Hidromek Wheeled Excavator HMK 210 W-4 Final Tier 4 Stage IV Operation And Maintenance Manual

OPERATION AND MAINTENANCE MANUAL Final Tier 4 / Stage IV WHEELED EXCAVATORS HMK 210 W-4 HİDROMEK 2020

CAUTION Always keep this manual in the operator’s cab. Read, understand and follow all safety instructions given in this manual before operating the machine.

Copyright © Hidromek All copyrights are reserved by HIDROMEK–HIDROLIK VE MEKANIK MAKINE IMALAT SANAYI ve TICARET ANONIM ŞIRKETI. Copying or reproducing whole or part of this document, part of text or picture without written consent of HIDROMEK beforehand is strictly forbidden.

Publication No: H237324401 Date of publication: 17.01.2020

Rev No: 03 Original Instructions

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MACHINE IDENTIFICATION INFORMATION

-

GENERAL

Machine Owner;

Machine;

Name:

Date of Production (Month / Year):

Address:

Warranty Start Date (Day/ Month / Year):

City:

Machine Operation Hour on Delivery:

Postal code:

Dealer Name:

Product Identification Number:

Dealer Code:

Dealer Stamp and Signature:

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MACHINE IDENTIFICATION - SERIAL NUMBERS

Machine; Type

:

Model

:

Machine Serial Number

:

Product Identification Number

:

Engine; Type

:

Model

:

Engine Serial Number

:

DOC Serial Number

:

SCR Serial Number

:

Components; Travel Unit Serial Number

:

Main Pump Serial Number

:

Main Control Valve Serial Number

:

Swing Unit Plate Serial Number

:

Operator's Cab Serial Number

:

Front Axle Serial Number

:

Rear Axle Serial Number

:

Transmission Serial Number

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TABLE OF CONTENTS 1. INTRODUCTION ........................................................................................................................................... 1 1.1. FOREWORD .......................................................................................................................................... 1 1.2. SAFETY INFORMATION........................................................................................................................ 1 1.3. DESCRIPTION AND INTENDED USE ................................................................................................... 2 1.4. CE MARKING AND DECLARATION OF CONFORMITY ....................................................................... 2 1.5. CHARACTERISTICS OF THE MACHINE .............................................................................................. 2 1.6. EXHAUST EMISSION REGULATION RELATED PARTS ..................................................................... 2 1.7. BREAK-IN OPERATION......................................................................................................................... 3 1.8. SPARE PARTS AND SERVICE ............................................................................................................. 3 1.9. COPYRIGHT .......................................................................................................................................... 3 1.10. DRIVING LICENSE .............................................................................................................................. 3 1.11. IDENTIFICATION PLATES .................................................................................................................. 4 1.12. MAIN COMPONENTS PLATES ........................................................................................................... 6 2. SAFETY ......................................................................................................................................................... 7 2.1. GENERAL CAUTION ............................................................................................................................. 7 2.2. CAUTION DURING OPERATING ........................................................................................................ 12 2.3. CAUTION ON MAINTENANCE ............................................................................................................ 26 2.4. ATTACHED POSITIONS SAFETY LABEL ........................................................................................... 32 3. DESCRIPTION ............................................................................................................................................ 41 3.1. LOCATION OF MAIN PARTS ............................................................................................................... 41 3.2. DETAIL OF OPERATOR’S CAB ........................................................................................................... 42 3.3. INSTRUMENT PANEL ......................................................................................................................... 43 3.4. MENU ITEMS ....................................................................................................................................... 50 3.5. MEDIA .................................................................................................................................................. 69 3.6. OPERA INSTRUMENT PANEL ............................................................................................................ 71 3.7. USB / AUX CONNECTIONS ................................................................................................................. 74 3.8. EXTERNAL SOCKET (12 V) ................................................................................................................ 74 3.9. STARTER KEY ..................................................................................................................................... 74 3.10. HOURMETER .................................................................................................................................... 75 3.11. CUP HOLDER / ASH TRAY ................................................................................................................ 75 3.12. CONVENIENT STORAGE.................................................................................................................. 75 3.13. CONVENIENT STORAGE BOX ......................................................................................................... 75 3.14. SWITCHES ......................................................................................................................................... 76 3.15. DOZER BLADE AND OUTRIGGER CONTROL LEVER .................................................................... 78 3.16. STEERING ......................................................................................................................................... 79 3.17. SAFETY LOCKING DEVICE .............................................................................................................. 85 3.18. ADJUSTING ARMREST HEIGHT ...................................................................................................... 85 3.19. ARMREST ANGLE ADJUSTMENT .................................................................................................... 86 3.20. CONSOLE ANGLE ADJUSTING LEVERS......................................................................................... 86 3.21. LEFT CONSOLE LIFTING LEVER ..................................................................................................... 87 3.22. LEVERS ............................................................................................................................................. 88 3.23. SWING LOCK ..................................................................................................................................... 90 3.24. ACCELERATOR AND BRAKE PEDALS ............................................................................................ 91 3.25. FUSE / RELAY BOX ........................................................................................................................... 93 3.26. AUTOMATIC/MANUAL MODE SWITCH............................................................................................ 95 3.27. BATTERY RELAY .............................................................................................................................. 95 3.28. BATTERY MASTER SWITCH ............................................................................................................ 96 3.29. HEATER AND AIR CONDITION......................................................................................................... 97 3.30. LIGHTER .......................................................................................................................................... 100 3.31. BOTTLE HOLDER ............................................................................................................................ 100 3.32. COOL BOX ....................................................................................................................................... 100 3.33. CONVENIENT STORAGE AND CONVENIENT STORAGE BOX.................................................... 100 3.34. EMERGENCY EXIT.......................................................................................................................... 100 3.35. FIRST-AID KIT .................................................................................................................................. 100 3.36. FRONT WINDSHIELD ...................................................................................................................... 101 3.37. DOOR ............................................................................................................................................... 102 3.38. DOOR LOCK MECHANISM ............................................................................................................. 102 3.39. SIDE WINDOW ................................................................................................................................. 103 3.40. FIRE EXTINGUISHER (OPTIONAL) ................................................................................................ 103 3.41. FRONT AND REAR CURTAIN ......................................................................................................... 104 3.42. SUNROOF ........................................................................................................................................ 104 v

3.43. SUN SHADE ..................................................................................................................................... 104 3.44. OPERATOR'S CAB INTERIOR LIGHTING ...................................................................................... 104 3.45. ADJUSTING MIRRORS ................................................................................................................... 105 3.46. OPERATOR’S SEAT ADJUSTMENT ............................................................................................... 105 3.47. SEAT BELT ...................................................................................................................................... 106 4. OPERATION ............................................................................................................................................. 107 4.1. INSPECTIONS BEFORE STARTING THE ENGINE .......................................................................... 107 4.2. STARTING THE ENGINE ................................................................................................................... 108 4.3. WARM-UP OPERATION .................................................................................................................... 110 4.4. INSPECTIONS AFTER STARTING THE ENGINE ............................................................................. 111 4.5. UREA SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM ......... ERROR! BOOKMARK NOT DEFINED. 4.6. OPERATING THE MACHINE ............................................................................................................. 114 4.7. TRAVEL DIRECTION CONTROL ...................................................................................................... 116 4.8. SWINGING THE MACHINE................................................................................................................ 116 4.9. OPERATING ATTACHMENTS .......................................................................................................... 117 4.10. OPERATING DOZER BLADE AND OUTRIGGERS ......................................................................... 118 4.11. CRUISE FUNCTION......................................................................................................................... 119 4.12. PROHIBITIONS DURING OPERATION........................................................................................... 120 4.13. CAUTIONS DURING OPERATION .................................................................................................. 122 4.14. CAUTIONS WHEN TRAVELING ON A SLOPE ............................................................................... 123 4.15. ADDITIONAL WORKS USING HYDRAULIC EXCAVATORS .......................................................... 124 4.16. LIFTING ............................................................................................................................................ 125 4.17. REPLACING THE BUCKET ............................................................................................................. 126 4.18. CHECKS AFTER FINISHING WORK ............................................................................................... 127 4.19. STOPPING THE ENGINE ................................................................................................................ 127 4.20. CHECK AFTER STOPPING THE ENGINE ...................................................................................... 127 4.21. HANDLING THE ENGINE WITH TURBOCHARGER ....................................................................... 128 4.22. LOCKING SYSTEM .......................................................................................................................... 129 4.23. TRANSPORTATION ........................................................................................................................ 130 4.24. PREPARING THE MACHINE BASED ON WEATHER CONDITIONS ............................................. 134 4.25. LONG TERM STORAGE .................................................................................................................. 135 4.26. INSTRUCTIONS ON WITHDRAWAL FROM USE AND UTILIZATION ............................................ 137 5. TROUBLESHOOTING .............................................................................................................................. 138 5.1. WHEN TO SUSPECT A TROUBLE CASE ......................................................................................... 138 5.2. TOWING METHOD ............................................................................................................................ 138 5.3. TOWING HOLE FOR LIGHT OBJECTS ............................................................................................. 139 5.4. CAUTIONS UNDER SPECIAL CIRCUMSTANCES ........................................................................... 139 5.5. ELECTRIC DISCHARGE.................................................................................................................... 140 5.6. POOR BATTERY CHARGING ........................................................................................................... 141 5.7. OVERHEATING ................................................................................................................................. 141 5.8. ABNORMAL (LOW) OIL PRESSURE ................................................................................................. 142 5.9. ENGINE .............................................................................................................................................. 143 5.10. HYDRAULIC SYSTEM ..................................................................................................................... 146 5.11. ELECTRIC SYSTEM ........................................................................................................................ 148 5.12. OTHER TROUBLES ......................................................................................................................... 148 6. MAINTENANCE ........................................................................................................................................ 149 6.1. CAUTIONS IN MAINTENANCE ......................................................................................................... 149 6.2. OIL, FUEL, COOLANT AND DIESEL EXHAUST FLUID .................................................................... 153 6.3. PERIODIC REPLACEMENT OF MAIN PARTS .................................................................................. 160 6.4. INSPECTION AND MAINTENANCE LIST.......................................................................................... 161 6.5. EVERY 10 HOURS (BEFORE STARTING)........................................................................................ 164 6.6. EVERY 50 HOURS (WEEKLY SERVICE) .......................................................................................... 176 6.7. FIRST 250 HOURS ............................................................................................................................. 178 6.8. EVERY 250 HOURS (MONTHLY SERVICE) ..................................................................................... 182 6.9. EVERY 250 HOURS HYDRAULIC BREAKER HOURS ..................................................................... 184 6.10. EVERY 500 HOURS (3 - MONTH SERVICE) ................................................................................... 185 6.11. EVERY 1000 HOURS (6 MONTHS SERVICE) ................................................................................ 194 6.12. EVERY 2000 HOURS (ANNUALLY) SERVICE ................................................................................ 196 6.13. EVERY TWO YEARS OF SERVICE ................................................................................................. 197 6.14. EVERY 4500 HOURS ....................................................................................................................... 202 6.15. WHEN REQUIRED ........................................................................................................................... 203 7. SPECIFICATIONS..................................................................................................................................... 209 7.1. TECHNICAL SPECIFICATIONS OF HMK 210 W-4 ........................................................................... 209 vi

8. EQUIPMENT AND ATTACHMENTS ........................................................................................................ 222 8.1. GENERAL PRECAUTIONS ............................................................................................................... 222 8.2. CAUTION WHEN FITTING THE WORKING EQUIPMENT ................................................................ 222 8.3. SELECTION OF ATTACHMENT ........................................................................................................ 223 8.4. PROTECTION AGAINST FALLING OR FLYING OBJECTS (FOPS) ................................................. 223 8.5. PROTECTION AGAINST TIPPING AND ROLLING OVER ................................................................ 223 8.6. HANDLING TIRES .............................................................................................................................. 224 8.7. HYDRAULIC BREAKER ..................................................................................................................... 225 8.8. QUICK COUPLING ATTACHMENT ................................................................................................... 229 9. APPENDIX ................................................................................................................................................ 230 9.1. HAND SIGNALS ................................................................................................................................. 230 9.2. CONTACTS ........................................................................................................................................ 236 10. ALPHABETICAL INDEX ......................................................................................................................... 237

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WARRANTY CONDITIONS During warranty period of the machine, all the failures related to material or workmanship defects will be repaired by Hidromek (or authorized dealers) free of charge. During warranty period, if the machine is used out of its intended purpose, if it is modified without prior written consent of Hidromek, if periodical maintenance is not duly conducted by Hidromek (or authorized dealers), and if original spare parts or wear parts recommended by Hidromek are not used, warranty conditions will be null and void.

Main parts and components of the machine such as buckets, lifting arms etc. are designed and manufactured for certain applications. If machine is used out of its intended purpose, performance of such parts and components cannot be guaranteed.

Warranty certificate is valid only for the machine it belongs to. For their claims during warranty period, customers will be requested to provide warranty certificate and periodical maintenance invoices issued by authorized service dealers.

Failures happening when the machine is used by unauthorized people without an operator's license will be out of warranty coverage. Operator must be competent, sufficiently trained and should be prove these with professional qualification certificates.

Periodical replacement parts, wear parts and/or materials such as oil, fuel, antifreeze, filters, linings etc. are not under warranty coverage. Glasses, mirrors, pins & bushings, V-belts, teeth, electric cables, bulbs, lamps, turning lamps and parts made of elastic materials such as rubber and plastic are not under warranty coverage.

Warranty claims related to tires and diesel engine will be evaluated by their manufacturer according to their own warranty policy and their decision will be final.

Repair and maintenance of radio/cassette player/ CD player and similar devices will be made by their suppliers through their service dealers.

Any kind of failures and/or damages originating because of hitting, collision, dropping, rolling, tilting the machine or operating or parking the machine in improper conditions will be out of warranty coverage.

viii

It is the customer’s responsibility to follow machine's operation hours and periodical maintenance time and request service from Hidromek. If maintenance cannot be conducted in time and machine continues to operate as such, possible defects or damages will not be under warranty coverage.

For the service works to be done under warranty, customer has to deliver the machine to Hidromek Authorized Service or Dealer. In case repair or maintenance of machine is not allowed for some reason or repair or maintenance is delayed and defective machine continues to operate, possible defects or damages will not be under warranty coverage. In case machine fails during warranty period, the time spent for repair will be added to warranty period.

Hidromek's responsibility is limited to repairing the machine within a reasonable time. Customer cannot raise any claim for the time spent for repair and for the time machine is away from work.

Hidromek is free to decide to replace failed parts partially or fully or to reuse them after the repair.

Replaced parts are Hidromek's property. Lost or missing parts are out of warranty coverage.

Performance of Hidromek labeled original parts, which are designed for Hidromek machines, cannot be assured when they are installed on another equipment.

Works which are not covered within warranty even during warranty period will be charged according to current Hidromek parts and labor rates.

All the warranty claims during warranty period will be submitted in written to authorized Hidromek Services, Hidromek Branch Offices or Hidromek After Sales Service Department. If failure under warranty needs to be fixed at Hidromek workshop or at any Hidromek Authorized Service or Dealers, transportation costs will be customer's liability and will not be under warranty coverage.

1. INTRODUCTION 1.1. FOREWORD This manual contains information and data regarding safety, operation, transportation, lubrication, maintenance and repair of an excavator.

You must read and study this manual carefully and fully understand the operation, lubrication, maintenance and repair information before operating this machine. Failure to follow this manual can result in serious accidents and loss of warranty.

This manual is not intended to train the operator in the art of excavation. Therefore, to use this machine, you must be an experienced operator in excavation and must have a valid operator’s license.

WARNING If you operate this machine without due care, it may result in serious injury.

Mechanics and operators must read this manual carefully before operating or performing lubrication, maintenance and repair on this machine. This manual should be stored in the literature storage area in the operator’s compartment, so that all personnel handling the machine can read it periodically.

Read this manual repeatedly and study until you become familiar with controls and operations of the machine.

If this manual is lost or damaged, please consult your HİDROMEK dealer.

When the machine is handed over to another party for any reason, this manual should always accompany the machine.

The safety, operation, maintenance and repair information described in this manual are limited to the specified intended usage of the machine.

Some photographs, illustrations or information in this publication may not reflect details or attachments available on your machine. Guards and covers may have been removed for illustrative purposes.

1.2. SAFETY INFORMATION Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the information regarding operation, lubrication, maintenance and repair of the machine and its components.

The safety symbols used in this manual or on the machine are classified as follows: Safety Symbols Contents This symbol is used to indicate a situation where a great DANGER possibility of serious injury or death is present.

This symbol is used to indicate WARNING a situation where a potential of injury or death exists.

This symbol is used to indicate a situation where a great CAUTION possibility of injury or damage to the machine is present.

This symbol is used where a possibility of damage or shortening of service life of the IMPORTANT machine is present. It is also used to show a safe work practice and as a reminder for safety.

It is impossible to cover and include all of the cases and situations where danger might be involved.

Therefore, the safety related contents depicted in this manual or on this machine can not cover all of them. When operating the machine, keep safety in mind at all times and use your own judgment, to prevent injury and damage to yourself, to others and to the machine.

Continuing improvement and advancement of product design may have caused changes to your machine which are not included in this publication.

NOTE This manual is copyrighted with all rights reserved.

No part of this manual may be copied, in whole or in part, without a written consent from HIDROMEK

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1.3. DESCRIPTION AND INTENDED USE This machine is a hydraulic excavator. Main areas of usages are as follows:    

Excavating Digging Leveling Loading

Detailed working method Refer to "4.15. Additional Works Using Hydraulic Excavators".

This manual contains the information on safety, operation, inspection and maintenance related to the specified usage.

Safety related areas other than specified in this manual should be considered as users own responsibilities.

Operations outside the specified usage of this machine should never be attempted without consulting Hidromek or without using additional equipment that are suitable for the work as to be recommended by Hidromek.

1.4. CE MARKING CONFORMITY

AND

DECLARATION OF

NOTE Applies only to machines marketed within the EU/EEA. This machine is CE marked. This means that, when delivered to the customer, the machine meets the applicable “Essential Health and Safety Requirements”, according to the EU Machine Safety Directive. Any person carrying out any alteration that might affect the safety of the machine will be responsible for possible consequences.

The machine is supplied together with a Declaration of Conformity with the EU Machine Safety Directive.

If the machine is used for purposes or with special bodies or add-ons, other than described in these instructions, safety must at all times and in each case be maintained. The person carrying out such action is also responsible for the action, which in some cases, may require issuing of a new CE marking and of a new Declaration of Conformity in compliance with the EU Machine Safety Directive.

HİDROMEK is only responsible for the changes, which are made by HİDROMEK.

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1.5. CHARACTERISTICS OF THE MACHINE Advanced Electronic Control System features the following capabilities and characteristics:  Power mode and Working mode selection according to the working condition  Gradual engine speed increase by means of a potentiometer dial  Instant automatic increase of excavating force when needed  Automatic warm-up of engine  One touch Auto-idle and canceling  Automatic deceleration and idling of engine when the controls are not attended.  Engine overheat prevention  Instant monitoring of fuel consumption and machine operating parameters  Self-diagnostic  High output, durable, water cooled diesel engine with common rail fuel injection system with intercooler and cooled EGR system  High durability, silent hydraulic pump and cushioned type hydraulic cylinders  Advanced hydraulic control system for efficient operation of working tools with optimized performance  Safety locking device equipped control lever console  Air-conditioned, ergonomically designed operator's cabin equipped for comfort and convenience of the operator.  Redesigned cab to offer maximum visibility and internal space  Secure, ergonomic and comfortable operator’s seat  Improved vibration and shock dampening thanks to use of 6 viscomounts between the cabin and the chassis.  Shock relief valve for swing brake  Stand-by hydraulic piping and connection fittings for hydraulic breaker 1.6. EXHAUST EMISSION REGULATION RELATED PARTS This engine has been certified under the domestic and international exhaust emission regulations. Do not remove or modify the equipped parts related to the exhaust gas control system.

CAUTION If the instructions in this Operation and Maintenance Manual are not followed and the emission control system begins to function improperly, the engine monitoring system will display a warning. If this warning is ignored and the engine continues to be operated, the engine output power and speed will be restricted and the machine will become inoperable.

1.7. BREAK-IN OPERATION This machine has been adjusted and tested before it is shipped from the factory.

Abnormal operation at early stages may reduce the performance and life of the machine. Therefore, operate the machine for the first 100 hours carefully.

Pay attention to the following during this running-in period:  Allow the engine to idle for 5 minutes after starting the engine.  Do not overload the attachments.  Do not change engine speed too rapidly when starting, accelerating, stopping or turning.

1.8. SPARE PARTS AND SERVICE HİDROMEK warrants to its customers the supply of spare parts and after sales services for the machines they buy for at least 10 years from the date of manufacture.

1.9. COPYRIGHT Copyright of this book belongs to “HİDROMEKHİDROLİK VE MEKANİK MAKİNA İMALAT SANAYİ VE TİCARET ANONİM ŞİRKETİ”. This book covers instructions for effective use and maintenance of the machine and is intended for use by people who are trained, certified and authorized to use, maintain, and repair the machine. HİDROMEK can not be held responsible in case any problem arises due to misuse of the machine and holds the rights to take legal actions in case of such non-conformities.

1.10. DRIVING LICENSE To be able to use this machine the operator must have a valid driving license necessary for operation of this type of machine according to the national, provincial, state or local regulations; and you must also be experienced in use of this machine and its attachments.

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1.11. IDENTIFICATION PLATES 1.11.1. LOCATION OF THE MACHINE ID PLATE This nameplate is attached on the lower right hand side of the operator’s compartment. The manufacturer’s name, machine type and model information, machine serial number, engine power value, operating weight, manufacturing date and PIN number are given on the nameplate. Do not forget to inform your service about your machine serial number while ordering spare parts.

PIN number is machine identification number. It has 17 alphanumeric characters. For example;

4

1.11.2. ENGINE IDENTIFICATION PLATES The engine number is required for engine registration and inspection. Provide your Hidromek Authorized Service with names of the engine manufacturer, type, etc. in addition to the engine number when you are having the machine repaired or are ordering replacement parts, so that the Hidromek Authorized Service can provide service more effectively and efficiently.

DANGER Before checking the engine number, make sure to stop the engine to prevent your body from being caught in the rotating parts and confirm that the engine and Urea SCR system are cooled down. Be careful not to get burned with the heat from the exhaust system, the high temperature coolant or the heat from the engine itself during inspection or maintenance.

1.11.2.2. ENGINE ID LABEL It is attached to the cylinder head cover.

Figure. Label of 6HK1 engine is shown as an example 1.11.2.3. EMISSION LABEL PLATE

1.11.2.1. ENGINE NAME PLATE ISUZU 4HK1:

It is attached to the cylinder head cover.

It is stamped on the right side bottom part of the cylinder block.

The emission labels on the engine indicate very important instructions and information that you should respect to ensure safe and proper operation of the engine. Be sure to read them before using the engine.

The descriptions in the emission labels are only about the engine unit.

5

1.12. MAIN COMPONENTS PLATES Transmission Plate

Main Pump Plate

Main Control Valve Plate

Swing Unit Plate

6

Front & Rear Axle Plates

Operator's Cab Plate

Name plate is hanged on the left hand side of the operator's cab.

2. SAFETY 2.1. GENERAL CAUTION 2.1.1. OPERATORS MUST HAVE CERTAIN QUALIFICATIONS People who use or operate hydraulic excavators must be:  Physically: have a good vision, hearing, coordination, and be capable of performing all functions safely as required for the operation of the machine.  Mentally: be able to understand and apply established rules, regulations, and safe practices; be alert, using good judgment for his own safety and for safety of the others; be willing to do his/her job in a correct and responsible manner.

2.1.4. WEAR PROTECTIVE CLOTHES AND SAFETY EQUIPMENT Wear well fitting clothing. Never wear personal items, which may be caught by control lever or components or oiled clothes, which can easily catch fire.

Wear appropriate protective clothing and safety equipment in accordance with working conditions when operating and maintaining the machine.

Do not wear radio/cassette headphones while operating the machine.

 Emotionally: be calm and capable of withstanding stress and make judgments concerning his/her own physical and mental conditions.  Trained: Have read and understood the operator’s instructional manual, hand signals chart and warning decals, and be skilled and knowledgeable in all operational and maintenance aspects of the machine.  Licensed: have a legally valid license as required by laws and regulations in effect.

2.1.2. OBSERVE ALL SAFETY RULES ON-SITE Only certified personnel may operate or maintain this machine.

Observe all rules, cautions and procedures for safety when operating or maintaining the machine.

When working with a signalman, work according to the specified signals.

2.1.3. INSTALL ALL GUARDS AND SAFETY DEVICES Ensure all of the guards and covers are correctly installed. Repair or replace damaged items.

Know the correct usage of safety locking device lever and safety belt, and use as recommended.

Safety locking lever  Refer to Chapter 3.17. “Safety Locking Device".

