Hidromek Alpha Series Operation Maintenance Manual Y10_13051

Description

Contents:
1. INTRODUCTION
1.1. FOREWORD
1.2. CE MARKING AND EMC DIRECTIVE
1.3. IDENTIFICATION PLATE
1.4. BACKHOE LOADER
1.4.1. DESCRIPTION OF THE MACHINE AND ITS ITENDED USE
1.4.2. DESIGNATION OF “LEFT SIDE” and “RIGHT SIDE”
1.5. SAFETY NOTICES
1.6. OTHER NOTICES
1.7. ENVIRONMENTAL STANDARDS
1.8. WARNING SYMBOLS
1.9. COPYRIGHT
1.10. SPARE PARTS AND SERVICE
2. SAFETY
2.1. GENERAL SAFETY INFORMATION
2.2. SAFETY PRECAUTIONS
2.2.1. WELDING
2.2.2. MACHINE CONTROL LEVERS
2.2.3. VISIBILITY
2.2.4. ROPS / FOPS STRUCTURE
2.2.5. SPARKS
2.2.6. DRINKS AND DRUGS
2.2.7. FAILURE OF ENGINE OR STEERING
2.2.8. USA FEDERAL CLEAN AIR ACT
2.2.9. RECOMMENDATIONS
2.3. PRE-START SAFETY
2.3.1. OBSERVE SAFETY PRECAUTIONS
2.3.2. WEAR PROTECTIVE CLOTHING
2.3.3. READ AND UNDERSTAND THE OPERATING MANUAL
2.3.4. KEEP OPERATING MANUAL IN CABIN
2.3.5. PAY ATTENTION TO EMERGENCIES
2.3.6. SAFETY AT THE JOB SITE
2.3.7. PRE-START INSPECTION
2.3.8. SIGNS, SIGNALS & FLAGMEN
2.3.9. KEEP FIRE AWAY FROM FUEL & OIL
2.3.10. TO GET ON AND OFF THE MACHINE.
2.3.11. APPLY PARKING BRAKE BEFORE LEAVING THE MACHINE
2.3.12. ENGAGE LEVER SAFETY LOCKS BEFORE LEAVING THE MACHINE
2.3.13. HOT SURFACES & FLUIDS
2.3.14. USE PROPER ATTACHMENT
2.3.15. PREVENT FIRE
2.4. SAFETY DURING OPERATION
2.4.1. STARTING THE ENGINE
2.4.2. PASSENGERS
2.4.3. DRIVING
2.4.4. ROLL-OVER PROTECTION
2.4.5. SLEWING
2.4.6. OPERATING ON HILLSIDES & SLOPES
2.4.7. WORKING AROUND UTILITY LINES
2.4.8. LIFTING
2.4.9. ICE & SNOW ON THE JOB SITES
2.4.10. UNSTABLE GROUND OR FILLING
2.4.11. DANGER ZONE
2.4.12. RESTRICTED WORKING AREAS
2.4.13. LEGAL LIABILITY
2.4.14. EXPERIMENTAL OPERATIONS
2.4.15. PARKING THE MACHINE
2.4.16. KEEP UNAUTHORIZED PEOPLE AWAY
2.4.17. CHECK ATTACHMENT LOCK PINS
2.4.18. STOWAGE OF ATTACHMENTS
2.4.19. VENTILATION IN CLOSED AREAS
2.4.20. EMERGENCY EXIT
2.4.21. UNINTENTIONAL SHUT-OFF DURING OPERATION
2.4.22. UNINTENTIONAL SHUT-OFF DURING TRAVEL
2.4.23. STEERING CONTROL IN EMERGENCY
2.5. INSPECTION & MAINTENANCE SAFETY
2.5.1. PREVENT UNAUTHORIZED START
2.5.2. STOP THE ENGINE BEFORE SERVICING
2.5.3. ENGAGE CONTROL LEVER SAFETY LOCKS
2.5.4. ENGAGE ATTACHMENT LOCKS
2.5.5. MAINTENANCE POSITION
2.5.6. KEEP THE MACHINE CLEAN
2.5.7. PRESSURIZED FLUIDS
2.5.8. SUPPORT THE MACHINE
2.5.9. REFUELING
2.5.10. HYDRAULIC PRESSURE
