Hidromek Excavator HMK140LC-3 to HMK490LC-3 Operation Maintenance Manual H347322401 EN

Description

Contents:
1. FOREWORD
2. OCCUPATIONAL SAFETY INFORMATION
3. GENERAL INFORMATION
3.1. DESCRIPTION AND INTENDED USE
3.2. CE MARKING AND DECLARATION OF CONFORMITY
3.3. SPECIFICATIONS OF THE MACHINE
3.4. BREAK-IN OPERATION
3.5. SPARE PARTS AND SERVICE
3.6. COPYRIGHT
4. DRIVING LICENSE
5. IDENTIFICATION PLATE
5.1. LOCATION OF THE MACHINE ID PLATE
5.2. LOCATION OF ENGINE ID PLATE
5.3. MAIN COMPONENT PLATES
6. GENERAL PRECAUTIONS
6.1. OPERATORS MUST HAVE CERTAIN QUALIFICATIONS
6.2. OBSERVE ALL SAFETY RULES ON-SITE
6.3. INSTALL ALL GUARDS AND SAFETY DEVICES
6.4. WEAR PROTECTIVE CLOTHES AND SAFETY EQUIPMENT
6.5. MODIFICATIONS
6.6. BEFORE LEAVING THE MACHINE
6.7. USE HANDRAILS AND FOOTHOLDS TO GETTING ON/OFF THE MACHINE
6.8. DO NOT ALLOW FIRE NEAR FUEL AND OIL
6.9. PAY ATTENTION TO HOT FLUID
6.10. DO NOT INHALE DUST CONTAINING ASBESTOS
6.11. PAY ATTENTION TO MOVING PARTS
6.12. MACHINE FIRE EXTINGUISHER AND FIRST-AID KIT
6.13. PROTECTION FROM FALLING OR FLYING OBJECTS
6.14. BEFORE WORKING IN THE VICINITY OF GAS LINES
6.15. PRECAUTIONS FOR OPTIONAL WORKING ATTACHMENTS
6.16. DO NOT REMOVE FRONT ATTACHMENT OR COUNTERWEIGHT
6.17. PRECAUTIONS FOR POLYMERS AND ELASTOMERS
7. PRECAUTIONS DURING OPERATION
7.1. BEFORE STARTING THE ENGINE
7.1.1. MAKE SURE THE WORK SITE IS SECURE
7.1.2. CHECK ON AND AROUND THE MACHINE
7.1.3. PREVENT FIRE
7.1.4. VENTILATE INDOORS
7.1.5. KEEP MIRRORS AND WINDOWS CLEAN
7.1.6. CHECK AROUND THE OPERATOR’S SEAT
7.1.7. SIGNAL BEFORE STARTING THE ENGINE
7.2. AFTER STARTING THE ENGINE
7.2.1. PRECAUTIONS IMMEDIATELY AFTER STARTING THE ENGINE
7.2.2. BE ALERT WHILE OPERATING
7.2.3. DIRECTION OF MACHINE BEFORE TRAVELING
7.2.4. MAKE SURE NO ONE IS AROUND THE MACHINE BEFORE SWINGING OR REVERSING
7.2.5. PRECAUTIONS DURING TRAVELING
7.2.6. TRAVELING ON A SLOPE
7.2.7. NEVER PERFORM DANGEROUS WORKS
7.2.8. KNOW THE WORKING RANGE OF THE MACHINE
7.2.9. NEVER APPROACH A HIGH VOLTAGE LINE
7.2.10. OVERHEAD OBSTRUCTIONS
7.2.11. POOR LIGHTING CONDITIONS
7.2.12. SNOW REMOVAL
7.2.13. UNSTABLE GROUND
7.2.14. WORKING ON A SLOPE
7.2.15. PARKING
7.3. HAND SIGNALS
7.4. TRANSPORTATION
7.4.1. PRECAUTIONS WHILE LOADING/UNLOADING
7.4.2. PRECAUTIONS DURING TRANSPORTATION
7.5. BATTERY
7.5.1. PRECAUTIONS WHEN HANDLING BATTERIES
7.5.2. STARTING THE ENGINE USING BOOSTER CABLES
7.6. TOWING
7.7. LIFTING OBJECTS