Safety Belt (Seat Belt)  Refer to chapter 3.46.

“Seat Belt" Incorrect operation of the safety device may cause serious injury.

2.1.5. MODIFICATIONS Modifications without consent of HIDROMEK may cause safety related problems, and invalidate warranty.

If modifications are required, contact HİDROMEK or your local dealer.

HİDROMEK is not responsible for injury or defects due to modifications without permission duly obtained from Hidromek.

2.1.6. BEFORE LEAVING THE MACHINE Lock the safety-locking lever securely before leaving the operators seat. If a control lever is not locked and activated inadvertently, the machine or attachments may operate suddenly, and cause serious injury or death.

Make sure you lower the attachment to the ground, lock the safety-locking device, stop the engine, and lock the door when leaving the machine.

Never forget to remove the starter key.

Safety locking lever  Refer to Chapter 3.17. “Safety Locking Device".

Also lifting the left console is useful which will provide more space when getting into or out of the cab. For more information refer to Chapter 3.21.

"Left Console Lifting Lever".

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2.1.7. USE HANDRAILS AND FOOTHOLDS TO GET ON/OFF THE MACHINE  Do not jump on/off a machine. Especially, never get on/off a machine while it is moving.  Never grasp the control lever to get on/off.  Make sure to support the body (by maintaining 3 points of contact by use of feet and hands) by use of handrail and foothold.  If your shoes, the handrails or footholds are covered with oil or mud, wipe them off immediately. Especially, clean the windows, rear view mirrors and lights.  When you have to hold onto the door handrail while getting on/off the cabin or moving to the rear of the machine, ensure that the cabin door is locked against the cab wall.

2.1.8. DO NOT ALLOW FIRE NEAR FUEL AND OIL Antifreeze, fuel and oil are flammable. Keep away from open flame or other fire hazards.

Never put a burning cigarette or match near flammables.

Before adding fuel, stop the engine and put out your cigarette.

Wipe up spilled oil immediately.

Tighten the caps on containers for fuel or oil securely.

Keep fuel or oil in a well-ventilated place.

Do not use fuel or oil for cleaning.

Keep fuel or oil in a protected place designated for this purpose.

2.1.9. HANDLE WITH CARE UNDER HIGH TEMPERATURE Immediately after stopping the machine, the temperature of the hydraulic oil, engine oil and engine coolant will be very high and pressure will be accumulated. In this condition, while you replace a filter, drain the oil or coolant, or open the cap pay attention as the hot fluid will will eject under trapped pressure and cause burning.

To prevent spouting of the hot coolant:  Stop the engine.  Wait until the temperature is lowered.  Hold the cap with a thick cloth to protect yourself from unintentional hazards.  Turn the cap slowly to release the inner pressure, and then open the cap.

While operating or immediately after stopping the machine, the engine, manifold, muffler and turbocharger are very hot. Take care not to touch these components.

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2.1.10. DO NOT INHALE DUST CONTAINING ASBESTOS If you inhale dust containing asbestos, it may cause a disorder of the respiratory system and can cause cancer.

This machine and its components as delivered to you from the factory does not contain asbestos; however, if you handle any materials that might contain asbestos while you work with the machine, observe the following measures.  Never use compressed air as a cleaning tool.  Avoid brushing or grinding material containing asbestos.  Apply a mist of water on material containing asbestos.  Wear an approved respirator.

2.1.11. PAY ATTENTION TO MOVING PARTS The area near moving parts (between upper and lower frame, moving parts of attachment, engine compartment, etc.) may cause death or injury. When you perform inspection or maintenance in these areas, lock or secure the moving the parts and pay special attention.

When tires are lifted to maintain the lower frame, support with hardwood blocks. Never support the body with boom or arm alone.

2.1.12. MACHINE FIRE EXTINGUISHER AND FIRST-AID KIT Make available a fire extinguisher, and read carefully the directions for use.

Make available a first-aid kit and instruction booklet.

Display the measures to be taken in case of fire or accident.

Display the names and telephone numbers of personnel to contact in case of an emergency.

2.1.13. PROTECTION FLYING MATERIALS

FROM

FALLING

OR

 Install the necessary protection guards according to working conditions while working with breaker, working at quarries and demolition or where falling or flying materials can enter the operator's cab (see 8.4).  Do not operate or travel with the front window open.  Ensure that unauthorized people are kept away at safe distance both from the machine and the source of falling/scattering materials.

9

2.1.14. BEFORE WORKING IN THE VICINITY OF GAS LINES Always contact the authorities of the gas lines or the nearest gas utility before beginning to work.

Determine jointly what specific precautions must be taken to insure safety.

Use a signal person. The sole responsibility of the signal person is to observe and signal the operator.

The signal person must be in direct communication with the operator, and the operator must pay close attention to signals.

2.1.15. CAUTION FOR OPTIONAL WORKING ATTACHMENT Read this manual and the attachment manual before operating with attachments.

Do not use an attachment, which is not authorized

by HİDROMEK. Accidents or machine damage from unauthorized attachments shall be considered as user's own responsibilities.

2.1.16. DO NOT REMOVE FRONT ATTACHMENT OR COUNTERWEIGHT Do not remove front attachment or counterweight, otherwise machine may become unbalanced and serious accidents due to tipping over of the machine may occur with death or injury.

Hidromek is not responsible for such an improper use.

2.1.17. CAUTION FOR POLYMERS AND ELASTOMERS Some elements of machine are made from polymers and elastomers such as viton sealing rings, teflon rings, piston seals, electric cable insulating materials. These materials contain hazardous fluoro-carbons. When these materials are burnt, they release highly toxic gases and harmful substances for skin and respiratory tracts. When handling a burnt machine observe the following safety procedures.

Do not touch component or surrounding area. Wear thick rubber gloves and protective goggles.

Dispose hazardous waste according to the regulations.

Discard gloves and other items that have been in contact with fluoro-carbons.

Wash contaminated area with calcium hydroxide or other suitable alkaline solution.

See a medical doctor, if redness, stinging and swelling appears after contact with fluoro-carbons.

10

Figure - Counterweight dismounted machine

Figure - Attachments dismounted machine

2.1.18. HANDLING OF ACCUMULATOR WARNING The accumulator is charged with high-pressure nitrogen gas.

To prevent serious injury or death, handle it with care and observe the following: Do not hit, drill, or weld the accumulator.

Keep away from open flame or any source of heat.

Request the HİDROMEK dealer to discharge the accumulator prior to disposal.

If you operate the boom control lever downward with the engine stopped, the accumulator enables the attachment to move by its own weight. After the attachment is at rest, ensure that the safety locking lever is in LOCKED position.

2.1.18.1. HYDRAULIC ACCUMULATOR An accumulator is installed on the hydraulic pilot circuit of Attachments and is used to accumulate stand-by hydraulic pressure. If the starter key is turned to start position (ON) when the engine is stopped by turning the start key to the stop position (OFF) and all the operations are stopped, the control circuit of attachment can still be activated by using this accumulated pressure. In this case, put the operation lever at descent position to lower attachments by its own weight.

2.1.18.2. RELEASING THE PRESSURE OF CONTROL CIRCUIT OF ACCUMULATOR Lower the attachment to the ground completely.

After stopping the engine, turn the start switch to operation position (ON).

When the safety locking system is released, remove the pressure of control circuit by moving control levers and pedals of attachment forward/reverse, left/right to each end position.

Turn the start switch to stop position (OFF), and pull the safety-locking lever to operate the safety locking system.

The pressure may not be totally relieved even after performing the above. If you need to remove and replace the hydraulic accumulator then contact Hidromek Authorized Service.

WARNING The SAFETY LOCK LEVER must be pulled in LOCKED position to prevent machine controls from an accidental movement. The operator must lock the safety lever before he leaves the operator’s seat and especially during maintenance and repair work unless it is necessary to operate the machine for this purpose.

If not, an accidental movement of any control lever will cause the machine or an attachment to move, and will cause serious injury or death.

When the safety lock lever is at straight position, the safety locking system is UNLOCKED. Make sure to rotate safety lock lever down to correctly engage the LOCKED position.

"LOCKED"

See Chapter 3.17. “SAFETY LOCKING DEVICE".

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2.2. CAUTION DURING OPERATING 2.2.1. BEFORE STARTING THE ENGINE 2.2.1.1. MAKE SURE THE WORK SITE IS SECURE Check site conditions before starting the work.

Examine the geological stratum and soil of the working site, and then decide the optimum working method.

Always work on a level site as possible.

In case of working on-road, use a lead man or set up a barricade to make vehicular and pedestrian traffic secure (Use hand signals as told in Chapter 9.1.

“Hand Signals").

Know where water pipes, gas pipes or high-voltage cables are buried, contact related company to spot their location.

When working in water or crossing a stream, check the condition of bed, depth and speed of the current in advance. If the upper rollers submerge in water, do not work.

For more information about permissible depth of water refer to "Chapter 4.13. Cautions During Operation".

2.2.1.2. CHECKS ON AND AROUND THE MACHINE Be sure the machine is properly lubricated. Verify that fuel, lubricating oil, coolant and hydraulic oil reservoirs are filled to the proper levels according to the manufacturer’s instructions.

Walk around machine to check all safety related items, including guards or plates, and inspect if any maintenance is required.

Visually inspect the machine for evidence of physical damage, such as cracking, bending, or deformation of plates or welds.

Loose or missing hardware, bolts, or nuts, should be properly tightened or replaced.

Check for leaks of fluid. Hydraulic system leaks must be corrected before the machine is operated.

Inspect all hydraulic hoses, especially those that flex in service, and replace if necessary. Secure all caps and filler plugs for all systems.

2.2.1.3. PREVENT FIRE Flammable materials such as wood, twigs, dried leaves or paper near the engine may cause fire.

Remove them.

Check for fuel, lubricant and hydraulic oil leakage. If leakage is present repair the defective parts before using.

Checking points  Refer to 4.1. Inspections before starting the engine.

Know how to use the fire extinguisher and where it is kept.

12

Figure. Water level

Figure. Gas pipes

2.2.1.4. VENTILATE INDOORS Engine exhaust gases are extremely dangerous.

If you start the engine, use solvents or perform welding indoors, ensure there is adequate ventilation indoors.

2.2.1.5. KEEP MIRRORS AND WINDOWS CLEAN Clean the windows and lights.

Adjust the rear view mirrors to obtain optimal visibility when sitting in the operator’s seat. Clean the mirrors and windows, replace any broken glass.

Make sure the necessary headlights or working lights are installed in accordance with working conditions and are working properly.

Clean mud or grease from your shoes and walkways before you get on or operate the machine. Be sure the foot pedals are clean and dry to eliminate the risk of your shoes slipping off the pedals.

2.2.1.6. CHECK AROUND THE OPERATOR’S SEAT Never put parts or tools around the operator’s seat.

They may interfere with the safety-locking lever or switch and cause an accident. Use the machine’s tool box to store them.

Mud, oil or snow on the floor, levers, handrails or step, can cause you to slip or fall. Wipe them clean.

The excavator cab is designed for only one person.

Do not allow anyone other than the operator to get inside the cabin or on the machine.

Check if the seat belt and fittings are damaged or worn excessively.

Safety belt  Refer to "Chapter 3.46. SEAT BELT".

2.2.1.7. SIGNAL BEFORE STARTING THE ENGINE Make sure no one is near the machine before you get on.

Never start the engine when a warning tag is hung on any control device. (Example:' Do not start' or 'Under maintenance') Before starting the engine, give an alarm by sounding the horn.

Start the engine and operate the machine only when sitting in the operator's seat correctly and make sure the safety belt is attached.

13

2.2.1.8. CHECK TIRES Recommended air pressure must be maintained in every tire.

Daily checks assure that inflation is correct. If your periodic check discloses a tire that is continuously losing air, a leak is indicated and must be repaired.

During your pressure checks, also inspect for:  Objects wedged between duals or embedded in tires.  Mismatched duals. Diameters should be equal as well as amount of thread wear.  Missing valve caps and wheel lugs.  Cuts, tears, and breaks that may need repair.  Abnormal or uneven wear.  Damaged or poor fitting rim or rim flanges.  Projecting body hardware, loose fender bolts, spring clips- anything that could contact a tire.

WARNING Do not burn or weld on wheels or rims.

CHECK TIRE PRESSURE Check pressure of tires before starting operation with the machine. A certain air pressure rise during operation is normal and should not be reduced.

Overloads or over speeds may produce increased tire pressure due to heat. Reduce your load or decrease speed or stop the machine until the tires cool down.

14

2.2.2. AFTER STARTING THE ENGINE 2.2.2.1. PRECAUTIONS IMMEDIATELY AFTER STARTING ENGINE  Check all gauges and indicators for proper readings.  Check for any alarm message indications on instrument panel, if there is such a message, do not operate the machine.  Be sure the area is safe for operation.  Listen for unusual noises, sounds and vibrations.  Test the engine speed control switch.  Operate each control to check their functioning and to get the feel of the machine.

2.2.2.2. BE ALERT WHILE OPERATING  Do not read  Do not drink  Do not eat  Do not operate the machine when you are under the adverse influence of alcohol, drugs, or medication.  Do pay attention to your work. If you must turn your attention elsewhere, stop the machine.  You must not allow fatigue or intensive work requirements to negatively influence your concentration and your good judgment. Better safe than sorry!

2.2.2.3. DIRECTION OF MACHINE BEFORE TRAVELLING Know for sure the direction of lower chassis before operating the traveling lever.

2.2.2.4. MAKE SURE NO ONE IS NEAR THE MACHINE BEFORE SWINGING OR REVERSING Use a lead man in dangerous or poor visibility conditions.

Make sure no one exists within the swing radius zone or operating route.

Before moving, give an alarm by horn or signal and make sure that no one stays around the machine within the danger zone.

There are blind-angle portions at the rear of the machine. Pay attention to the area when swinging.

Ensure the route is clear before reversing.

15

2.2.2.5. PRECAUTIONS DURING TRAVELLING If traveling retract the attachment as shown in-the following figure, and raise it 40 ~ 50 cm off the ground.

When it is unavoidable to operate the attachment during traveling, do not operate the lever abruptly.

When traveling on uneven road, keep the speed low.

When turning, do not operate abruptly.

Travel slowly when turning.

When driving over obstacles or on an inclined surface, operate the machine so as not to lean on one side more than 10 degrees.

2.2.2.6. TRAVELLING ON A SLOPE Pay attention not to roll over or slip while traveling on a slope.

If traveling on a slope, raise the bucket 20 ~ 30cm from the ground. In case of an emergency, immediately lower it onto the ground to stop.

Never turn or traverse on a slope. If necessary, first come down to level ground, and make detour, then climb to your designated area.

Traveling on a slope  Refer to 4.14. Cautions when traveling on a slope.

If traveling on a slope keep the machine longitudinal axis in line with the slope, and lower the traveling speed.

16

2.2.2.7. NEVER PERFORM DANGEROUS WORKS Stop the machine far from the edges of a digging area.

Do not dig or undercut the ground supporting underneath the machine. The ground can collapse causing the machine to fall and/or to be buried. If necessary, prop up sufficiently so that the ground will not collapse.

Do not undercut overhead ground because the overhang could collapse onto the machine.

2.2.2.8. KNOW THE WORKING RANGE OF THE MACHINE Be sure the attachment or load will not be obstructed during lifting or swinging. When lifting a load, do not lift, swing or stop unnecessarily fast.

Be sure the area is clear of the people before swinging or moving in any direction. Never swing or position attachment or load over people or vehicle cabs. Never allow personnel to walk or work under any part of the machine or load while the machine is operating.

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2.2.2.9. NEVER APPROACH A HIGH VOLTAGE WIRE You may receive an electric shock if the machine is too close to a high voltage wire. A narrow proximity even though without a physical contact will cause electrocution from the power line!

Observe the following to prevent accidents: Maintain the recommended distance from the power lines.

Use a lead man.

If the attachment contacts a live wire, stay in the cab, and if the machine is operational, try to break away the circuit by moving the attachment away from the high voltage wire.

If working near a high voltage wire, do not allow people to approach the machine.

Contact the electric company before you start to work near overhead power lines.

Secure the following distance between the machine and the wire for safety.

2.2.2.10. OVERHEAD OBSTRUCTIONS Take special care when operating in places with limited height such as tunnels, underground bridges or power lines.

2.2.2.11. POOR LIGHTING CONDITIONS When working in poorly illuminated conditions, use headlights.

In buildings, tunnels, etc., switch the lights on.

Do not operate the machine when visibility is poor such as a heavy fog, snow or rain.

2.2.2.12. SNOW REMOVAL An icy road is very slippery, so do not make sharp turns or brake suddenly.

Particularly, when traveling on inclined surfaces, travel at low speed.

Take special care during snow removal work because the road condition can’t be seen.

2.2.2.13. UNSTABLE GROUND When operating in dangerous places, take action to ensure safety before proceeding with the work.

Danger of falling rocks or landslides are particularly high at the edges of steeps or pits.

When operating in areas with a risk of falling rocks, ensure the falling object protection structure (FOPS) is fitted.

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0 ~ 50.000V

Min. Distance Between Machine And Wire For Safety 3.0 m

50.000 ~ 200.000V

4.5 m

200.000 ~ 350.000V

6.0 m

350.000 ~ 500.000V

7.5 m

500.000 ~ 750.000V

10.5 m

750.000V ~

13.5 m

Voltage On Wire

2.2.2.14. WORKING ON A SLOPE When swinging or operating the attachment on a slope, the machine may get unbalanced and roll over. Pay special attention.

It is very dangerous to swing downhill with a loaded bucket. Never operate in this manner.

If it is necessary to work on slopes, grade a level ground under the machine and then continue to work.

DO NOT SWING!

PILE UP THE EARTH

2.2.2.15. PARKING Park the machine on level ground. If it is unavoidable to park on a slope, put a wooden block under each tire and lower the attachment to the ground.

If parking on a road is needed, arrange flags, barricade, lights or other warning markers without obstructing the traffic.

If you have to leave the machine, lower the attachment to ground, lock the safety-locking device, stop the engine, take the starter key and lock the door.

Do not leave the machine where there is a risk of falling objects, landslide or ground collapsing.

2.2.2.16. USE OUTRIGGERS FOR OPTIMUM STABILITY If outriggers are available on your machine, use them for optimum stability. If it is necessary support with uniform pad.

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2.2.2.17. WORKING IN A TUNNEL Tünel gibi zorlu koşullarda çalışan makinelerin periyodik kontrol ve bakım süreleri ve işletilme şartları normal şartlarda çalışan makinelere göre farklılık gösterir.

Tünelde çalıştırılacak makine, uygun donanıma ve ataşmanlara sahip olmalıdır.

Tünellerde kullanılacak kırıcı braketi tünel tipi braket olmalıdır ve sadece Hidromek’in onayladığı kırıcı markaları kullanılmalıdır. Tünelde kullanılacak hidrolik kırıcılar tünel dışında kullanılanlardan farklıdır.

Makineye bağlanacak bom, arm, kırıcı, kırıcı braketi vb. ataşmanlar yalnız Hidromek’in onayı alındıktan sonra kullanılabilir. Aksi takdirde, makinede meydana gelebilecek hasar ve arızalardan Hidromek sorumlu tutulamaz.

Tünelde kullanılabilecek hidrolik kırıcı modelleri, hidrolik yağ tipi, filtre, bakım periyotları gibi hususlarda detaylı bilgi için Hidromek'e başvurunuz.

Bu Kullanım ve Bakım El Kitabında tavsiye edilen standart Hidrolik yağlar yerine çinkosuz yağ kullanılması önerilir.

Hidrolik Sistemdeki kirliliği azaltmak için Bypass Filtre kullanılabilir.

Hidrolik yağ değişim periyodunun 2000 saatten 1000 saate, hidrolik tank havalandırma elemanı değişim periyodunun ise 1000 saatten 500 saate düşürülmesi gerekir.

Hidrolik kırıcı dönüş filtresini (varsa) bu kitapta belirtilenden daha sık değiştirmek gerekebilir.

Filtre ve yağ değişim aralıklarını belirlemek için hidrolik yağı düzenli olarak analiz edin.

Maden ocakları ve tünellerde çalışırken, Düşen Cisimlere Karşı Muhafaza (FOG) kullanın.

DİKKAT Hidrolik kırıcı ile, maden ocakları ve tünellerde veya düşen ya da sıçrayan maddelerin olabileceği diğer ortamlarda çalışırken, çalışma koşullarına göre gereken koruyucu muhafazaları kullanın. Çalışma ortamına uygun muhafazalar için HİDROMEK yetkili servisleriyle görüşün.

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2.2.3. TRANSPORTATION 2.2.3.1. CAUTION WHILE LOADING/UNLOADING Pay special attention to loading and unloading.

Operate the engine at low rpm, and set machine travel speed to low.

Choose a firm, level place, and keep adequate distance from the road shoulder.

Make sure the strength, width; length and thickness of the planks are safe for loading/unloading. If they bend excessively, support with blocks.

Remove grease, oil, mud, ice, etc. from the planks and trailer bed to prevent the machine from slipping sideways.

Never change course on the planks. If it is unavoidable, first descend from the planks and then change course.

When swinging on the trailer, operate slowly because the base is unstable.

After loading, block each tire and secure the machine with tie downs of adequate load rating so that the machine cannot move.

Cover the exhaust pipe to prevent turbocharger damage.

Lock the cab door and lower the antenna.

A: Angle of the slope should be less than 15° 2.2.3.2. CAUTION DURING TRANSPORTATION When transporting, observe all local, provincial, state regulations governing the weight, width height and length of a load.

Choose a transport route taking into account the overpass clearances, bridge and road load limits, wide load prohibitions and travel hours.

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2.2.4. BATTERY 2.2.4.1. CAUTION WORKING WITH USED BATTERIES Battery electrolyte consists of water and sulphuric acid, so it may be harmful on clothes or skin. If the battery electrolyte is spilled on your clothes or skin, immediately flush with clean water.

If battery electrolyte is spattered into the eyes, immediately flush with clean water and consult a medical doctor.

If you accidentally swallow the battery electrolyte, drink a great quantity of water, milk or vegetable oil, or eat a raw egg, and then immediately consult a doctor.

Always wear safety glasses when handling the battery.

There is a danger of explosion because hydrogen gas is emitted. Never approach with a burning cigarette or fire near the battery, and never do any work which may cause sparks.

When checking or handling the battery, first stop the engine and turn the start key to OFF. Make sure both poles do not make contact with metals such as tools.

Make sure the terminals are tightened firmly. A loose terminal may cause sparking due to poor contact and cause explosion of accumulated gases.

When installing the cables, make sure which is the (+) terminal and (-) terminal.

Tighten the battery plug securely.

2.2.4.2. STARTING USING BOOSTER CABLES Wear safety glasses when starting by use of booster cables (jump starting).

When starting by use of another machine, the normal machine and disabled machine must not make physical contact.

When installing the cable, first connect positive terminal, and when detaching it, first disconnect ground terminal (normally, negative terminal).

Pay attention that any tool doesn’t cause contact between a terminal and the chassis, as it will cause sparking. Take precautions to prevent such occurrence.

Verify the connection of booster cables. The positive terminal and negative terminal must not make contact.

The cable must be connected to upper frame last. In this case, sparks will occur, so connect it as far from the battery as possible. Start procedure by use of booster cable Refer to 5.5.1. Starting the Engine with Booster Cables (Jump start).

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2.2.5. TOWING Improper towing may cause serious injury.

When towing the machine use wire ropes that are certified, in good condition and are of adequate load rating and length.

Never perform towing on a slope.

Never use a wire rope, which is kinked, twisted or damaged.

Never straddle a cable or wire rope.

When towing the disabled machine, make sure that no one is between the machines. Keep all persons at a safe distance for protection, should the cable break.

Make sure the connection points of disabled unit and towing machine are in a straight line, and then attach the cables.

Insert a protective device between the wire rope and the machine to prevent damage.

Do not tow this machine if the wire rope is attached to the towing eye.

Towing  Refer to "Chapter 5.2. Towing Method" 2.2.6. LIFTING OBJECTS For lifting objects, see 4.16.

2.2.6.1. GENERAL PRECAUTIONS

2.2.6.1.1. LIFTING HOLES When lifting, use holes and eyes provided for lifting only.

When lifting, pay attention to the following: DO NOT hang the wire rope onto a bucket tools to lift objects.

DO NOT wind the wire rope around boom or arm to lift objects.

2.2.6.1.2. CHECK FOR ANY ABNORMALITY Before lifting, check the followings for a sign of abnormality.

Crack or deformation on connections or welds to the body.

Crack or damage on the lifting holes.

During periodic inspection (monthly and 6 monthly), add a check item for "Abnormality on lifting holes" on the inspection list, and inspect and record the result.

2.2.6.1.3. SELECTING THE WORK PLACE Before you start to work, examine the ground and the nature of soil, and select a firm and level place to prevent a possibility of roll over. Always make safety around the work-site your priority.

