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Subject : Matters needing attention for maintenance and accessories
1. First welcome you to have used our product and thank you for great coordination in
business.
2. In case the equipment is in faults, it should be maintained by our Company or the
company appointed by our Company using standard parts.
3. At present, In some markets there have been some forged and fake imported parts
and some unauthorized and untrained companies or persons to maintain the
products of our company, causing many problems left and seriously affecting the
equipment performance and operation life.
4. In view of the above, the customers are requested to pay attention to followings:
1) The adopting of non-standard parts may not have obvious effects on the
equipment in short time, however, it will certainly have a series of harmful effects
later. In order to prevent the damage to the equipment or the performance
deterioration causing severer loss, never use non-standard parts.
2) When the customer is purchasing the parts, it is necessary to purchase products
from our company or the company authorized by our company for selling the
parts, and be careful for the discrimination. Welcome to contact our company if
there is doubtful phenomenon.
3) If the customer requires to maintain the equipment, it is requested to contact our
company or the company authorized by our company.
4) In case of the equipment faults arising from the maintenance with non-standard
parts or by the unauthorized company or persons, our Company do not bear the
responsibilities for the warranty service, even within the Warranty period.
5. Thank you once again for the business cooperation at normal times.
Attention Please
- 1 -
With best regards

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Summary of Contents for Hyundai HL660+

  • Page 1 Attention Please Subject : Matters needing attention for maintenance and accessories 1. First welcome you to have used our product and thank you for great coordination in business. 2. In case the equipment is in faults, it should be maintained by our Company or the company appointed by our Company using standard parts.
  • Page 2 Contents Preface………………………………………………………….3 Safety Regulations……………………………………………...5 Uses and Operation Manual……………………………………44 Maintenance Manual……………………………………………88 - 2 -...
  • Page 3: Preface

    If the manual is lost or is too dirty to be read, please ask for a new manual from HYUNDAI CONSTRUCTION EQUIPMENT or the appointed dealers of our corporation. If you decide to sale the machine, make sure that you give the manual to new user at the same time.
  • Page 4 at the earlier due time of the two time-cycles mentioned above. If it is under extreme bitter, dusty or humid working environment, there should be much more frequent lubrication maintenance than it regulates in the “Regular Maintenance”. During maintenance, the listed maintenance items should be done repeatedly.
  • Page 5: Safety Regulations

    Safety Regulations Please read and be familiar with all the safety regulations, or it will cause heavy injuries and deaths. - 5 -...
  • Page 6 Explain of warning signs and their locations Every part name of the machine: 1、bucket 2、connecting rod 3、boom 4、rocker arm 5、rocker arm cylinder 6、front wheel 7、 front mudguard 8、 boom cylinder 9、 combination headlamp 10、 front frame 11、 steering cylinder 12、 fuel tank 13、 rear mudguard 14、 hydraulic oil tank 15、 caution light 16、 cabin 17、 rear wheel 18、engine hood 19、air reservoir 20、rear frame 21、counterweight、22 reversing camera 23、...
  • Page 7 Warning signs and their locations There are several specific warning signs on your machine. Their location and description of the hazard are introduced in this section. Please take time to familiarize yourself with these signs. Make sure that you can read all the warning signs. If the words or pictures on these signs are not clear, please change or clean them with cloth, soapsuds, but remember not to use detergent, petrol for cleaning.
  • Page 8 SIGN Explain SIGN Explain Warning, the Lock the lever to loader turns, it keep the loader will be dangerous from turning. at the hinge. Read and understand the Warning manual carefully before operating the loader. ⚫ Security mark three(Both side of the front frame)...
  • Page 9 SIGN Explain SIGN Explain Read and Warning, oil fluid understand the spurts out from the manual carefully pore of the pipe. before operating the loader. Warning, oil fluid spurts out from the joint. ⚫ Security mark four(Rear mudguard& counterweight) SIGN Explain SIGN Explain...
  • Page 10 ⚫ Security mark five(Hydraulic oil tank and the top of engine hood) SIGN Explain SIGN Explain Warning, Hot Warning, Do not liquid spurt out open the filler cap at from the filler cap. high temperatures. ⚫ Security mark six(the top of engine hood,)...
  • Page 11 SIGN Explain SIGN Explain Warning, Do not touch the engine exhaust pipe, the temperature is very high ⚫ Security mark seven(counterweight, left side) SIGN Explain SIGN Explain Warning, Improper Warning, Battery operation may fluid is corrosive. cause a battery fire. Warning, Read and Improper...
  • Page 12 ⚫ Security mark eight(Left side of engine hood) SIGN Explain SIGN Explain Warning, Stay Warning, Cut off away from the the power first, to wheels to avoid repair the electrical being run over. apparatus element. Warning, Only all Warning, Hands the parts of the are not allowed to machine stop...
  • Page 13: General Precautions