7.7.1. GENERAL PRECAUTIONS
7.7.2. PRECAUTIONS DURING LIFTING
8. PRECAUTIONS FOR MAINTENANCE
8.1. BEFORE MAINTENANCE
8.1.1.1. READ THE MANUAL
8.1.1.2. HANG A WARNING TAG
8.1.1.3. USE PROPER TOOLS
8.1.1.4. REPLACE SECURITY PARTS PERIODICALLY
8.1.1.5. FIRST STOP THE ENGINE
8.1.1.6. PRECAUTIONS DURING FILLING FUEL OR OIL
8.1.1.7. COOLANT LEVEL
8.1.1.8. USING LAMPS
8.2. DURING MAINTENANCE
8.2.1.1. OFF-LIMITS TO UNAUTHORIZED PERSON
8.2.1.2. HANDLING AN ATTACHMENT
8.2.1.3. WORKING UNDER THE MACHINE
8.2.1.4. KEEP THE MACHINE CLEAN
8.2.1.5. PRECAUTIONS FOR HIGH-PRESSURE HOSES
8.2.1.6. PRECAUTIONS FOR HIGH-PRESSURE OIL
8.2.1.7. WORKING AROUND EXTREMELY HOT AREAS
8.2.1.8. PRECAUTIONS FOR HIGH PRESSURE OF GREASE IN TRACK TENSION ADJUSTER
8.2.1.9. PRECAUTIONS FOR RECOIL SPRING WHEN DISASSEMBLING THE TRACK
8.2.1.10. ROTATING FAN AND BELT
8.2.1.11. DISPOSAL OF WASTE MATERIALS
8.2.1.12. PRECAUTIONS FOR WELDING
9. LOCATIONS OF SAFETY LABELS
9.1. LOCATIONS OF ATTACHED LABELS
9.2. CONTENTS OF SAFETY DECALS
10. MAIN COMPONENTS
10.1. LOCATIONS OF MAIN PARTS
10.2. DETAILS OF OPERATOR’S CAB
11. OPERATOR’S CAB
11.1. INSTRUMENT PANEL
11.2. MENU ITEMS
11.2.1. LANGUAGE
11.2.2. STATUS INFORMATION
11.2.3. PERIODIC MAINTENANCE
11.2.4. OPERATING HOURS
11.2.5. SETTINGS
11.2.6. FAILURES
11.2.7. MACHINE INFORMATION
11.3. OPERA INSTRUMENT PANEL
11.4. MUSIC PLAYER
11.5. USB / AUX CONNECTIONS
11.6. EXTERNAL SOCKET (12V)
11.7. STARTER KEY
11.8. HOURMETER
11.9. CUP HOLDER / ASHTRAY
11.10. CONVENIENT STORAGE
11.11. CONVENIENT STORAGE BOX
11.12. SWITCHES
11.13. SAFETY LOCKING DEVICE
11.14. ADJUSTING ARMREST HEIGHT
11.15. ARMREST ANGLE ADJUSTMENT
11.16. CONSOLE ANGLE ADJUSTING LEVERS
11.17. LEFT CONSOLE LIFTING LEVER
11.18. LEVERS
11.18.1. ATTACHMENT CONTROL LEVER
11.18.2. ATTACHMENT CONTROL LEVER (PROPORTIONAL CONTROL) (OPTIONAL)
11.18.3. TRAVEL PEDAL / LEVER
11.19. FUSE / RELAY BOX
11.20. AUTOMATIC/MANUAL MODE SWITCH
11.21. BATTERY RELAY
11.22. HEATER AND AIR CONDITIONER
11.22.1. HEATER AND AIR CONDITIONER VENTS
11.22.2. CONTROL UNIT
11.23. LIGHTER / 24V SOCKET
11.24. BOTTLE HOLDER
11.25. COOL BOX
11.26. CONVENIENT STORAGE AND CONVENIENT STORAGE BOX
11.27. EMERGENCY EXIT
11.28. FIRST-AID KIT
11.29. FRONT WINDSHIELD
11.30. DOOR
11.31. DOOR LOCK MECHANISM
11.32. SIDE WINDOW
11.33. FIRE EXTINGUISHER (OPTIONAL)
11.34. FRONT AND REAR CURTAINS
11.35. SUNROOF
11.36. SUN SHADE
11.37. OPERATOR’S CAB INTERIOR LIGHTING