23

2.2.6.1.4. DO NOT RIDE THE ATTACHMENT

 Never allow anyone to ride on the attachment or on the load. This is an extremely dangerous practice and it is strictly forbidden.

2.2.6.1.5. KEEP WORKING AREA CLEAR  Never let anyone enter the working area of the machine.

2.2.6.1.6. DESIGNATE A LEADER  Prior to lifting, designate a signalman, and obey his instructions. Observe the signalman's instructions for the working method and procedure.

2.2.6.1.7. HANDLING OF WIRE ROPES • Wear protective gloves prior to handling wire ropes.

• Ensure that the wire rope, hooks and shackles are certified, in good condition and of adequate load rating.

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2.2.6.2. CAUTION DURING LIFTING

2.2.6.2.1. OPERATE SLOWLY Run the engine at low rpm.

Do not operate the levers abruptly.

Do not turn, lift or stop unnecessarily fast.

Check the limits of height, width and weight, and do not work beyond the limit.

Make the rope length between objects and hook as short as possible so that the object will not swing.

2.2.6.2.2. DO NOT LEAVE OPERATOR’S SEAT Do not leave operator’s seat with the object suspended. When you leave operator's seat, lower the object to a safe place and engage the safetylocking device.

Safety locking device  Refer to 3.17. Safety Locking System

2.2.6.2.3. DO NOT EXCEED CAPACITY Working beyond the capacity of the machine may cause an accident or breakdown.

Know the weight of the load. The combined weight of the load and lifting devices must be less than the rated lifting capacity of the machine.

Do not attempt to lift an overload or exert an impact on a load to move it.

Do not use the swing or arm-in operation to drag a load.

2.2.6.2.4. NEVER TRAVEL WITH A SUSPENDED LOAD Never travel with the load suspended from the hook.

2.2.6.2.5. LET EVERYBODY BE AWAY FROM THE BOOM CYLINDER Keep everybody away from the boom cylinder. While lifting, hoses might burst and can cause serious accidents.

If hoses burst, boom might fall by its gravity and cause accidents.

25

2.3. CAUTION ON MAINTENANCE 2.3.1. BEFORE MAINTENANCE 2.3.1.1. READ MANUAL Read and understand operation and maintenance manual before maintenance.

2.3.1.2. HANG THE WARNING TAG If anyone starts the engine or touches the levers by mistake during inspecting or maintaining, serious injury may occur.

Hang a "DO NOT OPERATE” warning tag on the control lever.

If necessary, place signs around the machine.

2.3.1.3. USE PROPER TOOLS It is very dangerous to use broken or deteriorated tools, or to use the tools for inappropriate purpose.

Use proper tools for maintenance.

2.3.1.4. REPLACE SECURITY PARTS PERIODICALLY Replace the following parts periodically Fuel system: Fuel hose, return hose, fuel tube cap Hydraulic system: Pump outlet hose, flange hose Replace above parts periodically even if they are not damaged.

Immediately replace above parts if they are damaged.

Periodical replacement of main parts  Refer to Chapter 6.3.

2.3.1.5. FIRST STOP THE ENGINE Before you attempt any maintenance operation on the machine carefully read and understand the operation and maintenance manual.

When inspecting or maintaining the machine, put it on a firm and level place, and stop the engine.

If the engine must be operated for maintenance such as flushing the radiator core, lock the safety-locking lever. This work requires two men. One man shall be sitting on the operator's seat to stop the engine at any time. Take care not to touch any lever by mistake. Use the release knob to release the safetylocking device.

The man performing maintenance must take every precaution that the moving parts do not catch his clothes, objects he is wearing or members of his body.

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“DO NOT OPERATE”

2.3.1.6. CAUTION ADDING FUEL OR OIL Add fuel or oil in a well-ventilated area.

Before adding fuel, stop the engine, DO NOT smoke, DO NOT approach with flame.

Wipe out spilled fuel or oil immediately.

Tighten the caps on containers for fuel or oil securely.

2.3.1.7. COOLANT LEVEL If it is required to add to coolant to the radiator, stop the engine, and wait until the engine and radiator has cooled down.

Before removing the cap, loosen it slowly to release the inner pressure.

2.3.1.8. USAGE OF LIGHT When inspecting the fuel, oil, coolant or battery electrolyte, use the explosion proof type lights.

There is a risk of explosion if a light other than explosion proof type lights is used.

2.3.2. DURING MAINTENANCE 2.3.2.1. OFF-LIMITS TO PERSON OTHER THAN CONCERNED During maintenance, keep non-essential personnel out of the work area. Pay attention to persons around the work-site.

Pay special attention when grinding, welding or using a large hammer.

2.3.2.2. DETACHED ATTACHMENT When detaching or installing the attachment, make sure it will not fall.

The attachments must be well stabilized and supported to avoid roll-over.

Do not stand, do not let anybody near the attachment when assembling or disassembling an attachment 2.3.2.3. WORKING UNDER THE MACHINE Before inspecting or maintaining under the machine, lower the attachment to the ground or to the lowest level possible.

When working under the machine, first put a block strong enough under the tires, and then continue to work.

If the machine is not supported sufficiently, never work under the machine.

27

2.3.2.4. KEEP THE MACHINE CLEAN Grease, oil, and mud on the machine cause very slippery and dangerous surfaces. Keep the machine clean at all times. Do not use water or steam to clean inside the operator's cab. Water can cause the electrical systems to malfunction or cause system damage.

Clean the machine thoroughly before performing inspection and maintenance procedures. It is easier and safer to locate problems and to perform maintenance when the machine is clean. The possibility of contamination of the hydraulic system is also reduced. Do not wash the machine while the engine is running. During washing the machine observe the following procedures:  Park the machine on a hard and level ground.  Spray at an angle that will not damage the wick of the doors and windows.  Do not wash the machine with hot water.  Use a soft brush during cleaning.  When rinsing use only water.  Always lubricate the machine after washing.

During high pressure washing observe precautions below: WARNING Too high pressure and too short distance may cause damage to the paint finish and other surfaces of the machine. Avoid using cleaning agents or chemicals in order to minimize the risk of damage to the paint finish. Clean more frequently under heavy operating conditions or in a dusty environment.

Specification of water

Value

Temperature

Max. 50 °C

Pressure

Max. 80 bar

A distance of between the nozzle and the machine Water spray time (on the same point)

Min. 50 cm

28

Max. 15 sec

2.3.2.5. PRECAUTIONS FOR HIGH-PRESSURE HOSES Never bend or hit high-pressure hoses. Never use bent or damaged pipes, tubes or hoses.

Tighten loose fittings and replace damaged fuel hoses and hydraulic hoses. Fuel or oil leakage may start fire.

2.3.2.6. PRECAUTIONS FOR HIGH-PRESSURE OIL The hydraulic circuit is under pressure at all times, regardless of the engine dead or operating. Never add or drain the oil or inspect or maintain hydraulic system until you are sure that the internal pressure is released.

2.3.2.7. WORKING AROUND EXTREMELY HOT AREAS Hydraulic oil, engine oil and engine coolant are very hot and under pressure immediately after the machine is stopped. In this condition, if you attempt to replace a filter, drain the oil or coolant, or open the cap, hot fluid may cause burning or scalding.

To prevent spouting of hot coolant: Stop the engine.

Wait until the temperature is lowered.

Turn the cap slowly to release the inner pressure, and then open the cap.

DANGER While operating or immediately after stopping the machine, the engine, manifold, muffler and turbocharger are very hot. Be careful not to touch these components.

To release internal pressure: Main circuit Stop the engine, turn the starter switch to operating position (ON) and operate the right / left control levers to forward, reverse, right and left several times.

Hydraulic tank Stop the engine and release internal pressure through the breather.

Release the pressure in tank  Refer to chapter 6.1.29.2. "Releasing pressure in tank".

Diesel / hydraulic oil escaping under pressure can penetrate the skin and eyes causing serious injury.

DO NOT use your hands to search for leaks. Check leaks with a piece of cardboard.

Wear safety goggles and gloves. If an accident occurs, immediately consult a physician.

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2.3.2.8. CHANGING TIRES Changing tires or adding air can be a hazardous business. Under pressure, a tire and rim assembly packs the potential explosive power of TNT. Special tools and procedures are required for changing truck.

2.3.2.9. CAUTION AS CHECK TIRE PRESSURE Maintenance on wheels and tires must be performed by people who trained and qualified in advance.

Check tires pressure from a position facing the tread of the tire, not the side.

Use long handled gauge to keep your body away from the trajectory path of rims and wheels.

Always use a safety cage in fig to inflate tires or add air after servicing for your safety.

2.3.2.10. ROTATING FAN AND BELT Tie up long hair, do not wear loose clothing or dangling jewelry or necklaces when you work on the machine. They may be caught by the rotating parts.

Do not put your hands or tools near any rotating parts.

If you become entangled, serious injury or death could result.

2.3.2.11. DISPOSAL OF WASTE MATTER Never discharge waste oil to drains, lakes or rivers.

When draining the oil from the machine, drain it into suitable containers.

Never drain oil directly into the ground.

Observe all related regulations when disposing of hazardous fluids and materials such as oil, fuel, coolant, filters and batteries.

2.3.2.12. CAUTION FOR WELDING Ensure that there is good ventilation in welding area.

Turn off the starter switch before welding.

Disconnect battery terminals and remove batteries.

Detach electronic control unit’s cables before welding otherwise serious damage will occur on electronic parts.

When welding, first remove paint around the area to be welded. Heated paint gives off harmful gases.

Do not weld near flammable materials such as polymers, elastomers, flammable fluids. Before you weld components which contains flammable materials, remove them from the welding area.

Make sure a fire extinguisher exists.

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2.3.2.13. WHEN THE ENGINE COOLANT IS HOT Do not loosen or remove the radiator cap. Doing so would be dangerous because steam and hot air can shoot out.

2.3.2.14. WHEN THE SILENCER AND EXHAUST PIPES ARE HOT While the engine is running, the urea SCR system is purging, and immediately after operating, the silencer and exhaust piping are extremely hot. Be extremely careful to avoid mistakenly touching these when performing works nearby. Otherwise, you could get burned.

2.3.2.15. IF THE BATTERY GOES FLAT When charging the battery from an external power source, remove the battery cables to protect the alternator.

2.3.2.16. DO NOT CLIMB ONTO THE ENGINE The engine is the vital part of the machine. Do not step on the engine or climb onto it. The head cover and the various connectors may be damaged, leading to an engine failure.

2.3.2.17. MAKE SURE THE ENGINE IS INSPECTED AT REGULAR INTERVALS Inspections and maintenance enable you to use the engine without any problems. They also provide the engine to have a longer service life.

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2.4. ATTACHED POSITIONS SAFETY LABEL Always keep the safety labels clean. Replace the damaged labels with new ones. Safety labels are also attached on various places as well as the positions indicated below.

2.4.1. ATTACHED POSITIONS

Lifting capacity Technical Specifications

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2.4.2. CONTENTS OF SAFETY DECAL 1. Emergency hammer warning

3. Pressurized hydraulic oil or coolant warning

This decal is located on the rear window of the cab.

Use emergency hammer to break through window glass in an emergency situation.

The door and the rear window are the emergency exits of the operator's cab.

Take the emergency hammer from the pillar at the rear left hand side of the cab and break the window glass.

2. Risk of fire when refueling warning

One of these decals is located on the hydraulic tank and the other is located on the radiator.

This decal is located on the fuel tank.

Stop the engine before refueling. When refueling, do not smoke, keep fire and sparks away.

Do not open any of the caps if the engine is running.

After stopping the engine wait for the engine to cool down.

Do not remove the cap under high temperature since hydraulic oil may gush out.

Open the cap slowly to release the internal pressure.

Wear protective gloves.

Hold the cap with a piece of thick cloth.

Do not screw the drain plug under high temperature.

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4. Hydraulic oil tank caution 6. Notes of handling battery caution

This decal is located on the hydraulic tank.

Do not fill fuel in the hydraulic tank.

Do not mix different brands of oils.

Change oil and filters periodically.

CAUTION Move the attachments to correct position. For more information refer to "Hydraulic tank level check".

Check hydraulic oil level by sight gauge.

Oil level should be on the center mark of the gauge. If the level is low, open the cover on the tank to add hydraulic oil.

5. Protecting operator's cab caution

This decal is located on the right hand side window of the operator's cab.

Objects that hit the operator's cab at front or fall to the top may injure or kill the operator.

If there is a risk of object falling in the worksite, install necessary protective guards as defined in the chapter 8.4.

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This decal is located on the battery cover.

Carelessness on handling could cause battery to ignite and explode.

The inflammables like the contact of electric lines, sparks and cigarettes are dangerous.

Before repairing (welding etc.) remove the (+) terminal of the battery.

When using booster cables, do handle with care to prevent short-circuit.

Battery fluid may harm your eyes and burn anything it touches.

If the battery acid gets on your skin or clothing, flush with plenty of water immediately.

If it gets into your eyes, flush with fresh water and then get medical aid.

Care should be taken to keep away from children.

7. General precautions

9. General precautions

This decal is located on the right hand side window of the operator's cab.

This is decal located on the right hand side window of the operator's cab.

For operation safety, correct maintenance and maximum efficiency read the operating and maintenance manual.

When arm and boom of the machine is raised, do not stay under the attachments. Before leaving the operator's seat lower the bucket to the ground and stop the engine.

Instrument panel does not show all information about the machine. During daily maintenance, not only the maintenance jobs listed in the instrument panel but also every part of the machine that is listed in the operating and maintenance manual should be checked.

Engine settings are adjusted in the factory and so are all the hydraulic equipment settings. In case of any problem refer to the operating and maintenance manual or contact Hidromek Authorized Service.

8. Hot surfaces

NEVER APPROACH HIGH VOLTAGE TRANSMISSION LINE You may receive an electric shock if the machine is too close to a high voltage transmission line. A narrow proximity even without a physical contact will cause electrocution from the power line.

Take extreme caution around high voltage transmission lines. Leave necessary distance between the lines and the machine. To learn about minimum distances and more refer to Chapter 2.2.2.9.

ATTACHMENT MAY HIT TO OPERATOR'S CAB Careless control of arm and boom may cause attachment to crash into operator's cab or to windshield glass which results in material damage, personnel injury or death.

PRECAUTIONS BEFORE MAINTENANCE Before repairing read and understand the operating and maintenance manual.

Before working with the machine or performing maintenance jobs, park the machine on a flat and firm ground.

Stop the engine and take the starter key with you.

FASTEN YOUR SEAT BELT Fasten your seat belt before starting engine and keep it fastened. Seatbelt is the most necessary part of the ROPS system.

If the machine starts tipping over by a result of an accident, do not remove your seat belt and never try to jump out.

This decal is located on the engine hood.

Do not touch hot surfaces.

Machine components may become very hot after operating or waiting under the sun that they can harm your skin. Wear protective clothing and gloves.

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10. Precautions for filter elements

13. Caution for arm

This decal is located on the air filter.

Periodic maintenance, cleaning and replacing of filter elements will increase engine performance and extend its lifetime.

11. Precautions about windshield

This decal is located on the arm.

When the arm is raised, keep people away. Arm may suddenly fall down and cause injury or death.

14. Do not step on the engine hood warning

This decal is located on the windshield.

After opening the windshield make sure it’s locked from both sides.

12. Electrical circuit caution

This decal is located on the engine hood.

This decal is located on the rear console, under the mat and near the fuse box cover.

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15. Left console lock caution

17. Read operating and maintenance manual warning This decal is located on the right hand side window of the operator's cab.

This decal is located in front of the left console.

16. Left console lifting lever caution

This decal is located near the left console lifting lever.

To use the machine more effectively and safely read and understand the operating and maintenance manual completely before operating the machine.

Keep this manual in the operators cab at all times.

Keep it clean and complete. If lost or damaged, ask your HIDROMEK dealer or service station for a new copy.

If you do not understand any point, or if you feel information contained in this manual is missing or incomplete, or erroneous, consult your service or dealer for appropriate information.

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18. Rotating parts of the engine warning

20. Overload warning switch

This decal is located on the radiator.

When performing any inspection or maintenance DO NOT wear loose clothing or jewelry as they may be caught in the rotating parts or linkages of the engine. Keep your hands, hair, feet, and clothing away from moving parts. Protective components of the rotating equipment/parts may only be removed after the rotation of the part is completely stopped. Protective components such as engine/motor covers, doors, bonnet and guards must be reattached properly after maintenance or repair work.

19. Falling hazard warning

This decal is located on the right hand side window of the operator's cab.

Overloading the machine can affect the machine's balance and cause it to tip over. Tipping over can cause serious or even fatal damage to the operator. To lift the objects with the machine, overload warning switch must be installed and operating correctly.

21. GPS warning

This decal is located on the machine at 3 different points.

When you climb the machine for maintenance or control you may fall down. Wear nonslip safety shoes and use equipment suited for work safety.

Clean the oil, snow etc. from the machine and let it dry. When climbing the machine always contact at 3 points.

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This decal is located on the right hand side window of the operator's cab.

This machine is equipped with Smartlink satellite tracking system. At blasting areas, gas stations, near explosive materials Smartlink system should be deactivated to prevent fire or unexpected explosions.

22. Quick coupling warning

24. Coolant level warning

This decal is located on the reservoir tank.

This decal is located on the right hand side window of the operator's cab.

25. Antifreeze warning

Make sure the pins on the bucket or other attachments are placed correctly on the quick coupling and locked properly.

23. Keep away from working area warning

This decal is located on the reservoir tank.

Engine coolant is a mixture of antifreeze and water in 50:50 ratio. It protects the engine down to -35 °C. For more information see Chapter 6.2. "Oil, Fuel, Coolant And Diesel Exhaust Fluid".

This decals are located on the counterweight.

Do not allow people to enter the worksite. Always keep necessary distance with the machine.

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26. Fuel line cleaning system

This decal is located on the inner side of the pump door on the right hand side.

On machines having fuel line cleaning system, refer to chapter "6.10.1. Changing Fuel Filter Elements" for more information about changing fuel filters and cleaning fuel line.

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3. DESCRIPTION 3.1. LOCATION OF MAIN PARTS In this manual, machine direction is determined from the operator seat as illustrated.

1. Bucket 2. Link 3. Yoke 4. Bucket Cylinder 5. Arm 6. Dozer Blade 7. Front Axle 8. Cab 9. Lower Frame

10. Cardan Shaft 11. Hydraulic Tank 12. Transmission 13. Air Filter 14. Rear Axle 15. Muffler 16. Counterweight 17. Outrigger 18. Cowling

19. Fuel Tank 20. Battery 21. Swing Motor 22. Swing Bearing 23. Boom Cylinder 24. Arm Cylinder 25. Boom

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3.2. DETAIL OF OPERATOR’S CAB

1. Instrument Panel 2. Steering Wheel 3. Accelerator Pedal 4. Brake Pedal 5. Steering Column 6. Footrest 7. Safety Lever 8. Operating Lever 9. Left Console Lifting Lever 10. Switches 11. Heater and Air Conditioner 12. Operator's Seat 13. Starter Key 14. Switch 15. Opera Instrument Panel

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16. Dozer Blade and Outrigger Control Lever 17. Cup Holder / Ash Tray 18. Storage Place 19. AUX / USB Connections 20. External Socket (12 V) 21. Hour meter 22. Cool Box 23. Convenient Storage Box 24. Bottle Holder 25. Lighter (24 V) 26. Fuse / Relay Box Cover 27. Convenient Storage 28. Radio/USB Music Player 29. Armrest (Rotated Up)

3.3. INSTRUMENT PANEL

Section A: Warning and indicator lights Warning indicators are shown on this section of the monitor.

Section C: MODE Indicators Selected/activated modes can be viewed on this section.

Section B: Gauges/Camera This section shows gauges and also camera views if selected.

Section D: MENU Keys Menu keys are located on this section of the monitor.

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Section A: Warning and indicator lights 1. Battery charge indicator 2. “Engine oil pressure low” warning light 3. “Air filter clogged” warning light 4. Engine warning indicator 5. “Parking brake applied” indicator 6. “Joystick safety lock engaged” warning light 7. Failure warning light 8. “Buzzer muted” warning light 9. “Swing lock engaged” indicator 10. “Reduced engine power (Derate)” warning light 11. High altitude function indicator

Section B: Gauges/Camera 22. Travel direction indicator 23. Diesel Exhaust Fluid (DEF/AdBlue®) level gauge 24. Hydraulic oil temperature gauge 25. Fuel level gauge 26. Engine speed indicator 27. Engine coolant temperature gauge

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12. Seat belt warning light 13. "Urea SCR Purge Disabled" warning light 14. "Urea SCR system is purging" warning light 15. "DPF regeneration is active" warning light 16. “Diesel Exhaust Fluid (DEF/AdBlue®) level is low” warning light 17. Swing Align Indicator 18. Cruise Control Indicator 19. “Quick coupling lock disengaged” warning light 20. “Axle lock” indicator 21. Message and Error Display

Section C: MODE Indicators 28. Power mode indicator 29. Preheat indicator 30. Auto Idle mode indicator 31. Travel mode indicator 32. Power boost indicator 33. Work mode indicator

Section D: MENU Keys 34. Home key 35. Camera key 36. Menu key 37. Back (Cancel) key 38. Radio key 39. USB/MP3 player key 40. AUX key

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1. Battery charge indicator: This indicator light comes on when the alternator is not charging the battery. Thus, the voltage from the battery falls and simultaneously “Charging Error” message comes on the Display Panel. Should this happen while the engine is running, it means that all the electrical components of the machine are energized by the battery. In this case, park the machine in a suitable area and call a Hidromek Authorized Service or Dealer.

7. Failure warning light: This warning light comes on when any failure occurs on the machine.

8. Buzzer muted warning light: This warning light comes on when the buzzer is muted using the Buzzer Mute Switch on the Opera Instrument Panel.

Buzzer warns the operator in case of an error. If the error is not critical and stopping the operation of the machine is not necessary, the operator may cancel the buzzer and continue working.

2. Engine oil low pressure indicator: This indicator comes on when the engine oil pressure decreases under specified value. In this case, immediately stop the engine, park the machine in a suitable area and call a HIDROMEK Authorized Service or Dealer.

9. "Swing lock engaged" warning light: This symbol illuminates when swing lock is engaged. This indicator is available for wheeled excavators.

3. "Air cleaner clogged" indicator: This indicator comes on when the air filter is clogged. When it comes on, replace the air filter elements.

10. Reduced engine power (Derate) indicator light: This indicator comes on when the engine output is restricted because of the low DEF/AdBlue® level in the tank or there is an abnormality with either the DEF/AdBlue® quality or the DEF/AdBlue® injection system.

4. Engine warning indicator: This light comes on in case of a failure in engine electronic control system.

An error code comes on Display Panel.

Refer to Chapter "DEF/AdBlue® Warning Light (REFILL DEF/AdBlue®)".

CAUTION When the engine warning indicator light comes on, or the engine failure code is displayed in the Instrument Panel, immediately contact Hidromek Authorized Service.

11. High altitude function indicator: This light comes on when high altitude function is enabled.

5. “Parking brake applied” indicator: This light comes on when the parking brake is applied. This indicator is available for wheeled excavators.

12. Safety belt warning light: Warns the operator that the seat belt is not fastened. Always fasten your seat belt before operating the machine.

6. "Joystick safety lock engaged" warning light: This warning light comes on when the lock lever is pushed down and the control of all attachments is disabled. When the safety lock lever is in the upper position, this warning light comes off and control of attachments is enabled.

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13. "Urea SCR system is disabled" warning light: Warns the operator that SCR purging process is disabled.

lock indicator light is on. This indicator is available for wheeled excavators.

14. "Urea SCR system is purging" warning light: Warns the operator that SCR purging process is started and being carried away.

15. "DPF regeneration is active" warning light: This light comes on during active regeneration and it is available in HMK 60 CR excavators.

16. "Diesel exhaust fluid (DEF/AdBlue®) level is low" warning light: This warning light comes on when DEF/AdBlue® level in the tank is low or when there is an abnormality with either the DEF/AdBlue® quality or the DEF/AdBlue® injection system.

Refer to Chapter "4.5.3. DEF/AdBlue® Warning Light (REFILL DEF/AdBlue®)".

21. Message and Error Display (MED) area All information, failure messages and codes are displayed in this area (For details call HIDROMEK Authorized Service or Dealer).

22. Travel direction indicator Indicates the selected travel direction with F, N, R letters which means the transmission is set to Forward, Neutral or Reverse direction, respectively.

This indicator is available for wheeled excavators.

17. Swing Align Indicator: If upper chassis and lower chassis was not aligned to each other this light glows in red. When the upper chassis is aligned with lower chassis this light glows in green. This indicator is available for wheeled excavators.

18. Cruise Control Indicator: Indicator light comes on when cruise function is on. This indicator is available for wheeled excavators.