    General precautions General precautions Safety requirement ⚫ Only the authorized and qualified persons can operate and maintain the machine. ⚫ Abide by all the safety rules, cautions and orders, when operating and maintaining the machine. ⚫ Don’t operate the machine when you are not well, or after drink liquor or when you feel sleepy after taking medicine.
  • Page 14: Getting On And Off The Machine

    General precautions ⚫ Pressure air can cause personal injury. When using pressure air for cleaning, wear a protective face shield, protective clothing and protective shoes, use a max air pressure of less 0.3MPa for cleaning purposes. ⚫ All the protective articles should be checked whether in normal condition before using.
  • Page 15 General precautions Cautions for fire prevention The fuel, lubricant in the engine, hydraulic oil in the hydraulic system, hydraulic power oil, gear oil in drive system, braking liquid in the brake system and antifreeze in radiating system, all these liquids can be ignited, especially fuel is inflammable and quite dangerous. One must pay attention to the followings: ⚫...
  • Page 16 General precautions ⚫ Don’t use compressed air when cleaning. ⚫ Use water to clean to make the dust drop down. ⚫ It is dangerous if there is asbestos dust in air. Operate the machine at upwind place if it is possible.
  • Page 17 General precautions ⚫ Properly support equipment or accessories when working under the machine. Don’t depend on the hydraulic cylinder to hold. If the control institutions move or hydraulic pipe leaks, any attachment will drop down. So one can’t do any adjustment when the machine turns or engine starts.
  • Page 18 General precautions ⚫ Our corporation will be not responsible for those injuries, accidents and any breakdown of the machine if it is not a permitted attachment. Guarantee ventilation working in closed space ⚫ If starting engine or dealing fuel, cleaning parts or painting in a closed or stuffy place, open the windows and doors to guarantee ventilation and avoid gas poison.
  • Page 19 General precautions ⚫ Make sure all the clamps, guards of hose and tube are installed correctly to prevent vibration or friction. ⚫ When removing pipes of air-condition compressor, prevent naked flame or it will produce poisonous gas.
  • Page 20: Operation Cautions

    Operation cautions Operation Cautions ⅠBefore engine start The safety about the working place ⚫ Before working, make sure that there is not any abnormal situation that may cause danger. ⚫ Check the terrain and situation of the working place and guarantee the best and safe working method.
  • Page 21: When Starting The Engine

    Operation cautions blocked in the air filter, whether there is damage on the wires. ⚫ Adjust the operator’s seat for easy operation. Make sure the safety belt and its fix are in good conditions. Change the belt every 3years. ⚫ Check all the gauges in good conditions, and whether the control rod is in HOLD position. ⚫...
  • Page 22 Operation cautions ⚫ Check whether there is abnormal situation about the machine’s sound, vibration, heat, smell and gauges. Check leakage of hydraulic oil, lubricant, air or fuel. ⚫ Repair the machine immediately if there is any abnormal condition. It may cause injury or damage the machine, if working under unsuitable conditions.
  • Page 23 Operation cautions around. ⚫ Move at a low speed and avoid sudden direction changing if driving on the scraggly ground. ⚫ Avoid obstacles when driving. If there is need to cross over an obstacle, lower the implement to the ground and move at low speed. ⚫...
  • Page 24 Operation cautions Forbidden operation ⚫ In order to prevent the rolling of the machine or the damage of the implement caused by overload, make sure the loads don’t surpass the regulated capacity. ⚫ Our corporation is not responsible for the damages, accidents or injuries caused by overload. Help Not overload Be careful when down...
  • Page 25 Operation cautions The direction of the bucket when up and down the ramp Don’t be close to high-voltage cable ⚫ Don’t let the machine touch the overhead cable. Even close to high-voltage cable, it may cause electric shock. Keep safety distance between the machine and cable according to the right table shows: ⚫...
  • Page 26: Cautions For Operation

    Operation cautions Cautions for operation ⚫ Don’t be too close to the edge of the cliff. When building a dyke, filling earth or filling cliff, one can use a pile of earth to push another pile. ⚫ When the machine pushing the earth down the cliff or the top of ramp, the load will become light suddenly.
  • Page 27: The Use Of Brake