2.5.11. TYRE INFLATION & WHEEL NUTS
2.5.12. ROTATING PARTS IN THE ENGINE
2.5.13. ELECTRICAL SYSTEM
2.5.14. SAFE LIGHTING
2.5.15. WASTE MATERIALS
2.5.16. CLEANERS
2.5.17. SEALS
2.6. BATTERY SAFETY
2.6.1. WEAR PROTECTIVE EQUIPMENT
2.6.2. KEEP AWAY FROM FIRE AND FLAMES
2.6.3. CHARGING BATTERY
2.6.4. STARTING WITH A BOOSTER BATTERY
2.7. WARNING LABELS & DECALS
2.7.1. “READ THE OPERATING AND MAINTENANCE MANUAL” WARNING LABEL
2.7.2. “LIFT CYLINDER LOCK” WARNING
2.7.3. “AIR FILTER CLOGGED” LABEL
2.7.4. “KEEP CLEAR OF WORKING AREA” WARNING FOR BACKHOE
2.7.5. “SAFE WORKING LOAD” LABEL
2.7.6. “BEFORE PERFORMING ANY MAINTENANCE or INSPECTION STOP THE ENGINE, REMOVE IGNITION KEY AND READ OPERATING MANUAL” WARNING FOR ROTATING AND HOT PARTS AND SURFACES.
2.7.7. “BATTERY” WARNING
2.7.8. “TRANSMISSION OIL CONTROL” CAUTION
2.7.9. “FUEL SPECIFICATIONS” WARNING LABEL
2.7.10. “FUEL TANK” CAUTION
2.7.11. “ELECTRICAL EQUIPMENT” WARNING
2.7.12. “BATTERY CUT-OFF RELAY” WARNING LABEL
2.7.13. “KEEP CLEAR OF WORKING AREA” WARNING FOR LOADER
2.7.14. “DO NOT PINCH YOUR HANDS” WARNING
2.7.15. TELESCOPIC DIPPER – HYDRAULIC BREAKER SELECTING VALVE
2.7.16. “HYDRAULIC BREAKER AND AUGER OPERATION” LABEL
2.7.17. “BACKHOE BOOM SLEW LOCK PIN” CAUTION
2.7.18. “EMERGENCY EXIT” CAUTION
2.7.19. “HYDRAULIC OIL TANK” CAUTION
2.7.20. “AUTOMATIC-MANUAL MODE” LABEL
2.8. PROHIBITED MACHINE OPERATION
2.8.1. DO NOT USE THE SLEWING FORCE OF THE BACKHOE FOR GRADING
2.8.2. DO NOT HAMMER WITH THE BUCKET
2.8.3. NEVER USE THIS MACHINE OTHER THAN ITS INTENDED USE
2.8.4. DO NOT USE THE BACKHOE LOADER FOR LIFTING PEOPLE
2.8.5. DO NOT IMPACT HYDRAULIC CYLINDERS TO STROKE END REPEATEDLY
2.8.6. NEVER EXCEED THE CAPACITY OF THE MACHINE
2.8.7. DO NOT USE BUCKET TO BREAK OR CUT
2.8.8. DO NOT DRIVE WITH THE STABILIZERS EXTENDED
2.9. END OF WORKSHIFT MAINTENANCE & INSPECTION
3. DESCRIPTION
3.1. FRONT INSTRUMENT PANEL
3.1.1. THROTTLE PEDAL
3.1.2. DOUBLE PEDAL BRAKING SYSTEM
3.1.3. DRIVE CONTROL LEVER
3.1.4. RIGHT HAND SIDE MULTIFUNCTIONAL LEVER
3.1.5. STEERING WHEEL ADJUSTMENT LEVER
3.1.6. COMPARTMENTS AND STOWAGE PLACES FOR OBJECTS
3.1.7. INSTRUMENT PANEL
3.2. RIGHT HAND SIDE INSTRUMENT PANEL
3.2.1. LOADER JOYSTICK
3.2.2. HAND (PARKING) BRAKE
3.2.3. THROTTLE LEVER
3.2.4. BOOM LOCK HANDLE
3.2.5. RIGHT HAND SIDE INSTRUMENT AND CONTROL PANEL (ALPHA)
3.3. LEFT HAND SIDE CONSOLE
3.3.1. BACK AND FRONT GLASS HANDLER