19. "Quick coupling lock disengaged" warning light: This light comes on when the quick coupling attachment switch is kept pressed for disengaging quick coupling lock. Refer to Chapter 8.8. Quick Coupling Attachment.

20. “Axle lock” indicator: This light comes on when the front axle lock is engaged. When it is locked, axle can’t oscillate. When it is unlocked, axle oscillates according to the ground structure. At position ON, oscillation cylinders are at locked position and axle

23. Diesel Exhaust Fluid (DEF/AdBlue®) level gauge: Shows the level of Diesel Exhaust Fluid (DEF/AdBlue®). The amount of DEF/AdBlue® remaining in the tank is indicated with "F" representing full and "E" representing empty.

24. Hydraulic oil temperature gauge: This shows the temperature of the oil in the hydraulic system.

Error message appears with buzzer sound on the display when hydraulic oil temperature is higher than permitted operating temperature.

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HP (High Power Mode): For heavy load operations and operations which need high speed and power.

Productivity is the priority and fuel consumption is secondary.

F (Fine Mode): For fine control operations. Operator uses this mode when the load is to be positioned accurately and with controlled movements.

WARNING 25. Fuel level gauge: This shows the fuel level in the tank. When the fuel level is in the yellow zone, “LOW FUEL LEVEL” warning will be displayed.

26. Engine speed display: This display shows the engine speed as rpm instantaneously.

27. Engine coolant temperature gauge: This shows the temperature of the engine coolant.

28. Power mode indicator: This indicator shows the active power mode as selected from the “POWER” button. Power modes are E, P, HP and F respectively.

Use F mode for safety while loading/unloading machine or lifting objects.

29. Preheat indicator: This indicator comes on when the glow plugs are energized to assist engine starting in cold weather. Preheat function is controlled automatically by the engine control module (ECM).

30. Auto idle mode indicator: This indicator lamp comes ON when the Auto-Idle function is active.

Refer to Chapter 3.4. OPERA INSTRUMENT PANEL for more information about "Auto Idle On-Off / Auto Warm up Cancellation" Key.

31. Travel mode indicator: This indicator displays the selected travel speed mode. Turtle symbol comes on when low speed is selected. Rabbit symbol comes on when high speed is selected.

E (Economy) mode: For light digging and loading operations where fuel economy is the priority.

P (Power Mode): For general digging and loading operations where performance is as important as fuel economy.

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32. Power boost on indicator: This indicator comes on when the power boost is on. Power boost is controlled electronically depending on hydraulic pressure. Power boost will be on in accordance with a predetermined period and then it will be off automatically.

33. Work mode indicator: Activate work mode can be viewed through this indicator. When the engine is started, default work mode is adjusted to digging.

Press the Work button on the Opera Instrument Panel to change the active work mode. The work mode sequences are given in the table depending on the type of the machine.

Default Mode

34. Home key Touch to return the home page.

Digging 1

Pressing sequence to the work button

Refer to "Chapter 3.4.7.2. Attachment Settings" for more information about configuration of the optional attachments.

Selected optional attachment

2

Digging

3

Selected optional attachment

35. Camera key Touch to view the camera. Touch again to view the next camera.

Touch home key or back key to exit from the camera page

36. Menu key Touch to enter the menu.

Digging mode: Hydraulic oil is being sent to attachments without any priority.

Optional attachment mode: Various types of hydraulic attachments can be connected to the machine. Activated attachment symbol is displayed.

37. Back (Cancel) key Touch to exit current page/menu and return to previous page/menu.

38. Radio key Touch to open the radio page.

This symbol shows that the active attachment is a single acting attachment.

The number shows the attachment number which is assigned during creating the attachment under settings page.

39. USB/MP3 player key Touch to open the USB/MP3 player page.

40. AUX key Touch to open the AUX page.

This symbol shows that the active attachment is a double acting attachment.

The number shows the attachment number which is assigned during creating the attachment under settings page.

When the optional attachment is selected, the active attachment number will be displayed near the WORK optional attachment icon. Active attachment can be selected and attachment configuration can be changed through the instrument panel's menu, under the "Settings>Attachment Settings" page.

There is an alternative shortcut to open this menu: select the optional attachment using the work button and touch the WORK optional attachment icon on the instrument panel.

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3.4. MENU ITEMS Touch the menu key (1) to enter the main menu.

Alternatively, keep the menu/enter button on Opera Instrument Panel pressed for 3 seconds.

When entered, on the B Section of the instrument panel, instead of Gauges/Camera, the main menu is displayed.

1. Menu key 2. Home key 3. Back (Cancel) Key The main menu includes 7 sub-menus as listed below: LANGUAGE Use this menu to set the machine control menu in your preferred language.

STATUS INFO Operational parameters such as Machine Parameters, Engine Parameters, and Optional Attachment Parameters can be viewed through this menu.

WORKING HOURS Different types of operating hours can be registered and viewed on this menu.

MAINTENANCE Hours remaining to the next maintenance, last maintenance hours and maintenance period can be adjusted. After maintenance performed, remaining hours can be reset to adjusted value.

FAILURES Previously displayed alarms and warning messages that are registered in the control system can be viewed.

MACHINE INFORMATION Software versions of the machine control unit, Instrument panel, Opera, Optional Attachment, Smartlink, Attachment Control Unit, and machine type information can be viewed through this menu.

SETTINGS Settings can be done through this menu.

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3.4.1. LANGUAGE To set your preferred language, perform the followings: Touch the “Lisan/Language” button to open the Language page.

Touching the button with a name of your desired language on, highlights that button and sets that language as the current language.

If you cannot see your desired language, slide the page up.

To exit from the menu, touch the back key or home key. Also, you can press the back key or home key on the Opera Instrument Panel.

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3.4.2. STATUS INFO To view the status information contents follow these steps: Touch the “Status Info” button to open the Status Info page.

The below listed pages exists under the Status Info page.      

Machine Parameters Engine Parameters Optional Attachment Parameters Opera Smartlink Air Conditioner

Touch the title that you would like to display.

To exit from the menu, touch the back key or home key. Also, you can press the back key or home key on the Opera Instrument Panel.

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3.4.3. WORKING HOURS Touch on the “Working Hours” button to open the Working Hours page.

The following Working Hours can be monitored through the control panel.

Only trip hours can be changed, others are not adjustable.

To exit from the menu, touch the back key or home key. Also, you can press the back key or home key on the Opera Instrument Panel.

Ignition-on time

0.00

Machine working time

0.00

Trip time

0.00

Travel time

0.00

Digging mode time

0.00

Trenching mode time

0.00

L1 single acting time

0.00

L1 double acting time

0.00

E mode time

0.00

P mode time

0.00

HP mode time

0.00

F mode time

0.00

Low idle time

0.00

Rpm 1000-1100 time

0.00

Rpm 1100-1200 time

0.00

Rpm 1200-1300 time

0.00

Rpm 1300-1400 time

0.00

Rpm 1400-1500 time

0.00

Rpm 1500-1600 time

0.00

Rpm 1600-1700 time

0.00

Rpm 1700-1800 time

0.00

Rpm 1800-1900 time

0.00

Rpm 1900-2000 time

0.00

Rpm 2000+ time

0.00

Power boost time

0.00

Display working time

0.00

Display manual mode working time

0.00

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3.4.4. MAINTENANCE Touch the “Maintenance” button to open the Maintenance page.

The operator can register any maintenance activity that he performed and update the control menu. If it is not updated on time, an alarm buzzes and update message comes on the display.

Before 20 hours to a periodic maintenance, a notification message is displayed on the page. After the maintenance period ends, the system continues displaying the message for another 50 hours.

On the periodic maintenance list; oncoming, current, and elapsed maintenances are displayed in different colors.

Periodic maintenance menu covers various maintenance issues that differ according to the type of the machine.

The below listed periodic maintenance items exists under the maintenance page:                      

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Fuel pre-filter Main fuel filter Engine oil filter Engine oil Hydraulic return filter Hydraulic pilot filter Hydraulic suction strainer Hydraulic tank breather Hydraulic oil Brake filter (wheeled excavator only) AC filters Swing unit reduction oil Travel gearbox oil Transmission oil (wheeled excavator only) Front axle oil (wheeled excavator only) Rear axle oil (wheeled excavator only) Blow-by oil separator (4JJ1 engine) DPD filter (Tier4i only) DEF/AdBlue® filter (Tier4 only) Engine coolant Hydraulic breaker filter (optional) Hydraulic by-pass filter (optional)

3.4.4.1. Confirming a periodic maintenance

3.4.4.2. Editing the maintenance interval

After performing a periodic maintenance activity, touch “Maintenance” button to open the Maintenance page.

You can change each maintenance interval.

Touch maintenance activity that you want to confirm.

For example touch "Main fuel filter change".

Touch "Confirm maintenance" button to confirm the maintenance activity.

Touch the maintenance activity that you want to edit.

For example touch "Main fuel filter change".

Touch (-) or (+) buttons to change the maintenance interval.

After, touch back or home key to exit page.

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3.4.5. FAILURES Previously displayed alarms and warning messages and machine working hour of their first appearance is listed in this page.

3.4.6. MACHINE INFORMATION Installed software versions are displayed on this page.

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3.4.7. SETTINGS 1. Brightness 2. Attachment Settings 3. Auto Power Boost 4. Travel Power Boost 5. Travel Speed Up 6. Auto Idle Time 7. High Altitude 8. Camera 9. Horn 10. Overload 11. Low Idle Engine Auto Stop 12. Regeneration Inhibit 13. Inducement Escape

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3.4.7.1. Brightness

1. Touch “Settings” sub-menu on the main menu.

2. Touch “Brightness” to enter the Brightness page.

Adjusting the display brightness level: 3. To increase the brightness of the screen, touch and rotate the slider (1) CW. To decrease the brightness, touch and rotate the slider (1) to CCW. Brightness level is displayed between 0-100, inside the circular slider.

Turning the display brightness off/on: 4. Touch the "Brightness off" button (2) to turn the display brightness completely off.

5. Touch the screen with minimum 2 fingers to turn the brightness on again.

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3.4.7.2. Attachment Settings As an option, excavators can be equipped with a single or double acting hydraulic piping for attachments on hydraulic line 1 and a double acting low flow hydraulic piping on hydraulic line 2.

WARNING Be sure that there is no one in the working area during attachment installation and adjustment.

When adjusting the optional attachment, operating values must be set according to the values given by the attachment manufacturer. For any problems about these settings, consult Hidromek Authorized Services or Dealer.

Hydraulic Line 1 (High flow) (L1): This line can be used with attachments such as hydraulic breakers or crushers. It can be adjusted to operate as single or double acting and flow setting can be adjusted to the required value. If the machine is equipped with a pressure relief valve on this line, pressure setting for the attachment can be adjusted.

1. Left Proportional Control (Adjustable) 2. Left Joystick Auxiliary Button 3. Horn Figure. Left Joystick

WARNING Adjust the position of the 3-way ball valve and set the attachment settings on the instrument panel for an optional attachment or a hydraulic breaker.

3-way ball valve: If hydraulic breaker is connected to the hydraulic line, L1 single acting attachment should be selected on the instrument panel and 3-way ball valve should be rotated to "B" Breaker position. If a double acting attachment is connected to this line, L1 double acting attachment should be selected on the instrument panel and 3-way ball valve should be rotated to "R" position. Ensure that 3-way ball valve is rotated to the correct position. Otherwise, the attachment can be damaged.

4. Right Proportional Control 5. Null 6. Right Joystick Auxiliary Button(Hydraulic Breaker) Figure. Right Joystick

Figure. Mechanical 3-way ball valve On machines with electrical type 3-way ball valve: When active attachment is adjusted to a single or double acting attachment, the position of the 3-way ball valve is adjusted automatically according to the active attachment type.

Hydraulic Line 2 (Low flow) (L3): This line is used with attachments such as crushers, shears, polyps, log grapples and for the situations in which an extra hydraulic line is required (especially rotary attachments). It has low pressure and low flow settings.

7. Double Acting Foot Pedal Figure. Foot pedal

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On the instrument panel, 10 different types of attachments can be restored with their configuration.

Follow the steps below to configure the Optional Attachments on the Instrument Panel:

2. Attachment name: Touch the keyboard button (9) to turn the keyboard on. Touch the attachment name textbox. Using the keyboard, enter a name for the attachment. Touch the keyboard button again to turn the keyboard off.

3.4.7.2.1. Adding new attachment 1. Add attachment: 3. Single/double acting selection: To add new attachment, touch Add button (A). New number (8) will be defined and attachment configuration window will be displayed.

Choose if the attachment is single or double acting using the horizontal scroll bar.

4. Flow adjustment: Touch (-) or (+) to adjust the flow value of the hydraulic line 1 (L1).

Adjusted flow is kept constant by the control unit, independent from engine speed.

In some cases, if adjusted flow is out of range according to adjusted engine speed, a warning message is displayed on the instrument panel to warn the operator to increase or decrease the engine speed.

CAUTION Flow on hydraulic line might be slightly different than adjusted value due to alteration in system parameters like: hydraulic oil temperature, engine speed, etc.

5. Pressure adjustment (optional): This adjustment can be performed on machines equipped with pressure relief valve.

Touch (-) or (+) to adjust the pressure value of the hydraulic line 1 (L1).

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6. Selecting control method: Proportional controllers, buttons on left/right joysticks, and double acting foot pedal can be selected as the control method of the attachments on hydraulic lines. Control method can be adjusted as on/off control, toggle control or proportional control.

On/off control: Hydraulic flow will be supplied to the attachment on optional hydraulic line when selected control is engaged continuously. When selected control is disengaged, hydraulic flow stops.

Toggle control: Hydraulic flow will be supplied continuously to the optional hydraulic line if the selected control is engaged for one time. When selected control is engaged one more time, hydraulic flow stops.

Proportional control: Hydraulic flow rate will be supplied to the optional hydraulic line according to the controller rate. If the controller is moved fully, maximum flow rate will be supplied to the hydraulic line.

- Right Joystick Toggle - Right Joystick On-Off - Right Joystick Proportional -Fine - Right Joystick Proportional -Normal - Right Joystick Proportional -Quick - Electrical Proportional Pedal - Toggle - Electrical Proportional Pedal - On - Off - Electrical Proportional Pedal - Fine - Electrical Proportional Pedal - Normal - Electrical Proportional Pedal - Quick 7. Saving the attachment configuration: Touch save button to save the configuration and close the attachment configuration window.

Touch "X" button on top right corner to quit without saving the configuration.

3.4.7.2.2. Editing the configuration of an attachment 1. Touch attachment window.

2. Touch edit button (B).

Follow the steps in "Adding new attachment" section to configure the attachment.

6.1. L1 control method selection: Touch L1 control method selection button (10).

Choose the proper control method for the hydraulic line 1 from the list below:

3.4.7.2.3. Deleting an attachment 1. Touch attachment window.

2. Touch delete button (C).

3.4.7.2.4. Selecting the active attachment

-None - Left Joystick Toggle - Left Joystick On-Off - Left Joystick Proportional -Fine - Left Joystick Proportional -Normal - Left Joystick Proportional -Quick - Right Joystick Toggle - Right Joystick On-Off - Right Joystick Proportional -Fine - Right Joystick Proportional -Normal - Right Joystick Proportional -Quick - Electrical Proportional Pedal - Toggle - Electrical Proportional Pedal - On - Off - Electrical Proportional Pedal - Fine - Electrical Proportional Pedal - Normal - Electrical Proportional Pedal - Quick 6.2. L3 control method selection: Touch L3 control method selection button (11).

Choose the proper control method for the hydraulic line 2 from the list below: -None - Left Joystick Toggle - Left Joystick On-Off - Left Joystick Proportional -Fine - Left Joystick Proportional -Normal - Left Joystick Proportional -Quick

1. To select the active optional attachment, touch the attachment window. Active attachment color becomes green.

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2. Press back key or home key after the attachment is selected.

3. To operate the active attachment, press work button on the Opera Instrument Panel until WORK optional attachment icon appears on the instrument panel.

Optional attachment icon is a hydraulic breaker symbol when single acting attachment is selected and a crusher symbol when double acting attachment is selected. When the optional attachment is selected, the active attachment number will also be displayed near the WORK optional attachment icon.

This symbol shows that the active attachment is a single acting attachment.

The number shows the attachment number which is assigned during creating the attachment under settings page.

This symbol shows that the active attachment is a double acting attachment.

The number shows the attachment number which is assigned during creating the attachment under settings page.

When this optional attachment is selected by the WORK MODE selector key, the control system will automatically adjust the settings for the active attachment. Make sure you have correctly set the operating parameters for the attachment you are going to use and that this attachment is made active from the Create Attachment menu.

There is an alternative shortcut to open the Create Attachment menu: select the optional attachment using the work button and touch the WORK optional attachment icon on the instrument panel.

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3.4.7.3. Auto Power Boost

3.4.7.4. Travel Power Boost (If exists)

If this function is on, power boost will be activated automatically depending on hydraulic pressure. Auto Power boost function can be enabled or disabled through this setting.

If this function is enabled; when the machine starts traveling, the power boost will be activated. Travel Power boost function can be enabled or disabled through this setting.

1. Touch “Settings” sub-menu on the main menu.

1. Touch the “Settings” sub-menu on the main menu.

2. Touch the “Auto Power Boost" to enter the Auto Power boost page.

2. Touch the “Travel Power Boost” to enter the Travel Power boost page.

3. Touch the Enable/Disable button to enable or disable the function.

3. Touch the Enable/Disable button to enable or disable the function.

The status of the function is indicated above the change button as "Function Enabled" or "Function Disabled".

The status of the function is indicated above the change button as "Function Enabled" or "Function Disabled".

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3.4.7.5. Travel Speed Up

3.4.7.6. Auto Idle Time

If the machine starts traveling when the "Travel Speed Up Function" is "ON", diesel engine speed is increased automatically by the control unit to enable higher speed to travel. This function can be enabled or disabled through this setting.

For the auto idle function to take effect, auto idle must be activated. To activate or deactivate the auto idle press the Auto Idle On-Off Switch on the Opera Instrument Panel. When auto idle is activated, the auto idle symbol comes on the instrument panel.

Proceed with the following steps to set Auto Idle Times:

1. Touch the “Settings” sub-menu on the main menu.

2. Touch the “Travel Speed Up” to enter the Travel Speed Up page.

3. Touch the Enable/Disable button to enable or disable the function.

The status of the function is indicated above the change button as "Function Enabled" or "Function Disabled".

1. Touch the “Settings” sub-menu on the main menu.

Touch the “Auto Idle Time” to view preset settings.

2. There are two Auto Idle Times. If attachments are not controlled, engine speed will decrease to 1200 rpm after the selected Auto Idle Time A (Auto Idle) in seconds. If attachments are not controlled for a further time of Auto Idle Time B (Idle) in seconds, engine speed will be decreased to idle speed.

Auto Idle Time A can be set at any value between 4 seconds to 30 seconds.

Touch (-) or (+) to adjust the Auto Idle Time A. Auto Idle Time B can be set at any value between 20 seconds to 250 seconds.

Touch (-) or (+) to adjust the Auto Idle Time B.

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3.4.7.7. High Altitude

3.4.7.8. Camera

High altitude function can be enabled or disabled and high altitude operation percentage can be adjusted through this setting.

Travel camera can be activated or deactivated through this setting.

This function can be enabled while working on high altitudes in order to eliminate engine stall and black smoke emission. High Altitude Operation Percentage should be adjusted to proper level according to operation altitude.

When this function is activated, the default camera will be displayed automatically when the machine starts traveling.

1. Touch the “Settings” sub-menu on the main menu.

1. Touch “Settings” sub-menu on the main menu.

2. Touch “High Altitude” to enter the High Altitude page.

2. Touch the “Camera” to enter the Camera page. It is indicated on the on/off button if the Automatic travel camera function is on or off with numbers "1", "0", respectively.

3. Touch the button to enable the function.

3. Touch the Enable/Disable button to enable or disable the function.

4. Touch the button to disable the function.

The status of the function is indicated above the change button as "Function Enabled" or "Function Disabled". When this function is enabled, high altitude function indicator will display green on the instrument panel.

High altitude function indicator High Altitude Operation Percentage: High Altitude Operation percentage can be adjusted using (-) and (+) buttons.

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3.4.7.9. Horn

3.4.7.10. Overload (If exists)

Starting Horn, Travel Horn (if exists) and Swing Horn (if exists) functions can be enabled or disabled through this setting.

Overload Function can be enabled or disabled and Overload Alarm Threshold Pressure (bar) can be adjusted through this setting.

When the lifting pressure of the boom cylinders reaches the adjusted Overload Alarm Threshold Pressure, a warning message appears on the instrument panel and buzzer sounds.

1. Touch “Settings” sub-menu on the main menu.

2. Touch “Horn” to enter the Horn page.

There are three different kind of horn settings.

1. Touch “Settings” sub-menu on the main menu.

If the Starting Horn is enabled, horn sounds when the starting key turned to ON position.

2. Touch “Overload” to enter the Overload page.

If the Travel Horn is enabled, horn sounds when machine travels.

3. Touch the Enable/Disable button to enable or disable the function.

If Swing Horn is enabled, horn sounds when upper chassis swings.

The status of the function is indicated above the change button as "Function Enabled" or "Function Disabled".

To enable/disable the horn, use the sliding on/off button near each function.

Overload Alarm Threshold Pressure:

It is indicated on the on/off button if the function is on or off with numbers "1", "0", respectively.

Overload Alarm Threshold Pressure can be adjusted using (-) and (+) buttons.

3. Touch the button to enable the function.

4. Touch the button to disable the function.

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3.4.7.11. Low Idle Engine Auto Stop Low Idle Engine Auto Stop function can be enabled or disabled and Engine auto-stop countdown timeout can be adjusted through this setting.

1. Touch “Settings” sub-menu on the main menu.

2. Touch “Low Idle Engine Auto Stop” to enter the Low Idle Engine Auto Stop page.

3. Touch the Enable/Disable button to enable or disable the function.

The status of the function is indicated above the change button as "Function Enabled" or "Function Disabled".

Engine auto-stop countdown timeout: Engine auto-stop countdown timeout can be adjusted using (-) and (+) buttons.

The status of the function is indicated above the change button as "Function Enabled" or "Function Disabled".

WARNING Operating the engine while Purge Inhibit function is enabled, the aftertreatment functioning stops and will cause severe damage to the exhaust system components: DPD, DOC, and SCR. Enable the Purge Inhibit function only in dangerous working conditions where exhaust system may cause a fire or an explosion.

After operating the machine while this function is enabled, move the machine to a safe place and purge Urea SCR System. For more information refer to Chapter 4.5. Urea Selective Catalytic Reduction (SCR) System.

3.4.7.12. Regeneration Inhibit Purge Inhibit function can be enabled or disabled through this setting.

If automatic or manual purging has not been completed within a predetermined amount of time due to purging being inhibited, the engine warning light will be illuminated and purging will become impossible, so do not inhibit purging unless necessary.

1. Touch “Settings” sub-menu on the main menu.

2. Touch “Regeneration Inhibit” to enter the Regeneration Inhibit page.

3. Touch the Enable/Disable button to enable or disable the function.

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3.4.7.13. Inducement Escape If automatic and manual Urea SCR Purging is not completed within a specific period, Engine Control Unit limits the engine speed and torque.

In this situation, if an emergency condition is occurred and it is necessary to move the machine immediately, then this limitation can be cancelled for a short time using this function.

Inducement Escape function can be enabled through this setting for a pre-determined duration.

After the time elapsed, it is disabled automatically by the control unit.

1. Touch “Settings” sub-menu on the main menu.

2. Touch “Inducement Escape” to enter the Inducement Escape page.

3. Touch the Enable/Disable button to enable or disable the function.

The status of the function is indicated above the change button as "Function Enabled" or "Function Disabled".

WARNING Enable Inducement Escape function only in emergency situations to move the machine out of the danger zone. Do not operate attachments in this mode. Consult HIDROMEK AUTHORIZED SERVICE to have the problem fixed as soon as possible.

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3.5. MEDIA When the media key on the opera instrument panel is pressed, media page is displayed on the side panel.

There are 3 different media pages in the Instrument Panel: Radio, USB and AUX. Each time the media key is pressed, it switches between these pages.

3.5.1. RADIO Radio page can be opened by media key or by touching the radio key on the instrument panel.

Saving a radio station to favorite radio stations list: 1. Touch radio key and turn the radio on.

2. Find the radio frequency using down/up seek keys (4 and 5).

3. Touch favorite radio stations key (7) to open favorite radio station window.

There are 3 groups (A, B, C) and in each group there are 9 favorite radio stations.

1. Radio key 2. Volume control 3. Mute key 4. Radio Down Tune Seek key 5. Radio Up Tune Seek key 6. Radio frequency 7. Favorite radio stations key 8. Favorite radio station groups 9. Favorite radio station list

4. Touch the favorite radio station button at least two seconds to save the current radio frequency to the favorite station.

Playing a radio station from favorite radio stations list: 1. Touch radio key (1) and turn the radio on.

