Hidromek HMK102B K4 SUPRA & ALPHA GREENTEC Operation Manual Y2503201 2025

Description

Contents:
1. INTRODUCTION
1.1. COPYRIGHT
1.2. DRIVING LICENSE
1.3. SPARE PARTS AND SERVICE
1.4. ENVIRONMENTAL STANDARDS
1.5. SAFETY NOTICES
1.6. OTHER NOTICES
1.7. IDENTIFICATION PLATES
1.7.1. MACHINE SERIAL NUMBER PLATE
1.7.2. ENGINE SERIAL NUMBER PLATE
1.7.3. DOC AND DPF SERIAL PLATE
1.7.4. EMISSIONS CERTIFICATION
1.7.5. FOPS/ ROPS CERTIFICATE
1.8. BACKHOE LOADER
2. SAFETY
2.1. GENERAL SAFETY INFORMATION
2.2. SAFETY PRECAUTIONS
2.2.1. WELDING
2.2.2. JOYSTICKS
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. SAFETY PRECAUTIONS
2.3.2. PROTECTIVE CLOTHING
2.3.3. OPERATION AND MAINTENANCE MANUAL
2.3.4. OPERATION AND MAINTENANCE MANUAL LOCATION
2.3.5. EMERGENCIES
2.3.6. SAFETY AT THE JOB SITE
2.3.7. SIGNS, SIGNALS & SIGNALMAN
2.3.8. FIRE
2.3.9. HOT SURFACES & FLUIDS
2.3.10. USE PROPER ATTACHMENT
2.3.11. TO GET ON AND OFF THE MACHINE
2.3.12. VISIBILITY
2.3.13. PRE-START INSPECTION
2.4. SAFETY DURING OPERATION
2.4.1. PASSENGERS
2.4.2. STARTING THE ENGINE
2.4.3. DRIVING
2.4.4. ROLL-OVER PROTECTION
2.4.5. SLEWING
2.4.6. WORKING AROUND UTILITY LINES
2.4.7. OPERATING ON HILLSIDES & SLOPES
2.4.8. LIFTING
2.4.9. ICE & SNOW ON THE JOB SITES
2.4.10. UNSTABLE GROUND OR FILLING
2.4.11. DANGER ZONE
2.4.12. RESTRICTED WORKING AREAS
2.4.13. LEGAL LIABILITY
2.4.14. VENTILATION IN CLOSED AREA
2.4.15. PARKING THE MACHINE
2.4.16. EMERGENCY EXIT
2.4.17. UNINTENTIONAL SHUT-OFF DURING OPERATION
2.4.18. UNINTENTIONAL SHUT-OFF DURING TRAVEL
2.4.19. BEFORE LEAVING THE MACHINE
2.5. INSPECTION & MAINTENANCE SAFETY
2.5.1. PROTECTIVE CLOTHING
2.5.2. STOP THE ENGINE
2.5.3. ENGAGE JOYSTICKS SAFETY LOCKS
2.5.4. PREVENT UNAUTHORIZED START
2.5.5. CHECKING ATTACHMENT LOCK PINS
2.5.6. SECURING ATTACHMENTS
2.5.7. ENGAGE ATTACHMENT LOCKS
2.5.8. MAINTENANCE POSITION
2.5.9. KEEP THE MACHINE CLEAN
2.5.10. PRESSURIZED FLUIDS
2.5.11. SUPPORT THE MACHINE
2.5.12. REFUELING
2.5.13. HYDRAULIC PRESSURE
2.5.14. TYRE INFLATION & WHEEL NUTS
2.5.15. ROTATING PARTS IN THE ENGINE
2.5.16. ELECTRICAL SYSTEM
2.5.17. SAFE LIGHTING
2.5.18. WASTE MATERIALS
2.5.19. CLEANERS
2.5.20. SEALS
2.6. BATTERY SAFETY, MAINTENANCE AND WARNINGS