    Operation cautions other places that height is limited. When dumping to the dumping truck, make sure there is no person around the machine. Don’t let the bucket rump the cab of the dumping truck. In order not to rump other subjects to cause accident, the machine should move at a safe speed, especially at the places that is limited Be careful of bumping...
  • Page 28 Operation cautions earthquake. ⚫ The earth piled on the ground and around the ditch is soft. And it may sink due to the weight or vibration of the machine and make the machine turn over. ⚫ Tie the safety belt if the working place has the danger of falling stones or turning over. Park the machine ⚫...
  • Page 29 Operation cautions tank) to heat the hydraulic oil. This can make the machine have good reaction and prevent from being out of control. ⚫ If the electrolyte in the battery freezes, don’t charge the battery or start the motor by other power source.
  • Page 30 Operation cautions ⚫ When transporting, the machine can be separated into several parts. Contact our corporation’s dealer to accomplish this work. Ⅳ Cautions for using and maintaining the battery Preventions from danger The electrolyte of battery contains vitriol and it can produce hydrogen. So it may cause serious injury or fire if one dealing with battery wrongly.
  • Page 31: Charge The Battery

    Operation cautions ⚫ When connecting step-up cable, turn off the start switch of both normal and abnormal machines. ⚫ When installing step-up cable, connect “+” pole first. Cut off “-“ pole first when removing ⚫ The last connection of the ground wire connects ground wires to the engine body of the abnormal machine.
  • Page 32 Operation cautions ⚫ If the abnormal machine is towed by the other one, make sure that the steel ropes can support the weight of the abnormal machine. ⚫ There should be no twist, broken wires or shrink diameter on the ropes. ⚫...
  • Page 33: Cautions For Maintenance

    Cautions for maintenance Cautions for maintenance ⅠBefore maintenance Troubleshooting notice If the maintenance you do is not mentioned in the “Operation and Maintenance Manual”, it may cause unexpected breakdowns. Please contact dealers of our corporation. Alarming tags ⚫ When operator is maintaining machine or filling fuels, the operator may be injury or death if others start the engine or operate the control rods.
  • Page 34 Cautions for maintenance Appoint a man to charge when operating with others ⚫ When repair machine or remove the implements, appoint a man to charge and others obey him. ⚫ When cooperate with others, it may cause serious accident by misunderstanding. Water level of the radiator When checking water level of the radiator, stop engine first.
  • Page 35 Cautions for maintenance piston rod of lift arm’s cylinder. Limit the returning of the cylinder to prevent dropping down of the implement. Proper tools Use proper tools to work with. It may cause injury by using damaged, low-grade, broken or temporary alternative tools.
  • Page 36: Working Under The Machine

    Cautions for maintenance ⚫ Don’t smoke when checking and maintenance. Smoke at the assigned spot. ⚫ When checking fuel, lubricant or electrolyte, use explosion-proof lighting equipment and can’t use lighter or match for lighting. ⚫ Move all the inflammables to safe places when burnishing or welding on frame. ⚫...
  • Page 37 Cautions for maintenance Maintenance when the frame is jacking up ⚫ Use humper to lock the front and rear frame when the implements or frame is lifting. Put the control rods to “neutral” position, lock the control rods. Block the implements and frame.
  • Page 38 Cautions for maintenance the workers should keep contact with others. ⚫ Be careful when the working location is close to the turning parts, for it has the danger of rolling in by the turning parts. ⚫ Don’t let any tools or any parts of body touches fan or fan belt.
  • Page 39: Cautions For Battery

    Cautions for maintenance Cautions for battery When repairing electric system or doing welding work on the machine, remove the “-” pole of the battery or turn off the electric power to prevent the flowing of current. Find out the abnormal locations ⚫...
  • Page 40 Cautions for maintenance pressure completely. ⚫ Wear safety glasses and leather gloves. ⚫ If the pipe is leaking, it is wet around, so check whether there are cracks or knurls on the hoses or tubes. If it is difficult to find out, contact our dealers. ⚫...
  • Page 41 Cautions for maintenance 4. Has the leakage of water and oil been checked? All the bolts tightened? ⚫ Check when the engine running The detailed information about checking is in “Maintenance when engine is running” from “Cautions for Maintenance”. Pay attention to the following items to guarantee safety: Do the parts that need repair and maintenance work normally? Whether the hydraulic system is leak when engine’s rotary rate increases or exerts load.
  • Page 42 Cautions for maintenance corrosion of rim parts. ⚫ In order to avoid over inflation, there should be proper inflating equipment and ⚫ In order to avoid excessive inflation, it is necessary to have appropriate equipment and personnel training to ensure. Leakage or the damage of rims is due to the incorrect using of the inflating equipment.
  • Page 43 Cautions for maintenance Change main safe parts periodically Main parts changed periodically Q’TY Change cycle Hydraulic tank filter Every half a year or 1000 hours (which becomes due first) Fuel tubes(fuel tank to diesel prefilter) Fuel tubes(diesel prefilter to fuel pump) Fuel tubes(fuel pump—diesel filter)...
  • Page 44: Uses And Operation Manual

