Hidromek HMK 102B ALPHA Operation Maintenance Manual Y10_13059

Description

Contents:
1. INTRODUCTION
1.1. FOREWORD
1.2. CE MARKING AND EMC DIRECTIVE
1.3. IDENTIFICATION PLATES
1.3.1. MACHINE SERIAL NUMBER PLATE
1.3.2. ENGINE SERIAL NUMBER PLATE
1.4. 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. OPERATING ON HILLSIDES & SLOPES
2.4.6. WORKING AROUND UTILITY LINES
2.4.7. LIFTING
2.4.8. ICE & SNOW ON THE JOB SITES
2.4.9. UNSTABLE GROUND OR FILLING
2.4.10. DANGER ZONE
2.4.11. RESTRICTED WORKING AREAS
2.4.12. LEGAL LIABILITY
2.4.13. EXPERIMENTAL OPERATIONS
2.4.14. PARKING THE MACHINE
2.4.15. KEEP UNAUTHORIZED PEOPLE AWAY
2.4.16. CHECK ATTACHMENT LOCK PINS
2.4.17. STOWAGE OF ATTACHMENTS
2.4.18. VENTILATION IN CLOSED AREA
2.4.19. EMERGENCY EXIT
2.4.20. UNINTENTIONAL SHUT-OFF DURING OPERATION
2.4.21. UNINTENTIONAL SHUT-OFF DURING TRAVEL
2.4.22. 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. “SAFE WORKING LOAD” LABEL
2.7.5. “BEFORE PERFORMING ANY MAINTENANCE or INSPECTION STOP THE ENGINE, REMOVE IGNITION KEY AND READ OPERATING MANUAL” WARNING FOR ROTATING AND HOT PARTS AND SURFACES.
2.7.6. “BATTERY” WARNING
2.7.7. “TRANSMISSION OIL CONTROL” CAUTION
2.7.8. “FUEL SPECIFICATIONS” WARNING LABEL
2.7.9. “FUEL TANK” CAUTION
2.7.10. “ELECTRICAL EQUIPMENT” WARNING
2.7.11. “KEEP CLEAR OF WORKING AREA” WARNING FOR LOADER
2.7.12. “EMERGENCY EXIT” CAUTION
2.7.13. “DO NOT PINCH YOUR HANDS” WARNING
2.7.14. “HYDRAULIC OIL TANK” CAUTION
2.8. PROHIBITED MACHINE OPERATION
2.8.1. DO NOT HAMMER WITH THE BUCKET
2.8.2. NEVER USE THIS MACHINE OTHER THAN ITS INTENDED USE
2.8.3. DO NOT USE THE BUCKET FOR LIFTING PEOPLE
2.8.4. DO NOT IMPACT HYDRAULIC CYLINDERS TO STROKE END REPEATEDLY
2.8.5. NEVER EXCEED THE CAPACITY OF THE MACHINE
2.9. END OF WORKSHIFT MAINTENANCE & INSPECTION
3. DESCRIPTION
3.1. FRONT INSTRUMENT PANEL
3.1.1. THROTTLE PEDAL
3.1.2. DOUBLE PEDAL BRAKE 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
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3.2.3. 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. REAR WINDOW AND REAR WINDOW WIPER
3.5.1. OPENING THE REAR WINDOW
3.5.2. CLOSING THE REAR WINDOW
3.6. DOOR
3.7. DOOR FIXING MECHANISM
3.8. ROOF
3.8.1. INTERIOR LIGHT
3.8.2. COAT HANGER
3.9. TOOLBOX
3.10. SAFETY STRUT
3.11. OPENING THE ENGINE HOOD
3.12. OPENING THE SIDE PANELS
3.13. 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
4.13. BRAKING
4.14. THE LOADER OPERATION
4.14.1. LOADER OPERATION IN BANKS AND STOCKPILES
4.14.2. LOADING TRUCKS
4.14.3. RESCUING A STUCK MACHINE
4.14.4. GRADING WITH LOADER
4.14.5. WORKING ON SLOPES
4.14.6. LOWERING THE ATACHMENTS IN CASE OF UNEXPECTED POWER CUT-OFF
4.15. REPLACING ATTACHMENTS
4.15.1. LOADER BUCKET
4.15.2. REPLACING BUCKET TEETH
4.16. TRANSPORTING THE MACHINE
4.17. TOWING PROCEDURE FOR A DISABLED MACHINE
4.18. LIFTING BY A CRANE
4.19. PRESERVING THE MACHINE FOR STORAGE
