Hidromek HMK 102B SUPRA & ALPHA Operation Maintenance Manual Y17_02201 2023

Description

Contents:
1. INTRODUCTION
1.1. FOREWORD
1.2. CE, UKCA MARKING AND EMC DIRECTIVE
1.3. IDENTIFICATION PLATES
1.3.1. MACHINE SERIAL NUMBER PLATE
1.3.2. ENGINE SERIAL NUMBER PLATE
1.3.3. DOC AND DPF SERIAL PLATE
1.3.4. PUMP ELECTRONIC UNIT
1.3.5. EMISSIONS CERTIFICATION
1.4. LOADER
1.4.1. DESCRIPTION OF THE MACHINE AND ITS INTENDED 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 OPERATION MANUAL
2.3.4. KEEP OPERATION 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 & SIGNALMAN
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 OPERATION AND MAINTENANCE MANUAL” WARNING LABEL
2.7.2. “LIFT CYLINDER LOCK” WARNING LABEL
2.7.3. “AIR FILTER CLOGGED” WARNING LABEL
2.7.4. “SAFE WORKING LOAD” WARNING LABEL
2.7.5. “BEFORE PERFORMING ANY MAINTENANCE or INSPECTION STOP THE ENGINE, REMOVE IGNITION KEY AND READ OPERATION MANUAL” WARNING FOR ROTATING AND HOT PARTS AND SURFACES.
2.7.6. “BATTERY” WARNING LABEL
2.7.7. “TRANSMISSION OIL CONTROL” WARNING LABEL
2.7.8. “FUEL SPECIFICATIONS” WARNING LABEL
2.7.9. “FUEL TANK” WARNING LABEL
2.7.10. “ELECTRICAL EQUIPMENT” WARNING LABEL
2.7.11. “BATTERY CUT-OFF RELAY” WARNING LABEL
2.7.12. “KEEP CLEAR OF WORKING AREA” WARNING FOR LOADER
2.7.13. “DO NOT PINCH YOUR HANDS” WARNING LABEL
2.7.14. “EMERGENCY EXIT” WARNING LABEL
2.7.15. “HYDRAULIC OIL TANK” DECAL
2.7.16. “FIRE EXTINGUISHER” DECAL
2.7.17. “WAIT TO DISCONNECT LAMP” WARNING LABEL
2.7.18. “AUTOMATIC-MANUAL MODE” LABEL
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 LOADER 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
2.8.6. DO NOT USE BUCKET TO BREAK OR CUT
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
3.2.3. FOUR WHEEL STEERING MODE SELECTING SWITCH (ON HMK 102S MODELS)
3.2.4. RIGHT HAND SIDE INSTRUMENT AND CONTROL PANEL (SUPRA)
3.2.5. RIGHT HAND SIDE INSTRUMENT AND CONTROL PANEL (ALPHA)
3.3. LEFT HAND SIDE CONSOLE
3.3.1. BACK AND FRONT GLASS HOLDER
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 WINDOW 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
3.14. BATTERY DISCONNECT SWITCH
3.14.1. WAIT TO DISCONNECT LAMP
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. AFTER STARTING ENGINE
4.5. DRIVING THE MACHINE
4.5.1. TRAVELING IN REVERSE DIRECTION
4.6. JUMP STARTING THE ENGINE
4.7. AFTERTREATMENT SYSTEM OPERATION
4.7.1. DEF SYSTEM PURGE
4.7.2. DPF REGENERATION INHIBIT
4.7.3. DPF+SCR SYSTEM WARNING INDICATORS
4.7.4. DPF REGENERATION STRATEGY
4.7.5. DPF REGENERATION ESCALATION LEVELS
4.7.6. INDUCEMENT STRATEGY
4.8. BASIC PRECAUTIONS FOR OPERATION IN COLD AND HOT CLIMATE
4.8.1. IN COLD WEATHER
4.8.2. IN HOT WEATHER
4.9. PREPARATIONS FOR TRAVEL
4.9.1. TESTING THE PARKING BRAKE
4.10. STOPPING THE ENGINE
4.11. AFTER STOPPING ENGINE
4.12. STOPPING and PARKING THE MACHINE
4.13. UNINTENTIONAL SHUT DOWN DURING TRAVEL