3.3.2. COOLER STOWAGE BOX
3.4. OPERATOR’S SEAT
3.5. BACKHOE JOYSTICKS
3.6. AUXILIARY VALVE PEDAL
3.7. REAR WINDOW AND REAR WINDOW WIPER
3.7.1. OPENING THE REAR WINDOW
3.7.2. CLOSING THE REAR WINDOW
3.8. DOOR
3.9. DOOR’S WINDOW FIXING MECHANISM
3.10. ROOF
3.10.1. INTERIOR LIGHT
3.10.2. COAT HANGER
3.11. TOOLBOX
3.12. SAFETY STRUT
3.13. OPENING THE ENGINE HOOD
3.14. OPENING THE SIDE PANELS
3.15. OPENING THE FRONT PANEL
4. OPERATION
4.1. GENERAL
4.1.1. BEFORE STARTING
4.1.2. CLEANLINESS INSPECTION
4.1.3. DAMAGE INSPECTION
4.1.4. TYRE INSPECTION
4.1.5. GETTING IN AND OUT OF THE CAB
4.2. BEFORE STARTING THE ENGINE
4.3. STARTING THE ENGINE
4.4. DRIVING THE MACHINE
4.4.1. TRAVELING IN REVERSE DIRECTION
4.5. JUMP STARTING THE ENGINE
4.6. BASIC PRECAUTIONS FOR OPERATION IN COLD AND HOT CLIMATE
4.6.1. IN COLD WEATHER
4.6.2. IN HOT WEATHER
4.7. PREPARATIONS FOR TRAVEL
4.7.1. TESTING THE PARKING BRAKE
4.8. STOPPING and PARKING THE MACHINE
4.9. UNINTENTIONAL SHUT DOWN DURING TRAVEL
4.10. STEERING IN CASE OF EMERGENCY
4.11. FIELD TEST OF THE EMERGENCY STEERING
4.12. ENGAGING ATTACHMENT SAFETY LOCKS
4.12.1. ENGAGING LOADER ARM SAFETY STRUT
4.12.2. DISENGAGING SAFETY STRUT
4.12.3. ENGAGING BACKHOE BOOM LOCK
4.12.4. DISENGAGING BACKHOE BOOM LOCK
4.12.5. BACKHOE SLEW LOCK
4.12.6. STABILIZER SHOE LOCK
4.13. CONTROLLING HYDRAULIC CLAMP CYLINDERS
4.14. SIDESHIFTING THE BACKHOE
4.14.1. MANUAL
4.14.2. AUTOMATIC (OPTIONAL)
4.15. TELESCOPIC DIPPER (OPTIONAL)
4.15.1. EXTENDING THE TELESCOPIC DIPPER
4.15.2. RETRACTING AND LOCKING THE TELESCOPIC DIPPER
4.15.3. TELESCOPIC DIPPER SAFETY LOCK
4.15.4. TELESCOPIC DIPPER – HYDRAULIC BREAKER SELECTING VALVE
4.16. BRAKING
4.17. THE LOADER OPERATION
4.17.1. LOADER OPERATION IN BANKS AND STOCKPILES
4.17.2. LOADING TRUCKS
4.17.3. RESCUING A STUCK MACHINE
4.17.4. GRADING WITH LOADER
4.18. THE BACKHOE OPERATION
4.18.1. HINTS ON OPERATION OF BACKHOE
4.18.2. CORRECT DIGGING METHOD
4.18.3. EXCAVATION ON SLOPES
4.18.4. LOWERING THE ATACHMENTS IN CASE OF UNEXPECTED POWER CUT-OFF
4.19. REPLACING ATTACHMENTS
4.19.1. LOADER BUCKET
4.19.2. BACKHOE BUCKET
4.19.3. REPLACING BUCKET TEETH
4.20. TRANSPORTING THE MACHINE
4.21. TOWING PROCEDURE FOR A DISABLED MACHINE
4.22. LIFTING BY A CRANE
4.23. PRESERVING THE MACHINE FOR STORAGE
4.23.1. MAINTENANCE OF THE MACHINE DURING AND AFTER STORAGE
4.24. INSTRUCTIONS ON WITHDRAWAL FROM USE AND UTILIZATION