4.19.1. MAINTENANCE OF THE MACHINE DURING AND AFTER STORAGE
4.20. 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. PERIODIC MAINTENANCE
5.4.1. FIRST 50 HOURS MAINTENANCE
5.5. TABLE of LUBRICANTS & FLUIDS
5.6. PRE-START (EVERY 8 HOURS) INSPECTION & MAINTENANCE
5.6.1. WALK-AROUND INSPECTION
5.6.2. CHECKING ENGINE OIL LEVEL
5.6.3. CHECKING COOLANT LEVEL
5.6.4. CHECKING ENGINE FLUID LEAKS
5.6.5. CHECKING & CLEANING THE ENGINE AIR PRE-CLEANER (DUST SEPARATOR)
5.6.6. CHECKING / CHANGING ENGINE AIR FILTER
5.6.7. AIR FILTER CLOGGED WARNING LIGHT
5.6.8. CHECKING FUEL LEVEL
5.6.9. CHECKING TRANSMISSION OIL LEVEL
5.6.10. CHECKING HYDRAULIC OIL LEVEL
5.6.11. HYDRAULIC OIL TANK CAP
5.6.12. CHECKING THE TYRE PRESSURE
5.6.13. GREASING
5.6.14. DRAINING FUEL SYSTEM PRIMARY FILTER / WATER SEPARATOR
5.7. WEEKLY (EVERY 50 HOURS) INSPECTION & MAINTENANCE
5.7.1. DRAINING THE FUEL TANK
5.7.2. CHECKING THE ELECTROLYTE LEVEL OF BATTERY
5.7.3. CHECKING THE ROPS/FOPS OPERATOR’S CABIN
5.7.4. GREASING
5.7.5. INSPECT HOSES AND CLAMPS
5.7.6. REPLACE THE HOSES AND THE CLAMPS
5.8. EVERY 100 HOURS INSPECTION & MAINTENANCE
5.8.1. CHECKING AND LUBRICATING THE PARKING BRAKE
5.9. EVERY 250 HOURS INSPECTION & MAINTENANCE
5.9.1. CHECKING THE DIFFERENTIAL OIL LEVEL OF THE AXLES
5.9.2. CHECKING THE OIL LEVEL IN HUBS
5.10. EVERY 500 HOURS INSPECTION & MAINTENANCE
5.10.1. CHANGING ENGINE OIL AND ENGINE OIL FILTER
5.10.2. OIL CHANGE INTERVALS
5.10.3. OIL VISCOSITY GRADE
5.10.4. CHANGING THE HYDRAULIC RETURN FILTER
5.10.5. CLEANING AND CHANGING OPERATOR’S CABIN HEATER AIR FILTER
5.10.6. INSPECT BELT
5.10.7. INSPECT BELT TENSIONER
5.11. EVERY 500 HOURS OR 1 YEAR INSPECTION & MAINTENANCE
5.11.1. REPLACING FUEL SYSTEM PRIMARY FILTER (WATER SEPARATOR) ELEMENT
5.11.2. FUEL SYSTEM SECONDARY FILTER – REPLACE
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
5.12.5. CHANGING THE HYDRAULIC OIL
5.12.6. CHANGING & CLEANING THE SUCTION STRAINER
5.13. EVERY 1500 HOURS MAINTENANCE
5.13.1. REPLACING ENGINE CRANKCASE BREATHER ELEMENT
5.14. EVERY 2000 HOURS MAINTENANCE
5.14.1. DESCRIPTION OF COOLANT
5.14.2. COOLANT FILLING CAP
5.14.3. CHANGING COOLING SYSTEM COOLANT
5.14.4. INSPECTING AFTERCOOLER CORE
5.14.5. INSPECTING ALTERNATOR
5.14.6. INSPECTING ENGINE MOUNTS
5.15. EVERY 3000 HOURS MAINTENANCE
5.15.1. ALTERNATOR AND FAN BELTS – REPLACE
5.16. WHEN REQUIRED
5.16.1. REPLACING FUSES
5.16.2. MAINTENANCE OF AIR-CONDITIONER (OPTIONAL)
5.16.3. REPLACING LIGHT BULBS
5.16.4. BATTERY – REPLACE
5.16.5. DISCONNECTING BATTERY OR BATTERY CABLE
5.16.6. CLEANING THE ENGINE
5.16.7. BLEEDING THE FUEL SYSTEM
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. QUICK COUPLING
7.3. TILTING FORKS
7.3.1. SETTING FORKS UP FOR OPERATION
7.3.2. STOWING THE FORKS
7.3.3. SPACING THE FORKS
7.3.4. MAINTENANCE
7.4. LOG GRAB
7.5. GRADING BLADE
7.6. AIR COMPRESSOR
7.7. FORKLIFT ATTACHMENT & CLAMSHELL BUCKET
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