Hyundai HL960 Wheel Loader service manual
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About the Hyundai Construction Equipment Wheel Loaders
Hyundai factory service manuals for wheel loaders: 107 models, from the compact HL630 series to the HL985A.
Hyundai HL960 Wheel Loader - Factory Service Manual
This is Hyundai's factory service manual for the HL960 wheel loader, including the high-lift HL960 XT. It is a 615-page PDF in 7 sections: the same workshop manual Hyundai dealers use.
It covers the Hyundai HL960 wheel loader.
The HL960 at a glance
These figures are taken from the specifications section of this manual.
| Engine | Cummins QSB6.7, 6-cylinder turbocharged diesel, 225 hp (gross) at 2,200 rpm |
| Operating weight | 18,800 kg (41,450 lb); HL960 XT 19,600 kg (43,210 lb) |
| Bucket capacity | 3.3 m³ (4.3 yd³) heaped, with bolt-on cutting edge |
| Transmission | ZF 4WG 210 4-speed powershift (ZF 5WG210 5-speed optional) |
| Top speed | 39.5 km/h (24.5 mph) |
| Breakout force | 16,670 kg (36,750 lb) |
| Hydraulics | Variable piston main pump, 280 kgf/cm² (3,980 psi) system pressure |
About the Hyundai HL960 wheel loader
A wheel loader works hardest in its powertrain and loader hydraulics: transmission, axles, brakes, the lift and tilt circuit and the steering. Those are the systems where the factory figures and procedures matter.
What is inside, section by section
Its chapters cover the engine, the fuel system, the transmission and drivetrain, axles and final drives, brakes, the hydraulic system, the electrical system, steering and the work equipment.
- General (27 pages) - safety hints; full specifications for the HL960 and HL960 XT with bolt-on edge and tooth buckets; weights of every major component; tightening torques for major components, bolts, nuts and hose fittings; and an operational checkout record sheet.
- Engine (14 pages) - structure and function, engine speed and stall rpm checks, and the fuel warmer system.
- Power train system (258 pages) - the largest section: the ZF transmission, drive shafts and axles, with fault codes, operational checks, troubleshooting, tests and adjustments, and full disassembly and assembly.
- Brake and fan system (61 pages) - structure and function, checks and troubleshooting, tests and adjustments, disassembly and assembly.
- Steering system (58 pages) - including the EHPS steering valve: function, checks, adjustments and overhaul.
- Work equipment (87 pages) - main pump, main control valve, cylinders and loader linkage: function, checks, tests and adjustments, disassembly and assembly.
- Electrical system (110 pages) - component locations, wiring circuits, the monitoring system, electrical component specifications, connectors and electrical troubleshooting.
What you can do with it
- Find the cause of a fault before replacing parts
- Remove, overhaul and refit major components
- Set pressures, clearances and adjustments to the factory values
- Use the right torque values and tightening sequences
- Read the wiring and hydraulic diagrams when tracing a problem
Who uses it
Owners and mechanics who need to read HL960 transmission fault codes, check stall speed, set brake and steering pressures, or rebuild the transmission, axles or hydraulic cylinders.
Make sure it is your model
This manual covers the HL960 and HL960 XT. The HL960A and HL960A HD, the HL960HD and the HL960 T3 have their own manuals. Check the model plate on your machine before ordering.
Questions about this manual
Which machines does this manual cover?
The Hyundai HL960. If your machine has a different model number, look for the manual for that model.
Is it the original manufacturer manual?
Yes. It is Hyundai's own service manual, not a third-party reprint or a summary.
How do I receive it?
It is a PDF. After payment it is available to download from your account, and you can read it on a computer, tablet or phone or print the pages you need. No printed book is shipped.
