Hidromek Motor Grader HMK MG230-5 Operation Manual R23034401 2026

Description

Contents:
1. INTRODUCTION
1.1. GENERAL INFORMATION
1.2. CE DECLARATION OF CONFORMITY AND EMC DIRECTIVE
1.3. BEFORE STARTING OPERATION AND MAINTENANCE
1.4. INTENDED USE OF MACHINE
1.5. DIRECTIONS OF MACHINE
1.6. SAFETY INFORMATION
1.7. “CORRECT” AND “WRONG” MARKINGS IN SOME FIGURES
1.8. COPYRIGHT
1.9. DRIVING LICENSE
1.10. SPARE PARTS ORDERING PROCEDURE
1.11. LOCATION OF MACHINE AND ENGINE ID PLATES
1.11.1. MACHINE SERIAL NUMBER PLATE
1.11.2. ENGINE SERIAL NUMBER PLATE
1.11.3. DOC AND SCR SERIAL PLATE
1.11.4. PUMP ELECTRONIC UNIT
1.11.5. EMISSIONS CERTIFICATION
1.12. LOCATION OF HOURMETER (IF EQUIPPED)
1.13. TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR INFORMATION
2. SAFETY
2.1. LOCATIONS OF WARNING LABELS AND DECALS
2.2. CONTENTS OF WARNING LABELS AND DECALS
2.3. GENERAL PRECAUTIONS
2.3.1. OPERATORS MUST HAVE CERTAIN QUALIFICATIONS
2.3.2. OBSERVE ALL SAFETY RULES ON-SITE
2.3.3. HANDLING ELECTRIC ACCESSORIES
2.3.4. PRECAUTIONS WHEN GETTING IN OR OUT OF OPERATOR’S CAB
2.3.5. USE TIGHT-FITTING CLOTHES AND PROTECTIVE EQUIPMENT
2.3.6. KEEP FIRE EXTINGUISHER AND FIRST AID KIT INSIDE OPERATOR’S CAB
2.3.7. IN CASE OF PROBLEM
2.3.8. FIRE PREVENTION
2.3.9. PAY ATTENTION TO HOT FLUID
2.3.10. DO NOT INHALE DUST CONTAINING ASBESTOS
2.3.11. PAY ATTENTION TO MOVING PARTS
2.3.12. PROTECTION FROM FALLING OR FLYING OBJECTS
2.3.13. WHEN LEAVING THE MACHINE
2.3.14. EMERGENCY EXIT FROM OPERATOR’S CAB
2.3.15. PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES
2.3.16. PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS
2.3.17. CLEANING OPERATOR’S CAB WINDOWS
2.3.18. PRECAUTIONS WHEN STANDING UP FROM OPERATOR’S SEAT
2.3.19. BEWARE OF ARTICULATING PORTION
2.3.20. PRECAUTIONS WHEN RUNNING ENGINE INDOORS
2.3.21. VENTILATE INDOORS
2.3.22. WELDING PRECAUTIONS
2.3.23. CALIFORNIA PROPOSITION 65
2.3.24. READ OPERATION AND MAINTENANCE MANUAL
2.3.25. SIGNALS OF SIGNALMAN
2.3.26. MAKE SURE WORK SITE IS SAFE
2.3.27. FUELING
2.3.28. UNAUTHORIZED MODIFICATIONS
2.3.29. PRECAUTIONS FOR POLYMERS AND ELASTOMERS
2.3.30. DO NOT MODIFY THE ENGINE
2.4. PRECAUTIONS BEFORE OPERATION
2.4.1. TRAVELING ON SLOPES
2.4.2. STOPPING OF ENGINE UNEXPECTEDLY
2.5. PRECAUTIONS DURING OPERATION
2.6. PRECAUTIONS DURING ROAD CONSTRUCTION