2.7. WARNING LABELS & DECALS
2.7.1. “READ THE OPERATION AND MAINTENANCE MANUAL” LABEL
2.7.2. FUEL TANK AND FUEL SPECIFICATIONS LABEL
2.7.3. EMISSION CONTROL SYSTEM INFORMATION AND WARNING LABEL
2.7.4. “BATTERY CUT-OFF RELAY” WARNING LABEL
2.7.5. BACKHOE BOOM SLEW LOCK PIN WARNING LABEL
2.7.6. “DO NOT PINCH YOUR FOOT” WARNING LABEL
2.7.7. DO NOT PINCH YOUR HANDS WARNING LABEL
2.7.8. WASHING OPERATIONS WARNING LABEL
2.7.9. “KEEP CLEAR OF WORKING AREA FOR BACKHOE” WARNING LABEL
2.7.10. HYDRAULIC OIL TANK LABEL
2.7.11. TRANSMISSION OIL CONTROL WARNING LABEL
2.7.12. “LOADER LIFT CYLINDER LOCK” WARNING LABEL
2.7.13. “KEEP CLEAR OF WORKING AREA” WARNING LABEL FOR LOADER (LEFT)
2.7.14. “KEEP CLEAR OF WORKING AREA” WARNING LABEL FOR LOADER (RIGHT)
2.7.15. “WAIT TO DISCONNECT LAMP” WARNING LABEL
2.7.16. “STOP THE ENGINE, REMOVE THE IGNITION KEY AND READ THE OPERATION MANUAL BEFORE CHECKING AND SERVICING HOT AND ROTATING PARTS” WARNING LABEL
2.7.17. SAFE WORKING LOAD WARNING LABEL
2.7.18. AIR FILTER WARNING LABEL
2.7.19. ANTI-FREEZE WARNING LABEL
2.7.20. BATTERY WARNING LABEL
2.7.21. EMERGENCY EXIT WARNING LABEL
2.7.22. “ELECTRICAL EQUIPMENT” WARNING LABEL
2.7.23. DO NOT SIT ON TRIMS WARNING LABEL
2.7.24. “AUTOMATIC-MANUAL MODE” LABEL
2.8. PROHIBITED MACHINE OPERATION
2.8.1. DO NOT USE THE SLEWING FORCE OF THE BACKHOE FOR GRADING
2.8.2. DO NOT HAMMER WITH THE BUCKET
2.8.3. NEVER USE THIS MACHINE OTHER THAN ITS INTENDED USE
2.8.4. DO NOT USE THE BACKHOE LOADER FOR LIFTING PEOPLE
2.8.5. DO NOT IMPACT HYDRAULIC CYLINDERS TO STROKE END REPEATEDLY
2.8.6. NEVER EXCEED THE CAPACITY OF THE MACHINE
2.8.7. DO NOT USE BUCKET TO BREAK OR CUT
2.8.8. DO NOT DRIVE WITH THE STABILIZERS EXTENDED
2.9. END OF WORKSHIFT MAINTENANCE & INSPECTION
3. DESCRIPTION
3.1. FRONT CONSOLE
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 DEPTH ADJUSTMENT LEVER
3.1.6. STEERING WHEEL ANGLE ADJUSTMENT PEDAL
3.1.7. COMPARTMENTS AND STOWAGE PLACES FOR OBJECTS
3.1.8. FRONT DISPLAY PANEL AND WARNING LIGHTS
3.2. RIGHT HAND SIDE INSTRUMENT PANEL
3.2.1. STABILIZER CONTROL LEVERS
3.2.2. THROTTLE DIAL
3.2.3. PARKING BRAKE LEVER (ALPHA)
3.2.4. BOOM LOCK HANDLE (ALPHA)
3.2.5. RIGHT HAND SIDE CONTROL PANEL SWITCHES