    Uses and operation manual Uses and Operation Manual NOTE: Read and understand the instructions in this manual before operating the machinery. Correct operation will realize safety, obtain high working efficiency and prolong the lifecycle of the machine. - 44 -...
  • Page 45 Uses and operation manual Application The loader is a type of heavy-duty engineering machinery mainly used for loading and unloading loose materials in mines, construction sites, road-building projects, ports and freight yards. With its high efficiency, the loader is suitable for bulldozing, excavating, lifting and towing as well as loading.
  • Page 46 Uses and operation manual NOTE The precautions of operation, maintenance and safety rules listed in this manual only suit for the machine used in a proper way. Our cooperation will not afford any responsibility if the users operate the machine which is not regulated in the manual. All these responsibilities are afforded by users themselves.
  • Page 47 Uses and operation manual ENGINE Description HL660+ / HL665+ HL660L+ / HL665L+ Maker WEICHAI WEICHAI Model WD10G220E23 WD10G220E23 Emission regulation Tier II Tier II Power(Net) 162kW(220HP)/2000rpm 162kW(220HP)/2000rpm 900N· m/1300~1500rpm 900N· m/1300~1500rpm Max. torque Displacement 9.726L 9.726L No. of cylinders 6 EA 6 EA HYDRAULIC SYSTEM Description...
  • Page 48 Uses and operation manual AXLES Description HL660+ / HL665+ HL660L+ / HL665L+ Conventional only Conventional only Differential front type Conventional only Conventional only Differential rear type ±10° ±10° Rear axle oscillation STEERING Description HL660+ / HL665+ HL660L+ / HL665L+ Pump type Fix gear pump Fix gear pump Flow rate...
  • Page 49 Uses and operation manual HL660+/HL665+ DIMENSIONS All dimensions are approximate Long Long Standard boom Standard boom Description Description (mm) (mm) (mm) (mm) Dump clearance at Overall height(Cabin) 3540 3540 3150 3560 45° (Full lift) Dump angle Reach at 45° (Full lift) 1315 1475 Overall length...
  • Page 50 Uses and operation manual HL660L+/HL665L+ DIMENSIONS All dimensions are approximate Long Long Standard boom Standard boom Description Description (mm) (mm) (mm) (mm) Dump clearance at Overall height(Cabin) 3540 3540 3100 3420 45° (Full lift) Dump angle 45° 45° Reach at 45° (Full lift) 1220 1440 Overall length...
  • Page 51 Uses and operation manual MEMO - 51 -...
  • Page 52 Uses and operation manual Operation equipment and monitoring system Direction wheel This machine is of all hydraulic coaxial flow amplification steering system with direction wheel in cab which connects to steering. When the machine works normally, if turning the direction wheel clockwise, the machine turns right, if turning the direction wheel counter clockwise, the machine turns left.
  • Page 53: Starting Switch

    Uses and operation manual Power switch Starting switch Starting switch Starting switch(also called electric lock)is located at the control board of the right side of the instrument panel, from left to right , they are 1、2、3、4 four positions respectively. First connect the red button (electric switch) shown in the figure and then start the start switch.
  • Page 54: Accelerator Pedal

    Uses and operation manual Braking Pedal The braking pedal locates at the left front side of the operator’s seat. Step down the braking pedal, the front and rear driving axle brake realizes brake. And at the same time, connect braking lamp switch and the lamp lights. Loose the braking pedal to release parking brake.
  • Page 55 Uses and operation manual The transmission control handle is installed on the lower left of the steering wheel, and the front and back are F2 (forward two), F1 (forward one), N (neutral) and R1 (backward one). Mechanical control handle The working device control handle is installed on the right side of the driver's chair, and there are two operating handles.
  • Page 56 Uses and operation manual Hydraulic control handle (Optional configuration) The working device control handle is installed on the right side of the driver's chair to control the working device for operation. The left and right pushing handle is used to control the movement of the bucket, and the front and back pushing handle is used to control the movement of the boom.
  • Page 57 Uses and operation manual Pull the handle to the most backward position, and it will keep at that position. There is no hold force when the handle is at the most forward position. When the bucket is moving from the angle of maximum retracting to the dumping angle, it should push the handle forward continuously (it will return to neutral position automatically after loosening hand).
  • Page 58 Uses and operation manual 2、Switches Combination headlamp switch Control the headlamp on or off Combination tail lamp switch Control the tail lamp on or off Front wiper switch Control the Front wiper on or off, the switch has 3 gears, respectively stop, slow and fast. Front wiper water switch Control the front glass kettle motor to spray water.
  • Page 59 Uses and operation manual 3、Turn signal and near and far light control handle When the handle is flipped forward, the left turn signal blinks. When the handle is flipped backward, the right turn signal blinks. The handle is in position 0 and the light is off. When the handle knob is turned to 1, the backlight of the instrument and switch lights up, and the small light of the headlight lights up;...
  • Page 60: Function Of The Key