11.38. ADJUSTING MIRRORS
11.39. OPERATOR’S SEAT ADJUSTMENT
11.40. SEAT BELT
11.40.1. FASTENING THE SEAT BELT
11.40.2. ADJUSTING LENGTH OF THE BELT
12. STARTING THE MACHINE
12.1. CHECK BEFORE STARTING THE ENGINE
12.1.1. HANDLING ACCUMULATOR
12.2. STARTING THE ENGINE
12.2.1. STARTING AT NORMAL TEMPERATURE
12.2.2. STARTING IN COLD WEATHER
12.3. AFTER THE ENGINE STARTS
12.4. OPERATING THE MACHINE
12.4.1. FORWARD TRAVEL
12.5. TRAVEL DIRECTION CONTROL
12.6. STOPPING AND PARKING THE MACHINE
12.7. SWINGING THE MACHINE
12.8. OPERATING ATTACHMENTS
12.9. PROHIBITIONS DURING OPERATION
12.10. PRECAUTIONS DURING OPERATION
12.10.1. CHECKING THE TRAVEL UNIT REDUCTION GEAR OIL
12.11. PRECAUTIONS WHEN TRAVELING ON A SLOPE
12.12. RESCUING THE MACHINE FROM SWAMP
12.12.1. IF ONE TRACK IS STUCK
12.12.2. IF BOTH TRACKS ARE STUCK
12.13. ADDITIONAL WORKS USING HYDRAULIC EXCAVATORS
12.13.1. BACKHOE WORK
12.13.2. SHOVELING
12.13.3. DITCHING
12.13.4. LOADING
12.14. LIFTING
12.15. REPLACING THE BUCKET
12.16. PARKING THE MACHINE
12.17. CHECKS AFTER FINISHING WORK
12.18. STOPPING THE ENGINE
12.19. CHECKS AFTER STOPPING THE ENGINE
12.20. LOCKING SYSTEM
13. TRANSPORTATION
13.1. LOADING AND UNLOADING
13.2. PRECAUTIONS ON LOADING
13.3. PRECAUTIONS ON TRANSPORTATION
13.4. LIFTING THE MACHINE
13.5. SEA TRANSPORTATION
14. PREPARING THE MACHINE BASED ON WEATHER CONDITIONS
14.1. HANDLING THE MACHINE IN COLD WEATHER
14.2. PREPARATIONS FOR COLD WEATHER
14.2.1. FUEL AND LUBRICANT
14.2.2. COOLANT
14.2.3. BATTERY
14.3. PRECAUTIONS AFTER FINISHING WORK
14.4. PREPARATIONS FOR HOT WEATHER
15. LONG TERM STORAGE
15.1. BEFORE LONG TERM STORAGE
15.2. DURING LONG TERM STORAGE
15.3. END OF LONG TERM STORAGE
15.4. INSTRUCTIONS ON WITHDRAWAL FROM USE AND UTILIZATION
16. TROUBLESHOOTING
16.1. WHEN TO SUSPECT A TROUBLE CASE
16.2. TOWING METHOD
16.2.1.1. RELEASING PARKING BRAKE
16.3. TOWING HOLE FOR LIGHT OBJECTS
16.4. PRECAUTIONS UNDER SPECIAL CIRCUMSTANCES
16.5. ELECTRIC DISCHARGE
16.5.1. STARTING THE ENGINE WITH BOOSTER CABLES (JUMP START)
16.6. POOR BATTERY CHARGING
16.7. OVERHEATING
16.8. ABNORMAL (LOW) OIL PRESSURE
16.9. ENGINE TROUBLE
16.10. HYDRAULIC SYSTEM
16.10.1. HYDRAULIC PUMP
16.10.2. TRAVELING, SWINGING AND ATTACHMENTS
16.10.3. HYDRAULIC CYLINDERS
16.11. ELECTRIC SYSTEM
16.12. OTHER TROUBLES
17. PRECAUTIONS FOR MAINTENANCE
18. GENERAL MAINTENANCE
18.1. OIL, FUEL AND COOLANT
18.1.1. OIL
18.1.2. FUEL