3.2.6. STARTER KEY
3.2.7. RIGHT HAND SIDE DISPLAY AND CONTROL PANEL
3.3. LEFT HAND SIDE CONSOLE
3.3.1. FRONT AND REAR GLASS HOLDER
3.3.2. COOLER STOWAGE BOX
3.4. OPERATOR’S SEAT
3.5. JOYSTICKS
3.5.1. CRUISE CONTROL SWITCH
3.5.2. JOYSTICK SAFETY SWITCH
3.5.3. JOYSTICK POSITION CHANGE SWITCH
3.5.4. TRAVEL AND LOADER POSITION
3.5.5. BACKHOE POSITION
3.6. LOADER JOYSTICK (MECHANICALLY CONTROLLED MACHINES)
3.6.1.1. BUTTON FUNCTIONS
3.6.1.2. LOADER JOYSTICK SAFETY LOCK
3.7. BACKHOE CONTROL LEVERS (MECHANICALLY CONTROLLED MACHINES)
3.7.1. HYDRAULIC BREAKER PEDAL (ELECTRICAL) (IF EXISTS)
3.8. REAR WINDOW AND REAR WINDOW WIPER
3.8.1. OPENING THE REAR WINDOW
3.8.2. CLOSING THE REAR WINDOW
3.8.3. REAR WINDOW WIPER
3.9. ROOF
3.9.1. INTERIOR LIGHTS
3.9.2. COAT HANGER
3.10. SAFETY STRUT
3.11. TOOLBOX
3.12. DOOR
3.13. DOOR WINDOW FIXING MECHANISM
3.14. OPENING THE ENGINE HOOD
3.14.1. OPENING THE SIDE PANELS
3.14.2. REMOVING THE FRONT PANEL
3.15. BATTERY DISCONNECT SWITCH
4. OPERATION
4.1.1. GENERAL CONTROL
4.1.2. TYRE INSPECTION
4.1.3. GETTING IN AND OUT OF THE CAB
4.2. ENGINE
4.2.1. BEFORE STARTING THE ENGINE
4.2.2. STARTING THE ENGINE
4.3. AFTERTREATMENT SYSTEM OPERATION
4.3.1. DPF REGENERATION INHIBIT
4.3.2. DPF SYSTEM WARNING INDICATORS
4.3.3. DPF REGENERATION STRATEGY
4.3.4. DPF REGENERATION ESCALATION LEVELS
4.4. BASIC PRECAUTIONS FOR OPERATION IN COLD WEATHER
4.5. DRIVING THE MACHINE
4.5.1. TRAVELING IN REVERSE DIRECTION
4.6. BRAKING
4.7. PREPARATIONS FOR TRAVEL
4.7.1. MECHANICAL PARKING BRAKE TENSION ADJUSTMENT
4.7.2. TESTING THE PARKING BRAKE
4.8. STOPPING AND PARKING THE MACHINE
4.9. UNINTENTIONAL SHUT DOWN DURING TRAVEL
4.9.1. STEERING IN CASE OF DANGER
4.9.2. TESTING THE STEERING FUNCTION WHEN THE ENGINE IS NOT RUNNING
4.10. ENGAGING ATTACHMENT SAFETY LOCKS
4.10.1. LOADER ARM SAFETY STRUT
4.10.2. ENGAGING LOADER ARM SAFETY STRUT
4.10.3. DISENGAGING SAFETY STRUT
4.10.4. BACKHOE BOOM LOCK
4.10.5. DISENGAGING BACKHOE BOOM LOCK
4.10.6. BACKHOE SLEW LOCK
4.10.7. STABILIZER SHOE LOCK
4.11. CONTROLLING HYDRAULIC CLAMP CYLINDERS
4.12. SIDESHIFTING THE BACKHOE
4.12.1. MANUAL SHIFT
4.12.2. AUTOMATIC SHIFT (OPTIONAL)
4.13. TELESCOPIC ARM (OPTIONAL)
