Hidromek Excavator HMK 65ZT-5 Operation Maintenance Manual H347345401 EN

Description

Contents:
1. INTRODUCTION
1.1. FOREWORD
1.2. OCCUPATIONAL SAFETY INFORMATION
1.3. DESCRIPTION AND INTENDED USE
1.4. CE, UKCA MARKING AND DECLARATION OF CONFORMITY
1.5. SPECIFICATIONS 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. LOCATION OF ENGINE PLATES
1.11.3. MAIN COMPONENT PLATES
2. SAFETY
2.1. GENERAL PRECAUTIONS
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 GETTING ON/OFF THE MACHINE
2.1.10. DO NOT ALLOW FIRE NEAR FUEL AND OIL
2.1.11. PAY ATTENTION TO HOT FLUID
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 OBJECTS
2.1.16. BEFORE WORKING IN THE VICINITY OF GAS LINES
2.1.17. PRECAUTIONS FOR OPTIONAL WORKING ATTACHMENTS
2.1.18. DO NOT REMOVE FRONT ATTACHMENT OR COUNTERWEIGHT
2.1.19. PRECAUTIONS FOR POLYMERS AND ELASTOMERS
2.1.20. HANDLING OF ACCUMULATOR
2.2. EMISSION CONTROL SYSTEM
2.2.1. DIESEL PARTICULATE FILTER (DPF)
2.3. PRECAUTIONS DURING OPERATION
2.3.1. BEFORE STARTING THE ENGINE
2.3.2. AFTER STARTING THE ENGINE
2.3.3. TRANSPORTATION
2.3.4. BATTERY
2.3.5. TOWING
2.3.6. LIFTING OBJECTS
2.4. PRECAUTIONS FOR MAINTENANCE
2.4.1. BEFORE MAINTENANCE
2.4.2. DURING MAINTENANCE
2.5. LOCATIONS OF SAFETY LABELS
2.5.1. LOCATIONS OF ATTACHED LABELS
2.5.2. CONTENTS OF SAFETY DECALS
3. DESCRIPTION
3.1. LOCATIONS OF MAIN PARTS
3.2. DETAILS 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 AND AUX CONNECTIONS
3.8. EXTERNAL SOCKET (12V)
3.9. STARTER KEY
3.10. CUP HOLDER
3.11. CONVENIENT STORAGE
3.12. CONVENIENT STORAGE BOX
3.13. SWITCHES
3.14. SAFETY LOCKING DEVICE
3.15. ADJUSTING ARMREST HEIGHT
3.16. LEFT CONSOLE LIFTING LEVER
3.17. LEVERS
3.17.1. ATTACHMENT CONTROL LEVER
3.17.2. ATTACHMENT CONTROL LEVER (PROPORTIONAL CONTROL) (OPTIONAL)
3.17.3. DOZER BLADE CONTROL LEVER
3.17.4. TRAVEL PEDAL / LEVER
3.18. FUSE / RELAY BOX
3.19. AUTOMATIC/MANUAL MODE SWITCH
3.20. BATTERY RELAY
3.21. BATTERY MASTER SWITCH
3.22. HEATER AND AIR CONDITIONER
3.22.1. HEATER AND AIR CONDITIONER VENTS
3.22.2. CONTROL UNIT
3.23. EMERGENCY EXIT
3.24. FIRST-AID KIT
3.25. FRONT WINDSHIELD
3.26. DOOR
3.27. DOOR LOCK MECHANISM
3.28. SIDE WINDOW
3.29. FIRE EXTINGUISHER (OPTIONAL)
3.30. REAR CURTAIN
3.31. SUN SHADE
3.32. OPERATOR’S CAB INTERIOR LIGHTING
3.33. ADJUSTING MIRRORS
3.34. OPERATOR’S SEAT ADJUSTMENT
3.35. SEAT BELT
3.35.1. FASTENING THE SEAT BELT
3.35.2. 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
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. REDUCED ENGINE POWER INDICATOR LIGHT
4.4.10. ABNORMAL NOISE OF ENGINE AND COLOR OF EXHAUST SMOKE
4.4.11. COOLANT TEMPERATURE
4.4.12. HOUR METER (CUMULATIVE OPERATING HOUR COUNTER)
4.4.13. BE CAREFUL WITH THE TOO COLD ENGINE
4.4.14. WHEN THE WARNING LIGHT COMES ON
4.4.15. WHEN THE ENGINE COOLANT IS HOT
4.4.16. DPF REGENERATION
