Hidromek Excavator HMK 150 WR-5 Operation Maintenance Manual H237355401 EN

Description

Contents:
1. INTRODUCTION
1.1. FOREWORD
1.2. SAFETY INFORMATION
1.3. DESCRIPTION AND INTENDED USE
1.4. CE, UKCA MARKING AND DECLARATION OF CONFORMITY
1.5. CHARACTERISTICS OF THE MACHINE
1.6. EXHAUST EMISSION REGULATION RELATED PARTS
1.7. BREAK-IN OPERATION
1.8. SPARE PARTS AND SERVICE
1.9. COPYRIGHT
1.10. DRIVING LICENSE
1.11. IDENTIFICATION PLATES
1.11.1. LOCATION OF THE MACHINE ID PLATE
1.11.2. ENGINE IDENTIFICATION PLATES
1.12. MAIN COMPONENTS PLATES
2. SAFETY
2.1. GENERAL CAUTION
2.1.1. OPERATORS MUST HAVE CERTAIN QUALIFICATIONS
2.1.2. OBSERVE ALL SAFETY RULES ON-SITE
2.1.3. INSTALL ALL GUARDS AND SAFETY DEVICES
2.1.4. WEAR PROTECTIVE CLOTHES AND SAFETY EQUIPMENT
2.1.5. MODIFICATIONS
2.1.6. DO NOT MODIFY THE ENGINE
2.1.7. HANDLING ELECTRIC ACCESSORIES
2.1.8. BEFORE LEAVING THE MACHINE
2.1.9. USE HANDRAILS AND FOOTHOLDS TO GET ON/OFF THE MACHINE
2.1.10. DO NOT ALLOW FIRE NEAR FUEL AND OIL
2.1.11. HANDLE WITH CARE UNDER HIGH TEMPERATURE
2.1.12. DO NOT INHALE DUST CONTAINING ASBESTOS
2.1.13. PAY ATTENTION TO MOVING PARTS
2.1.14. MACHINE FIRE EXTINGUISHER AND FIRST-AID KIT
2.1.15. PROTECTION FROM FALLING OR FLYING MATERIALS
2.1.16. BEFORE WORKING IN THE VICINITY OF GAS LINES
2.1.17. CAUTION FOR OPTIONAL WORKING ATTACHMENT
2.1.18. DO NOT REMOVE FRONT ATTACHMENT OR COUNTERWEIGHT
2.1.19. CAUTION FOR POLYMERS AND ELASTOMERS
2.1.20. HANDLING OF ACCUMULATOR
2.2. CAUTION DURING OPERATING
2.2.1. BEFORE STARTING THE ENGINE
2.2.2. AFTER STARTING THE ENGINE
2.2.3. TRANSPORTATION
2.2.4. BATTERY
2.2.5. TOWING
2.2.6. LIFTING OBJECTS
2.3. CAUTION ON MAINTENANCE
2.3.1. BEFORE MAINTENANCE
2.3.2. DURING MAINTENANCE
2.4. ATTACHED POSITIONS SAFETY LABEL
2.4.1. ATTACHED POSITIONS
2.4.2. CONTENTS OF SAFETY DECAL
3. DESCRIPTION
3.1. LOCATION OF MAIN PARTS
3.2. DETAIL OF OPERATOR’S CAB
3.3. INSTRUMENT PANEL
3.4. MENU ITEMS
3.4.1. LANGUAGE
3.4.2. STATUS INFO
3.4.3. WORKING HOURS
3.4.4. MAINTENANCE
3.4.5. FAILURES
3.4.6. MACHINE INFORMATION
3.4.7. SETTINGS
3.5. MEDIA
3.5.1. RADIO
3.5.2. USB
3.5.3. AUX
3.6. OPERA INSTRUMENT PANEL
3.7. USB / AUX CONNECTIONS
3.8. EXTERNAL SOCKET (12 V)
3.9. STARTER KEY
3.10. CUP HOLDER / ASH TRAY
3.11. CONVENIENT STORAGE
3.12. CONVENIENT STORAGE BOX
3.13. SWITCHES
3.14. DOZER BLADE AND OUTRIGGER CONTROL LEVER
3.14.1. CONTROL LEVER ON MACHINES WITH ELECTRICAL-TYPE CENTER JOINT
3.15. STEERING
