Hidromek Backhoe Loader Maestro Series Operation Maintenance Manual Y10_13101

[Hyundai]

Download this document, you need 500 Gallons

Hidromek Backhoe Loader Maestro Series Operation Maintenance Manual Y10_13101
Size: 16.58 MB
Format: PDF
Language: English
Brand: Hidromek
Type of Machine: Backhoe Loader
Type of Manual: Operation Maintenance Manual
Model: Hidromek Maestro Series Backhoe Loader
Serial Number: A19001 -
Part Number: Y10_13101
Publication Date: 2015
Number of Pages: 202 Pages

Contents:
1. INTRODUCTION

1.1. FOREWORD​

1.2. CE MARKING AND EMC DIRECTIVE​

1.3. IDENTIFICATION PLATE​

1.4. BACKHOE 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. 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. SLEWING​

2.4.6. OPERATING ON HILLSIDES & SLOPES​

2.4.7. WORKING AROUND UTILITY LINES​

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. EXPERIMENTAL OPERATIONS​

2.4.15. PARKING THE MACHINE​

2.4.16. KEEP UNAUTHORIZED PEOPLE AWAY​

2.4.17. CHECK ATTACHMENT LOCK PINS​

2.4.18. STOWAGE OF ATTACHMENTS​

2.4.19. VENTILATION IN CLOSED AREA​

2.4.20. EMERGENCY EXIT​

2.4.21. UNINTENTIONAL SHUT-OFF DURING OPERATION​

2.4.22. UNINTENTIONAL SHUT-OFF DURING TRAVEL​

2.4.23. 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. “KEEP CLEAR OF WORKING AREA” WARNING FOR BACKHOE​

2.7.5. “SAFE WORKING LOAD” LABEL​

2.7.6. “BEFORE PERFORMING ANY MAINTENANCE or INSPECTION STOP THE ENGINE, REMOVE IGNITION KEY AND READ OPERATING MANUAL” WARNING FOR ROTATING AND HOT PARTS AND SURFACES.​

2.7.7. “BATTERY” WARNING​

2.7.8. "TRANSMISSION OIL CONTROL" CAUTION​

2.7.9. “FUEL SPECIFICATIONS” WARNING LABEL​

2.7.10. "FUEL TANK” CAUTION​

2.7.11. “ELECTRICAL EQUIPMENT” WARNING​

2.7.12. “BATTERY CUT-OFF RELAY” WARNING LABEL​

2.7.13. "DO NOT PINCH YOUR FOOT" WARNING LABEL​

2.7.14. “KEEP CLEAR OF WORKING AREA” WARNING FOR LOADER​

2.7.15. “DO NOT PINCH YOUR HANDS” WARNING​

2.7.16. TELESCOPIC DIPPER - HYDRAULIC BREAKER SELECTING VALVE​

2.7.17. “HYDRAULIC BREAKER AND AUGER OPERATION” LABEL​

2.7.18. "BACKHOE BOOM SLEW LOCK PIN" CAUTION​

2.7.19. "EMERGENCY EXIT" CAUTION​

2.7.20. “HYDRAULIC OIL TANK” CAUTION​

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 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 SWITCH​