2.7. PRECAUTIONS AFTER OPERATION
2.8. PRECAUTIONS DURING SERVICE AND MAINTENANCE
2.8.1. HANG A WARNING TAG
2.8.2. DO NOT SMOKE
2.8.3. WASTE DISPOSAL
2.8.4. HIGH-PRESSURE OIL WARNING
2.8.5. PRESSURIZED AIR
2.8.6. INFLATING TIRES
2.8.7. PRECAUTIONS RELATED TO BATTERY AND ELECTRICAL SYSTEM
2.8.8. KEEP THE MACHINE CLEAN
2.9. GETTING ON OR OFF MACHINE
3. KNOW YOUR MOTOR GRADER
3.1. MAIN COMPONENTS AND PARTS
3.2. OPERATOR’S CAB
3.3. STEERING COLUMN
3.3.1. STEERING WHEEL
3.3.2. STEERING COLUMN TILT PEDAL
3.3.3. TURN SIGNAL / HIGH-LOW BEAM LEVER
3.3.4. USB / AUX SOCKET
3.3.5. STARTER SWITCH
3.4. INSTRUMENT PANEL
3.4.1. HYDRAULIC OIL TEMPERATURE
3.4.2. SPEEDOMETER
3.4.3. FUEL LEVEL
3.4.4. DIESEL EXHAUST FLUID (DEF) (Adblue®) LEVEL GAUGE
3.4.5. ARTICULATION GAUGE
3.4.6. ENGINE SPEED
3.4.7. ENGINE COOLANT TEMPERATURE
3.4.8. AIR PRESSURE LEVEL
3.4.9. “PURGING NEEDED” WARNING LIGHT
3.4.10. “EMISSION SYSTEM MALFUNCTION” WARNING LIGHT
3.4.11. FAILURE WARNING LIGHT
3.4.12. “STOP ENGINE” WARNING LIGHT
3.4.13. “CHECK ENGINE” WARNING LIGHT
3.4.14. “ENGINE OIL PRESSURE LOW” WARNING LIGHT
3.4.15. “BATTERY IS NOT CHARGING” WARNING LIGHT
3.4.16. “GLOW PLUGS ACTIVATED” WARNING LIGHT
3.4.17. “LOW BEAM OR HIGH BEAM” WARNING LIGHT
3.4.18. “FRONT GLASS DEFROSTER” WARNING LIGHT
3.4.19. “REAR GLASS DEFROSTER” WARNING LIGHT
3.4.20. “MIRROR DEFROSTER” WARNING LIGHT
3.4.21. “PARKING BRAKE APPLIED” WARNING LIGHT
3.4.22. N/A
3.4.23. “FASTEN CO-OPERATOR’S SEAT BELT” WARNING LIGHT (IF AVAILABLE ON YOUR MACHINE)
3.4.24. “FASTEN OPERATOR’S SEAT BELT” WARNING LIGHT
3.4.25. “TRANSMISSION OIL TEMPERATURE HIGH” WARNING LIGHT
3.4.26. “DIFFERENTIAL LOCK” WARNING LIGHT
3.4.27. “DEFECTIVE EMERGENCY STEERING SYSTEM” WARNING LIGHT
3.4.28. “LEFT TURN SIGNAL” WARNING LIGHT
3.4.29. “RIGHT TURN SIGNAL” WARNING LIGHT
3.4.30. “AIR CONDITIONER” WARNING LIGHT
3.4.31. SET TEMPERATURE (INSIDE THE OPERATOR’S CAB)
3.4.32. FAN BLOWER SPEED
3.4.33. “INDOOR AIR RECIRCULATION” WARNING LIGHT
3.4.34. ACTIVE FOLDER NAME
3.4.35. “USB CONNECTED” WARNING LIGHT
3.4.36. CURRENT SONG INFORMATION
3.4.37. DURATION OF THE CURRENT SONG
3.4.38. CHRONOMETER
3.4.39. DAILY KM COUNTER (TRIP)
3.4.40. CLOCK
3.4.41. THERMOMETER (AMBIENT TEMPERATURE)
3.4.42. DIGITAL HOURMETER
3.4.43. KM COUNTER
3.4.44. RADIO FREQUENCY
3.4.45. VOLUME INDICATOR
3.4.46. REGISTERED RADIO STATIONS