3.15.1. STEERING COLUMN
3.15.2. INDICATOR LIGHTS
3.15.3. SPEED SELECTION SWITCH
3.15.4. FORWARD REVERSE DIRECTION SELECTION SWITCH (FNR)
3.15.5. MULTI-FUNCTION LEVER
3.15.6. “MODE SELECTION” SWITCH
3.15.7. “HAZARD WARNING LIGHT” SWITCH
3.16. SAFETY LOCKING DEVICE
3.17. ADJUSTING ARMREST HEIGHT
3.18. ARMREST ANGLE ADJUSTMENT
3.19. CONSOLE ANGLE ADJUSTING LEVERS
3.20. LEFT CONSOLE LIFTING LEVER
3.21. LEVERS
3.21.1. OPERATING LEVERS
3.21.2. OPERATING LEVERS (PROPORTIONAL CONTROL)
3.22. SWING LOCK
3.23. ACCELERATOR AND BRAKE PEDALS
3.23.1. ACCELERATOR PEDAL
3.23.2. BRAKE PEDAL
3.23.3. BRAKE SYSTEM TEST PROCEDURE
3.24. FUSE / RELAY BOX
3.25. AUTOMATIC/MANUAL MODE SWITCH
3.26. BATTERY RELAY
3.27. BATTERY MASTER SWITCH
3.28. HEATER AND AIR CONDITION
3.28.1. HEATER AND AIR CONDITIONER VENTS
3.28.2. CONTROL UNIT
3.29. LIGHTER
3.30. BOTTLE HOLDER
3.31. COOL BOX
3.32. CONVENIENT STORAGE AND CONVENIENT STORAGE BOX
3.33. EMERGENCY EXIT
3.34. FIRST-AID KIT
3.35. FRONT WINDSHIELD
3.36. DOOR
3.37. DOOR LOCK MECHANISM
3.38. SIDE WINDOW
3.39. FIRE EXTINGUISHER (OPTIONAL)
3.40. FRONT AND REAR CURTAIN
3.41. SUNROOF
3.42. SUN SHADE
3.43. OPERATOR’S CAB INTERIOR LIGHTING
3.44. ADJUSTING MIRRORS
3.45. OPERATOR’S SEAT ADJUSTMENT
3.46. SEAT BELT
3.46.1. FASTENING THE SEAT BELT
3.46.2. ADJUSTING LENGTH OF THE BELT
4. OPERATION
4.1. INSPECTIONS BEFORE STARTING THE ENGINE
4.2. STARTING THE ENGINE
4.2.1. STARTING AT NORMAL TEMPERATURE
4.2.2. STARTING IN COLD WEATHER
4.3. WARM-UP OPERATION
4.3.1. AUTOMATIC WARM-UP OPERATION
4.3.2. WARMING-UP HYDRAULICS
4.4. INSPECTIONS AFTER STARTING THE ENGINE
4.4.1. “ENGINE OIL PRESSURE IS LOW” WARNING LAMP
4.4.2. ENGINE WARNING LIGHT
4.4.3. BATTERY CHARGE WARNING LAMP
4.4.4. ENGINE TEMPERATURE GAUGE
4.4.5. HYDRAULIC OIL TEMPERATURE GAUGE
4.4.6. FUEL LEVEL GAUGE
4.4.7. AIR CLEANER IS CLOGGED INDICATOR
4.4.8. AUTO WARM UP INDICATOR
4.4.9. DEF/AdBlue® INJECTION SYSTEM WARNING LIGHT
4.4.10. REDUCED ENGINE POWER INDICATOR LIGHT
4.4.11. PARKING INDICATOR
4.4.12. LOW BRAKE PRESSURE
4.4.13. AXLE LOCK INDICATOR
4.4.14. ABNORMAL NOISE OF ENGINE AND COLOR OF EXHAUST SMOKE
4.4.15. BRAKE TEST
4.4.16. COOLANT TEMPERATURE
4.4.17. HOUR METER (CUMULATIVE OPERATING HOUR COUNTER)
4.4.18. BE CAREFUL WITH THE TOO COLD ENGINE
4.4.19. WHEN THE WARNING LIGHT COMES ON
4.4.20. WHEN THE ENGINE COOLANT IS HOT
4.5. EXHAUST GAS AFTERTREATMENT SYSTEM
4.6. OPERATING THE MACHINE
4.6.1. FORWARD TRAVEL
4.6.2. BEFORE TRAVELING
