.
Relieve tank pressure with the engine off by
removing the cap slowly to prevent burns
from hot oil.
- In order to protect high pressure fuel system, please drain
water in water separator before starting the engine.
- In order to prevent tubocharger failure, please allow more
then 5 minutes cool down period(no load low idle operation)
before shutting the engine off.
0-15

(25) ULTRA LOW SULFUR DIESEL (item 36)
This warning label is positioned on the left side of
fuel filler neck.
Use ultra low sulphur fuel only.
Ultra low sulphur fuel sulphur content ≤ 15
ppm
If ultra low sulphur diesel is not used, the af-
tertreatment diesel particulate filter can be
damaged.
(26) EMERGENCY FIRE HOLE (item 37)
This warning label is positioned inside of the engine
hood inlet cover.
It is possible to fight the fire manually
through two holes on the screen.
Holes for manual firefighting can be ac-
cessed by opening the inlet covers on the
right and left side.
Firefighting can take place using the holes
on the screen, which provide access to the
engine compartment with, e.g., handheld fire
extinguisher.
The extinguishing agent contains glycol
which may cause injuries in case of contact.
Avoid contact. In case of contact with the
eyes, rinse with water. In case of skin con-
tact, wash with soap and rinse with water.
Always contact a doctor after contact with
the extinguishing agent.
(27) NO STEP (Item 38)
This warning label is positioned on the engine hood.
Don't step on the engine hood.
ULTRA LOW SULFUR FUEL ONLY
PLEASE REFER TO THE DRIVER’S
MANUAL.
CAUTION
Inlet cover
Label is positioned for holes
inside of the inlet covers
0-16