4.14. STEERING IN CASE OF EMERGENCY
4.15. FIELD TEST OF THE EMERGENCY STEERING
4.16. ENGAGING ATTACHMENT SAFETY LOCKS
4.16.1. ENGAGING LOADER ARM SAFETY STRUT
4.16.2. DISENGAGING SAFETY STRUT
4.17. FOUR WHEEL STEERING SYSTEM (HMK 102S MODEL)
4.17.1. REALIGNMENT OF FOUR WHEEL STEERING SYSTEM (HMK 102S MODEL ONLY)
4.18. BRAKING
4.19. THE LOADER OPERATION
4.19.1. LOADER OPERATION IN BANKS AND STOCKPILES
4.19.2. LOADING TRUCKS
4.19.3. RESCUING A STUCK MACHINE
4.19.4. GRADING WITH LOADER
4.19.5. WORKING ON SLOPES
4.19.6. LOWERING THE ATACHMENTS IN CASE OF UNEXPECTED POWER CUT-OFF
4.20. REPLACING ATTACHMENTS
4.20.1. LOADER BUCKET
4.21. TRANSPORTING THE MACHINE
4.22. TOWING PROCEDURE OF A DISABLED MACHINE
4.23. LIFTING BY A CRANE
4.24. PRESERVING THE MACHINE FOR STORAGE
4.24.1. MAINTENANCE OF THE MACHINE DURING AND AFTER STORAGE
4.25. INSTRUCTIONS ON WITHDRAWAL FROM USE AND UTILIZATION
5. MAINTENANCE
5.1. GENERAL INFORMATION
5.2. GENERAL SAFETY PRECAUTIONS
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. PRESSURIZED AIR AND WATER
5.2.5. HOT SURFACES & FLUIDS
5.2.6. WARM UP THE ENGINE OIL
5.2.7. ATTACH “DO NOT OPERATE” WARNING
5.2.8. INSPECT WASTE OILS & FILTERS
5.2.9. PREVENT CONTAMINATION
5.2.10. SEALS & ‘O-RINGS’
5.2.11. WEAR PROTECTIVE CLOTHING
5.2.12. CLEANING PARTS
5.2.13. RELEASE RESIDUAL HYDRAULIC OIL PRESSURE
5.2.14. ENGAGE ATTACHMENT SAFETY LOCKS
5.2.15. HANDLING POLYMERS AND ELASTOMERS CONTAINING FLUORO-CARBON
5.2.16. PRECAUTIONS WHEN WORKING WITH A/C REFRIGERANTS
5.2.17. PRECAUTIONS TO BE TAKEN DURING WORKING WITH EXHAUST PIPE
5.2.18. DISPOSAL OF WASTES AND PROTECTION OF THE ENVIRONMENT
5.2.19. USE OF BIODEGRADABLE SYNTHETIC OILS
5.3. INSPECTION & MAINTENANCE CHART
5.4. PERIODIC MAINTENANCE
5.4.1. FIRST 50 HOURS MAINTENANCE
5.5. LUBRICANTS & FLUIDS
5.5.1. DIESEL EXHAUST FLUID (DEF)
5.5.2. COOLANT
5.5.3. DIESEL FUEL REQUIREMENTS
5.5.4. VISCOSITY RECOMMENDATIONS ACCORDING TO TEMPERATURE
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. AIR FILTER CLOGGED WARNING LIGHT
5.6.7. CHECKING FUEL LEVEL
5.6.8. INSPECTING ENGINE AIR CLEANER SERVICE INDICATOR
5.6.9. CHECKING DRIVEN EQUIPMENT
5.6.10. CHECKING TRANSMISSION OIL LEVEL
5.6.11. CHECKING HYDRAULIC OIL LEVEL
5.6.12. HYDRAULIC OIL TANK CAP
5.6.13. CHECKING THE TYRE PRESSURE
5.6.14. GREASING
5.6.15. DRAINING THE WATER FROM THE FUEL FILTER
5.7. WEEKLY (EVERY 50 HOURS) INSPECTION & MAINTENANCE
5.7.1. DRAINING THE FUEL TANK
5.7.2. CHECKING THE ROPS/FOPS OPERATOR’S CABIN
5.7.3. GREASING
5.7.4. CLEANING AIR FILTER INNER ELEMENT
5.7.5. INSPECT HOSES AND CLAMPS
5.7.6. REPLACING HOSES AND CLAMPS
5.7.7. CHECKING THE ELECTROLYTE LEVEL OF BATTERY
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
5.9.3. CLEANING FRONT AND REAR AXLE BREATHERS
5.9.4. CLEANING TRANSMISSION BREATHER
5.10. EVERY 500 HOURS INSPECTION & MAINTENANCE
5.10.1. CLEANING RADIATOR
5.10.2. REPLACING THE HYDRAULIC RETURN FILTER