4.5. OPERATING THE MACHINE
4.5.1. FORWARD TRAVEL
4.6. TRAVEL DIRECTION CONTROL
4.7. STOPPING AND PARKING THE MACHINE
4.8. SWINGING THE MACHINE
4.9. OPERATING ATTACHMENTS
4.10. PROHIBITIONS DURING OPERATION
4.11. PRECAUTIONS DURING OPERATION
4.11.1. CHECKING THE TRAVEL UNIT REDUCTION GEAR OIL
4.12. PRECAUTIONS WHEN TRAVELING ON A SLOPE
4.13. RESCUING THE MACHINE FROM SWAMP
4.13.1. IF ONE TRACK IS STUCK
4.13.2. IF BOTH TRACKS ARE STUCK
4.14. ADDITIONAL WORKS USING HYDRAULIC EXCAVATORS
4.14.1. BACKHOE WORK
4.14.2. SHOVELING
4.14.3. DITCHING
4.14.4. LOADING
4.15. LIFTING
4.16. REPLACING THE BUCKET
4.17. PARKING THE MACHINE
4.18. CHECKS AFTER FINISHING WORK
4.19. STOPPING THE ENGINE
4.20. INSPECTION AFTER STOPPING THE ENGINE
4.21. OPERATION OF OPERATOR’S CAB LIFTING FUNCTION
4.22. HANDLING THE ENGINE WITH TURBOCHARGER
4.22.1. PRECAUTIONS DURING STARTING THE ENGINE
4.22.2. PRECAUTIONS DURING STOPPING THE ENGINE
4.23. LOCKING SYSTEM
4.24. TRANSPORTATION
4.24.1. LOADING AND UNLOADING
4.24.2. PRECAUTIONS ON LOADING
4.24.3. PRECAUTIONS ON TRANSPORTATION
4.24.4. LIFTING THE MACHINE
4.24.5. SEA TRANSPORTATION
4.25. PREPARING THE MACHINE BASED ON WEATHER CONDITIONS
4.25.1. PREPARATIONS FOR COLD WEATHER
4.25.2. PRECAUTIONS AFTER FINISHING WORK
4.25.3. PREPARATIONS FOR HOT WEATHER
4.26. LONG TERM STORAGE
4.26.1. BEFORE LONG TERM STORAGE
4.26.2. DURING LONG TERM STORAGE
4.26.3. END OF LONG-TERM STORAGE
4.27. INSTRUCTIONS ON WITHDRAWAL FROM USE AND UTILIZATION
5. TROUBLESHOOTING
5.1. WHEN TO SUSPECT A TROUBLE CASE
5.2. TOWING METHOD
5.3. TOWING HOLE FOR LIGHT OBJECTS
5.4. PRECAUTIONS UNDER SPECIAL CIRCUMSTANCES
5.5. ELECTRIC DISCHARGE
5.5.1. STARTING THE ENGINE WITH BOOSTER CABLES (JUMP START)
5.6. POOR BATTERY CHARGING
5.7. OVERHEATING
5.8. ABNORMAL (LOW) OIL PRESSURE
5.9. ENGINE TROUBLE
5.10. HYDRAULIC SYSTEM
5.10.1. HYDRAULIC PUMP
5.10.2. TRAVELING, SWINGING AND ATTACHMENTS
5.10.3. HYDRAULIC CYLINDERS
5.11. ELECTRICAL SYSTEM
5.12. OTHER TROUBLES
6. MAINTENANCE
6.1. PRECAUTIONS FOR MAINTENANCE
6.1.1. HÄ°DROMEK 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. CHECKING THE TRACK
6.1.17. PRECAUTIONS WHEN WASHING THE MACHINE
6.1.18. CHECK BEFORE AND AFTER WORK
6.1.19. PRECAUTIONS DURING WORK IN DUSTY CONDITIONS
6.1.20. DISCARDED PARTS, OILS AND OTHER LIQUIDS
6.1.21. HÄ°DROMEK RECOMMENDED OILS AND GREASE
6.1.22. OIL
6.1.23. FUEL
6.1.24. COOLANT
6.1.25. GREASE
6.1.26. STORING OIL AND FUEL
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 OIL, GREASE AND COOLANT
6.2.3. RECOMMENDED FUEL
6.2.4. 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. ENGINE OIL LEVEL CHECK
6.5.6. FUEL LEVEL CHECK
6.5.7. HYDRAULIC OIL LEVEL CHECK
6.5.8. ELECTRIC WIRING CHECK
6.5.9. CLEANING THE FILTER OF HYDRAULIC TANK BREATHER
6.5.10. CHECKING AND REPLACING THE BUCKET TEETH
6.5.11. FAN BELT