    Uses and operation manual stations. AUX function: Support for U disk /SD card MP3 format file playback, support mobile phone, MP3 external audio input. Sound function: Support POP /ROCK /Classic /FLAT sound. Bluetooth function: Support Bluetooth phone connection and Bluetooth music playback function.
  • Page 61 Uses and operation manual 2、MP3(USB/SD/MMC) playback 2.1 In the radio working mode, the USB flash drive /SD playback mode will be automatically switched to the USB flash drive /SD playback mode Short press to play the top/next song in U disk /SD; Long press to rewind/forward to play the current song.
  • Page 62: Instrument Interface

    Uses and operation manual JAZZ jazz /POP pop /ROCK rock /Classic /FLAT normal /EQOF(sound effect off) sound effects. After the electronic sound effect is turned on, the bass BS and treble TE values cannot be manually set. 5、bluetooth setting Turn on the Bluetooth of the mobile phone and search for the new "Device" function. When the system obtains signal contact with the mobile phone, it will prompt whether the mobile phone is connected to the device.
  • Page 63 Uses and operation manual The tachometer is used to detect the engine speed in real time. 2. Engine water temperature meter The water temperature meter is used to detect the cooling water temperature of the engine in real time. The symbol is .
  • Page 64 Uses and operation manual When the water temperature sensor is shorted, the first line of the LCD displays Coolant-temp-sen-short-circuit. When the water temperature sensor is open, the first line of the LCD displays Coolant-temp-sen-open-circuit. When the Fuel sensor is short-circuited, the first line of the LCD screen displays: "fuel-sensor-short-circuit"...
  • Page 65 Uses and operation manual When the battery voltage is lower than 16V, the LCD displays "Low battery-voltage" at the first line. LCD screen second line: Display vehicle system voltage. The third line of the LCD screen: displays the total working time of the device. Stop immediately when the brake pressure indicator is low.
  • Page 66: Horn Switch

    Uses and operation manual temperature indicator Torque converter The torque converter oil temperature value flashes when it oil temperature alarm enters the red zone. red. Transmission low Blinking red when the oil pressure is below the specified value. oil pressure indicator Gearbox failure (red) When the TCU is faulty, light the indicator and turn red.
  • Page 67: Air Conditioner

    Uses and operation manual 9、Air conditioner The unit is equipped with an air conditioning system to provide warm and cool air to the cab in cold and hot weather. The rotating fan control switch (1), the fan starts to work, the air output has three levels (L, M, H) can be adjusted, the rotating refrigeration switch (2) left cooling capacity decreases, the right rotation cooling capacity increases.
  • Page 68 Uses and operation manual 1-The lever that controls the movement of the forward and backward positions. 2- The lever to adjust the Angle of the seat back 3-Lever for conditional bearing capacity 12、Use of door lock The cab is one side (left) door. If the lock is in the locked state, the lock core cannot be pushed down.
  • Page 69: Rearview Mirror Adjustment

    Uses and operation manual When the driver is operating this machine, be sure to close both the left and right doors to ensure safety. 13、Rearview mirror adjustment Above the cab of the machine, there is a rearview mirror on the left and right sides. Before operating the machine, the rearview mirror must be adjusted to ensure that the driver has a good rear view.
  • Page 70 Uses and operation manual Run-in a new loader Run-in of a new loader can prolong the life of the machine, eliminate hidden troubles and avoid heavy breakdowns. When the user has a new loader, do operation and maintenance of the machine according to the break-in regulation and then can use it normally.
  • Page 71: Operation