5. MAINTENANCE
5.1. GENERAL INFORMATION
5.2. GENERAL SAFETY
5.2.1. DISPOSAL OF HAZARDOUS WASTE
5.2.2. STOP THE ENGINE AND PARK THE MACHINE
5.2.3. KEEP THE MACHINE CLEAN
5.2.4. HOT SURFACES & FLUIDS
5.2.5. WARM UP THE ENGINE OIL
5.2.6. ATTACH “DO NOT OPERATE” WARNING
5.2.7. INSPECT WASTE OILS & FILTERS
5.2.8. PREVENT CONTAMINATION
5.2.9. SEALS & ‘O-RINGS’
5.2.10. WEAR PROTECTIVE CLOTHING
5.2.11. CLEANING PARTS
5.2.12. RELEASE RESIDUAL HYDRAULIC OIL PRESSURE
5.2.13. ENGAGE ATTACHMENT SAFETY LOCKS
5.2.14. HANDLING POLYMERS AND ELASTOMERS CONTAINING FLUORO-CARBON
5.2.15. PRECAUTIONS WHEN WORKING WITH A/C REFRIGERANTS
5.2.16. PRECAUTIONS TO BE TAKEN DURING WORKING WITH EXHAUST PIPE
5.2.17. DISPOSAL OF WASTES AND PROTECTION OF THE ENVIRONMENT
5.2.18. USE OF BIODEGRADABLE SYNTHETIC OILS
5.3. INSPECTION & MAINTENANCE CHART
5.4. ENGINE DESCRIPTION
5.4.1. RECORD ENGINE SERIAL NUMBER
5.4.2. ENGINE OPTION CODES
5.5. PERIODIC MAINTENANCE
5.5.1. MAINTENANCE HINTS
5.5.2. FIRST 50 HOURS MAINTENANCE
5.6. TABLE of LUBRICANTS & FLUIDS
5.7. PRE-START (EVERY 8 HOURS) INSPECTION & MAINTENANCE
5.7.1. CHECKING ENGINE OIL LEVEL
5.7.2. CHECKING COOLANT LEVEL
5.7.3. CHECKING FUEL FILTERS
5.7.4. CHECKING ENGINE FLUID LEAKS
5.7.5. CHECKING & CLEANING THE ENGINE AIR PRE-CLEANER (DUST SEPARATOR)
5.7.6. CLEANING THE AIR PRE-CLEANER
5.7.7. CHECKING AIR CLEANER
5.7.8. CHECKING FUEL LEVEL
5.7.9. CHECKING TRANSMISSION OIL LEVEL
5.7.10. CHECKING HYDRAULIC OIL LEVEL
5.7.11. HYDRAULIC OIL TANK CAP
5.7.12. CHECKING THE TYRE PRESSURE
5.7.13. GREASING
5.8. WEEKLY (EVERY 50 HOURS) INSPECTION & MAINTENANCE
5.8.1. DRAINING THE FUEL TANK
5.8.2. CHECKING THE CLEARANCE OF INNER PLATES OF THE STABILIZERS
5.8.3. CHECKING THE ELECTROLYTE LEVEL OF BATTERY
5.8.4. CHECKING THE ROPS/FOPS OPERATOR’S CABIN
5.8.5. CHECKING AND READJUSTING WEAR PADS OF TELESCOPIC ARM
5.8.6. CLEANING AIR FILTER INNER ELEMENT
5.9. EVERY 100 HOURS INSPECTION & MAINTENANCE
5.9.1. CHECKING AND LUBRICATING THE PARKING BRAKE
5.10. EVERY 250 HOURS INSPECTION & MAINTENANCE
5.10.1. CHECKING THE DIFFERENTIAL OIL LEVEL OF THE AXLES
5.10.2. CHECKING THE OIL LEVEL IN HUBS
5.10.3. CHANGING ENGINE OIL AND REPLACING FILTER
5.10.4. OIL CHANGE INTERVALS
5.10.5. OIL VISCOSITY GRADE
5.10.6. REPLACING FUEL FILTER ELEMENTS
5.11. EVERY 500 HOURS INSPECTION & MAINTENANCE
5.11.1. CHECKING CRANKCASE VENT SYSTEM
5.11.2. CHECKING AIR INTAKE SYSTEM