4.13.1. TELESCOPIC ARM SAFETY LOCK
4.13.2. CONTROLLING THE TELESCOPIC ARM
4.13.3. TELESCOPIC ARM – HYDRAULIC BREAKER SELECTING VALVE
4.14. LOADER OPERATION
4.14.1. LOADING TRUCKS
4.14.2. RESCUING A STUCK MACHINE
4.14.3. GRADING WITH LOADER
4.15. THE BACKHOE OPERATION
4.15.1. HINTS ON OPERATION OF BACKHOE
4.15.2. CORRECT DIGGING METHOD
4.15.3. EXCAVATION ON SLOPES
4.15.4. LOWERING THE ATACHMENTS IN CASE OF UNEXPECTED POWER CUT-OFF
4.16. REPLACING ATTACHMENTS
4.16.1. LOADER BUCKET
4.16.2. BACKHOE BUCKET
4.16.3. REPLACING BUCKET TEETH
4.17. TRANSPORTING THE MACHINE
4.18. TOWING PROCEDURE OF A DISABLED MACHINE
4.19. LIFTING BY A CRANE
4.20. PRESERVING THE MACHINE FOR STORAGE
4.20.1. MAINTENANCE OF THE MACHINE DURING AND AFTER STORAGE
4.21. INSTRUCTIONS ON WITHDRAWAL FROM USE AND UTILIZATION
5. TROUBLESHOOTING
5.1. ENGINE MALFUNCTIONS
5.2. HYDRAULIC SYSTEM MALFUNCTIONS
5.3. TRANSMISSION MALFUNCTIONS
5.4. BRAKE SYSTEM MALFUNCTIONS
5.5. ELECTRICAL SYSTEM MALFUNCTIONS
6. MAINTENANCE
6.1. MAINTENANCE PRECAUTIONS
6.1.1. STOP THE ENGINE AND PARK THE MACHINE
6.1.2. ATTACH “DO NOT OPERATE” WARNING
6.1.3. ENGAGE ATTACHMENT SAFETY LOCKS
6.1.4. WEAR PROTECTIVE CLOTHING
6.1.5. KEEP THE MACHINE CLEAN
6.1.6. PREVENT CONTAMINATION
6.1.7. HOT SURFACES & FLUIDS
6.1.8. WARM UP THE ENGINE OIL
6.1.9. DISPOSAL OF HAZARDOUS WASTE
6.1.10. SEALS & O–RINGS
6.1.11. RELEASE RESIDUAL HYDRAULIC OIL PRESSURE
6.1.12. HANDLING POLYMERS AND ELASTOMERS CONTAINING FLUORO-CARBON
6.1.13. PRECAUTIONS WHEN WORKING WITH A/C REFRIGERANTS
6.1.14. PRECAUTIONS TO BE TAKEN DURING WORKING WITH EXHAUST PIPE
6.1.15. USE OF BIODEGRADABLE SYNTHETIC OILS
6.1.16. DISPOSAL OF WASTES AND PROTECTION OF THE ENVIRONMENT
6.2. PERIODIC MAINTENANCE
6.2.1. FIRST 50 HOURS MAINTENANCE
6.3. INSPECTION & MAINTENANCE CHART
6.4. LUBRICANTS & FLUIDS
6.4.1. VISCOSITY RECOMMENDATIONS ACCORDING TO TEMPERATURE
6.4.2. COOLANT
6.4.3. DIESEL FUEL
6.5. PRE-START INSPECTION &MAINTENANCE (EVERY 8 HOURS)
6.5.1. INSPECT THE ENGINE FOR LEAKS AND FOR LOOSE CONNECTIONS
6.5.2. CHECKING ENGINE OIL LEVEL
6.5.3. CHECKING COOLANT LEVEL
6.5.4. CHECKING TRANSMISSION OIL LEVEL
6.5.5. CHECKING FUEL LEVEL
6.5.6. CHECKING HYDRAULIC OIL LEVEL
6.5.7. CHECKING THE TYRE PRESSURE