    Uses and operation manual Note When checking various oil levels, do according to the relevant regulations After run-in Check all bolts and nuts, particularly those on the covers of engine air cylinders, exhaust pipe, front and rear axles, wheel rims, driving shaft connections, and engine fasten bolts, front and rear frame connection bolts etc., and see that they are well tightened.
  • Page 72 Uses and operation manual 6. Make sure the implement rod at neutral position. 7. Make sure the transmission rod at neutral position. 8. Check the hand brake at loose position. 9. Push down the power switch, insert the key to the electric lock and turn it clockwise at first position to connect the whole machine’s electricity, alarm the horn to warn others not to close to the machine, for it is ready to start.
  • Page 73 Uses and operation manual The travelling operation of the machine 1. Operate the implement control rod, make the bucket turn backward to limited position; lift the lift arm to transporting position, that is, it is about 400mm from the lower connection point to the ground.
  • Page 74 Uses and operation manual bucket forward, make the bucket teeth or edge insert into or support the ground to guarantee safe. 6. Check the inosculation of each shift. Drive the machine to level ground, inosculate each shift respectively and check each shift’s reactions. 7.
  • Page 75 Uses and operation manual When the machine drives at high speed, unless emergency, one can’t press the brake pedal to bottom quickly to avoid sudden brake, thus, cause accident or damage the machine. Park the machine 1. Park the machine on a level ground, there should be no falling stones, coast or the danger of flood.
  • Page 76 Uses and operation manual Park the machine for a long time If the machine needs to parking for a long time, do as the following shows: 1) Before storing ⚫ Clean every part of the machine and dry it. Storing it in the dry warehouse. If the machine can only be stored in the open air, park it on the concrete ground that is easy to drain off water and cover it with canvas.
  • Page 77 Uses and operation manual as well. ⚫ Add grease to each moving shaft, driving shaft. ⚫ Before starting the machine, wipe out the grease on the cylinder rod. - 77 -...
  • Page 78 Uses and operation manual Loader work operation I Preparation for working Before working, use the machine to lever the work site, filling pits, moving stones and other obstructions which will damage the tires or hamper operation. If using the machine to dump material onto the truck or skip car, adjust the height of the lift arm’s lifting limited equipment according to the height of the truck or skip car.
  • Page 79 Uses and operation manual Cooperative loading method Cooperative loading method suits for loading strong or sticky materials. The operation before inserting the stack is of the same with general loading method. After the bucket inserts the stack of material and can’t move forward further, the operator pulls backward the lift arm control rod and then pulls it back to neutral position.
  • Page 80: Dumping Operation

    Uses and operation manual It is not permitted to lift the bucket to a higher position to do transporting work, or it will cause the turn-over of the machine. Dumping operation Dumping onto the truck or skip car When the loader full of material is about 15m from the truck or skip car, loosen the governor pedal first.
  • Page 81 Uses and operation manual After dumping, pull the bucket control rod to the most backward position, and the bucket turns backward continuously to the level place the bucket and then pull it back to the neutral position. Operator operates transmission control rod to the reverse position and then loosen brake pedal to let the machine leave the truck or skip car.
  • Page 82: Method Of Operation

    Uses and operation manual Towing operation For towing operation, a flat car with 20 tons should be prepared. Do the followings: Joint the flat car to the draw bar security. Install a braking system with good performance on the flat car. The bucket is in the transporting position.
  • Page 83: Operation In Cold Weather

    Uses and operation manual and raises the lift arm to dump the material and then the loader returns to its original position. If the truck is not full, the truck should go forth by one truck’s width. After doing next load working, the loader returns to its original position and the truck that is not full reverses to the front of the loader, and then the loader dumps material again.
  • Page 84 Uses and operation manual day’s work, do the following works: 1. Clean the mud, water or snow sticky on the machine. Avoid those entering seal ring and then damaging the seal performance. 2. Parking the loader on the dry ground. If it is not possible, stop the loader on wood board. Use wood board to prevent the loader from freezing on the ground, which is easy to start next day.
  • Page 85 Uses and operation manual Machine’s transportation Before loading, investigate the passage‘s height, width and its permitted loading capacity, and also investigate the overall height, width and its permitted loading capacity after the machine placing on the transporting vehicle. If the height or width surpass, consult our company or our dealers for solution.
  • Page 86 Uses and operation manual Machine’s hoisting 1. It should be ordered and operated by the persons who know very well about the knowledge of hoisting. 2. Calculate the max. hoisting weight of the crane and the bearing capacity of the tools. (The machine’s hoisting weight is 17300±5%kg),to guarantee hoisting safety.
  • Page 87 Uses and operation manual If the braking system has problem, and then the brake can’t be used, so pay special attention when towing. Cautions for towing 1. Before release the parking brake, block the tires to avoid the moving of the machine. If the machine isn’t blocked well, it will move.
  • Page 88: Maintenance Manual

    Maintenance manual Maintenance Manual Note Do maintenance according to the periodical time and the maintenance procedure of the manual. Good maintenance can prolong the machine’s life and guarantee safety. - 88 -...
  • Page 89: Periodical Maintenance

    The listed periodical maintenance in the manual uses working time table and calendar. HYUNDAI CONSTRUCTION EQUIPMENT requires to do the maintenance according to the above two cycles but to see which becomes due first. If the working environment is of extreme condition, dusty or humid, then it should do much more frequent lubricating maintenance.
  • Page 90 Maintenance manual 5. Add lubricant to the lubricating points according to the indication of the whole machine’s lubrication diagram. 6. Check the oil level of the brake booster pump. ⚫ Every two weeks or every 100 working-hours maintenance Do the above maintaining items first. 1.
  • Page 91 Maintenance manual 11. Check the oil level of the brake booster pump. ⚫ Every three months or every 500 working-hours maintenance Do the above maintaining items first. 1. Check the deepness of antifreeze and the coolant additive. 2. Change fuel prefilter of the diesel tank and the fuel prefilter and fine filter of the engine. 3.
  • Page 92: Cooling Water