2. Touch favorite radio stations key (7) to open favorite radio station window.

3. Touch the favorite radio station button that you would like to listen. The radio station you selected starts to play and the color of the button becomes green.

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3.5.2. USB

3.5.3. AUX

1. USB key 2. Volume control 3. Mute key 4. Previous song key 5. Play key 6. Stop key 7. Next song key 8. Progress bar 9. USB file/folder list

If you want to listen to music of an external audio device, connect an external audio device through AUX input using a suitable cable.

Connect a USB device through USB input if you would like to listen to MP3 file in a USB device.

If a USB device is inserted, MP3 files in a USB device will be playing after setting the instrument panel to USB mode by pressing USB key (1) on the instrument panel or the media key on the opera instrument panel.

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Set the instrument panel to AUX mode by pressing AUX key (1) on the instrument panel or press the media key on the opera instrument panel.

If audio file of audio device is playing, you can listen to music through audio speakers inside the operator's cab.

Sound level can be adjusted in the range from 0 to 100. If the sound level is not sufficient even the volume is increased, check the sound level of connected external device.

3.6. OPERA INSTRUMENT PANEL

1. Engine Start / Stop Button

13. Media Key

2. Buzzer Mute Button

14. SRC key

3. Axle lock switch

15. Radio Down Tune Seek / Previous Song Button

4. Camera Key

16. Radio Up Tune Seek / Next Song Button

5. Auto Idle On-Off / Auto Warm Up Cancellation

17. Working Lamp Switch (Boom)

6. Home Key

18. Beacon Lamp Key

7. Back (Cancel) Key

19. Working Lamps Switch (Operator's cab)

8. Power Mode Selecting Switch

20. Volume Adjust and Music Player ON/OFF Button

9. Low / High Travel Speed Selection Button

21. Headlights Switch

10. Work Mode Selecting Switch

22. INFO (Information) Key

11. One Touch Idle Switch

23. Throttle Control Dial

12. Cruise function switch

24. Menu Search and Confirmation Knob

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1. Engine Start / Stop Button This button is used to start and to stop the engine.

After turning the starting switch "ON", keep this button pressed to start the engine. If you press this button again while the engine is running, the engine will be stopped.

2. Buzzer Mute (Volume OFF) Button If some failure occurs on the machine, a buzzer warns the operator. When this key is pressed, the buzzer is temporarily muted.

3. Axle lock switch This switch is used to lock and unlock the front axle.

When it is locked, axle can’t oscillate. When it is unlocked, axle oscillates according to the ground structure. At position ON, oscillation cylinders are at unlocked position and axle lock indicator light is off.

4. Camera Key This key is used to display the camera on the instrument panel.

Press once to display the camera.

Press it again to display the next camera (if exists).

Press it for the third time to display the next camera (if exists).

Press Home Key or Back Key to exit.

5. "Auto Idle On-Off / Auto Warm Up Cancellation" Key Cancel auto warm up function, or either turn the auto idle function on or off by pressing this key.

Auto idle on-off steps: On the main display by pressing the auto idle button, this function will be switched on or off.

temperature values are obtained. This is an automatic function of the engine control system; the operator will have no control on it unless this function cancelled manually.

After the engine coolant and hydraulic oil warmed up adequately, or 15 minutes elapsed after the engine start, then the engine speed will change according to the selected power mode and the position of the speed control dial.

6. Home Key While inside the menu, press this key to return to the main page.

7. Back (Cancel) Key Press this key to exit from the current menu or to return to the previous menu.

8. Power Mode Selecting Switch Press to select among available power modes.

For more information refer to Instrument Panel section.

9. Low / High Travel Speed Selection Button This button is used to select low or high travel speed. On crawler machines Low Travel mode is default whereas the rubber wheeled machines will start with High Speed travel as a default mode.

10. Work Mode Selecting Switch Press to select among available work modes.

For more information refer to Instrument Panel section.

11. One Touch Idle Switch

Auto idle: There are two predefined levels for Auto-Idle activation. These Auto Idle Activation Levels can be set by the operator between (3-30 second) for the LEVEL-1 and between (20-250 seconds) for the LEVEL-2. When the Level-1 period has elapsed with no joystick control, the engine speed will be decreased to 1200 rpm. If attachments are not controlled for a further Level-2 period, the engine speed will be decreased to IDLE speed.

If the joysticks are operated in the meantime, then the engine speed will be recovered at the set value by the operator before the auto-idle activation took effect.

Auto warm up cancellation: Auto warm up function should only be canceled in an emergency situations. This can be done by pressing the auto idle cancellation button for 3 seconds on the main display.

Auto warm up: If engine coolant temperature is lower than 30 ˚C and/or hydraulic oil temperature is below 0 ˚C when the engine has been started, the engine speed will be gradually increased to 1200 rpm and auto warm up function will be switched on for a period of maximum 15 minutes until normal 72

If "one touch idle" switch is pressed on the instrument panel when auto-idle function is turned off, auto-idle function turns on and if the attachments are not controlled by that time machine sets the engine speed to 980 rpm without waiting adjusted auto-idle times. After the attachments are controlled, pre-adjusted settings are applied.

12. Cruise function switch CR function sets the engine RPM during traveling.

This function is available only on travel mode.

Refer to "Chapter 4.11. Cruise Funciton" for more information about how to use this function.

13. Media Key When this key is pressed, media page is displayed on the side panel.

Each time this key is pressed, it switches the media page between Radio, USB and AUX. 14. SRC key Each time this key is pressed, it switches the radio to the next favorite radio station. Favorite radio stations have 3 groups (A, B, C). This key only switches between the radio stations in the active group.

15. Radio Down Tune Seek / Previous Song Button To automatically select a radio station, momentarily press the DOWN TUNE SEEK button to search for the closest radio station.

To manually select a radio station, press the DOWN Tuning button for longer than 3 seconds.

The radio frequency will move down step by step each time you press button.

Also this button is used to select the previous song when the music player is in USB mode. Each time the button is pressed, the file number is decreased.

16. Radio Up Tune Seek / Next Song Button To automatically select a radio station, momentarily press the "UP TUNE SEEK" button to search for the closest radio station.

To manually select a radio station, press the UP Tuning button for longer than 3 seconds. The radio frequency will move up step by step each time you press the button.

Also this button is used to select next song when the music player is in USB mode. Each time the button is pressed, the file number is increased.

17. Working Lamps Switch (Boom) Press to turn the working lamps on the boom on.

Press again to turn the working lamps on the boom off.

18. Beacon Lamp Key It functions when the starting switch is turned ON. When you press this key, rotary lamp at the top of the operator's cabin lights up together with the light on the key. When the key is pressed again, rotary lamp and key light both turn off.

19. Working Lamps Switch (Operator's Cab) Press once to turn working lamps on the front side of the operator's cab on.

Press again to turn working lamps on the rear side of the operator's cab on. All of the working lamps on the front side and the rear side of the operator's cab turns on at the same time.

21. Headlights Switch This switch turns on/off the parking lamps and low beam headlights.

Press once to turn on the parking lamps.

Press again to turn on the low beam lights.

Press third time to turn the lights off.

22. INFO (Information) Key If the engine is running, INFO function is not active.

INFO function is used to receive information about the functions of other keys on the machine.

When INFO key is pressed once, INFO function activates, the functions of other keys on the machine are temporarily disabled and the lamp on the key lights up. While the INFO key is active, press the key of any function which you need to know, information about the function of that key will be displayed on the side panel.

When you press INFO key again, the function will be disabled and the lamp on the key turns off.

23. Throttle Control Dial The dial controls the engine speed manually. Turn the dial to the right to increase the engine speed; turn the dial to the left to reduce the speed.

WARNING Do not suddenly shut off the engine when operating at high speed. First, rotate dial to low speed to allow the engine and turbocharger speeds to stabilize, and then shut it off.

24. Menu Search and Confirmation Knob Press this knob continuously for 3 seconds to enter the menu.

When you enter the menu of instrument panel, by turning this knob to right or left, you can surf among the titles of the menu.

After deciding on the title you want to select, press this knob to confirm.

Press third time to turn all lights off.

20. Volume Adjust and Music Player ON/OFF Button Press the knob to turn on/off the music player.

Turning the knob increases or decreases the volume. Turn the knob to the right to increase the volume, turn it to the left to decrease the volume.

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3.7. USB / AUX CONNECTIONS

3.8. EXTERNAL SOCKET (12 V) There is an external electrical socket on the right hand side console.

WARNING Do not connect any device that uses energy more than 100 W. 3.9. STARTER KEY Starter key is used to start or stop the engine.

USB FUNCTION

"OFF" position The starter key can only be inserted or pulled out in the OFF position. In this position the electric circuit to the system is cut-off.

Connect a USB device through USB input if you want to listen to MP3 file in a USB device.

"ON" position The electric circuit to the engine is ON. Leave the key in this position after starting.

If a USB device is inserted, MP3 files in a USB device will be playing after setting the instrument panel to USB mode by pressing media key on the instrument panel or the media key on the opera instrument panel.

"START" position Used to start the engine. Release the key immediately after starting. The key returns to "ON" position.

USB SPECIFICATIONS

1) The essential features of the device are as follows : - Compatible with FAT, FAT12, FAT16 and FAT32 file systems.

- 200 Directories and 999 Files can be introduced in the USB device.

- TAG (ID3) file information of types V1.1, V2.2 and V2.3 can be displayed.

2) Only 20 characters can be displayed.

3) MULTI-CARD READER can not be supported.

4) Compatible with USB 1.1 and USB 2.0 standards.

5) USB device will be subjected to vibrations when it is connected. Disconnect the USB device to avoid any harm if it is not used.

AUX FUNCTION If you want to listen to music of an external audio device, connect an external audio device through AUX input using a suitable cable.

Set the instrument panel to AUX mode by pressing media key on the instrument panel or press the media key on the opera instrument panel.

If audio file of audio device is playing, you can listen to music through car audio speakers.

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3.10. HOURMETER

3.12. CONVENIENT STORAGE

Small objects like cell phones, mp3 players, glasses, wallets etc. can be stored in this place.

Also devices that are connected to the 12V socket may be stored here.

3.13. CONVENIENT STORAGE BOX It is mounted on the front console. It shows total operating hour of the machine.

In addition to hour meter, it is possible to see this value as well as the working hours, attachment hours and travel hours on the “Operating Hours” menu of the control panel.

3.11. CUP HOLDER / ASH TRAY

There is a storage box under the right armrest.

Cup holder is placed on the front side of the right hand side console. Ash tray is portable and it can be removed.

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3.14. SWITCHES

3. N/A

4. Front and Rear Working Lamps (optional) Turns on the working lamps that mounted on the top of the operator's cab. Press once to turn on the front working lamps. Press again to turn on front and rear working lamps together. Front and rear working lamps are optional equipment.

5. Engine emergency stop switch Use this switch if the engine can not be shut OFF and only in case of an emergency situation to stop the engine immediately.

1. Quick coupling switch (optional) For more information on using the switch refer to "Chapter 8.8. Quick Coupling Attachment".

2. Purge switch Press to either start or pause the manual purging process.

See "Chapter 4.5. Urea Selective Catalytic Reduction (SCR) System” for detailed information.

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6. Swing Lock Switch Press it to apply swing lock. For more information refer to Chapter 3.23. "Swing Lock".

7. Front Dozer Enabling Switch Press the upper side of the switch to enable and lower side of the switch to disable the dozer.

Figure. "Outrigger / Dozer" Enabling Switches (Machines with front dozer and rear stabilizers)

8. Rear Dozer Enabling Switch Press the upper side of the switch to enable and lower side of the switch to disable the dozer.

9. Front Left Outrigger Enabling Switch Press the upper side of the switch to enable and lower side of the switch to disable the outrigger.

10. Front Right Outrigger Enabling Switch Press the upper side of the switch to enable and lower side of the switch to disable the outrigger.

11. Rear Left Outrigger Enabling Switch Press the upper side of the switch to enable and lower side of the switch to disable the outrigger.

12. Rear Right Outrigger Enabling Switch Press the upper side of the switch to enable and lower side of the switch to disable the outrigger.

Figure. "Outrigger / Dozer" Enabling Switches (Machines with front stabilizers and rear dozer)

Figure. "Outrigger / Dozer" Enabling Switches (Machines with 4 stabilizers)

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3.15. DOZER BLADE CONTROL LEVER

AND

OUTRIGGER

3.15.1. CONTROL LEVER ON MACHINES WITH ELECTRICAL-TYPE CENTER JOINT This lever is located on the right hand side console near the right hand side control lever.

To move the stabilizers down, push the lever forward.

To move the stabilizers up, pull the lever backward.

Outriggers and dozer blade of which their enabling switches are activated, will move with the control of the dozer blade and outrigger control lever.

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3.16. STEERING It is used to change the traveling direction of the machine.

3.16.1. STEERING COLUMN It has Steering Wheel, Indicator Lights, Speed Selection Switch, and Multi-Function Lever, Mode Selection Switch and "Hazard Warning Light" Switch on it.

STEERING WHEEL HEIGHT ADJUSTMENT There is an adjusting lever (1) at the right hand side of the steering column. Pull the lever backward to unlock. Adjust the telescopic height and push the lever forward to lock at desired position.

STEERING WHEEL ANGLE ADJUSTMENT To tilt the steering column toward operator or toward windshield, push the pedal (2) and move the steering wheel in forward-backward direction.

1

2

1 - Steering wheel height adjusting lever 2 - Steering wheel angle adjusting pedal

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3.16.2. INDICATOR LIGHTS

1. Turn Signal Indicator Light (Left) Indicator light flashes when multi-function lever is pulled backward.

2. Cruise Function Indicator Light Indicator light comes on when cruise function switch is on.

3. Brake System Failure Indicator Light Indicator light comes on and buzzer sounds when brake charge pressure is below than required. At the same time “Low Brake Pressure” message comes on the display panel.

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4. Axle Lock Indicator Light Indicator light comes on steady when axle lock switch is off. If you press the axle lock switch on the opera instrument panel, this light goes off.

5. Flashing Headlight Indicator Light Indicator light comes on when multi-function lever is lifted up half.

6. Turn Signal Indicator Light (Right) Indicator light flashes when multi-function lever is pushed forward.

3.16.3. SPEED SELECTION SWITCH

3.16.4. FORWARD REVERSE SELECTION SWITCH (FNR)

DIRECTION

2

1. Speed selection switch It is placed on the right hand side of the steering column.

SPEED CHANGE There are two speeds available in both forward and reverse. Push the upper side of the switch to select the first gear. Push the lower side of the switch to select the second gear.

2. FNR (Forward-Reverse direction selection switch) Forward or reverse direction is selected by using the 3-position switch behind the Joystick.

DRIVING FORWARD Push the upper side of the switch to move forward and machine will move forward.

NEUTRAL POSITION Center position (N position) of this switch is neutral position.

DRIVING BACKWARD Push the lower side of the switch to move backwards and machine will move backwards.

WARNING Ensure that the FNR switch is in neutral position and engine is running at idle whenever the machine is stopped.

Before changing forward or reverse direction, first stop the machine.

When using the drive control switch, pay attention and check the direction of lower frame.

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3.16.5. MULTI-FUNCTION LEVER It is located on the right hand side of the steering column. Switches on lever and their functions are as follows.

RIGHT TURN SIGNAL To signal a right turn, pull the lever backward.

Push the lever forward to turn off the signal.

LEFT TURN SIGNAL To signal a left turn, push the lever forward.

Pull the lever backward to turn off the signal.

FLASHING HEADLIGHTS Headlights flash when the lever lifted up half.

HIGH BEAM High beam of headlights is “ON” when the lever is lifted up complete.

If the same operation is repeated, high beam headlights will “OFF”.

CAUTION Low beam of headlights should be used when driving on public roads in order not to disturb other drivers for safety in traffic. High beam of headlights may disturb the eyes of other drivers and may cause fatal accidents.

HORN Push the button on the top end of the lever to switch the horn on.

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CONTINUOUS WINDSCREEN WIPER "0" Position : Wiper doesn't operate.

"I" Position : When barrel is turned in forward direction wiper operates continuously in slow mode.

WINDSCREEN WASHER Pull barrel to the steering column to spray water on the windscreen. Windscreen washer button is around the horn button.

CAUTION Make sure that there is sufficient amount of washer fluid in the washer reservoir before operating the washer.

"II" Position : When barrel is turned in forward direction again wiper operates continuously in fast mode.

Windscreen washer reservoir

INTERMITTENT WINDSCREEN WIPER "0" Position : Wiper doesn't operate.

"J" Position : When barrel is turned in backward direction wiper operates intermittently.

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3.16.6. "MODE SELECTION" SWITCH

3.16.7. "HAZARD WARNING LIGHT" SWITCH

Switch is located on the left hand side of the steering column. This switch has 3 positions.

Positions and their functions are as in the following: PARK MODE Select “P” mode, when the machine is in park mode. In this position parking brake is applied. At this position attachment operation and travel operation are not available.

WORK AND TRAVEL MODE Select “W&T” mode for travel and operation. At this position, do not use Cruise (CR) function. The parking brake is released.

TRAVEL MODE Select “T” mode, when machine travels without doing operation. Attachment operation is unavailable. CR function is available in this mode.

The parking brake is released.

1. Mode Selection Switch CAUTION When the switch is in the “P” or “T” position the control levers are not functional.

To avoid unexpected attachment operation, put the mode selection switch in “T” position.

Although it is possible to travel with the “W&T” mode, exercise extreme caution since the front attachment will operate if the control lever is accidently touched.

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2. Hazard Warning Light Switch This switch is used to inform emergency to the others during the operating and urgent parking.

When this switch is operated, Flasher Hazard Warning Lights on.

3.17. SAFETY LOCKING DEVICE WARNING The SAFETY LOCK LEVER must be pulled in LOCKED position to prevent machine controls from an accidental movement. The operator must lock the safety lever before he leaves the operator’s seat and especially during maintenance and repair work unless it is necessary to operate the machine for this purpose. The hydraulic system is disabled to function even though the levers can be moved.

If not, an accidental movement of any control lever will cause the machine or an attachment to move, and will cause serious injury or death.

When the safety lock lever is at straight position, the safety locking system is UNLOCKED. Make sure to rotate the safety lock lever down to correctly engage the LOCKED position.

Do not use the control levers to get on and off the machine, the machine may suddenly operate and cause serious injury or death.

"LOCKED"

This system is used to stop the attachment, swing and travel unit. Pull the safety-locking lever equipped on the left control console to lock out the hydraulic control levers. The control levers and travel pedals (levers) are available to move even in the hydraulic "LOCKED" position.

"UNLOCKED"

3.18. ADJUSTING ARMREST HEIGHT Height of the right and left armrests can be adjusted independently. There is a star knob at the back of the armrest. Turn the star knob to the left.

With the aid of the spring armrest will be moved to the top upper position. Press the armrest down and set it to the desired position then tighten the star knob by turning it to the right.

Star knob

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3.19. ARMREST ANGLE ADJUSTMENT The inclination of the armrests can be modified by turning the adjustment knob.

Adjust the armrest to the desired position.

3.20. CONSOLE ANGLE ADJUSTING LEVERS Angle of the consoles can be adjusted independently by levers at the front.

Hold the lever with one hand and hold the console with other hand.

Console can be locked at 3 different positions.

Adjust the best position and release the lever.

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3.21. LEFT CONSOLE LIFTING LEVER Left console lifting lever is at the back of the left joystick. It is used to provide more space when getting in and out of the operator's cab.

After lifting left console all operating and travel levers gets locked even though the safety locking device is in unlocked position.

To lift the console pull the lever (1) while sitting on the operator's seat. Console will move from position 1 to position 2.

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3.22. LEVERS 3.22.1. OPERATING LEVERS

■ LEFT OPERATING LEVER

■ RIGHT OPERATING LEVER

This lever controls swing and arm operations.

This lever controls the boom and the bucket operations.

The horn button is located on this lever.

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There is an optional attachment switch on it.

3.22.2. OPERATING LEVERS (PROPORTIONAL CONTROL)

1 3 2

Left operating lever

8

4

5 6

Right operating lever

7 9

Left operating lever

1. Rotator proportional control (optional) 2. Rotator right turn (optional) 3. Rotator left turn (optional) 4. Shear proportional control (optional) 5. Shear open or breaker (optional)

Right operating lever

6. Shear close (optional) 7. FNR (forward reverse direction selection switch) 8. N/A 9. Horn

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3.23. SWING LOCK Before travelling the machine, apply the swing lock.

Otherwise swing direction will change according to the probable failure and cause dangerous accidents while traveling.

CAUTION Push lock pin down while traveling. Otherwise dangerous accidents can occur.

(ELECTRO-HYDRAULIC SWING LOCK) Swing lock button (6) is located on the right console. Use the button to hydraulically lock the upper chassis to lower chassis 6

When upper side of the button is pressed swing motor brake is applied. When lower side of the button is pressed swing motor brake is released.

Follow the procedure below to apply swing lock: 1. Swing the upper chassis and align it with lower chassis.

2. Push the swing lock button.

Figure. Electro-hydraulic Swing Lock

3. Wait for 3 seconds without controlling the attachments.

4. If upper chassis and lower chassis was not aligned to each other, in the control panel a red lamp comes on and "upper chassis is not centered" message appears. Release the swing lock and align the upper chassis with lower chassis until green lamp comes on in the control panel. Then press the button to apply the swing lock.

5. When swing lock is applied

symbol comes

on in the control panel.

Follow the procedure below to release swing lock: 1. Press the swing lock button.

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3.24. ACCELERATOR AND BRAKE PEDALS 3.24.1. ACCELERATOR PEDAL This pedal is located on the right hand side of the steering console.

The accelerator pedal controls the engine speed for traveling.

When this pedal is depressed during the Speed Selection Switch is at 1st step either forward or reverse, the machine will start off.

Machine traveling speed increase or decrease according to the amount of the pedal is depressed.

CAUTION If upper body is turned 180, the machine is handled in the opposite direction of the forward and reverse. Therefore, before depressing the pedal, confirm the direction of the upper body.

3.24.2. BRAKE PEDAL This pedal is located on the right hand side of the steering console.

Brake pedal operates the brake system.

When the pedal is pressed to its maximum position, it will lock into position. To release the brake pedal from the locked position, press down on the release pedal. It is used to slow down and stop the machine.

WARNING Prior to excavating depress the brake pedal and engage the latch mechanism to lock the service brake in the applied position.

If parking brake has been manually released do not rely on the locked service brakes to hold the machine.

For safety and protection of brake system, lower the dozer blade and stabilizer to the ground and support the machine before working.

Do not use the service brakes unnecessarily since over-heating could occur, causing brake performance to deteriorate.

When finishing work or parking the machine always releases the service brake pedal.

Before starting work, always check the performance of the service brakes.

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The service brake is used to prevent the machine from being pulled or pushed when excavating. The service brake is locked and released by latch as shown in figure.

When working, lock the service brake.

Emergency Braking: At a service brake failure, the braking effect of the hydrostatic drive is also additionally acting. This braking is not adjustable and cannot be influenced by the operator.

3.24.3. BRAKE SYSTEM TEST PROCEDURE • Start the engine and select power mode “P”.

• Run the engine for about 5-10 minutes to warmup and stop the engine.

• Turn the ignition key to “ON” position without starting engine.

• "Brake pressure low" warning light must not come ON. In this mode press the brake pedal fully and release. Repeat the process several times with some waiting periods between pedal operations.

Pedal must be pressed at least 3 times before the "brake pressure low" warning light comes ON. If not, the accumulator may be faulty. Do not move the machine and call Hidromek Authorized Service for help.

WARNING Do not operate a machine whose brakes are faulty.

All maintenance and repair works on the brake system must be performed only by an authorized Hidromek service.

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3.25. FUSE / RELAY BOX Fuses are equipped to protect the electric system from an electrical overload. Fuse box cover is under the mat of convenient storage.

IMPORTANT When replacing fuses, make sure to turn the starter key to “stop” (OFF) position.

When replacing fuses, ensure that they are of the same capacity.

FUSE / RELAY BOX

REPLACEMENT METHOD Open the cover placed at heater cover.

Remove the burnt fuse using a fuse holder tool.

Install a new fuse, which has the same capacity as the old one.

Placement of fuses and relays is shown in the figure.