5.10.3. CHANGING AIR CONDITIONER INNER AND OUTER FILTER ELEMENTS
5.10.4. REPLACING THE TRANSMISSION OIL FILTER
5.11. EVERY 500 HOURS OR 1 YEAR INSPECTION & MAINTENANCE
5.11.1. REPLACING ENGINE OIL AND ENGINE OIL FILTER
5.11.2. OIL CHANGE INTERVALS
5.11.3. OIL VISCOSITY GRADE
5.11.4. REPLACING FUEL FILTER ELEMENT
5.12. EVERY 1000 HOURS INSPECTION & MAINTENANCE
5.12.1. INSPECTING BELT
5.12.2. CHECKING BELT TENSIONER
5.12.3. CHANGING TRANSMISSION OIL AND CLEANING THE SUCTION STRAINER
5.12.4. CHANGING THE DIFFERENTIAL OIL OF THE AXLES
5.12.5. CHANGING THE OIL OF HUBS
5.12.6. CHANGING THE HYDRAULIC OIL
5.12.7. REPLACING & CLEANING THE SUCTION STRAINER
5.12.8. INSPECTING WATER PUMP
5.13. EVERY 1500 HOURS MAINTENANCE
5.13.1. CHANGING THE DIFFERENTIAL OIL OF THE AXLES (102S)
5.13.2. CHANGING THE OIL OF HUBS (102S)
5.14. EVERY 2000 HOURS MAINTENANCE
5.14.1. INSPECTING AFTERCOOLER CORE
5.14.2. INSPECTING ALTERNATOR
5.14.3. INSPECTING ENGINE MOUNTS
5.14.4. INSPECTING STARTING MOTOR
5.15. EVERY 3000 HOURS MAINTENANCE
5.15.1. CLEANING / REPLACING DIESEL EXHAUST FLUID FILTER
5.15.2. REPLACING ALTERNATOR AND FAN BELTS
5.16. EVERY 2 YEARS OR 3000 HOURS MAINTENANCE
5.16.1. DESCRIPTION OF COOLANT
5.16.2. COOLANT FILLING CAP
5.16.3. CHANGING COOLING SYSTEM COOLANT
5.17. EVERY 4000 HOURS MAINTENANCE
5.17.1. CLEANING AND TEST AFTERCOOLER CORE
5.18. EVERY 4500 HOURS MAINTENANCE
5.18.1. INSPECTING TURBOCHARGER
5.19. EVERY 6000 HOURS MAINTENANCE
5.19.1. REPLACING DEF INJECTOR
5.20. EVERY 10000 HOURS MAINTENANCE
5.20.1. REPLACING DEF MANIFOLD FILTERS
5.21. WHEN REQUIRED
5.21.1. OBTAINING ENGINE OIL SAMPLE
5.21.2. BLEEDING THE FUEL SYSTEM
5.21.3. FILLING DIESEL EXHAUST FLUID
5.21.4. FLUSHING DIESEL EXHAUST FLUID TANK
5.21.5. CLEANING DEF FILLER SCREEN
5.21.6. MAINTENANCE OF AIR-CONDITIONER
5.21.7. REPLACING FUSES
5.21.8. REPLACING LIGHT BULBS
5.21.9. REPLACING BATTERY
5.21.10. DISCONNECTING BATTERY OR BATTERY CABLE
5.21.11. CLEANING THE ENGINE
5.21.12. REPLACING AIR FILTER ELEMENTS
6. SPECIFICATIONS
6.1. TECHNICAL SPECIFICATIONS OF HMK 102B
6.2. TECHNICAL SPECIFICATIONS OF HMK 102S
6.3. LIFTING REGULATIONS AND SAFE WORKING LOADS (SWL)
6.3.1. LIFTING REGULATIONS
6.3.2. SAFE WORKING LOADS
6.4. SOUND and VIBRATION
6.4.1. SOUND
6.4.2. VIBRATION
7. OPTIONAL EQUIPMENT
7.1. GENERAL
7.2. QUICK COUPLINGS
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
7.3.5. MAINTENANCE OF THE PLANETARY REDUCER GEAR BOX
7.3.6. PERIODIC MAINTENANCE
7.3.7. RECOMMENDED OIL FOR LUBRICATION
7.4. LOG GRAB
7.5. GRADING BLADE
7.6. AIR COMPRESSOR
7.7. FORKLIFT ATTACHMENT & CLAMSHELL BUCKET
7.8. STREET SWEEPER
7.9. QUICK-COUPLER
7.9.1. QUICK-COUPLER PARTS
7.9.2. PERIODIC CHECK-UP
7.9.3. QUICK-COUPLER (LOADER)
8. APPENDIX
8.1. HAND SIGNALS
8.2. TABLE OF TORQUE VALUES FOR FASTENERS
8.3. CONTACTS
8.3.1. PLANTS AND AFTER SALES SERVICES
8.4. NOTES
9. ALPHABETICAL INDEX