3.5. MENU CONTENTS
3.6. SIDE CONTROL PANEL
3.6.1. WIPER SWITCHES
3.6.2. OPERA INSTRUMENT PANEL
3.6.3. SWITCHES (BUTTONS)
3.6.4. EXTERNAL POWER SOCKET (12V) / LIGHTER
3.6.5. MIRROR ADJUSTMENT LEVER (IF EQUIPPED)
3.7. SHIFTING GEARS
3.7.1.1. CHANGING MACHINE TRAVEL DIRECTION
3.8. ACCELERATOR PEDAL
3.9. BRAKE PEDAL
3.10. INCHING PEDAL
3.11. TRANSMISSION CONTROL LEVER
3.12. PARKING BRAKE SWITCH
3.13. THROTTLE DIAL
3.14. CONTROL LEVER
3.14.1. FUNCTION OF CONTROL LEVERS
3.15. OPERATOR’S SEAT
3.16. CO-OPERATOR’S SEAT
3.17. ADJUSTMENT OF SEAT BELT
3.17.1. FASTENING AND REMOVING BELT
3.18. ARTICULATION LOCK PIN
3.19. MECHANICAL HOURMETER (IF EQUIPPED)
3.20. EMERGENCY EXIT
3.21. FIRST AID KIT
3.22. WINDOW WASHER FILLER CAP
3.23. STORAGE COMPARTMENT
3.24. SIDE WINDOWS
3.25. DOOR
3.26. DOOR FIXING MECHANISM
3.27. FIRE EXTINGUISHER (if equipped)
3.28. BATTERY DISCONNECT SWITCH
4. OPERATION
4.1. NEW MACHINE BREAK-IN
4.2. PRE-START INSPECTION
4.2.1. PRECAUTIONS FOR INSPECTION
4.2.2. IF MACHINE HAS A PROBLEM
4.2.3. PRE-START INSPECTION LIST
4.3. BEFORE STARTING ENGINE
4.4. COLD WEATHER START
4.5. CHECKING EMERGENCY STEERING SYSTEM
4.6. STARTING ENGINE
4.7. AFTER STARTING ENGINE
4.8. BEFORE MOVING THE MACHINE
4.9. MOVING THE MACHINE
4.10. CHANGING SPEED
4.11. OPERATING ON SLOPES
4.12. OPERATING ON ROUGH TERRAIN
4.13. OPERATING ON SNOW AND ICE
4.14. STOPPING THE ENGINE
4.15. AFTER STOPPING ENGINE
4.16. STOPPING MACHINE
4.17. PARKING MACHINE
4.18. CLEAN EMISSION MODULE (CEM)
4.18.1. SELECTIVE CATALYTIC REDUCTION WARNING SYSTEM
4.18.2. WARNING INDICATORS
4.18.3. SCR WARNING LEVELS
4.18.4. SCR WARNINGS
4.18.5. MANUAL PURGING OF CEM
4.18.6. DEF LEVEL WARNINGS
4.19. PRECAUTIONS FOR USING ATTACHMENT CONTROLS
4.20. OPERATING ADJUSTMENTS
4.20.1. BLADE ANGLE
4.20.2. BLADE TILT
4.21. SCARIFIER DIGGING ANGLE (if equipped)
4.22. SCARIFIER PENETRATION (if equipped)
4.23. RIPPERS AND TEETH OF REAR MOUNTED RIPPER ATTACHMENT (if equipped)
4.24. RIPPER INSTALLATION FACING UPWARDS (if equipped)
4.25. RIPPER TOOTH POSITION (if equipped)
4.26. CENTERSHIFT BRACKET
4.27. HIGH BANK CUTTING – LEFT SIDE
4.28. PREPARATION FOR ROAD CONSTRUCTION
4.28.1. INSPECTION BEFORE STARTING TRIP
4.28.2. PRECAUTIONS WHILE TRAVELING
4.28.3. INSPECTION AT NEW LOCATION
4.29. TOWING THE MACHINE
4.30. TRANSPORTATION
4.31. LIFTING THE MACHINE BY CRANE