5.11.3. CHECKING BELT TENSIONER SPRING AND BELT WEAR(AUTOMATIC TENSIONER)
5.11.4. CHECKING ENGINE ELECTRICAL GROUND CONNECTIONS
5.11.5. CHECKING COOLING SYSTEM
5.11.6. PRESSURE TESTING COOLING SYSTEM
5.11.7. CHECKING AND ADJUSTING ENGINE SPEEDS
5.11.8. CHANGING THE HYDRAULIC RETURN FILTER
5.11.9. CHANGING AIR CONDITIONER INNER AND OUTER FILTER ELEMENTS
5.12. EVERY 1000 HOURS INSPECTION & MAINTENANCE
5.12.1. CHANGING TRANSMISSION OIL AND CLEANING THE SUCTION STRAINER
5.12.2. CHANGING THE TRANSMISSION OIL FILTER
5.12.3. CHANGING THE DIFFERENTIAL OIL OF THE AXLES
5.12.4. CHANGING THE OIL OF HUBS (102B-EVERY 1000 HOURS, 102S-EVERY 1500 HOURS)
5.12.5. CHANGING THE HYDRAULIC OIL
5.12.6. CHANGING & CLEANING THE SUCTION STRAINER
5.13. EVERY 2 YEARS MAINTENANCE
5.13.1. DESCRIPTION OF COOLANT
5.13.2. COOLANT FILLING CAP
5.13.3. FLUSHING AND REFILLING COOLING SYSTEM
5.13.4. TESTING THERMOSTATS OPENING TEMPERATURE
5.13.5. CHECK AND ADJUST VALVE CLEARANCE
5.14. MISCELLANEOUS
5.14.1. REPLACING FUSES
5.14.2. BLEEDING THE FUEL SYSTEM
5.14.3. MAINTENANCE OF AIR-CONDITIONER
5.14.4. CHECKING THE REFRIGERANT OF THE AIR CONDITIONER:
5.14.5. REPLACING LIGHT BULBS
6. SPECIFICATIONS
6.1. TECHNICAL SPECIFICATIONS OF HMK 102B
6.2. LIFTING REGULATIONS AND SAFE WORKING LOADS (SWL)
6.2.1. LIFTING REGULATIONS
6.2.2. SAFE WORKING LOADS
6.3. SOUND and VIBRATION
6.3.1. SOUND
6.3.2. VIBRATION
7. OPTIONAL EQUIPMENT
7.1. GENERAL
7.2. TILTING FORKS
7.2.1. SETTING FORKS UP FOR OPERATION
7.2.2. STOWING THE FORKS
7.2.3. SPACING THE FORKS
7.2.4. MAINTENANCE
7.3. HYDRAULIC BREAKER
7.3.1. PROCEDURE FOR INSTALLATION OF HYDRAULIC BREAKER
7.3.2. ADJUSTING HYDRAULIC BREAKER
7.4. HYDRAULIC AUGER
7.4.1. PROCEDURE FOR INSTALLATION OF HYDRAULIC AUGER
7.4.2. HINTS ON THE OPERATION OF HYDRAULIC AUGER
7.4.3. MAINTENANCE OF THE PLANETARY REDUCER GEAR BOX
7.4.4. PERIODIC MAINTENANCE
7.4.5. RECOMMENDED OIL FOR LUBRICATION
7.5. LOG GRAB
7.6. GRADING BLADE
7.7. AIR COMPRESSOR
7.8. FORKLIFT ATTACHMENT & CLAMSHELL BUCKET
7.9. TRAPEZOID DITCH BUCKET
7.10. RIPPER
7.11. SIDE SHIFT BUCKET
7.12. CLAMSHELL GRAB
7.13. WINCH
7.14. STREET SWEEPER
7.15. QUICK COUPLER
7.15.1. MOUNTING TO THE MACHINE
7.15.2. DISMOUNTING FROM THE MACHINE
8. APPENDIX
8.1. HAND SIGNALS
8.2. TABLE OF TORQUE VALUES FOR FASTENERS
8.3. CONTACTS
8.3.1. FACTORY AND SERVICE DEPARTMENT
8.4. NOTES
9. ALPHABETICAL INDEX