    Maintenance manual Important maintaining procedures ⚫ Maintenance of the engine coolant It is of great important for the correct maintaining of the cooling system. Too hot, too cold, corrosive pitting, gas etching, piston block and radiator block are common breakdowns. These will not only reduce the working efficiency of the machine, but also damage the engine.
  • Page 93 Maintenance manual The antifreeze’s brand and performance recommended: The lowest Mobil antifreeze (concentration) temperature(℃) percentage(%) —46 —40 —33 —25 —20 —15 —10 When changing antifreeze, use high quality antifreeze and fill it according to the instruction. ⚫ Additive Under the working temperature of the engine, all the water is corrosive, so there must be additive (SCA)...
  • Page 94 Maintenance manual ⚫ Method of checking the level of coolant The water radiator is located at the back part of the machine. 1. Wait for the coolant temperature dropping to less than 50℃, slowly open water radiator’s inlet cover to release pressure to avoid being hurt by high temperature vapor or high temperature coolant.
  • Page 95 Maintenance manual 暖风回水口 Warm air intake port Warm air return port Note When adding coolant, drain out the air from the pipe of engine cooling system. 5. Keep the water radiator’s inlet cover open. Start the engine, move at idle speed about 5 minutes and then move at high idle speed for 5 minutes.
  • Page 96 Maintenance manual system to warm air shift. 2. Turn the hand valve on the inlet pipe of the engine to connecting position. (At the connecting position, valve handle accords with the strike of the pipeline). 3. Start the engine, move at idle speed for 5 minutes and then stop engine. Turn the start switch to 1 gear shift to connect the whole electricity.
  • Page 97 Maintenance manual goes up to 80℃,run the engine for 5 minutes more. 10. Stop the engine and drain out the clean liquid. 11. Fill clean water to the engine cooling system to its normal level and keep it stably for 10 minutes.
  • Page 98 Maintenance manual Unscrew the fixing cover of Remove the filter element filter element counterclockwise 7. Clean the inside of the air filter case 8. Clean the main element with compressed air(pressure should be no less than 300kPa). 9. Scour from the inside of the main element along the wrinkle and then brush respectively and scour repeatedly along the wrinkle from inner and outer of the main element.
  • Page 99 Maintenance manual 13. Push the reset key of the service meter to make the meter reset. After cleaning the main element, start the engine, if the yellow piston of the service meter still rises to red scale or give off black smoke, change a new safety element. 14.
  • Page 100 Maintenance manual Kinds of oil When adding or changing each kind of fuel or oil, use the following regulated kinds to guarantee the machine can use normally. 1. The oil using in the plain area Name Kind Location Summer use Winter use Bearing, articulated...
  • Page 101 Maintenance manual Torque Torque converter, ZF TE-ML 03C Standard Mobil HD10W / Shell Beili S4 CX10 converter oil transmission Working steering Hydraulic oil ISO VG 32 Standard hydraulic system Engine oil SAE5W-40 Mobil multi-power No.1 Diesel engine Fuel oil No. -35 light diesel oil Diesel engine SAE80W-90 (...
  • Page 102 Maintenance manual Remove the oil inlet cover and can add diesel. When opening the cover, turn the cover counterclockwise until the cover is loose and then move out it. Don’t take out the inlet filter when adding the diesel. Clean the inlet filter and diesel tank periodically. Clean the diesel tank according to the following ways: Remove the flange cover at the bottom of the diesel tank and clean the tank inner side with diesel repeatedly until the oil drained out is clean.
  • Page 103 Maintenance manual ⚫ The amount of sulphur in the diesel The percentage of the sulfur in the diesel affects the choice of the engine oil and its changing cycle. During the burning process, sulfur forms sulfuric acid and sulfurous acid under chemical change.
  • Page 104 Maintenance manual extremely or it will damage the filter. Install the filter Prepare a new filter ⚫ Heat the diesel If the temperature is lower, and we need to heat the diesel, the diesel temperature should not be over 35℃,or the engine power will lose. Check the oil level of the engine.
  • Page 105: Change The Engine Oil