4.31.1. LIFTING PROCEDURE
4.31.2. LIFTING POINTS
4.32. SPECIAL SITUATIONS
4.32.1. OPERATING IN COLD WEATHER
4.32.2. OPERATING IN HOT WEATHER
4.32.3. OPERATING IN EXTREMELY DUSTY CONDITIONS
4.33. LONG TERM STORAGE OF MACHINE
4.33.1. STORAGE WITHIN ONE MONTH
4.33.2. BEFORE STORAGE
4.33.3. DURING STORAGE
4.33.4. AFTER STORAGE
4.34. INSTRUCTIONS ON WITHDRAWAL FROM USE AND UTILIZATION
4.35. OPERATION AND MAINTENANCE OF AIR CONDITIONER
4.36. OPERATING TECHNIQUES
4.36.1. MANEUVERING
4.36.2. “T” TURNING
4.36.3. TURNING AROUND BY ARTICULATING
4.36.4. GRADING WHILE S CURVING
4.36.5. BACKING OUT OF A DROP-OFF OR DITCH
4.36.6. LEVELING
4.36.7. “V” DITCHING
4.36.8. PULVERIZING
4.36.9. REPAIRING GRAVEL ROADS
4.36.10. MIXING
4.36.11. SPREADING
4.36.12. HIGH BANK CUTTING
4.36.13. SNOW REMOVAL
4.36.14. ARTICULATION (FRONT END OFF-SETTING)
5. MAINTENANCE
5.1. GENERAL INSTRUCTIONS
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. HANDLING POLYMERS AND ELASTOMERS CONTAINING FLUOROCARBON
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 ENVIRONMENT
5.2.18. USE OF BIODEGRADABLE SYNTHETIC OILS
5.3. PERIODICAL REPLACEMENT OF SAFETY- RELATED PARTS
5.4. PERIODIC INSPECTION OF SERVICE BRAKES
5.5. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS
5.6. OIL, FUEL, COOLANT
5.6.1. LUBRICANTS AND ANTIFREEZE
5.6.2. LUBRICATION CHART
5.6.3. DIESEL EXHAUST FLUID (DEF)
5.7. PERIODICAL INSPECTION AND MAINTENANCE LIST
5.8. CHECKS BEFORE STARTING
5.8.1. WALK AROUND INSPECTIONS TO BE CONDUCTED BEFORE STARTING ENGINE
5.8.2. INSPECTIONS TO BE CONDUCTED BEFORE STARTING ENGINE
5.8.3. INSPECTIONS AND OPERATIONS AFTER STARTING ENGINE
5.9. EVERY 10 HOUR OR DAILY MAINTENANCE
5.9.1. WALK-AROUND INSPECTION
5.9.2. CHECKING ENGINE COOLANT LEVEL
5.9.3. CHECKING ENGINE OIL LEVEL
5.9.4. CHECKING FUEL LEVEL
5.9.5. CHECKING DIESEL EXHAUST FLUID (DEF) (ADBLUE®) LEVEL AND SUPPLYING IF REQUIRED
5.9.6. CHECKING INFLATION PRESSURE OF TIRES
5.9.7. CHECKING BRAKE PEDAL
5.9.8. CHECKING INCHING PEDAL
5.9.9. CHECKING STEERING WHEEL
5.9.10. CHECKING ATTACHMENTS
5.9.11. DRAINING WATER AND SEDIMENT FROM AIR TANK
5.9.12. DRAINING WATER AND SEDIMENT FROM FUEL FILTERS
5.9.13. GREASING SLIDING SURFACES OF CIRCLE AND WEAR SHOES
5.9.14. GREASING CIRCLE GEAR AND PINION GEAR
5.9.15. CHECKING FOR FLUID LEAKAGE ON ENGINE
5.10. INITIAL 50 HOUR MAINTENANCE
