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

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Hidromek HMK 102B SUPRA & ALPHA Operation Maintenance Manual Y17_02201 2023
Size: 18.03 MB
Format: PDF
Language: English
Brand: Hidromek
Type of Machine: Backhoe Loader
Type of Manual: Operation Maintenance Manual
Model: Hidromek
HMK 102B SUPRA : From Serial Number E350001
HMK 102B ALPHA : From Serial Number E340001
HMK 102B SUPRA : From Serial Number F370001
HMK 102B ALPHA : From Serial Number F360001
Tier4 Final / Stage V
Part Number: Y17_02201
Publication Date: 2023
Number of Pages: 245 Pages

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