6.5.12. GREASING ATTACHMENT PINS
6.5.13. TIGHTENING TRACK SHOE BOLT
6.5.14. DRAINING SEDIMENT AND WATER FROM FUEL FILTERS
6.6. EVERY 10 HOURS (AFTER WORKSHIFT)
6.6.1. CLEANING THE MACHINE
6.7. FIRST 50 HOURS
6.7.1. REPLACING ENGINE OIL AND OIL FILTER
6.7.2. REPLACING THE OIL FILTER
6.8. EVERY 50 HOURS (WEEKLY SERVICE)
6.8.1. GREASING SWING GEAR BEARING (at 3 points)
6.8.2. REMOVING SEDIMENT FROM FUEL TANK
6.8.3. INSPECTING AND ADJUSTING TRACK TENSION
6.9. FIRST 250 HOURS
6.9.1. GREASING SWING UNIT REDUCTION GEAR
6.9.2. REPLACING SWING UNIT REDUCTION GEAR OIL
6.9.3. REPLACING TRAVEL UNIT REDUCTION GEAR OIL
6.10. EVERY 250 HOURS (MONTHLY SERVICE)
6.10.1. ADJUSTING FAN BELT TENSION
6.10.2. CHECKING SWING RING GEAR GREASE
6.10.3. CHANGING SWING GEAR BEARING GREASE (at 3 points)
6.10.4. TENSION ADJUSTMENT OF AIR CONDITIONER BELT
6.11. EVERY 500 HOURS (3 – MONTH SERVICE)
6.11.1. CHANGING FUEL FILTER ELEMENTS
6.11.2. REPLACING ENGINE OIL AND OIL FILTER
6.11.3. REPLACING THE OIL FILTER
6.11.4. CHECKING ANTIFREEZE DENSITY
6.11.5. CHECKING AND CLEANING RADIATOR, OIL COOLER AND CONDENSER FIN
6.11.6. GREASING SWING UNIT REDUCTION GEAR
6.12. EVERY 1000 HOURS (6-MONTHS SERVICE)
6.12.1. ENGINE VALVE CLEARANCE CHECK
6.12.2. STARTER AND ALTERNATOR CHECK AND CLEANING
6.12.3. REPLACING SWING UNIT REDUCTION GEAR OIL
6.12.4. CHECKING AIR CONDITIONER REFRIGERANT AMOUNT
6.12.5. REPLACING TRAVEL UNIT REDUCTION GEAR OIL
6.12.6. CHECKING AND REPLACING THE FILTER ELEMENT OF HYDRAULIC TANK BREATHER
6.12.7. REPLACING THE RETURN FILTER ELEMENT OF HYDRAULIC TANK
6.12.8. REPLACING OR IF NECESSARY, CLEANING AIR FILTER OUTER ELEMENT
6.12.9. REPLACING AIR CONDITIONER FILTERS
6.12.10. OPERATOR CAB FILTER
6.13. EVERY 1500 HOURS
6.13.1. CHANGING OIL SEPARATOR ELEMENT
6.13.2. CHECKING & CLEANING PCV VALVE (POSITIVE CRANKCASE VENTILATION VALVE)
6.13.3. CHECKING INJECTION PRESSURE AT FUEL INJECTION NOZZLE
6.13.4. CHECKING EGR COOLER
6.14. EVERY 2000 HOURS (ANNUAL SERVICE)
6.14.1. REPLACING THE OIL AND FILTER ELEMENTS OF HYDRAULIC TANK
6.15. EVERY TWO YEARS OF SERVICE
6.15.1. CLEANING COOLING SYSTEM AND REPLACING COOLANT
6.16. WHEN REQUIRED
6.16.1. FILLING FUEL (FUEL TRANSFER PUMP)
6.16.2. BLEEDING FUEL SYSTEM
6.16.3. BLEEDING HYDRAULIC SYSTEM
6.16.4. REPLACEMENT OF THE FUEL PIPING
7. SPECIFICATIONS
7.1. TECHNICAL SPECIFICATIONS OF HMK 65ZT-5
8. EQUIPMENT AND ATTACHMENTS
8.1. GENERAL PRECAUTIONS
8.2. PRECAUTIONS WHEN FITTING THE WORK 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. SELECTION OF TRACK SHOES
8.7. HYDRAULIC BREAKERS (OPTIONAL)
8.7.1. PERMISSIBLE WORKS
8.7.2. INCORRECT OPERATION METHODS
8.7.3. MAINTENANCE FOR HYDRAULIC BREAKER
8.7.4. WORKING IN THE TUNNEL
9. APPENDIX
9.1. HAND SIGNALS
9.2. COMMUNICATION INFORMATION
9.2.1. PLANTS AND AFTER SALES SERVICES
10. ALPHABETICAL INDEX