4.6.3. TRAVELING PROCEDURES
4.6.4. PARKING PROCEDURE
4.7. TRAVEL DIRECTION CONTROL
4.7.1. STEERING
4.7.2. DRIVING FORWARD AND REVERSE
4.8. SWINGING THE MACHINE
4.9. OPERATING ATTACHMENTS
4.10. OPERATING DOZER BLADE AND OUTRIGGERS
4.10.1. LOWERING OUTRIGGERS / DOZER BLADE
4.10.2. RAISING OUTRIGGERS
4.11. CRUISE FUNCTION
4.11.1. OPERATING CRUISE FUNCTION
4.12. PROHIBITIONS DURING OPERATION
4.13. CAUTIONS DURING OPERATION
4.14. CAUTIONS WHEN TRAVELING ON A SLOPE
4.15. ADDITIONAL WORKS USING HYDRAULIC EXCAVATORS
4.15.1. BACKHOE WORK
4.15.2. SHOVEL WORK
4.15.3. DITCHING WORK
4.15.4. LOADING WORK
4.16. LIFTING
4.17. REPLACING THE BUCKET
4.18. CHECKS AFTER FINISHING WORK
4.19. STOPPING THE ENGINE
4.20. CHECK AFTER STOPPING THE ENGINE
4.21. HANDLING THE ENGINE WITH TURBOCHARGER
4.21.1. PRECAUTIONS DURING STARTING THE ENGINE
4.21.2. PRECAUTIONS DURING STOPPING THE ENGINE
4.22. LOCKING SYSTEM
4.23. TRANSPORTATION
4.23.1. LOADING AND UNLOADING
4.23.2. CAUTIONS ON LOADING
4.23.3. PRECAUTIONS ON TRANSPORTATION
4.23.4. LIFTING THE MACHINE
4.23.5. SEA TRANSPORT
4.24. PREPARING THE MACHINE BASED ON WEATHER CONDITIONS
4.24.1. PREPARATION FOR COLD WEATHER
4.24.2. PRECAUTIONS AFTER FINISHING WORK
4.24.3. PREPARATION FOR HOT WEATHER
4.25.
4.25. LONG TERM STORAGE
4.25.1. BEFORE LONG TERM STORAGE
4.25.2. DURING LONG TERM STORAGE
4.25.3. END OF THE LONG TERM STORAGE
4.26. INSTRUCTIONS ON WITHDRAWAL FROM USE AND UTILIZATION
5. TROUBLESHOOTING
5.1. WHEN TO SUSPECT A TROUBLE CASE
5.2. CAUTIONS UNDER SPECIAL CIRCUMSTANCES
5.3. TOWING METHOD
5.4. ELECTRIC DISCHARGE
5.4.1. STARTING THE ENGINE WITH BOOSTER CABLES (JUMP START)
5.5. POOR BATTERY CHARGING
5.6. OVERHEATING
5.7. ABNORMAL (LOW) OIL PRESSURE
5.8. ENGINE
5.9. HYDRAULIC SYSTEM
5.9.1. HYDRAULIC PUMP
5.9.2. TRAVELING, SWINGING AND ATTACHMENT WORKING
5.9.3. HYDRAULIC CYLINDERS
5.10. ELECTRIC SYSTEM
5.11. OTHER TROUBLES
6. MAINTENANCE
6.1. CAUTIONS IN MAINTENANCE
6.1.1. HIDROMEK GENUINE SPARE PARTS
6.1.2. WINDOW WASHER FLUID
6.1.3. OIL AND GREASE
6.1.4. NEVER MIX OILS
6.1.5. CHECK HOUR METER
6.1.6. KEEP THE MACHINE CLEAN
6.1.7. CAUTIONS FOR HOT OIL AND WATER
6.1.8. CHECK FILTER
6.1.9. CAUTIONS WHEN ADDING OIL
6.1.10. KEEP CONTAMINATION AWAY
6.1.11. ATTACH WARNING TAG
6.1.12. OBSERVE ALL WARNINGS AND CAUTIONS
6.1.13. PRECAUTIONS WHEN WELDING
6.1.14. PRECAUTIONS ON FIRE
6.1.15. CLEANING MACHINED SURFACES
6.1.16. PRECAUTIONS WHEN WASHING THE MACHINE