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FUSE C/FA Nº Definition 1 Main Relay (Battery) 2 Wiper & Control Unit (Battery) 3 Park Lamp (Battery) 4 Air Condition (Battery) 5 Inside Light Timer (Battery) 6 Display (Battery) 7 Smartlink (Battery) 8 Hazard warning light (Battery) 9 DCU (Battery) 10 Engine Start Signal 11 Engine Control Unit (IGN.ON) 12 Display (IGN.ON) 13 Wiper & Control (IGN.ON) 14 Alternator 15 Safety Switch (IGN.ON) 16 17 Opera (IGN.ON) 18 OCU (IGN.ON)

Ampere 30A 10A 10A 5A 5A 5A 10A 5A 30A 5A 15A 5A 10A 10A 15A 5A 15A

FUSE C/FB Nº Definition Ampere 1 Air Condition Unit (IGN.ON) 20A 2 Lamp, Front Cabin (IGN.ON) 20A 3 Lamp, Rear Cabin (IGN.ON) 15A 4 Working Lamp, Boom (IGN.ON) 15A 5 Lamp, Rotary Beacon (IGN.ON) 10A 6 Head Lamp (IGN.ON) 10A 7 Fuel Pump (IGN.ON) 20A 8 Machine Control Unit (Power) 30A 9 Automatic Lubrication Display (IGN.ON) 5A 10 Automatic Lubrication Control (IGN.ON) 10A 11 Heater, Fuel (IGN.ON) 15A 12 Working lamp (IGN.ON) 15A 13 Fuel Transfer PumpA (IGN.ACC) 15A 14 Lighter (IGN.ACC) 10A 15 Convertor (IGN.ACC) 10A 16 Seat (IGN.ON) 20A 17 Horn (IGN.ON) 10A 18 Display (IGN.ACC) 5A 19 Opera (IGN.ACC) 5A 20 FUSE C/FC Nº Definition 1 Head Lamp - High Beam (IGN.ON) 2 Brake Lamp (IGN.ON) 3 Reverse Gear Lamp (IGN.ON) 4 Gear (IGN.ON) 5 Dozer & Outrigger (IGN.ON) 6 Signal (IGN.ON) 7 Lamp, Axle Lock (IGN.ON)

RELAY C/RA Nº Definition 1 Horn 2 Hydraulic Breaker 3 Boom Working Lamp 4 Parking Lamp 5 Head Lamp - Low Beams 6 Starter Safety RELAY C/RB Nº Definition 1 Main Relay 2 Lamp, Rotary Beacon 3 Lamp, Front Cabin 4 Lamp, Rear Cabin 5 Heater, Fuel 6 Fuel Transfer Pump RELAY C/RC Nº Definition 1 Lamp, Brake 2 Lamp, Reverse 3 Washer Pump 4 Starter Controller 5 Head Lamp, High Beam 6 Transmission Control RELAY C/RD Nº Definition 1 1. gear & 2. gear 2 Forward gear 3 Reverse gear 4 Brake (50 bar) RELAY C/RE Nº Definition 1 Buzzer, Machine Warning 2 Buzzer, Brake Pressure 3 Hazard warning light 4 Diode Box, FNR

Ampere 15A 5A 5A 10A 15A 5A 5A

1. Fuse, Battery relay 2. Fuse, Glow plugs 3. Fuse, Starter 4. Fuse, Battery

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3.26. AUTOMATIC/MANUAL MODE SWITCH Should the instrument panel fail to work, press manual switch to operate the system in manual mode. In this mode machine electronic control unit is deactivated and engine speed can be set by throttle control dial manually.

WARNING Use manual mode only in emergency situations to move the machine out of the danger zone. Do not operate attachments in this mode. Consult HIDROMEK AUTHORIZED SERVICE to have the problem fixed as soon as possible.

WARNING Operating the engine in manual mode stops the after treatment functioning and will cause severe damage to the exhaust system components: DPD, DOC, SCR.

3.27. BATTERY RELAY Battery relay is located under the air filter. When the operator stops the engine, it will automatically cut off the circuit after 7-8 seconds and an audio warning will be heard.

It will automatically cut the power off in case of an electrical short circuit or overload. This will prevent the electric wiring and components from burning or damage.

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3.28. BATTERY MASTER SWITCH CAUTION "Start" is available only when the master switch is at "ON" position. When checking electric system or parking the machine, ensure that the master switch is at "OFF" position for safety and to prevent battery discharge. Never put the master switch at "OFF" position while running the engine. In case of cut off, battery can't be charged or malfunction of electric system may occur.

The battery master switch is installed inside the toolbox located at the right hand side of the machine.

ON Position: Turn the key clockwise to supply power to the electrical system.

OFF Position: Turn the key counter clockwise to cut off electric power to the machine.

When battery disconnect switch is set in OFF position, running engine will be stopped. Use this switch in case of an emergency.

Allow 10 minutes after the engine has stopped before you turn the battery disconnect switch off.

Systems such as the engine controller (ECM) and SCR controller (DCU) continue to operate for approximately 10 minutes after the engine is stopped. This systems may malfunction if the battery power is turned off while these systems are still operating.

Disconnecting the battery power too soon may prevent cooling of the DEF/AdBlue® system and purging of the (DEF/AdBlue®) lines after the engine is shut down. Not allowing the DEF/AdBlue® system to be cooled can damage the system. Not allowing the DEF/AdBlue® purge to be performed can damage the DEF/AdBlue® system.

To restart the engine, set battery disconnect switch in ON position, then turn the starting switch key to START position.

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1. Battery master switch Figure. Battery master switch

3.29. HEATER AND AIR CONDITION HEATER AND AIR CONDITIONER VENTS

3.29.1. CONTROL UNIT The air conditioner installed in your machine is automatic. The automatic air conditioner is controlled through the air conditioner control panel which is on the left console in the operator cabinet. The condition of the air conditioner system can be monitored easily via the lamps on the buttons of the climate control panel.

1. Power button 2. Defroster button 3. Rear/Foot vent mode 4. Face/Rear/Foot vent mode 5. Air inlet selection button 6. Face/Defroster vent mode 7. Face/Rear vent button 8. Foot vent button 9. “Blower speed selection button” / “Air conditioner automatic mode ON/OFF” button 10. “Temperature control button” / “Air conditioner ON/OFF” button

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1. Power button: Used to turn the control unit ON or OFF.

2. Defroster button: Press this button to clear condensation or thaw frost on the windshields.

7. Face/Rear vent button: Press this button to direct the blowed air from the front and back vents of the operator’s cab.

8. Foot vent button: Press this button to direct the blowed air from the foot vents of the operator’s cab.

3. Rear/Foot vent button: Press this button to direct the blowed air from the back and foot vents of the operator’s cab.

4. Face/Rear/Foot vent button: Press this button to direct the blowed air from the front, back and foot vents of the operator’s cab.

9. “Blower speed selection button” / “Air conditioner automatic mode ON/OFF” button: Increasing blower speed: Turn the button to the left for increasing the blower fan speed. Adjusted level is indicated by the lamps around the button.

5. Air inlet selection button The lamp on the button lights up and the indoor recirculation mode is activated when this button is pressed. Air can not enter the operator’s cab from outside. Blower circulates the air inside the operator’s cab. This function is used particularly in dusty environments.

The outside air intake mode is activated when the button is pressed again. In this mode blower draws in the outdoor air and circulates it in the cabin.

6. Face vent / Defrost button: Press this button to direct the blowed air from front of the operator’s cab and to the windshields.

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Decreasing blower speed: Turn the button to the right for decreasing the blower fan speed. Adjusted level is indicated by the lamps around the button.

Air conditioner automatic mode: Press the button to switch ON or OFF the air conditioner automatic mode. In automatic mode, air conditioner automatically adjusts the open vents, blown air temperature and fan speed with respect to the temperature inside the operator’s cab.

10. “Temperature control button” conditioner ON/OFF” button

/

“Air

Increasing temperature: Turn the button to the right to increase the temperature of the blown air. Adjusted air temperature is indicated by the lamps around the button.

Decreasing temperature: Turn the button to the left to decrease the temperature of the blown air. Adjusted air temperature is indicated by the lamps around the button.

Air conditioner ON/OFF: Press the button to start or stop the air conditioner.

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3.34. EMERGENCY EXIT

3.30. LIGHTER There is a Cigarette Lighter placed on the rear console. Press it down to start the heater; it will eject in a few seconds. When it returns to its initial position, it is ready to use.

DANGER If the Cigarette Lighter does not eject, do not leave it pressed down. Remove the Cigarette Lighter and contact Hidromek Authorized Service.

Lighter socket can be used as a power supply for 24 Volt devices.

3.31. BOTTLE HOLDER On the front side of rear console there is a bottle holder.

The door and the rear window are the emergency exits of the operator's cab.

Take the emergency hammer from the pillar at the rear left hand side of the cab and break the windows.

3.35. FIRST-AID KIT

3.32. COOL BOX It is possible to keep food and drinks cool in the cool box while A/C works.

3.33. CONVENIENT STORAGE AND CONVENIENT STORAGE BOX There is a convenient storage place and a storage box on the rear console.

Make available a first-aid kit and instruction booklet on the convenient storage place.

Display the names and telephone numbers of personnel to contact in case of an emergency.

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3.36. FRONT WINDSHIELD Upper part of the window shield of the operator’s cab can be fully opened by sliding and parking it under the roof. Be careful and hold firmly when opening or closing the rear window as it is sliding.

WARNING The SAFETY LOCK LEVER must be pulled in LOCKED position to prevent machine controls from an accidental movement. The operator must lock the safety lever before he leaves the operator’s seat and especially during maintenance and repair work unless it is necessary to operate the machine for this purpose.

If not, an accidental movement of any control lever will cause the machine or an attachment to move, and will cause serious injury or death.

When the safety lock lever is at straight position, the safety locking system is UNLOCKED. Make sure to rotate safety lock lever down to correctly engage the LOCKED position.

"LOCKED"

Windshield closed position See Chapter DEVICE".

3.17.

“SAFETY

LOCKING 1

OPENING THE FRONT WINDSHIELD A) Hold the handles (1) at each side so that the latches are against your pointing fingers.

B) Pull to unlock the latches (2). Hold one of the side handle (1) and the bottom handle (3) and pull the windshield upwards and slide the windshield until it is latched under the roof in horizontal position.

C) After the windshield is stowed under the roof, check if the latches are secure and windshield is stable.

CLOSING THE FRONT WINDSHIELD A) Hold one of the handles (1) and press the unlock latch (4) at the back side of the operator's cab.

B) Windshield will move to the front by itself. Move the windshield all the way to close it.

C) Windshield will become in vertical angle and it will lock into its place. Since the front windshield is heavy pay attention to stand in suitable position when sliding the windshield.

4

Windshield opened and latched under the roof position

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3.37. DOOR Press the latch of the door handle (1) and open the door.

If the door is locked, unlock the door with the starter key (2).

Lock (2) the door with the key before leaving the machine.

1

2

Pull the latch (3) and push the door outside to open the door from inside the cab.

3

3.38. DOOR LOCK MECHANISM It is used to keep the operators cab door in full open state.

Open the door and fully rotate 180 degrees until it snaps into the lock mechanism on the rear side of the cab.

Verify that it is securely fixed.

Press the handle inside the operator’s cab to release the door.

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3.39. SIDE WINDOW Side window is on the left hand side of the operator's cab. This window may get opened to let air come in.

To open the rear side of the left window, press the latch with your thumb and slide the window forward.

To open the front side of the left window, press the latch with your thumb and slide the window backward.

3.40. FIRE EXTINGUISHER (OPTIONAL) Fire extinguisher should be mounted on the right hand side rear panel of operator's cab.

Connect the fire extinguisher mounting bracket to the panel with its screws and place the fire extinguisher.

Make available a fire extinguisher, and read carefully the directions for use.

Display the measures to be taken in case of fire or accident.

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3.41. FRONT AND REAR CURTAIN Front curtain mechanism is attached to the front windshield. Pull the front curtain down and leave it in the desired position. Pull the string on the left hand side of the curtain to roll the curtain back.

When pulling the string with one hand, hold the curtain with other hand, adjust the curtain and releasing the string to lock the curtain.

3.42. SUNROOF Unlock the latch and push the sunroof up to open.

3.43. SUN SHADE Shade under the sunroof can be opened to look up or let the sunlight in. Pull the shade to slide backward by holding from its handles.

3.44. OPERATOR'S CAB INTERIOR LIGHTING Interior light of the operator’s cabin is located on the rear side of the ceiling.

Switch of interior lightning has three positions.

Rear curtain can be extended and locked in two different positions. Latches are shown in the picture.

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1. Light is turned "OFF". Light turns "ON" when operator's cab door opens.

2. Light is always turned "OFF".

3. Light is always turned "ON".

3.45. ADJUSTING MIRRORS Adjust right and left mirror, so that the right and left side end of the machine can be seen on a part of mirrors.

3.46. OPERATOR’S SEAT ADJUSTMENT Adjust operator’s seat before operating the machine to obtain the most comfortable position.

1. Headrest Hold the headrest (1) with two hands and adjust the height and angle.

2. Weight Adjustment Turn adjusting knob (2) until the indicated weight corresponds to your own weight.

1

DANGER To prevent damage to health, the setting for the driver’s weight must be checked and adjusted as necessary before the vehicle is driven.

3. Seat pan depth adjustment To adjust the depth of the seat cushion, lift the R/H handle (3). By moving the seat cushion backwards or forwards the desired seating position can be reached.

7

4. Seat pan angle adjustment To adjust the angle of the seat pan, lift the L/H handle (4). By exerting pressure on or off the seat pan it can be moved to the desired angle position.

3

5. Seat Fore-Aft Adjustment Adjust desired distance forward and backward using adjustment lever of seat distance (5). Lift the lever, slide the seat to desired position, and release it to fix.

DANGER After setting the desired position try to move the seat and be sure that the locking lever is in its position. Otherwise the seat can move out of control and may cause severe injury.

6. Seat Base Fore-Aft Adjustment Adjust desired distance forward and backward using adjustment lever of seat base distance (6).

Lift the lever, slide the seat to desired position, and release it to fix.

5

4

2

6

7. Backrest Angle Adjustment Lift lever (7) to position the backrest at desired angle, and release the lever to fix.

DANGER The locking lever must latch into the desired position. It should not be possible to move the backrest into another position when it is locked.

8

8. Lumbar support By turning the adjustment knob (8) to the left or right, both the height and curvature of the backrest cushion can be individually adjusted. This increases both the seating comfort and the performance of the driver.

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9. Height adjustment The seat height can be adjusted with several settings. Raise the driver seat to the required height until it audibly latches into place. When the seat is raised above the highest setting (end stop), it drops back down to the lowest position.

1

WARNING If there is any problem with your seat, call your service. Never try to fix it on your own.

3.47. SEAT BELT  Seatbelts must be fastened before driving.  Check the conditions of the seatbelt and its parts every time you get in the machine.  If it is worn or involved in an accident or used in any other situation that might cause tension on the seatbelt, or if its attaching parts (loosening, swinging etc.) are not correctly fit, do not operate the machine before the problem is fixed.  Replace the seatbelts every 3 years periodically even if they have no apparent problems.  Do not make, or allow anybody to make any modifications to the seatbelt and its parts.

Seatbelts and their parts cannot be repaired.

Replace them if necessary.  If it is necessary to clean the seatbelt, you can wash it with natural soap and water. Leave it dry outside of its box and put back in the box correctly.

2

Fastening the seat belt

3.47.1. FASTENING THE SEAT BELT Adjust the operator’s seat to allow full travel lever stroke with operators back against the seat back.

After adjusting the seat, insert hook (2) into buckle (1). Pull them with both hands to check whether they are locked securely.

To remove the belt, push button (4) of buckle (1).

To lengthen the seat belt When removing the seatbelt, hold the seatbelt with your right hand and push the button with your left hand. Otherwise, the seatbelt may fly out and may cause unexpected accidents.

3.47.2. ADJUSTING LENGTH OF THE BELT To lengthen, pull the belt by turning hook (2) to your body as illustrated.

To shorten, pull the free end of the belt at hook (2).

Adjust the belt length suitable to your body and ensure the belt webbing is not twisted.

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To shorten the seat belt

4. OPERATION 4.1. INSPECTIONS BEFORE STARTING THE ENGINE For operator safety, comfortable operation and for an extended service life of the machine, keep track of the engine operation hours and the conditions of the machine parts during operation, and perform inspections at appropriate intervals, and provide maintenance works in accordance with the findings of the inspections.

When an inspection reveals an abnormality or there was an abnormality found during operation in the previous day or time, have the machine repaired at a Hidromek Authorized Service before it is operated again. If checks and inspections are not performed, serious problems may occur.

Before operation check the following items every day to ensure operator safety and extended service life of the machine: CAUTION Before operating the machine, read and understand this Operation and Maintenance Manual thoroughly in order to use the machine effectively and safely.

Keep this manual in the operator’s cab in the pocket beside the right hand side console for quick reference.

If the Operation and Maintenance Manual is lost or damaged, contact your Hidromek Authorized Dealer to order a new one.

Perform “Every 10 Hours inspection and maintenance” before daily operation of the machine.

Check under and around the machine and inspect for below items: 1. Check leakage of coolant 2. Check leakage of engine oil 3. Check leakage of fuel 4. Check hydraulic oil level in the tank 5. Check leakage of hydraulic oil 6. Check tire pressure 7. Check leakage of oil in swing units 8. Check attachments for damage 9. Check condition of lamps 10. Check for loose terminal or connector, or open circuit in electrical wiring 11. Check for looseness of bolts or nuts, the leakage of oil, fuel, or coolant, and the condition of attachment or hydraulic system around and under the machine.

12. Check looseness of cables and connectors and dust on high temperature parts 13. Check fuel level Climb to the machine, open the engine hood and check for below items: 1. Check engine oil level and contamination 2. Add engine oil if necessary 3. Check fan belt looseness and damage 4. Check coolant level from the coolant expansion tank

Open the right hand side door of the machine and check for below items: 1. Drain water from fuel filters Open the left hand side door of the machine and check for below items: 1. Check looseness and corrosion on battery terminals 2. Check battery electrolyte level 3. Turn the battery switch to "ON" position.

Get into the operator’s cab and check for below items: 1. Check if the horn is operating.

2. Fasten seat belt. Check for proper functionality and condition.

Turn the starter key to “ON” position and check for below items: 1. Check engine failure indicators.

2. Check all warning lamps and indicators on the instrument panel.

3. Check the fuel level indicator.

4. Check the air filter clogged indicator on the instrument panel. If it is ON, immediately replace the air filter outer element.

Replacing the air filter outer element ► Refer to Chapter 6.16.6. “Checking, changing, and if necessary cleaning air filter outer element”.

Figure. Air filter clogged indicator 5. Confirm that the engine emergency stop switch is turned "OFF" before starting the engine.

6. Before starting the engine, confirm that all controls are at neutral position and each switch such as windshield wiper, lighting, and air conditioner is turned off.

7. Ensure that if the left console is at the locked position.

Sound the horn, start the engine and check for below items: 1. Check engine starting condition and abnormal noise.

2. Check operation of lamps.

3. Check all warning lamps and indicators on the instrument panel.

4. Check attachment movements.

5. Depress switches to check whether head lights, working lamps and interior lamp light.

Sound the horn, travel the machine slowly and check for below items: 1. Check machine traveling speed.

Stop the engine and check for below items: 1. Check leakage of fuel, coolant and engine oil.

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4.2. STARTING THE ENGINE 4.2.1. STARTING AT NORMAL TEMPERATURE WARNING After checking for personnel and obstructions around the machine, sound the horn and start the engine.

WARNING Do not keep the starter switch turned to “START” for 20 seconds or longer. Operating the starter for too long might cause battery failure or might result in overheating and even a fire.

When starting the engine, make sure that no flammable material is present in the direction of exhaust outlet. If a flammable material is present, it is very dangerous because such material may be deformed, discolored or ignited, leading to a fire.

1. Place the accelerator, throttle and operation levers to the idling position.

CAUTION Never operate the control levers and button switches when starting.

2. Turn the starter switch to the "ON" position.

Also, when the preheat indicator light comes on, wait for 0 - 8 seconds until it turns off. This may not come on depending on the conditions.

CAUTION When an abnormal sound is heard from the starter motor, if the starting operation is continued, the starter motor can be burned out.

After disconnecting the battery cables, charge the battery from an external power source.

When the starting operation is performed repeatedly, starting the next motion without waiting for the starter motor to stop completely may damage or break the starter pinion and the engine ring gear.

Starter failure may occur if the engine is started when the battery has not been sufficiently charged.

5. When the engine is not started after the starting operating is performed repeatedly, an abnormality in the starting system can be suspected, so inspect the related parts.

CAUTION Do not turn the starter switch to the "OFF" position while the engine is running. Depending on the machine on which the engine is installed, this may cause a failure such as a malfunction of meters and battery charging failure.

Do not apply a starting aid to the intake system.

This may damage the engine.

NOTE In the cold season, when the engine is cold, the exhaust smoke (white smoke) may increase.

CAUTION Do not perform the starting operation while the preheat indicator light is on.

3. After confirming that the preheat indicator light has gone out, turn the starter switch to the "START" position to start the engine.

4. When the engine is not started with one operation, turn the battery and starter switch to "OFF". Have a break of 60 seconds or longer for starter functionality recovery and engine controller (ECM) communication process, and then perform the starting operation again.

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6. After starting the engine, follow steps in “Warming Up”.

CAUTION While the engine is running, the urea SCR system is purging, and immediately after operating, the exhaust piping is extremely hot.

Make sure that there are no flammable items such as plants, dry grass, paper waste, oil, or old tires nearby. Take extra caution when operating the machine indoors.

Be careful of the exhaust gas heat generated while the engine is idling, and especially while the urea SCR system is purging.

4.2.2. STARTING IN COLD WEATHER Before starting the engine, be sure to perform preheating. When it is difficult to start the engine, let it stand for a while to allow the battery to recover, perform adequate preheating, and then start the engine.

WARNING After performing a safety check for people and obstructions around the machine, honk the horn and start the engine.

Insert the key into the starter switch and turn the key to ON position. Wait until the preheat indicator turns off, then, turn the key to START position.

As an engine starting aid, pre-heating is required in cold weather starting. This system allows to start easily in cold weather and to reduce white smoke and noise at starting. When turning key switch to ON, glow plugs will grow red-hot to pre-heat the engine. At this time, check pre-heat indicator, if it is OFF. Pre-heating time is about 1 to 15 seconds depending on engine coolant temperature.

Release the key immediately after starting the engine. The starter switch returns to ON position automatically.

If the engine does not start, try to start the engine and start again.

If the engine does not start at all, check the electric system and contact HIDROMEK. IMPORTANT If the engine does not start even after the starter switch is turned to START position, return to STOP (OFF) position again.

Do not hold the key in the START position for more than 20 seconds without an interruption, as this could seriously damage the starting system.

In 2 minutes, try to start the engine again.

If abnormal sounds, excessive vibration, or abnormal operation occurs, turn the key to STOP (OFF) position immediately to stop the engine.

CAUTION In cold season, immediately after the engine is started, the operating sound of the engine may be slightly louder than when it is warmed up and the smoke of the exhaust gas may slightly increase, but this is not abnormal.

When the engine is not sufficiently warmed up, the engine oil is not supplied adequately, and a breakdown may result. Be practically careful in the cold season.

After starting the engine, follow steps in “Warming Up”.

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4.3. WARM-UP OPERATION CAUTION Avoid a quick increase of engine speed or load immediately after the engine is started. First, idle the engine for about 10 minutes, and then check the operating status of instruments and warning lights. Also, check for abnormal vibration from the engine, noise, and the conditions of smell and color in the exhaust gas.

4.3.1. AUTOMATIC WARM-UP OPERATION If the hydraulic oil temperature and the engine coolant temperature are low, the control system will start automatic warm-up operation. This will be observed particularly in cold weather operations.

Warm-up is necessary to prevent damage to the hydraulic system and the engine.

Proceed with the following steps for warming:

WARNING The SAFETY LOCK LEVER must be pushed in LOCKED position to prevent machine controls from an accidental movement.

When the safety lock lever is at straight position, the safety locking system is UNLOCKED. Make sure to rotate safety lock lever down to correctly engage the LOCKED position.

IMPORTANT If abnormal sounds, excessive vibration, or abnormal operation occurs, turn the key to OFF position immediately to stop the engine.

1. After starting the engine, “Engine Warm Up” message appears on MED to indicate that the engine cooling system and hydraulic system is warming-up. Message displays until the temperatures reach minimum required values.

2. While engine is automatically warming-up, the engine rpm is gradually increased to 1200 rpm and cannot exceed this value until the system is warm enough.

3. Engine warm-up operation may take up to 15 minutes depending on the external temperature.

4. In case it is necessary for emergency or maintenance needs, operator may cancel preheat function by pressing 3 seconds auto warm up stop switch to cancel pre-heat.

4.3.2. WARMING-UP HYDRAULICS 1. Lower the left control console to release the safety locking system, 2. Raise the bucket from the ground.

3. Slowly move attachments without a load for five minutes, swing clockwise / counterclockwise a few times, to circulate the oil through the system. Travel forward and reverse at low speed for about two revolutions of the drive sprocket.

4. If any abnormal operation such as delayed response occurs in any operation, warm up the hydraulics as described.

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"LOCKED"

See chapter 3.15. "SAFETY LOCKING DEVICE".

IMPORTANT Never operate the control levers with higher stroke when the hydraulic oil temperature is low.