5.11. EVERY 50 HOUR (OR WEEKLY) MAINTENANCE
5.11.1. CHECKING OIL LEVEL IN HYDRAULIC TANK, ADDING OIL
5.11.2. DRAIN WATER AND SEDIMENT FROM FUEL TANK
5.11.3. CHECKING BLADE GUIDE SHOES AND REPLACING WHEN NECESSARY
5.12. EVERY 250 HOUR (OR MONTHLY) MAINTENANCE
5.12.1. CHECKING TRANSMISSION OIL LEVEL, ADDING OIL IF LEVEL IS LOW
5.12.2. CHECKING BATTERY ELECTROLYTE LEVEL
5.12.3. CHECKING ALTERNATOR AND AIR CONDITIONER COMPRESSOR BELT TENSION
5.12.4. GREASING ARTICULATION LOCK PIN
5.12.5. GREASING STEERING CYLINDER JOINTS
5.12.6. CHECKING FOR LOOSE WHEEL HUB NUTS, TIGHTENING
5.12.7. CLEANING AIR CONDITIONER FILTER ELEMENTS, CHANGING IF REQUIRED
5.12.8. CLEANING AND IF NECESSARY, REPLACING FUEL TANK BREATHER ELEMENT
5.12.9. CLEANING REAR AXLE BREATHERS
5.12.10. CLEANING TRANSMISSION BREATHER ELEMENT
5.12.11. TESTING SERVICE BRAKE
5.12.12. TESTING PARKING BRAKE
5.12.13. TESTING EMERGENCY STEERING SYSTEM
5.12.14. CHECKING AND ADJUSTING CLEARANCE BETWEEN CIRCLE GEAR, DRAWBAR AND GUIDE SHOES
5.13. EVERY 500 HOUR OR 3 MONTH MAINTENANCE
5.13.1. CLEANING RADIATOR
5.13.2. REPLACING ENGINE OIL AND ENGINE OIL FILTER
5.13.3. OIL CHANGE INTERVALS
5.13.4. OIL VISCOSITY GRADE
5.13.5. REPLACING FUEL SYSTEM PRIMARY FILTER (WATER SEPARATOR) ELEMENT
5.13.6. REPLACING FUEL SYSTEM SECONDARY FILTER
5.13.7. REPLACING IN-LINE FUEL FILTER
5.13.8. CHECKING REAR AXLE OIL LEVEL AND ADDING IF REQUIRED
5.13.9. CHECKING OIL LEVEL IN TANDEM CASES
5.13.10. CHECKING OIL LEVEL IN CIRCLE REVERSE GEAR CASE
5.13.11. GREASING FRONT AXLE CENTER PIN, KNUCKLES AND TIE RODS
5.13.12. GREASING FRONT AXLE LEANING CYLINDER AND LINKAGE
5.13.13. GREASING DRAWBAR BALL JOINT
5.13.14. GREASING SCARIFIER LIFT CYLINDER AND LINKS (if equipped)
5.13.15. GREASING BLADE LIFT CYLINDERS
5.13.16. GREASING BLADE CROSSBAR AND LOCK CYLINDER
5.13.17. GREASING CIRCLE CENTERSHIFT CYLINDER, BLADE GUIDE BRACKETS AND BLADE TIP CYLINDERS
5.13.18. GREASING HYDRAULIC PUMP UNIVERSAL JOINT
5.13.19. GREASING ARTICULATION CYLINDERS
5.13.20. CLEANING AIR CONDITIONER CONDENSER
5.13.21. CLEANING AND INSPECTION OF RADIATOR FINS
5.13.22. CHANGING HYDRAULIC TANK BREATHER ELEMENT
5.14. EVERY 1000 HOUR (6 MONTH) MAINTENANCE
5.14.1. INSPECT BELT
5.14.2. INSPECT BELT TENSIONER
5.14.3. CHANGING HYDRAULIC TANK FILTER ELEMENT
5.14.4. CHECKING BALL JOINTS OF ATTACHMENTS FOR CLEARANCE