6.1.17. CHECK BEFORE AND AFTER WORK
6.1.18. PRECAUTIONS DURING WORK IN DUSTY CONDITIONS
6.1.19. DISCARDED PARTS, OILS AND OTHER LIQUIDS
6.1.20. HIDROMEK RECOMMENDED OILS AND GREASE
6.1.21. OIL
6.1.22. FUEL
6.1.23. COOLANT
6.1.24. GREASE
6.1.25. STORING OIL AND FUEL
6.1.26. DIESEL EXHAUST FLUID (DEF/AdBlue®)
6.1.27. FILTERS
6.1.28. ELECTRONIC PARTS
6.1.29. HYDRAULIC SYSTEM
6.2. OIL, FUEL, COOLANT AND DIESEL EXHAUST FLUID
6.2.1. CAPACITIES OF OIL, FUEL, COOLANT AND DIESEL EXHAUST FLUID
6.2.2. RECOMMENDED LUBRICATION OIL
6.2.3. RECOMMENDED FUEL
6.2.4. DIESEL EXHAUST FLUID (DEF/AdBlue®)
6.2.5. COOLANT
6.3. PERIODIC REPLACEMENT OF MAIN PARTS
6.4. INSPECTION AND MAINTENANCE LIST
6.5. EVERY 10 HOURS (BEFORE STARTING)
6.5.1. WALK-AROUND INSPECTION (VISUAL INSPECTION)
6.5.2. INSPECTING ENGINE STARTABILITY AND ABNORMAL NOISE
6.5.3. INSPECTING CONDITION OF THE ENGINE AT LOW SPEEDS AND DURING ACCELERATION
6.5.4. COOLANT LEVEL CHECK
6.5.5. CHECKING ENGINE OIL LEVEL
6.5.6. FUEL LEVEL CHECK
6.5.7. CHECKING DEF/AdBlue® LEVEL
6.5.8. REFILLING DEF/AdBlue®
6.5.9. HYDRAULIC OIL LEVEL CHECK
6.5.10. ELECTRIC WIRE CHECK
6.5.11. CLEANING THE FILTER OF HYDRAULIC TANK BREATHER
6.5.12. CHECKING AND CHANGING THE BUCKET TEETH
6.5.13. FAN BELT
6.5.14. GREASING ATTACHMENT PINS
6.5.15. CHECK TIRES FOR CORRECT PRESSURE AND DAMAGE
6.5.16. CHECK THE BRAKE
6.5.17. DRAINING SEDIMENT AND WATER FROM FUEL FILTERS
6.6. EVERY 50 HOURS (WEEKLY SERVICE)
6.6.1. GREASING SWING GEAR BEARING (at 3 points)
6.6.2. REMOVING SEDIMENT FROM THE FUEL TANK
6.6.3. GREASING DOZER BLADE PINS (12 POINTS)
6.6.4. GREASING OUTRIGGER PINS (8 POINTS)
6.6.5. GREASING FRONT AXLE PIN (1 POINT)
6.7. FIRST 250 HOURS
6.7.1. REPLACING RETURN FILTER ELEMENT OF HYDRAULIC OIL
6.7.2. CHANGING PILOT FILTER ELEMENT
6.7.3. GREASING SWING UNIT REDUCTION GEAR
6.7.4. REPLACING SWING UNIT REDUCTION GEAR OIL
6.7.5. REPLACING FRONT AND REAR AXLE DIFFERENTIAL OIL
6.7.6. REPLACING FRONT AND REAR AXLE PLANETARY GEAR OIL
6.7.7. REPLACING TRANSMISSION OIL
6.8. EVERY 250 HOURS (MONTHLY SERVICE)
6.8.1. CHECKING SWING RING GEAR GREASE
6.8.2. CHANGING SWING GEAR BEARING GREASE (at 3 points)
6.8.3. CHECKING BATTERY ELECTROLYTE LEVEL
6.9. EVERY 250 HOURS HYDRAULIC BREAKER HOURS
6.9.1. CHANGING HYDRAULIC BREAKER RETURN LINE FILTER
6.10. EVERY 500 HOURS (3 – MONTH SERVICE)
6.10.1. CHANGING FUEL FILTER ELEMENTS
6.10.2. REPLACING ENGINE OIL AND OIL FILTER
6.10.3. REPLACING ENGINE OIL FILTER