18.1.3. COOLANT
18.1.4. GREASE
18.1.5. STORING OIL AND FUEL
18.1.6. FILTERS
18.2. ELECTRONIC PARTS
18.3. HYDRAULIC UNITS
18.3.1. RELEASING INTERNAL PRESSURE IN MAIN CIRCUIT
18.3.2. RELEASING PRESSURE IN TANK AND RETURN CIRCUIT
19. USAGE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
19.1. FUEL, COOLANT AND LUBRICANTS
19.2. RECOMMENDED LUBRICATION OIL
19.3. RECOMMENDED FUEL
19.4. COOLANT
20. PERIODIC REPLACEMENT OF MAIN PARTS
21. INSPECTION AND MAINTENANCE LIST
21.1. MAINTENANCE LIST ACCORDING TO SERVICE INTERVAL
22. PERIODIC INSPECTION AND MAINTENANCE
22.1. EVERY 10 HOURS (BEFORE STARTING)
22.1.1. WALK-AROUND INSPECTION (VISUAL INSPECTION)
22.1.2. COOLANT LEVEL CHECK
22.1.3. ENGINE OIL LEVEL CHECK
22.1.4. FUEL LEVEL CHECK
22.1.5. HYDRAULIC TANK LEVEL CHECK
22.1.6. ELECTRIC WIRING CHECK
22.1.7. CLEANING THE FILTER OF HYDRAULIC TANK BREATHER
22.1.8. CHECKING AND REPLACING THE BUCKET TEETH
22.1.9. ALTERNATOR BELT TENSION CHECK
22.1.10. GREASING ATTACHMENT PINS
22.1.11. TIGHTENING TRACK SHOE BOLT
22.1.12. DRAINING SEDIMENT AND WATER FROM FUEL FILTERS
22.2. EVERY 10 HOURS (AFTER WORKSHIFT)
22.2.1. CLEANING THE MACHINE
22.3. EVERY 50 HOURS (WEEKLY SERVICE)
22.3.1. GREASING SWING GEAR BEARING (at 3 points)
22.3.2. REMOVING SEDIMENT FROM FUEL TANK
22.3.3. INSPECTING AND ADJUSTING TRACK TENSION
22.4. FIRST 250 HOURS
22.4.1. REPLACING THE RETURN FILTER ELEMENT OF HYDRAULIC OIL
22.4.2. CHANGING PILOT FILTER ELEMENT
22.4.3. GREASING SWING UNIT REDUCTION GEAR
22.4.4. REPLACING SWING UNIT REDUCTION GEAR OIL
22.5. EVERY 250 HOURS (MONTHLY SERVICE)
22.5.1. CHECKING SWING RING GEAR GREASE
22.5.2. CHANGING SWING GEAR BEARING GREASE (at 3 points)
22.5.3. CHECKING BATTERY ELECTROLYTE LEVEL
22.5.4. REPLACEMENT OF BLOW-BY GAS FILTER ELEMENT OF PCV (INTAKE RECIRCULATION) VALVE (ONLY FOR MITSUBISHI 4M50 ENGINES)
22.6. EVERY 250 HYDRAULIC BREAKER HOURS
22.6.1. REPLACING HYDRAULIC BREAKER RETURN LINE FILTER
22.7. FIRST 500 HOURS
22.7.1. REPLACING TRAVEL UNIT REDUCTION GEAR OIL
22.8. EVERY 500 HOURS (3 – MONTH SERVICE)
22.8.1. REPLACING FUEL FILTER ELEMENTS
22.8.2. REPLACING ENGINE OIL AND OIL FILTER
22.8.3. CLEANING FEED PUMP STRAINER
22.8.4. CLEANING ELECTROMAGNETIC PUMP FILTER (ONLY IN ISUZU ENGINES)
22.8.5. CHECKING ANTIFREEZE DENSITY
22.8.6. CHECKING AND CLEANING RADIATOR, OIL COOLER AND CONDENSER FIN
22.8.7. GREASING SWING UNIT REDUCTION GEAR
22.9. EVERY 1000 HOURS (6-MONTHS SERVICE)