5.14.5. GREASING BLADE SIDESHIFT CYLINDER
5.14.6. CHECKING AIR DRIER IN COMPRESSED AIR SYSTEM
5.15. EVERY 1500 HOUR MAINTENANCE
5.15.1. CLEANING / REPLACING DIESEL EXHAUST FLUID FILTER
5.15.2. REPLACING ENGINE CRANKCASE BREATHER ELEMENT
5.15.3. INSPECTING WATER PUMP
5.16. EVERY 2000 HOUR (ANNUAL) MAINTENANCE
5.16.1. INSPECTING AFTERCOOLER CORE
5.16.2. INSPECTING ALTERNATOR
5.16.3. INSPECTING ENGINE MOUNTS
5.16.4. INSPECTING STARTING MOTOR
5.16.5. INSPECTING TURBOCHARGER
5.16.6. INSPECT CLEAN EMISSIONS MODULE SUPPORT
5.16.7. CHANGING TRANSMISSION OIL AND CLEANING OIL STRAINER
5.16.8. CHANGING TRANSMISSION OIL FILTER
5.16.9. CHANGING REAR AXLE OIL AND CLEANING OIL STRAINER
5.16.10. CHANGING OIL IN TANDEM DRIVE CASES
5.16.11. CHANGING OIL IN CIRCLE GEAR REVERSE CASE
5.16.12. CHANGING OIL IN HYDRAULIC TANK
5.16.13. INSPECTION OF BLADE SLIP CLUTCH (if equipped)
5.16.14. CHECKING FRONT GEOMETRY (TOE- IN) AND ADJUSTING IF NECESSARY
5.16.15. CHANGING GREASE IN FRONT AXLE BEARING
5.16.16. REPLACING AIR DRIER IN COMPRESSED AIR SYSTEM
5.17. EVERY 2 YEAR OR 3000 HOUR MAINTENANCE
5.17.1. CHANGING COOLING SYSTEM COOLANT
5.17.2. REPLACING ALTERNATOR AND FAN BELTS
5.18. EVERY 10000 HOUR MAINTENANCE
5.18.1. REPLACING DEF MANIFOLD FILTERS
5.19. WHEN REQUIRED
5.19.1. OBTAINING ENGINE OIL SAMPLE
5.19.2. BLEEDING FUEL SYSTEM
5.19.3. FILLING DIESEL EXHAUST FLUID
5.19.4. FLUSHING DIESEL EXHAUST FLUID TANK
5.19.5. CLEANING DEF FILLER SCREEN
5.19.6. INFLATING TIRES
5.19.7. REPLACING AIR CLEANER INNER AND OUTER ELEMENTS
5.19.8. CLEANING AIR PRE-CLEANER
5.19.9. PERFORMING TOE-IN ADJUSTMENT
5.19.10. ADJUSTING CLEARANCE BETWEEN CIRCLE GEAR AND DRAWBAR
5.19.11. ADJUSTING BLADE SLIP CLUTCH (if equipped)
5.19.12. CHANGING CUTTING EDGES AND END BITS
5.19.13. CHANGING SCARIFIER/REAR MOUNTED RIPPER TEETH (if equipped)
5.19.14. CHANGING REAR MOUNTED RIPPERS (if equipped)
5.19.15. LAYOUT OF FUSES
5.19.16. SERVICING BATTERIES
5.19.17. CLEANING ENGINE
5.19.18. SERVICING TIRES
5.19.19. CHECKING AIR CONDITIONER REFRIGERANT AMOUNT
6. TROUBLESHOOTING
6.1. CHASSIS
6.1.1. TRANSMISSION
6.1.2. REAR AXLE, TANDEM DRIVES AND REAR WHEELS
6.1.3. STEERING WHEEL AND FRONT AXLE
6.1.4. SERVICE BRAKES
6.1.5. PARKING BRAKE
6.2. ATTACHMENTS
7. TECHNICAL SPECIFICATIONS
8. CONTACT INFORMATION
8.1. PLANT AND AFTER SALES SERVICES
9. ALPHABETICAL INDEX