6.10.4. CHECKING ANTIFREEZE DENSITY
6.10.5. CHECKING AND CLEANING RADIATOR, OIL COOLER AND CONDENSER FIN
6.10.6. CHECKING FRONT/REAR AXLE DIFFERENTIAL OIL LEVEL
6.10.7. CHECKING FRONT/REAR AXLE PLANETARY GEAR OIL LEVEL
6.10.8. GREASING AXLE JOINT HOUSING
6.10.9. GREASING FRONT / REAR SHAFT
6.10.10. GREASING SWING UNIT REDUCTION GEAR
6.10.11. REPLACING AIR CONDITIONER FILTERS
6.11. EVERY 1000 HOURS (6 MONTHS SERVICE)
6.11.1. REPLACING SWING UNIT REDUCTION GEAR OIL
6.11.2. CHANGING PILOT FILTER ELEMENT
6.11.3. CHANGING RETURN FILTER ELEMENT OF HYDRAULIC OIL
6.11.4. ENGINE VALVE CLEARANCE CHECK
6.11.5. STARTER AND ALTERNATOR CHECK AND CLEANING
6.11.6. CYLINDER COMPRESSION CHECK
6.11.7. ADJUSTMENT OF TENSION OF THE AIR CONDITIONER BELT
6.11.8. REPLACING THE FILTER OF HYDRAULIC TANK BREATHER
6.12. EVERY 1000 HOURS OR 3 YEARS
6.12.1. CHANGING THE FILTER CARTRIDGE OF THE SCR SUPPLY PUMP
6.13. EVERY 2000 HOURS (ANNUALLY) SERVICE
6.13.1. REPLACING OIL AND CLEANING OR REPLACING SUCTION STRAINER OF HYDRAULIC TANK
6.13.2. REPLACING FRONT AND REAR AXLE DIFFERENTIAL OIL
6.13.3. REPLACING FRONT AND REAR AXLE PLANETARY GEAR OIL
6.13.4. REPLACING TRANSMISSION OIL
6.14. EVERY TWO YEARS OF SERVICE
6.14.1. CLEANING COOLING SYSTEM AND REPLACING COOLANT
6.15. EVERY 4000 HOURS
6.15.1. CHANGING FAN BELT AND TENSIONING PULLEY
6.16. EVERY 6000 HOURS
6.16.1. CHANGE CRANKCASE VENTILATION
6.16.2. CLEAN EXHAUST GAS TURBOCHARGER COMPRESSOR INLET
6.17. WHEN REQUIRED
6.17.1. FILLING FUEL (FUEL TRANSFER PUMP)
6.17.2. REPLACING OR IF NECESSARY CLEANING AIR FILTER OUTER ELEMENT
6.17.3. BLEEDING FUEL SYSTEM
6.17.4. BLEEDING HYDRAULIC SYSTEM
6.17.5. CHECKING AIR CONDITIONER REFRIGERANT AMOUNT
6.17.6. REPLACEMENT OF THE FUEL PIPING
7. SPECIFICATIONS
7.1. TECHNICAL SPECIFICATIONS OF HMK 150 WR-5
8. EQUIPMENT AND ATTACHMENTS
8.1. GENERAL PRECAUTIONS
8.2. CAUTION WHEN FITTING THE WORKING EQUIPMENT
8.3. SELECTION OF ATTACHMENT
8.4. PROTECTION AGAINST FALLING OR FLYING OBJECTS (FOPS)
8.5. PROTECTION AGAINST TIPPING AND ROLLING OVER
8.6. HANDLING TIRES
8.6.1. TIRE CHANGING PROCEDURE
8.6.2. TIRE ROTATION
8.7. HYDRAULIC BREAKER
8.7.1. MAINLY AVAILABLE WORKS
8.7.2. INCORRECT METHODS
8.7.3. MAINTENANCE FOR HYDRAULIC BREAKER
8.7.4. WORKING IN THE TUNNEL
8.8. QUICK COUPLING ATTACHMENT (OPTIONAL)
8.8.1. PREPARATION FOR MOUNTING AND DISMOUNTING
9. APPENDIX
9.1. HAND SIGNALS
9.2. CONTACTS
9.2.1. FACTORY AND SERVICE DEPARTMENT
10. ALPHABETICAL INDEX