Always perform the warm-up procedures to raise hydraulic oil temperature.

4.4. INSPECTIONS AFTER STARTING THE ENGINE After warming up, check whether the gauges, warning lamps and pilot lamps are as in the following.

4.4.1. “ENGINE OIL WARNING LAMP

4.4.3. BATTERY CHARGE WARNING LAMP Status: OFF

PRESSURE IS LOW”

Status: OFF

CAUTION Make sure to confirm that the alternator warning light turns off.

4.4.4. ENGINE TEMPERATURE GAUGE Status: NORMAL

After the engine is warmed up, confirm that the engine oil low indicator is turned off.

CAUTION Since the oil pressure is low immediately after the engine is started, take measurements after the engine is warmed up.

CAUTION For the following cases, immediately stop the engine, check the oil level and inspect for an oil leakage: The oil pressure warning light flashes or comes on When the oil level is normal and no oil leak is found, a failure in the hydraulic system can be suspected. Promptly consult a Hidromek Authorized Service.

4.4.5. HYDRAULIC OIL TEMPERATURE GAUGE Status: NORMAL

4.4.6. FUEL LEVEL GAUGE Status: NORMAL

4.4.2. ENGINE WARNING LIGHT Status: OFF

CAUTION When the failure indicator light comes on, or the engine failure code is indicated in the liquid crystal display (LCD) on the actual machine, promptly contact a Hidromek Authorized Service.

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4.4.7. AIR CLEANER IS CLOGGED INDICATOR

4.4.14. ABNORMAL NOISE OF ENGINE AND COLOR OF EXHAUST SMOKE

Status: OFF CAUTION Immediately after the engine is started, the engine sound is louder compared to the sound after the engine is warmed up, and also the color of the exhaust smoke becomes more whitened or more blackened than the smoke discharged during the normal operation. The engine sound and the color of the exhaust smoke turn to normal after the engine is warmed up.

During urea SCR system purging and its cancellation, the sound may change, but this does not indicate a failure.

If an abnormality is found in the engine sound or the color of the exhaust, immediately contact a Hidromek Authorized Service.

4.4.8. AUTO WARM UP INDICATOR Status: OFF

4.4.9. DEF/AdBlue® WARNING LIGHT

INJECTION

SYSTEM

Status: OFF

4.4.10. REDUCED ENGINE POWER INDICATOR LIGHT

4.4.14.1. ABNORMAL NOISE OF ENGINE Listen to the engine sound carefully, and if an abnormal noise is heard, check the engine and identify the possible cause.

4.4.14.2. COLOR OF EXHAUST SMOKE Check the combustion state of the fuel and the urea SCR system condition by observing the color of the exhaust smoke.

After the engine is warmed up, the color of the exhaust smoke becomes as follows without any load applied.

Status: OFF Color of exhaust smoke Colorless or light blue Black White

Combustion state of engine Normal Abnormal Abnormal

Also, inspect the exhaust pipe for leakage.

4.4.11. PARKING INDICATOR Status: OFF

CAUTION During urea SCR system purging, white smoke may be emitted temporarily, but this is not a failure.

When the engine is started in a low temperature, moisture vapor may be generated temporarily, but this is not a failure.

4.4.12. LOW BRAKE PRESSURE Status: OFF

4.4.13. AXLE LOCK INDICATOR Status: OFF

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4.4.15. BRAKE TEST Perform brake test as told in the chapter 3.24.3.

4.4.16. COOLANT TEMPERATURE Both too high and too low temperatures of the coolant can cause an engine malfunction. The temperature in the range of approx. 75~90°C (167~194°F) is suitable.

When the engine coolant temperature gauge reads a value exceeding the appropriate temperature, or when the coolant temperature warning light comes on, a dangerous condition of substantially heated engine can be suspected.

When the temperature of the coolant exceeds the appropriate temperature, the fuel flow is restricted.

After stopping the machine operation, decrease the engine speed to the level equal to the idling speed, and then confirm that the coolant temperature has dropped to the appropriate temperature before stopping the engine.

4.4.20. WHEN THE ENGINE COOLANT IS HOT Do not loosen or remove the radiator cap. Doing so would be dangerous because steam and hot air will spurt out.

CAUTION Avoid stopping the engine when it is overheated.

Operating the engine for a long period of time with a low coolant temperature not only increases the oil and fuel consumptions but also accelerates the engine wear, resulting in an engine failure.

4.4.17. HOUR METER (CUMULATIVE OPERATING HOUR COUNTER) The cumulative time during engine operation is counted. Confirm that it is always operating while driving. Perform inspection and maintenance on each part in accordance with the time count displayed in this hour meter.

CAUTION The hour meter cannot be reset.

4.4.18. BE CAREFUL WITH THE TOO COLD ENGINE When the engine is too cold, in addition to engine wear, it will also deteriorate fuel economy. While operating the machine, when the coolant temperature does not reach the appropriate temperature (approx. 75 - 90 °C (167 - 194 °F)) indefinitely, take an appropriate action such as inspecting or replacing the thermostat.

4.4.19. WHEN THE WARNING LIGHT COMES ON

CAUTION It is dangerous to ignore the warning light and continue operating the machine. Perform an inspection and take appropriate actions. When the meter shows an abnormality, take necessary actions.

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4.5. OPERATING THE MACHINE 4.5.1. FORWARD TRAVEL WARNING Make sure to read and understand all operating controls, Cautions, and Warnings before traveling.

Obey all traffic rules and regulations.

Do not travel faster than conditions allow.

Before putting the machine into gear, make sure in which direction the machine is facing. Locate the front section of the excavator and select the appropriate gear for the direction of travel desired.

Before moving, make sure that there are no personnel in the way or on the machine. Sound the horn to alert workers that you are above to move the machine.

Be sure the path is clear during travel, especially when traveling in reverse gear.

If an alarm buzzer sounds or a warning light turns “ON”, stop machine and determine the cause of the problem.

If an unusual sound or smell is noticed, immediately stop the machine and determine the cause of the problem.

Avoid sudden stops or turns.

The machine is top heavy. Make sure to make turns at a slow speed.

Take extreme caution when traveling on road shoulders or narrow streets.

Before leaving the operators seat, make sure to lock out all control systems and shut down the engine to avoid accidental activation.

WARNING The SAFETY LOCK LEVER must be pulled in LOCKED position to prevent machine controls from an accidental movement. The operator must lock the safety lever before he leaves the operator’s seat and especially during maintenance and repair work unless it is necessary to operate the machine for this purpose.

If not, an accidental movement of any control lever will cause the machine or an attachment to move, and will cause serious injury or death.

"LOCKED"

See chapter "3.17. SAFETY LOCKING DEVICE".

4.5.2. BEFORE TRAVELING 1) Raise the outrigger and dozer blade and make safe.

2) Before putting the machine into gear, make sure in which direction the machine is facing. Locate the front section of the excavator and select the appropriate gear for the direction of travel desired 3) Before moving the excavator, make sure that the swing lock pin has been engaged. This will prevent the excavator from accidentally rotating during traveling.

4) Before traveling make sure that axle lock switch is set to the OFF position.

5) Set the mode selection switch in the “T”, travel position.

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1. Axle lock switch

4.5.3. TRAVELING PROCEDURES 1. Make sure that “Brake System Failure Indicator Light”, buzzer and “Low Brake Pressure” message is off.

2. After making sure the front attachment is facing forward, set the mode selection switch in the “T”, travel position.

3. Using the FNR Switch, select forward or reverse travel direction and step on the accelerator pedal.

4. Test the brakes before beginning over the road travel.

5. During forward motion you can shift from speed range 1, to speed range 2 with using FNR Switch on the steering console. Downshifting from speed range 2 to speed range 1 should not be done if the machine is traveling at high rate of speed. Damage to the transmission could result.

6. To stop the machine, release slowly the accelerator pedal. The dynamic braking action of the machine’s momentum against the engine’s backpressure will begin to slow the machine. Step on the brake to bring the machine to stop.

IMPORTANT Never drive down a slope with speed range 2; otherwise dynamic braking action of the machine’s momentum will be insufficient. Drive down a slope with a speed range 1 and low speed traveling position. It can be impossible to stop the machine when brake failure is occur.

7. After traveling a long distance, front attachment, outriggers or dozer blade may begin to drift due to normal internal hydraulic leakage. Position the machine in a safe location and reposition the front attachment, outriggers or dozer blade.

4.5.4. PARKING PROCEDURE 1. Slowly release the pressure on the accelerator pedal.

2. Step on the brake to fully stop the machine.

3. Move the FNR Switch to the “N”, neutral position.

4. Reduce the engine speed to idle level from the instrument panel.

5. Lower the bucket and the dozer blade to the ground.

6. Pull the safety lock lever.

7. Move the mode selection switch to “P” park mode.

8. Shut the engine down.

9. If the machine is parked on a slope, insert the wheel chocks on the downhill side of the wheels to secure the machine.

NOTE: As the brake pedal is applied and if it is pressed all the way to the floor, a mechanical lock will engage and hold the pedal in the fully applied position.

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4.6. TRAVEL DIRECTION CONTROL CAUTION Before putting the machine into gear, make sure in which direction the machine is facing. Locate the front section of the excavator and select the appropriate gear for the direction of travel desired.

Never change the travel direction rapidly.

4.7. SWINGING THE MACHINE WARNING Check for personnel or obstructions around the machine before swinging.

Operate the left control lever to swing.

4.6.1. STEERING This machine can be turned by turning steering wheel to the desired direction.

4.6.2. DRIVING FORWARD AND REVERSE

1. FNR (Forward Reverse direction selection switch) DRIVING FORWARD Push this lever forward (F direction) and machine will move forward.

NEUTRAL POSITION Center position (N position) of this lever is neutral position.

DRIVING BACKWARD Pull this lever to the backward (R direction) and machine will move backward.

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Left turn

Right turn

4.8. OPERATING ATTACHMENTS

WARNING If a control lever is operated while auto idling, the engine speed returns to its original speed.

The left/right control levers control the attachments.

The left control lever is for arm, swing; the right control lever is for boom and bucket.

THE LEFT LEVER This lever controls swing and arm.

N Neutral (upper frame and arm are maintained at rest position.)

1: Arm out 2: Arm out and right swing 3: Right swing 4: Arm in and right swing 5: Arm in 6: Arm in and left swing 7: Left swing 8: Arm out and left swing

THE RIGHT LEVER This lever controls boom and bucket.

N: Neutral (boom and bucket are maintained at rest position.)

1: Boom lower 2: Boom lower and bucket out 3: Bucket out 4: Boom raise and bucket out 5: Boom raise 6: Boom raise and bucket in 7: Bucket in 8: Boom lower and bucket in

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4.9. OPERATING OUTRIGGERS

DOZER

BLADE

AND

Dozer Blade and outriggers are operated with dozer blade and outrigger lever located on right console.

4.9.1. LOWERING OUTRIGGERS / DOZER BLADE 1. Remove the locking pin from outrigger locking hole.

2. Place the locking pin in the storage hole.

3. Secure the locking pin in its storage hole with the cotter pin.

4. Repeat step 2-3 for each outrigger.

5. Turn each outrigger enabling switch (S) or Dozer Blade enabling switch (D) on.

6. Move the Outrigger Control Lever forward and lower the outriggers completely.

A: Down

B: Up

7. Turn each outrigger enabling switch or Dozer Blade enabling switch (D) off.

4.9.2. RAISING OUTRIGGERS 1. Before raising the outriggers turn the excavator to travel position.

2. Press and turn each outrigger enabling switch or Dozer Blade enabling switch (D) on.

Figure. "Outrigger / Dozer" Enabling Switches (Machines with front dozer and rear stabilizers)

3. Move Outrigger Control Lever forward and raise the outriggers completely.

4. Turn each outrigger enabling switch or Dozer Blade enabling switch (D) off.

5. Remove the locking pin from storage hole and insert it to outrigger locking hole.

6. Secure the pin with the cotter pin.

Figure. "Outrigger / Dozer" Enabling Switches (Machines with front stabilizers and rear dozer)

Figure. "Outrigger / Dozer" Enabling Switches (Machines with 4 stabilizers)

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4.10. CRUISE FUNCTION 4.10.1. OPERATING CRUISE FUNCTION WARNING The cruise function switch set only the engine RPM, not road speed. Engine RPM is set by throttle control dial.

1. Bring the machine to appropriate travel speed.

2. Set the engine RPM by rotating throttle control dial.

3. Press the cruise function switch located on the right console. This switch maintains the engine RPM setting by throttle control dial.

4. Set the appropriate engine RPM by using throttle control dial to either increase or decrease travel speed.

5. To disengage the Cruise Function press brake pedal or position the FNR Switch to neutral (N) or depress the Cruise Function Switch.

1. Throttle control dial 2. Cruise function switch

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4.11. PROHIBITIONS DURING OPERATION

WORKING BY SWING FORCE Never perform raking over the ground, demolition of buildings or thrusting bucket tooth into the ground by using swing force. This operation may cause damage to the machine and attachments.

WORKING BY TRAVELLING FORCE Never perform digging by traveling force, and thrusting bucket tooth into the ground. This can overload the rear of the machine and cause damage.

EXTENDING THE HYDRAULIC CYLINDER TO STROKE END Never operate the cylinder to its stroke end. This can overload the stopper in the cylinder and shorten the life span of the machine. Work with as much clearance as possible.

WORKING BY BUCKET DROP FORCE Never perform digging by dropping the boom, or using the bucket instead of a pick. Striking digging or continuous striking can overload the rear of the machine or damage the attachment. Also it is very dangerous.

WORKING BY DROP FORCE OF THE MACHINE BODY Never operate by dropping the machine body.

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DIGGING ROCKS Break the hard rock area using a breaker, and then perform digging to avoid damaging the machine and to improve work efficiency.

WARNING Remove side cutters of the buckets before working with rocks. Otherwise they may be broken. Use for digging only.

LIFTING For hydraulic excavators used in lifting operations, the machine must be equipped with a safety device and overload warning system. When lifting is done without this safety device and warning system, the operator and/or owner will be responsible for the injury (see 4.16).

CAUTION WHEN CONTROLLING THE LEVERS Never start up abruptly .

Never change direction abruptly from forward to reverse or reverse to forward.

Never stop abruptly while you are traveling at high speed.

CAUTION WHEN LOWERING THE BOOM AND SWINGING THE MACHINE When retracting the boom cylinders and lowering the boom, the boom may crash to the dozer blade or outriggers.

WARNING Do not lower the boom too much. When the boom lowered do not swing the machine. Otherwise attachments may damaged.

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4.12. CAUTIONS DURING OPERATION CAUTION WHEN TRAVELING Avoid running the machine over obstacles such as rocks or demolition debris. Such an operation may cause damage to the machine (especially the undercarriage). Therefore, remove the obstacle or make a detour. If it is not possible, lower the attachment close to the ground, and pass over the center of the tires slowly. If the obstacle causes the machine to lean more than 10°, never pass over it, travel around it.

LOW SPEED TRAVEL ON UNEVEN GROUND Keep the machine at low speed on uneven ground like rock or irregular area.

PERMISSIBLE DEPTH OF WATER WARNING When traveling out of water, the engine fan will be damaged if the rear of upper body is submerged under the water.

Be careful not to immerse the rear part of the upper structure in the water.

1. Do not operate equipment when front and rear axles, transmission, are under water.

2. It is possible to work and travel in shallow water if the ground is stable. If the terrain is rough or if the water is flowing heavy it is unsafe to operate the equipment.

3. When working in wet soil, the equipment can sink into the soft ground. Select solid ground to secure the equipment before starting work.

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4.13. CAUTIONS WHEN TRAVELING ON A SLOPE WARNING While traveling on a slope, keep the angle between boom and arm at 90 ~110° and raise the bucket 20 ~ 30 cm from the ground.

Never descend moving backward on a slope.

Never change direction or travel across on a slope. Change direction on level ground, if necessary first come down to level ground and make a detour.

If the machine slides, immediately lower the bucket to the ground.

To the extent possible, do not swing or operate the attachments unless it is necessary. The machine can turn over due to unbalance.

Especially, do not swing with a loaded bucket. In If it is necessary, pile up earth on the slope to make the ground flat and level 0.

Never travel on a slope of 30° or more.

BRAKING WHEN DESCENDING Turn the travel lever to neutral position to brake on a slope while descending.

IN CASE OF SHOES SLIPPING If the shoes slip on a slope, thrust bucket into the ground, and pull arm to ascend.

IN CASE OF ENGINE FAILURE In case of engine shut down while traveling on a slope, put the travel lever to neutral position and lower bucket down to the ground, then start the engine.

CAUTION ON A SLOPE If the engine shuts down on a slope, do not operate the swing function, since the upper structure could swing under its own weight and cause tipping or side slipping.

Be careful when opening or closing the doors on a slope, operational force may be changed rapidly.

Keep the doors closed.

DO NOT SWING

Descending

PILE UP THE EARTH 1) In case of descending on a slope of 15° or more, position the machine as illustrated and travel at low speed.

Ascending

2) In case of ascending on a slope of 15° or more, position the machine as illustrated and travel at low speed.

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4.14. ADDITIONAL WORKS USING HYDRAULIC EXCAVATORS The excavator is a multi-task machine capable of being fitted with a multitude of special attachments to perform many types of work. Only the simplest operations are described below.

4.14.1. BACKHOE WORK For digging work at a lower grade than the machine is located. When the angle between bucket cylinder and links, arm cylinder and arm is set to 90 ° respectively, the work efficiency of each cylinder will be maximum.

In case of digging works, take advantage of this angle to improve the work efficiency. The scope of arm digging work is at the angle of arm from 45 ° forward to 30 ° backward. There may be a little difference according to digging depth. Never use the cylinder up to its stroke end, but only within this range.

4.14.2. SHOVEL WORK For digging work in places higher than the machine. Bucket is attached in the reverse position.

4.14.3. DITCHING WORK Install a proper bucket for ditching work. Set tires in accordance with ditching work direction to work effectively.

In case of wide ditching work, ditch both sides in advance, then the center area.

4.14.4. LOADING WORK Position the dump truck so as to achieve a small swing radius and good visibility for the operator to work effectively.

Also read over the rear of the dump truck, rather than over the side, as this makes the operator’s work easier and increases efficiency.

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4.15. LIFTING For hydraulic excavators used in lifting operations, care to the following: In some countries, using an excavator for lifting work may be prohibited by national regulations.

The owner and/or operator is responsible to comply with the national regulations.

For hydraulic excavators used in lifting operations, the machine must be equipped with a safety device and overload warning system. When lifting is done without this safety device and warning system, the owner and/or operator will be responsible for the injury.

There is lifting capacity table in the operator’s cab.

It is the owner and/or operator responsibility to comply with the table. When loads are not accurately known is to be lifted the owner and/or operator responsible for the job shall ascertain that the weight of the load does not exceed the machine lifting capacity table.

WARNING If load is picked up from the sight zone and swung into the side zone, a tip-over could result causing deathly or fatal injury.

When lifting, care to the following: To prevent injury, do not exceed the rated load capacity of the machine.

For safe load handling use short slings to prevent excessive load swing.

When a lifting eye is used, the sling/lifting device must be fastened to the eye in a manner that will not allow it to come loose.

Do not lift or swing a load that exceeds machine load rating or in a way that impairs machine stability.

For safety, when lifting see 2.2.6.

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4.16. REPLACING THE BUCKET WARNING While striking the bucket pin with a hammer, metal chips may fly into your eyes. Always wear goggles, safety helmets and gloves while working.

Block the removed bucket to stabilize it.

Observe the signals when working with other persons.

1) Lower the bucket on to level ground.  When removing the bucket pins, lower the bucket to contact the ground lightly.

2) Remove the pin lock bolt and nut, and remove pins (A), (B), then remove the bucket.

IMPORTANT Keep the pins clean.

Do not damage the dust seals.

3) Align the arm to bucket hole (2) and the link to hole (1), and apply grease, then insert pins (A), (B).

WARNING Do not insert your fingers into the pin bores to check alignment, a serious injury could occur.

When mounting the bucket, O-ring is apt to be damaged, so put the O-ring at the arm position (see the illustration). When inserting the pin, be careful to insert it into the designated position.

4) Tighten the lock bolt and nut of each pin, and grease the pins.

WARNING Remove side cutters of the buckets before working with rocks. Otherwise they may be broken. Use for digging only.

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4.17. CHECKS AFTER FINISHING WORK Before stopping the engine, check the engine, coolant temperature (2), engine oil pressure (1) and remaining fuel level (3).

4.18. STOPPING THE ENGINE IMPORTANT Stopping the engine before it gets cooled down, affects the service life of the engine. DO NOT suddenly stop the engine except emergencies. If the engine is overheated, cool the engine down in low speeds before stopping.

1. Before stopping the engine, set the engine to idle speed to cool down for approx. 5 minutes. During this cooling down period, check for an abnormality in the engine sound, oil pressure, etc.

2. After confirming that the engine temperature has dropped to the specified level, turn the starter switch to "OFF".

3. Remove the starter key and leave the machine.

4. Before turning off the battery master switch, wait at least 10 minutes or more.

Systems such as the engine controller (ECM) and SCR controller (DCU) continue to operate for approximately 10 minutes after the engine is stopped. This systems may malfunction if the battery power is turned off while these systems are still operating.

During this period inspect the machine as described in “4.22 Inspections after stopping the engine”.

CAUTION Stopping the engine immediately after driving may cause a failure such as a seizure. Stop the engine after the engine temperature has dropped.

Make sure to place the starter switch in the "OFF" position after the engine is stopped or when the engine is left unused for a long time.

Otherwise the battery may run out.

Engine start / stop button

4.19. CHECK AFTER STOPPING THE ENGINE Check the machine for leakage of oil or water, and defects of the attachments and the tires.

Always refill the engine’s fuel tank completely after engine operation. By minimizing the amount of air in the fuel tank, moisture (air’s water content), freezing, corrosion causes and starting difficulties reduce.

Under 0 C, drain water from the fuel tank and prefilter to prevent freezing.

Remove papers or dead leaves from the engine compartment to prevent fire.

Remove soil deposits and debris from the axles and tires. In freezing conditions after cleaning the tires park the machine on wood planks.

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4.20. HANDLING TURBOCHARGER

THE

ENGINE

WITH

4.20.1. PRECAUTIONS DURING STARTING THE ENGINE For the engine starting procedure, refer to chapter "4.2. Starting the Engine".

CAUTION When the engine is cold, do not rev it with the gear placed in the neutral position.

When starting the engine after it that has been left unused for a long period of time (one month or longer), perform the following works: 1. With the air intake duct and oil inlet pipe being removed, add the engine oil to the turbocharger from the oil inlet port.

2. Then, rotate the impeller by hand to lubricate the bearing adequately.

3. When adding the oil, make sure that foreign matters such as dust do not enter from the filler port.

4. When oil adding is finished, securely install the oil pipe and the air intake duct.

4.20.2. PRECAUTIONS DURING STOPPING THE ENGINE Before stopping the engine, make sure to idle the engine for approx. 3 minutes. After driving is performed under a severe condition, idle the engine for approx. 5 minutes until the turbocharger is cooled down.

CAUTION For the engine with the turbocharger equipped, when the engine is stopped suddenly, the lubricated section on the turbocharger get dried from the high heat, leading to a turbocharger failure.

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4.21. LOCKING SYSTEM Lock at the following locations: 1. Door and windows of operator's cab 2. Fuel tank cap 3. Engine hood 4. Toolbox cover 5. Cover of the left box 6. Cover of the right box 7. Cover of personal box 8. Cover of the DEF/AdBlue® tank

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4.22. TRANSPORTATION WARNING When transporting the machine, the related laws and regulations governing the weight, width, height, length and securing of a load must be taken into consideration.

4.22.1. LOADING AND UNLOADING WARNING Be extremely cautious during loading and unloading.

Operate the engine at low rpm, and set machine travel speed to LOW. Choose a firm, level place, and keep at adequate distance from the road shoulder.

Make sure that the ramp is strong enough to bear the machine to be loaded/unloaded. If they bend excessively, support with blocks.

Remove grease, oil, mud, ice etc. from the ramp and the trailer bed to prevent the machine from slipping sideways.

Never maneuver on the ramp. If it is unavoidable, first descend from the ramp and then change course.

When swinging on the trailer, operate slowly because the base is unstable.

After loading, block each tire and secure the machine with tie downs of adequate load rating that the machine cannot move.

Cover the exhaust pipe to prevent any damage to the turbocharger.

Lock the cab door and lower the antenna.  Make sure to use the loading platforms for loading and unloading.

1) Apply the brake of the trailer, and insert blocks beneath the tires. Fix the loading platforms securely. Check whether the right and the left loading platforms are of same height respectively.  Be sure that the angle of loading platform is 15° or less.

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 Arrange the distance between loading platforms in such a way that they are aligned with the tires.  If you have to travel across a bridge, make sure that its capacity is rated for the weight of the machine and that it is wide enough.