3.1.5. STEERING WHEEL ADJUSTMENT LEVER​

3.1.6. COMPARTMENTS AND STOWAGE PLACES FOR OBJECTS​

3.1.7. INSTRUMENT PANEL​

3.1.8. HAZARD WARNING LIGHT SWITCH​

3.1.9. HEADLIGHTS & TAIL LIGHTS SWITCH​

3.1.10. MOTION STABILIZER SYSTEM (MSS) SWITCH (OPTIONAL)​

3.1.11. DIFFERENTIAL LOCK (If exists)​

3.1.12. FORWARD/REAR DIRECTION SELECTION (FNR) LOCKING SWITCH​

3.2. RIGHT HAND SIDE INSTRUMENT PANEL​

3.2.1. LOADER JOYSTICK​

3.2.2. LOADER JOYSTICK SAFETY LOCK​

3.2.3. HAND (PARKING) BRAKE​

3.2.4. THROTTLE LEVER​

3.2.5. RIGHT HAND SIDE INSTRUMENT AND CONTROL PANEL​

3.2.6. ASHTRAY / GLASS HANDLER​

3.2.7. BOOK POCKET​

3.2.8. BOOM LOCK HANDLE​

3.2.9. STABILIZER CONTROL LEVER (Only on machines with joystick type backhoe control levers)​

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. TOOLBOX​

3.6. BACKHOE CONTROL CONSOLE​

3.7. REAR WINDOW AND REAR WINDOW WIPER​

3.7.1. OPENING THE REAR WINDOW​

3.7.2. CLOSING THE REAR WINDOW​

3.8. INTERIOR LIGHT​

3.9. COAT HANGER​

3.10. BACKHOE JOYSTICKS (OPTIONAL)​

3.11. AIR CONDITION CONTROL PANEL (OPTIONAL)​

3.11.1. USING THE AIR CONDITION​

3.12. AUXILIARY VALVE PEDAL​

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​

4.12.3. ENGAGING BACKHOE BOOM LOCK​

4.12.4. DISENGAGING BACKHOE BOOM LOCK​

4.12.5. BACKHOE SLEW LOCK​

4.12.6. STABILIZER SHOE LOCK​

4.13. CONTROLLING HYDRAULIC CLAMP CYLINDERS​

4.14. SIDESHIFTING THE BACKHOE​

4.14.1. MANUAL​

4.14.2. AUTOMATIC (OPTIONAL)​

4.15. TELESCOPIC DIPPER (OPTIONAL)​

4.15.1. EXTENDING THE TELESCOPIC DIPPER​

4.15.2. RETRACTING AND LOCKING THE TELESCOPIC DIPPER​

4.15.3. TELESCOPIC DIPPER SAFETY LOCK​

4.15.4. TELESCOPIC DIPPER - HYDRAULIC BREAKER SELECTING VALVE​

4.16. BRAKING​

4.17. THE LOADER OPERATION​

4.17.1. LOADER OPERATION IN BANKS AND STOCKPILES​

4.17.2. LOADING TRUCKS​

4.17.3. RESCUING A STUCK MACHINE​

4.17.4. GRADING WITH LOADER​

4.18. THE BACKHOE OPERATION​

4.18.1. HINTS ON OPERATION OF BACKHOE​

4.18.2. CORRECT DIGGING METHOD​

4.18.3. EXCAVATION ON SLOPES​

4.18.4. LOWERING THE ATACHMENTS IN CASE OF UNEXPECTED POWER CUT-OFF​

4.19. REPLACING ATTACHMENTS​

4.19.1. LOADER BUCKET​

4.19.2. BACKHOE BUCKET​

4.19.3. REPLACING BUCKET TEETH​

4.20. TRANSPORTING THE MACHINE​

4.21. TOWING PROCEDURE FOR A DISABLED MACHINE​

4.22. LIFTING BY A CRANE​

4.23. PRESERVING THE MACHINE FOR STORAGE​

4.23.1. MAINTENANCE OF THE MACHINE DURING AND AFTER STORAGE​

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. ENGINE DESCRIPTION​

5.4.2. RECORD ENGINE SERIAL NUMBER​

5.4.3. ENGINE OPTION CODES​

5.5. PERIODIC MAINTENANCE​

5.5.1. FIRST 50 HOURS MAINTENANCE​

5.6. TABLE of LUBRICANTS & FLUIDS​

5.7. PRE-START (EVERY 8 HOURS) INSPECTION & MAINTENANCE​

5.7.1. CHECKING ENGINE OIL LEVEL​

5.7.2. CHECKING COOLANT LEVEL​

5.7.3. CHECKING FUEL FILTERS​

5.7.4. CHECKING ENGINE FLUID LEAKS​

5.7.5. CHECKING & CLEANING THE ENGINE AIR PRE-CLEANER (DUST SEPARATOR)​

5.7.6. CLEANING THE AIR PRE-CLEANER​

5.7.7. CHECKING AIR CLEANER​

5.7.8. CHECKING FUEL LEVEL​