6.5.8. GREASING
6.5.9. CHECKING THE ROPS/FOPS OPERATOR’S CABIN
6.5.10. DRAINING WATER FROM THE FUEL FILTER
6.5.11. CHECKING & CLEANING THE ENGINE AIR PRE-CLEANER (DUST SEPARATOR)
6.6. WEEKLY INSPECTION & MAINTENANCE (EVERY 50 HOURS)
6.6.1. DRAINING THE FUEL TANK WATER AND SEDIMENT
6.6.2. CHECKING THE ELECTROLYTE LEVEL OF BATTERY
6.6.3. CHECKING THE CLEARANCE OF INNER PLATES OF THE STABILIZERS
6.6.4. CHECKING AND READJUSTING WEAR PADS OF TELESCOPIC ARM
6.6.5. GREASING
6.6.6. CLEANING AIR FILTER INNER ELEMENT
6.7. EVERY 100 HOURS INSPECTION& MAINTENANCE
6.7.1. CHECKING AND LUBRICATING THE PARKING BRAKE (ALPHA)
6.8. EVERY 250 HOURS INSPECTION & MAINTENANCE
6.8.1. CHECKING THE DIFFERENTIAL OIL LEVEL OF THE AXLES
6.8.2. CHECKING THE OIL LEVEL IN HUBS
6.8.3. CLEANING FRONT AND REAR AXLE BREATHERS
6.8.4. CLEANING TRANSMISSION BREATHER
6.9. EVERY 500 HOURS INSPECTION & MAINTENANCE
6.9.1. CLEANING RADIATOR
6.9.2. REPLACING THE HYDRAULIC RETURN FILTER
6.9.3. REPLACING THE TRANSMISSION OIL FILTER
6.9.4. CHANGING AIR CONDITIONER INNER AND OUTER FILTER ELEMENTS
6.9.5. CHANGING AUTOMATIC REVERSIBLE FAN COMPRESSOR AIR FILTER (IF EXISTS)
6.10. EVERY 500 HOURS OR 1 YEAR INSPECTION & MAINTENANCE
6.10.1. REPLACING ENGINE OIL AND ENGINE OIL FILTER
6.10.2. REPLACING FUEL FILTER ELEMENT
6.11. EVERY 1000 HOURS INSPECTION& MAINTENANCE
6.11.1. INSPECTING BELT
6.11.2. CHECKING BELT TENSIONER
6.11.3. CHANGING TRANSMISSION OIL AND CLEANING THE SUCTION STRAINER
6.11.4. CHANGING THE HYDRAULIC OIL AND SUCTION STRAINER
6.11.5. INSPECTING WATER PUMP
6.11.6. CHANGING THE DIFFERENTIAL OIL OF THE AXLES
6.11.7. CHANGING THE OIL OF HUBS
6.12. EVERY 2000 HOURS MAINTENANCE
6.12.1. INSPECTING AFTERCOOLER CORE
6.12.2. INSPECTING ALTERNATOR
6.12.3. INSPECTING ENGINE MOUNTS
6.12.4. INSPECTING STARTING MOTOR
6.13. EVERY 3000 HOURS MAINTENANCE
6.13.1. REPLACING ALTERNATOR AND FAN BELTS
6.14. EVERY 2 YEARS MAINTENANCE
6.14.1. DESCRIPTION OF COOLANT
6.15. EVERY 4000 HOURS MAINTENANCE
6.15.1. CLEANING AND TEST AFTERCOOLER CORE
6.16. EVERY 4500 HOURS MAINTENANCE
6.16.1. INSPECTING TURBOCHARGER
6.17. WHEN REQUIRED
6.17.1. OBTAINING ENGINE OIL SAMPLE
6.17.2. BLEEDING THE FUEL SYSTEM
6.17.3. MAINTENANCE OF AIR-CONDITIONER