    Maintenance manual oil. Note Too much or too little engine oil will both cause engine damage. ⚫ Change the engine oil When it comes to the regulated oil changing cycle, change the engine oil. Park the machine at level ground and run the engine until the water temperature rises to 60℃ and stop the engine. Pull up the park brake button and remove the oil output bolt at the bottom of the engine oil plate to drain out the oil and fill it with container.
  • Page 106 Maintenance manual the engine oil level. ⚫ Change the engine oil filter 1. Clean the around area of the filter installation seat. 2. Use the belt wrench to remove the filter. 3. Clean the contact surface of the gasket on the installation seat with clean cloth. Remove the old O-seal ring that sticks on the installation seat.
  • Page 107 Maintenance manual 1. Before starting the cold machine, check the cold oil surface first in order to make it have enough oil when starting. It is of great necessity for the loaders that have been parking for a long time. 2.
  • Page 108 Maintenance manual demands and change the oil according to the regulated changing cycle or it will shorten the life of the transmission. The steps of changing transmission oil: 1. Start the engine to work for several hours to make the dirty things, metallic particles or sediments float on the oil.
  • Page 109 Maintenance manual front and rear driving axle’s oil outlet plug can’t remain at level position together, check the oil level of the front and rear driving axle respectively. 2. Put the transmission control rod at neutral position, pull up the parking brake button to avoid machine moving.
  • Page 110: Check The Hydraulic Oil Level

    Maintenance manual 4. Tighten the oil outlet plug at the center of the front axle. 5. Start the engine, push down the parking brake button to release brake. Put the transmission at 1st gear speed and move the machine slowly to make the oil outlet plug (located at the surface of the front driving axle wheel rim) at level position.
  • Page 111 Maintenance manual During changing oil, the machine will do various operation, the operate according to the safety regulation to guarantee safety. When changing oil, pay special attention to the cleanliness of the hydraulic oil and don’t let dirty things enter hydraulic system. 1.
  • Page 112 Maintenance manual Hydraulic oil tank filling port, return oil filter flange cover, cleaning port 5. Take apart the hydraulic oil radiator pipe and drain the oil left in the radiator. 6. Take apart the oil returning filter cover from the hydraulic tank, take out the element and change a new one.
  • Page 113 Maintenance manual 1. Remove the foreign materials in the bucket, park the machine on level ground, put the transmission control rod at neutral position and pull up parking brake button. Start the engine and run for 10 minutes at idle speed, and at the same time lift and drop lifting arm and move forward and backward the bucket repeatedly.
  • Page 114 Maintenance manual inflation pressure according to the machine’s using condition. Model Tire Model Standard Inflating Remarks pressure requirement 17.5-25-12PR(front wheel) 350-370KPa HL630L+ 360KPa HL635L+ 17.5-25-12PR(back wheel) 350-370KPa Appropriate HL660+ 23.5-25-16PR(front wheel) 360-380KPa adjustments HL665+ can be 370KPa HL660L+ made 23.5-25-16PR(front wheel) 360-380KPa HL665L+ according...
  • Page 115: Welding Operation

    Maintenance manual brake. After the machine stops, put the transmission control rod to neutral position, pull up the parking brake button and then loosen driving brake pedal. Check the machine’s braking distance and it should not be over 15m. Drive with a speed of 32 km/hour, spot brake. It should brake immediately and don’t deviate.
  • Page 116 Maintenance manual 5. The welding spot and ground cable should keep a distance within 1m. 6. Don’t let the seal ring and bearing between welding spot and ground cable. 7. Don’t cut or weld pipes and containers that have fuel, oil and hydraulic oil in them. 8.
  • Page 117 Maintenance manual ⚫ General torque standard Tighten the bolts according to the following required torque unless there is other special indication. Metric thread standard torque Standard torque(N.m) Thread sizes 8.8 degree strength 10.9 degree strength 10.5±1.5 26±4 52±7 72±6 90±12 120±10 145±20 195±15...
  • Page 118 Maintenance manual 360±50 570±80 875±100 ⚫ Charging regulations about non-maintenance battery The machine uses non-maintenance battery, obey the following regulations when using. The reasons for the battery deficiency of electricity 1. The vehicle is not started, but the electric appliances start for a long time. 2.
  • Page 119 Maintenance manual when disconnecting wires, first cut off the wires of “-” pole. ⚫ Battery charging regulation 1. Make sure the battery end pole clean and the charging loop connect well. 2. The charger’s “+” pole connects with the battery’s “+” pole. The charger’s “-” pole connects with the battery’s “-”...
  • Page 120 Maintenance manual whether the voltage at last phase come to16V. After placing for 24 hours, measure the voltage, consult the above table about the relations between voltage and charging time and then go on charging the battery. 4) If the electric eye is white, it may have bubble in the electric eye, and slightly shake the battery to remove the bubble.

This manual is also suitable for:

Hl665+Hl660Hl660lHl665l

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