5.7.9. CHECKING TRANSMISSION OIL LEVEL​

5.7.10. CHECKING HYDRAULIC OIL LEVEL​

5.7.11. HYDRAULIC OIL TANK CAP​

5.7.12. CHECKING THE TYRE PRESSURE​

5.7.13. GREASING​

5.8. WEEKLY (EVERY 50 HOURS) INSPECTION & MAINTENANCE​

5.8.1. DRAINING THE FUEL TANK​

5.8.2. CHECKING THE CLEARANCE OF INNER PLATES OF THE STABILIZERS​

5.8.3. CHECKING THE ELECTROLYTE LEVEL OF BATTERY​

5.8.4. CHECKING THE ROPS/FOPS OPERATOR’S CABIN​

5.8.5. CHECKING AND READJUSTING WEAR PADS OF TELESCOPIC ARM​

5.9. EVERY 100 HOURS INSPECTION & MAINTENANCE​

5.9.1. CHECKING AND LUBRICATING THE PARKING BRAKE​

5.10. EVERY 250 HOURS INSPECTION & MAINTENANCE​

5.10.1. CHECKING THE DIFFERENTIAL OIL LEVEL OF THE AXLES​

5.10.2. CHECKING THE OIL LEVEL IN HUBS​

5.10.3. CHANGING ENGINE OIL AND REPLACING FILTER​

5.10.4. OIL CHANGE INTERVALS​

5.10.5. OIL VISCOSITY GRADE​

5.10.6. REPLACING FUEL FILTER ELEMENTS​

5.11. EVERY 500 HOURS INSPECTION & MAINTENANCE​

5.11.1. CHECKING CRANKCASE VENT SYSTEM​

5.11.2. CHECKING AIR INTAKE SYSTEM​

5.11.3. CHECKING BELT TENSIONER SPRING AND BELT WEAR(AUTOMATIC TENSIONER)​

5.11.4. CHECKING ENGINE ELECTRICAL GROUND CONNECTIONS​

5.11.5. CHECKING COOLING SYSTEM​

5.11.6. PRESSURE TESTING COOLING SYSTEM​

5.11.7. CHECKING AND ADJUSTING ENGINE SPEEDS​

5.11.8. CHANGING THE HYDRAULIC RETURN FILTER​

5.11.9. CHANGING THE TRANSMISSION OIL FILTER​

5.11.10. CLEANING AND CHANGING OPERATOR’S CABIN HEATER AIR FILTER​

5.12. EVERY 1000 HOURS INSPECTION & MAINTENANCE​

5.12.1. CHANGING TRANSMISSION OIL​

5.12.2. CHANGING THE DIFFERENTIAL OIL OF THE AXLES​

5.12.3. CHANGING THE OIL OF HUBS​

5.12.4. CHANGING THE HYDRAULIC OIL​

5.12.5. CHANGING & CLEANING THE SUCTION STRAINER​

5.13. 2000 HOURS MAINTENANCE​

5.13.1. DESCRIPTION OF COOLANT​

5.13.2. COOLANT FILLING CAP​

5.13.3. FLUSHING AND REFILLING COOLING SYSTEM​

5.13.4. TESTING THERMOSTATS OPENING TEMPERATURE​

5.13.5. CHECK AND ADJUST VALVE CLEARANCE​

5.14. MISCELLANEOUS​

5.14.1. REPLACING FUSES​

5.14.2. BLEEDING THE FUEL SYSTEM​

5.14.3. MAINTENANCE OF AIR-CONDITIONER (OPTIONAL)​

5.14.4. REPLACING LIGHT BULBS​

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. TILTING FORKS​

7.2.1. SETTING FORKS UP FOR OPERATION​

7.2.2. STOWING THE FORKS​

7.2.3. SPACING THE FORKS​

7.2.4. MAINTENANCE​

7.3. HYDRAULIC BREAKER​

7.3.1. PROCEDURE FOR INSTALLATION OF HYDRAULIC BREAKER​

7.3.2. ADJUSTING HYDRAULIC BREAKER​

7.4. HYDRAULIC AUGER​

7.4.1. PROCEDURE FOR INSTALLATION OF HYDRAULIC AUGER​

7.4.2. HINTS ON THE OPERATION OF HYDRAULIC AUGER​

7.4.3. MAINTENANCE OF THE PLANETARY REDUCER GEAR BOX​

7.4.4. PERIODIC MAINTENANCE​

7.4.5. RECOMMENDED OIL FOR LUBRICATION​

7.5. LOG GRAB​

7.6. GRADING BLADE​

7.7. AIR COMPRESSOR​

7.8. FORKLIFT ATTACHMENT & CLAMSHELL BUCKET​

7.9. TRAPEZOID DITCH BUCKET​

7.10. RIPPER​

7.11. SIDE SHIFT BUCKET​

7.12. CLAMSHELL GRAB​

7.13. WINCH​

7.14. STREET SWEEPER​

7.15. QUICK COUPLER​

7.15.1. MOUNTING TO THE MACHINE​

7.15.2. DISMOUNTING FROM THE MACHINE​

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