6.17.4. REPLACING FUSES
6.17.5. REPLACING BATTERY
6.17.6. DISCONNECTING BATTERY OR BATTERY CABLE
6.17.7. REPLACING LIGHT BULBS
6.17.8. CLEANING THE ENGINE
6.17.9. REPLACING AIR FILTER ELEMENTS
7. SPECIFICATIONS
7.1. TECHNICAL SPECIFICATIONS OF HMK 102B
7.2. LIFTING REGULATIONS AND SAFE WORKING LOADS (SWL)
7.2.1. LIFTING REGULATIONS
7.2.2. SAFE WORKING LOADS
7.3. CYLINDERS
7.4. SOUND and VIBRATION
7.4.1. SOUND
8. OPTIONAL ATTACHMENTS
8.1. AUTOMATIC REVERSIBLE FAN
8.2. REAR VIEW SYSTEM
8.2.1. CAMERA SCREEN BUTTONS
8.3. LOADER GROUP
8.3.1. GENERAL PURPOSE BUCKET
8.3.2. MULTI PURPOSE BUCKET
8.3.3. FORKLÄ°FT APPARATUS
8.3.4. FORK ARMS
8.3.5. LEVELLING BLADE (SINGLE AXIAL)
8.3.6. LEVELLING BLADE (2 AXIAL DEGREE)
8.3.7. SNOW REMOVAL BLADE
8.3.8. LOG GRAPPLE (FIX TYPE)
8.3.9. LOG GRAPPLE (MOVABLE)
8.3.10. SCRAP COLLECTOR
8.3.11. TILTING BUCKET
8.3.12. PAPER COLLECTOR
8.3.13. BIG BAG
8.3.14. HOSE BURST VALVE (LOADER)
8.3.15. OVERLOAD WARNING SYSTEM (LOADER)
8.3.16. MOTION STABILIZER SYSTEM (MSS)
8.3.17. TILTING FORKS
8.3.18. SETTING FORKS UP FOR OPERATION
8.3.19. STOWING THE FORKS
8.3.20. SPACING THE FORKS
8.3.21. MAINTENANCE
8.4. BACKHOE GROUP
8.4.1. BACKHOE BUCKET
8.4.2. TILTING BUCKET
8.4.3. TRAPEZE BUCKET
8.4.4. SKELETON BUCKET
8.4.5. RIPPER
8.4.6. POLYP
8.4.7. EXCAVATOR THUMB ATTACHMENT
8.4.8. STABILISER RUBBER PAD
8.4.9. SLIDE SHIFT MECHANISM
8.4.10. TOWING HOOK
8.4.11. HOSE BURST VALVE (BACKHOE)
8.4.12. OVERLOAD WARNING SYSTEM (BACKHOE)
8.4.13. TUNNEL APPLICATIONS
8.5. SINGLE ACTING LINE
8.6. DOUBLE ACTING LINE
8.7. HYDRAULIC BREAKER
8.7.1. PROCEDURE FOR INSTALLATION OF HYDRAULIC BREAKER
8.7.2. MAINTENANCE FOR HYDRAULIC BREAKER
8.8. HYDRAULIC AUGER
8.8.1. PROCEDURE FOR INSTALLATION OF HYDRAULIC AUGER
8.8.2. MAINTENANCE OF THE PLANETARY REDUCER GEAR BOX
8.8.3. PERIODIC MAINTENANCE
8.9. QUICK-COUPLER
8.9.1. QUICK-COUPLER PARTS
8.9.2. PERIODIC CHECK-UP
8.9.3. QUICK-COUPLER (LOADER)
8.9.4. QUICK COUPLER MOUNTING TO THE MACHINE
8.9.5. DISMOUNTING FROM THE MACHINE
8.9.8. QUICK COUPLING ATTACHMENT (BACKHOE – HYDRAULIC TYPE)
9. APPENDIX
9.1. USAGE OF HAND SIGNALS
9.2. TABLE OF TORQUE VALUES FOR FASTENERS
9.3. CONTACTS
9.3.1. PLANTS AND AFTER SALES SERVICES