22.9.1. REPLACING SWING UNIT REDUCTION GEAR OIL
22.9.2. REPLACING PILOT FILTER ELEMENT
22.9.3. REPLACING TRAVEL UNIT REDUCTION GEAR OIL
22.9.4. REPLACING THE RETURN FILTER ELEMENT OF HYDRAULIC OIL
22.9.5. ENGINE VALVE CLEARANCE CHECK
22.9.6. STARTER AND ALTERNATOR CHECK AND CLEANING
22.9.7. CYLINDER COMPRESSION CHECK
22.9.8. TENSION ADJUSTMENT OF AIR CONDITIONER BELT
22.9.9. REPLACING THE FILTER OF HYDRAULIC TANK BREATHER
22.10. EVERY 2000 HOURS (ANNUAL SERVICE)
22.10.1. REPLACING OIL AND CLEANING OR REPLACING SUCTION FILTER ELEMENT OF HYDRAULIC TANK
22.11. EVERY TWO YEARS OF SERVICE
22.11.1. CLEANING COOLING SYSTEM AND REPLACING COOLANT
22.12. WHEN REQUIRED
22.12.1. REPLACING AIR CONDITIONER FILTER
22.12.2. REPLACING OR IF NECESSARY CLEANING AIR FILTER OUTER ELEMENT
22.12.3. REPLACING AIR FILTER INNER ELEMENT
22.12.4. BLEEDING FUEL SYSTEM
22.12.5. BLEEDING HYDRAULIC SYSTEM
22.12.6. REPLACING THE FUEL PIPING
22.12.7. CHECKING AIR CONDITIONER REFRIGERANT AMOUNT
23. SPECIFICATIONS
23.1. TECHNICAL SPECIFICATIONS OF HMK 140 LC-3
23.2. TECHNICAL SPECIFICATIONS OF HMK 220 LC-3, HMK 220 NLC-3 AND HMK 220 LC-3 LR
23.3. TECHNICAL SPECIFICATIONS OF HMK 300 LC-3, HMK 300 NLC-3, HMK 300 LC-3 LR
23.4. TECHNICAL SPECIFICATIONS OF HMK 370LC-3, HMK 370 NLC-3 AND HMK 370 LC-3 LR
23.5. TECHNICAL SPECIFICATIONS OF HMK 490 LC-3
24. GENERAL PRECAUTIONS
24.1. OCCUPATIONAL SAFETY
24.2. PRECAUTIONS WHEN FITTING THE WORK EQUIPMENT
24.3. SELECTION OF ATTACHMENT
24.4. PROTECTION AGAINST FALLING OR FLYING OBJECTS (FOPS)
24.5. PROTECTION AGAINST TIPPING AND ROLLING OVER
25. SELECTION OF TRACK SHOES
25.1. METHOD OF SHOE SELECTION
26. HYDRAULIC BREAKERS
26.1. PERMISSIBLE WORKS
26.2. INCORRECT OPERATION METHODS
26.3. ADJUSTMENTS FOR HYDRAULIC BREAKER
26.3.1. ADJUSTING HYDRAULIC BREAKER CURRENT
26.3.2. HYDRAULIC BREAKER ENGINE RPM ADJUSTMENT
26.3.3. TABLE OF HYDRAULIC BREAKER ADJUSTMENT VALUES
26.3.4. POSITIONING 3-WAY BALL VALVE
26.3.5. FLOW ADJUSTMENT
26.4. MAINTENANCE FOR HYDRAULIC BREAKER
27. QUICK COUPLING ATTACHMENT (OPTIONAL)
27.1. MOUNTING THE BUCKET
27.2. DISMOUNTING THE BUCKET
28. OPTIONAL ATTACHMENT-2 SETTINGS
28.1. OPTIONAL ATTACHMENT-2 CURRENT SETTINGS
28.2. OPTIONAL ATTACHMENT-2 ENGINE SPEED SETTINGS
28.3. SELECTED ATTACHMENT
28.4. POSITIONING 3-WAY BALL VALVE
28.5. ADDITIONAL HYDRAULIC LINE (OPTIONAL)
29. CONTACTS
29.1. FACTORY AND SERVICE DEPARTMENT
30. ALPHABETICAL INDEX
31. NOTES