2) Always travel at low speed.

3) Decide the direction and travel slowly onto the loading platforms. Load or unload the machine so that the attachments do not interfere with the trailer.  Never operate any levers other than the travel lever while the machine is on the loading platform.

4) Load the machine on the trailer properly and ensure it is firmly secured.

4.22.2. CAUTIONS ON LOADING WARNING Load the machine in a level and firm place, and keep ample distance from the side edge of platforms, ramps and road shoulder.

After loading the machine on the trailer, tie down the machine firmly and securely.

4) Block the machine by putting wedge blocks in both directions of all tires of the machine to prevent sliding on the trailer.

IMPORTANT Insert chock between the bucket and the trailer to prevent damage of the bucket cylinder during transportation.

1) Extend the boom and the arm cylinders up to their stroke end, and lower the boom with care.

 Do not allow the bucket cylinder rod to be in contact with any part of the trailer.

2) Stop the engine and remove the starter key.

3) Engage the safety locking system securely.

WARNING

5) Secure the machine by using chains as seen in the figure. Determine chain attaching points on the trailer so that chain angle will be approximately 45 degrees. Tighten all the chains.

4.22.3. PRECAUTIONS ON TRANSPORTATION

The SAFETY LOCK LEVER must be pulled in LOCKED position to prevent machine controls from an accidental movement. The operator must lock the safety lever before he leaves the operator’s seat and especially during maintenance and repair work unless it is necessary to operate the machine for this purpose.

If not, an accidental movement of any control lever will cause the machine or an attachment to move, and will cause serious injury or death.

When the safety lock lever is at straight position, the safety locking system is UNLOCKED. Make sure to rotate safety lock lever down to correctly engage the LOCKED position.

WARNING Choose a transport route in consideration of overpass clearances, bridge and road load limits, wide load prohibitions and travel hours.

Obey all regulations governing transportation of the machine.

IMPORTANT Close and lock the operators cab door.

Cover the exhaust pipe.

"LOCKED"

See Chapter DEVICE".

3.17.

“SAFETY

LOCKING

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4.22.4. LIFTING THE MACHINE DANGER 1. Crane operator should be well-trained and certified by an accredited crane operator testing organization.

2. Stop the engine. Take all safety precautions given in the operating & maintenance manual.

3. Hold the machine parallel to the ground when lifting.

4. Use certified cables, slings, shackles and hooks of adequate load rating.

5. Do not apply dynamic force to the cables and lifting equipment.

6. Never lift the machine while there is a person in the cab or on the machine.

7. Keep people away from the working area. Do not let anybody stay under or around the machine.

8. If installed, remove the optional attachments.

Optional attachments may affect the balance of the machine.

9. Lift the machine from a level and firm ground.

10. Never lift the machine in the way other than shown below. Improper lifting can cause load to shift and cause injury.

11. Read, understand and obey all local and national regulations.

5) Secure the machine by using chains as seen in the figure. Determine chain attaching points on the trailer so that chain angle will be approximately 45 degrees. Tighten all the chains.

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Lift the machine evenly from a level and firm ground.

1) Start the engine, and set the attachments as illustrated. Make the upper structure face forward.

Lower the outriggers to the ground.

2) Engage safety locking device.

3) Stop the engine, check the safety around the machine, and then get off. Close and lock the operator’s cab door, front windshield and engine hood securely.

4) As shown in the illustration, insert the lifting device with sufficient strength to carry the weight of the machine. On the front side, attach the wire rope around the boom. At rear side insert the wire rope under the outriggers and attach both sides to the lifting device on the top.

5) After installing all hoisting equipment, lift the machine a little to check its balance, if ok lift it slowly and evenly.

DANGER

Never attempt to lift the machine by using the lifting eyes of the counterweight.

Lifting eyes should break off due to excessive weight which may cause injury and damage.

4.22.5. SEA TRANSPORT In case of transportation by sea some components of the machine, which have a probability of forming rust, will be coated with antirust agent. Additionally duck covering wrapped around hydraulic cylinder rods are also covered with canvas.

IMPORTANT Before operating the machine, remove the duck covering (protector for rust) wrapped around cylinder rods. Otherwise, water will collect inside the cover and cause to occur corrosion. The other reason for necessity of removing duck covering is, squeezing into the cylinder gland and rod while operating the machine with duck covering.

IMPORTANT Ensure that there is no residual salt on the machine. Wash the machine after receiving.

Do not use high pressure while cleaning.

Do not use water directly to electrical parts, wiring, battery or alternator.

Clean residual antirust oil spray.

If the machine is not going to be operated for a long time after receiving, please see the part about machine storage in the operating and maintenance manual and apply instructions.

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4.23. PREPARING THE MACHINE BASED ON WEATHER CONDITIONS 4.23.1. PREPARATION FOR COLD WEATHER In cold weather, starting may be difficult and coolant may freeze, prepare the machine for starting as follows: 4.23.1.1. FUEL AND LUBRICANT Use fuel and lubricant that have lower viscosity.

Specified viscosity ► Refer to Chapter 6.2. "Oil, Fuel, Coolant And Diesel Exhaust Fluid".

In cold weather start the engine according to procedures mentioned in Chapter 4.2.2. “Starting in Cold Weather”. About procedures for warming up the machine, consult to Chapter 4.3. “Warm-up Operation”.

4.23.1.2. COOLANT WARNING Antifreeze solution is flammable. Keep away any source of open flame.

This machine is shipped with a concentration of 50% ethylene glycol antifreeze and 50% water for protection against temperatures down to -37°C. Caution on using antifreeze solutions: - Use antifreeze that does not contain any Nitrites, Amines or Phosphates.

- Use water mentioned in Chapter 6.2.5. Coolant.

- Flush the cooling system in a period of time given in inspection and maintenance list and refill it.

- Use an antifreeze solution throughout all seasons.

It will minimize the corrosion and elevate the boiling point of the coolant in hot weather despite a reduction in the cooling efficiency.

4.23.1.3. BATTERY WARNING A battery gas (hydrogen) is flammable. Do not expose to a sources of fire such as open flame, cigarettes, or sparks.

If battery electrolyte is splashed onto clothes or skin, immediately flush with clean water.

If battery electrolyte is splashed into the eyes, immediately wash with plenty of clean water and consult a doctor.

In cold weather, the battery capacity will be reduced. If the charging rate is low, the battery may freeze, so keep the battery 100% charged. Be careful regarding the charging state of the batteries when using heating devices in cold weather.

Refer to the table below to check the specific gravity of electrolyte and calculate the charging rate.

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Temperature of electrolyte (C)

Charging (%) 100 90 80 75

20

0

-10

-20

1.28 1.26 1.24 1.23

1.29 1.27 1.25 1.25

1.30 1.28 1.26 1.25

1.31 1.29 1.27 1.26

4.23.2. PRECAUTIONS AFTER FINISHING WORK Pay attention to the following points for sake of a smooth start the next day.

Remove clay grease or water from the machine. If the water on the hydraulic cylinder rod is frozen, the seal may be damaged. Clean it completely.

Park the machine on firm and dry ground. In unavoidable case, park it on wooden planks to prevent the tires from freezing on the ground.

Under 0˚C, drain water from the fuel tank and prefilter to prevent freezing.

In cold weather, the battery capacity is low. Cover battery or separate it from the machine and store in a warm place. Install it to the machine again the next day.

To prevent the battery from freezing, top up the electrolyte level with distilled water at the beginning of the days’ work and ensure the charging system is fully operational.

4.23.3. PREPARATION FOR HOT WEATHER In hot weather, perform the following:  Replace the oil or fuel with specified viscosity in accordance with Chapter 6.2. "Oil, Fuel, Coolant And Diesel Exhaust Fluid".

4.24. LONG TERM STORAGE Some specific precautions must be taken when machines are not used for a long time especially in winter and are stored for a long term. Checking procedures before and during the period of storage, and process which should be followed at the end of the storage period when the machine is to be used again are mentioned below.

4.24.1. BEFORE LONG TERM STORAGE

4.24.2. DURING LONG TERM STORAGE

Follow the processes below before storage:

During the period of storage, follow the steps mentioned below once a month: 1. To lubricate the movable parts. First, idle the machine for 5 minutes.

2. Then, fully extend and retract all the cylinders 3 times.

3. Move the machine in all gears and to all directions approximately 10 meters.

4. Fully turn the steering wheel in both directions 2 or 3 times.

5. If available run the air conditioner.

Before starting the machine:

1. Clean and dry all parts of the machine and keep the machine in a good ventilated area. If the machine is kept in open air, then place the attachments as shown below. Put wedges under the crawler and cover the machine.

2. Inflate the tires up to the working pressure. If it is possible, put wedges under the differentials to remove the load from the wheels.

3. Change all the oil in the machine.

4. Replace all the filters with new ones.

5. Fill the fuel tank and keep it full.

6. Cover all bare surfaces of the cylinders with grease.

7. If available, cut off the battery relay.

8. Disconnect the battery cables and cover them or keep them separately.

9. In cold weather (if the temperature is 0°C or lower), be sure that the amount of antifreeze is adequate against freezing.

10. Keep all the joysticks or control levers in neutral position. Activate the safety lever.

11. Lock the fuel and hydraulic tank breather.

12. Cover the exhaust and suction points.

13. Cover all uncovered holes of bolts, nuts and plugs (like eyebolt of the counterweight and boom)

1. Clean all the grease on the surface of hydraulic cylinders.

2. Check the general appearance, color and corrosion protection of the machine.

3. Check all hydraulic cylinder surfaces of the machine.

4. Check all oil and coolant levels of the machine.

5. Check the machine for oil, coolant and fuel leakage. If there is any leakage, fix it before filling up.

6. Check the pressure of the tires.

7. Shaft control: Grease the shafts if the machine is kept in a storage more than 6 months.

8. Check the functions of the levers, doors, windows, and also check the cover plates, cowling of the machine.

WARNING In case of operating in a closed area, open all windows to ventilate the room because of the exhaust gases.

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4.24.3. END OF THE LONG TERM STORAGE At the end of the long term storage, before using the machine, follow the steps below: 1. Clean all parts of the machine and clean the grease on the surface of hydraulic cylinders.

2. Check all the levels of fluid and if necessary fill it.

3. Check if there is any leakage or any wear on the belts and on the hoses of the machine.

4. Adjust the alternator and fan belt tension.

5. Grease all the grease nipples.

6. Start the engine and warm up the machine slowly up to the working temperature and check all the systems of the machine.

WARNING The piston rods of hydraulic cylinders are coated with grease to prevent rust.

Remove the grease before working.

Coat the piston rods of hydraulic cylinders with grease in long-term (more than one month) storage.

CAUTION When using the engine that has not been used for a long period of time (one month or longer), perform an inspection thoroughly before starting the engine. Also, confirm that there is no oil leakage and the oil has been sufficiently added to the specified level. If the oil level is insufficient, the oil is not supplied adequately, and a breakdown may result.

Replace the DEF/AdBlue® inside the DEF/AdBlue® tank if it is not used for a year or more. Failure to do so may result in a failure of the urea SCR system.

Start the engine and idle it at least for 10 minutes.

Also, make sure that the engine produces no abnormal noise.

For warming up operation, refer to "4.3. Warm-up Operation".

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4.25. INSTRUCTIONS ON WITHDRAWAL FROM USE AND UTILIZATION Excavator is a machine with a limited operating life like any other mechanism. When its operating life comes to its end, the machine should be dissembled as scrap. Some parts should be gathered to be used as secondary raw material, others should be discarded as scrap and the ones in the third category should be given to special companies for safe extraction and proper disposal of environmentally harmful materials.

Excavators should be dissembled under the following procedure to be discarded as scrap:  Remove all hoses and flexible tubes, and drain hydraulic oil into previously prepared containers.  Dismantle all hydraulic cylinders and drain the oil inside them into previously prepared containers.  Remove all gaskets and seals from hydraulic cylinders and gather them to be sent to hazardous substance disposal sites. Other parts of the cylinders are made of ferrous metals and subject to scrap metal collection.  Remove fillings of hydraulic cylinders and gather them to be sent to hazardous substance disposal sites.

Other disassembled parts, components materials should be treated as follows:

and

Metal parts: can be sent for scrap to be recycled.

Plastic parts: can be gathered and sent for recycling, if this is impossible – can be sent for scrap with other waste materials.

Oil and grease: can be sent to specialized companies for proper disposal of environmentally harmful materials and stuff (for burning and recycling).

Flexible tubes are usual wastes. If possible, we recommend to remove metal braids and send them for scrap. Hoses can be sent to the dump.

Gaskets and seals: can be sent to the dump.

Filter fillings: can be sent to specialized companies for proper disposal of hazardous substances (oil). The same procedure is for oily rag and oily saw dusts.

 Remove plastic parts, plain slide ways, slide shoe bearing of rack-bars, pilot ring of fillings and gaskets, bushings, and gather them to be sent for recycling.  Drain hypoid oil from wheel loaders undercarriage into the previously prepared containers.  Remove grease from all parts and gather it into the same container for used oil.  Remaining parts of the cylinders are made of metals. Most of them are made of steel, and only guide bush is made of bronze. All these metals can be recycled and used again for manufacture.

CAUTION Hydraulic oil and grease, even biodegradable, are very environmentally harmful. Avoid its contacting soil and its being absorbed by soil!

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5. TROUBLESHOOTING

5.2. TOWING METHOD

5.1. WHEN TO SUSPECT A TROUBLE CASE CAUTION When the engine is running at low speed, the following conditions are considered normal.

When pulling the arm forward, the arm speed becomes slow for an instant at almost vertical position

Make sure that the towing vehicle can handle the weight of the unit being towed and that it has adequate braking capacity.

Never use a damaged wire rope or chain. They could break and cause a serious accident.

Always wear gloves when handling a chain or wire rope.

When towing excavator use a wire rope or chain capable of handling the load.

Insert protective material such as thick cloths between frame and wire rope to prevent the wire rope from being damage.

There is an emergency actuating device on transmission to tow the machine in an emergency.

The emergency actuating device is to interrupt the power flow between input and output in case of a control pressure failure or a hydro-motor defect and thus allows an emergency towing of the vehicle.

The bucket speed becomes slow for an instant at almost parallel position.

Maximum towing speed: 10 km/h Maximum towing distance: 5 km Since there is no transmission lubrication, damages may occur due to lacking oil supply if the instructions are not observed.

For a longer distance it is best to have transported the defective vehicle on a low loader.

Activate the emergency actuation:  Switch off the engine.  Block the vehicle against rolling away.  Grease, nipple (1) by means of a grease gun pump until it comes visibly out at the pressure relief valve of the emergency actuation (3).

At the end and start of swing work, the brake valve makes a little noise.

When descending down a slope at low speed, the travel motor makes a little noise and vibration.

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Deactivate the emergency actuation:  Open the bleeder (2) of the emergency actuation device.  Shift into road speed (2. gear) (by doing this, you will automatically apply 30-35 bar control pressure).  Grease will come out of the bleeder.  Then close the bleeder again.

WARNING If the emergency actuating device is deactivated incorrectly, the transmission will be damaged during operation.

Emergency actuation deactivated:

No 1 2 3 4 5 6 7 8 9 10 11

: : : : : : : : : : :

Emergency actuation activated:

Name Set of springs (plate spring), for multi plate clutch Clutch, piston Multi-plate clutch Set of springs (plate spring), for multi plate brake Brake piston Pin Pressure ring for the emergency Ring for the emergency actuation Multi-plate brake Grease Grease nipple

Grease is applied to the pressure ring (7) pushing the brake piston (5) to the input housing until contact and thus the clutch piston (2) is driven over 2 pins (6).

WARNING No braking effect of the parking brake, when the release device is actuated.

No gear must be selected if the emergency control is activated.

5.3. TOWING HOLE FOR LIGHT OBJECTS WARNING Be sure to use shackles.

Make sure you attach the rope horizontal to the lower chassis.

Move the machine slowly.

5.4. CAUTIONS UNDER SPECIAL CIRCUMSTANCES Lubrication of attachments in severe applications When working in water the attachment pins that are submerged during the work cycle should be greased every few hours and upon completion of the days’ work.

When working under over load conditions, or digging in deep and wet locations, grease the attachment pins at regular intervals during the shift and at the end of the day’s work.  After greasing, operate the arm, boom and bucket several times, then grease again.

Towing shackle hole for light objects is located in the lower frame.

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5.5. ELECTRIC DISCHARGE WARNING

IMPORTANT

Battery fumes (gases) can explode; keep open flame, burning cigarettes and sparks away from the battery.

Battery electrolyte can damage clothes, burn skin and cause blindness. If electrolyte is splashed onto your skin or into your eyes flush with plenty of clean water for 10~15 minutes and immediately get medical help.

Always wear goggles or safety glasses when handling the battery.

When removing battery terminals: disconnect the (-) terminal first When installing battery terminals connect the (+) terminal first.

Avoid contact between the (+) terminal and the machine chassis, sparks may occur and cause explosion.

Avoid loose terminal, sparks may occur due to poor contact.

Booster cables and clips should be sized according to the battery capacity Use the same capacity battery and system voltage as the disabled machine Do not use corroded or damaged cables and clips.

Connect the clips firmly

5.5.1. STARTING THE ENGINE WITH BOOSTER CABLES (JUMP START) When starting the engine with booster cables, observe the following.

CAUTIONS WHEN CONNECTING DISCONNECTING THE BOOSTER CABLES WARNING When you start the engine with booster cables, wear safety goggles.

Ensure the positive (+) terminal does not contact the negative (-) terminal when connecting the cables.

When starting the engine from another machine, be careful that the source machine does not contact the disabled machine.

Prevent sparks around the battery; they could cause battery gases to explode.

Make sure that the booster cable connections are correct. The last cable is connected to the upper structure, but it should be connected as far from the battery as possible. (However, do not connect to the attachments).

When disconnecting the booster cables from the battery, disconnect in the reverse order.

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/

CONNECTING BOOSTER CABLE Turn the start switch to STOP position, and connect the booster cables in numbering order shown in the figure.

Turn the start keys of both the disabled machine and the normal machine to STOP position.

Connect the clip (1) of booster cable (A) to the battery positive (+) terminal of the machine to be boost started.

Connect the clip (2) to the battery positive (+) terminal of the engine which is running.

Connect the clip (3) of booster cable (B) to the battery negative (-) terminal of the engine, which is running.

STARTING THE ENGINE Make sure the clips are firmly connected to battery terminals.

Turn the key switch of normal machine to START position, and start the engine.

Turn the key switch of disabled machine to START position, and start the engine. If the engine does not start within 30 seconds, wait for 2 minutes between cranking attempts.

DISCONNECTING THE BOOSTER CABLES After the engine has started, the booster cables must be disconnected in the reverse order.

Disconnect clip (4) of the booster cable (B) from the upper structure.

Disconnect clip (3) from the battery negative (-) terminal of the running engine.

Disconnect clip (2) of the booster cable (A) from the battery positive (+) terminal of the running engine.

Disconnect clip (1) from the battery positive (+) terminal of the machine which was boost started.

5.6. POOR BATTERY CHARGING If the charge lamp illuminates while the engine is running. This is an indication of poor battery charging.

Check that the V-belts are correctly tensioned and free of damage.

Check the alternator, relays and other related writing for poor connection or damage. If they are normal, the charging system is faulty. Have the engine inspected by your dealer.

CAUTION Do not stop the engine when it’s overheated.

Operating the engine for a long time while the coolant level is low not only increases fuel and oil consumption of the engine, but also leads to wear damage on the engine and ultimately cause the engine to fail.

5.7. OVERHEATING WARNING Never attempt to open the radiator cap when the coolant is hot. Otherwise, hot coolant or steam may suddenly come out and burn you. Wait until the coolant is sufficiently cool before attempting to open the cap. Place a thick cloth over the cap and slowly turn it to open.

NOTE Do not stop the engine immediately. Otherwise, the coolant temperature may shoot up, possibly causing the engine to seize.

Top up the coolant little by little. Pouring a large amount of coolant which is at room temperature may cause the engine to crack.

1. Coolant level gauge 2. Coolant reservoir filling cap Figure. Coolant reservoir

High or low coolant temperatures might lead the engine to failure. Engine coolant temperature should be between 75-90°C. If engine coolant temperature indicator shows a value higher than the desired range, or if “OVERHEATING” warning message appears on control panel screen, operator must suspect that the engine is facing the very dangerous problem of overheating in the diesel engine.

When the coolant temperature is above the suitable range, fuel delivery to the engine is limited.

Stop the machine and run the engine at a speed slightly higher than idle speed to cool down the engine. When the gauge needle has dropped to the middle range of the scale, or when the coolant temperature warning lamp has gone out, stop the engine and perform the following steps.

1. Check the radiator hoses etc. for coolant leakage.

2. Check the V-belts for damage and proper tension.

3. Check the coolant level as explained in maintenance chapter. If it is necessary to add coolant, wait for the engine to cool down and then add coolant into the coolant reservoir tank.

4. Check that the front side of the radiator is free of trash etc.

5. If coolant is leaking or the engine overheats frequently, this is an indication of a faulty cooling system. Contact your dealer.

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5.8. ABNORMAL (LOW) OIL PRESSURE NOTE Check the oil pressure after the engine has been warmed up. The oil pressure gauge may show a high rating immediately after engine start when the engine is still cold.

If the oil pressure is low or the oil filter is clogged or oil pressure drops below minimum value then "engine oil low pressure indicator" in the instrument panel turns on. In this condition, stop the machine and the engine immediately and perform the following steps.

NOTE Stop the engine immediately. Otherwise, the engine may fail.

1. Check for oil leakage.

2. Check the oil level and top up as required.

Refer to Chapter 6.5.5. "Checking Engine Oil Level".

3. If the oil level is correct, but the oil pressure gauge needle indicates an abnormal pressure or the low oil pressure warning lamp or the oil filter warning lamp illuminates, contact your dealer.

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5.9. ENGINE Dependably performing inspection and maintenance prevents faults. Make sure to perform all inspection and maintenance services periodically. Also, quickly fix any small faults to prevent those leading serious faults.

When any of the failures listed below occurs, perform inspection and take action following the table.

If a repair cannot be performed by yourself, the corrective action shown in the table does not eliminate the problem or a failure location cannot be identified, contact the nearest Hidromek Authorized Service.

CAUTION In the "Corrective Action" column indicates that the failure requires a repair or adjustment, so contact the nearest Hidromek Authorized Service.

Symptom

The exhaust smoke is white

Cause

Corrective Action

Insufficient warming-up

Perform warming-up

Too much engine oil

Adjust to the appropriate oil amount

Failure of the engine control system Failure of the fuel system Continuous idling for a long period (two or more hours)

Raise the engine speed and confirm that white smoke is not emitted

Failure of the engine control system Clogging of the air cleaner The exhaust smoke is black

Replace the element

Failure of the fuel system Clogging of the exhaust system Urea SCR system is faulty

If you find any problem, look into a possible cause and get it corrected immediately to prevent a serious trouble.

If you ignore it and continue to operate the machine, it may cause a serious hazard. : Symbol means; causes mentioned on the list are to be repaired and adjusted by HIDROMEK Service Center. Call the nearest HIDROMEK Service Center.

Refer to the following list to plan your checks and maintenance. If the cause is not clear, call the nearest HIDROMEK Service Center.

Never attempt to check, disassemble or fix the engine, hydraulic system and electric system. Contact HIDROMEK dealer service center.

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Symptom

Starter does not turn or turns weakly.

Possible Cause

Remedy

Battery discharged.

Charge or change.

Battery terminal is disconnected, loose or corroded.

Correct corrosive part and tighten securely.

Starter ground terminal is disconnected, loose or corroded.

Correct corrosive part and tighten securely.

Engine oil viscosity is too high.

Change with oil of correct viscosity.

Starter or electrical system is failure.

Engine does not start

Engine emergency shutdown switch is on.

Engine emergency shutdown switch is turned off.

No fuel.

Make sure that there is no fuel leakage and replenish.

Air is in fuel system.

Bleed air.

Fuel filter is clogged.

Remove water and change element.

Fuel is frozen.

Make fuel pipes warm with hot water or wait until ambient temperature rises.

Injection pump is failure.

Starter turns.

Electromagnetic type fuel pump is failure.

Engine control system is failure.

Engine malfunction indicator lamp and LCD Display panel shows engine failure.

Strainer is clogged.

Pre-heating device is failure.

Lowering compression pressure.

Engine starts but stops soon.

Idling is too low

Adjust by idling control equipment on the machine. If adjustment is not possible, contact HIDROMEK dealer.

Fuel filter is clogged.

Remove water and change element.

Pre-fuel filter is clogged.

Clean or change element.

Strainer is clogged.

Engine control system is failure.

Air cleaner is clogged.

Clean or change element.

Injection pump is failure.

Electromagnetic type fuel pump is failure.

Engine does not stop.

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Engine oil is too much.

Make correct oil level. If adjustment is not possible, “◎”.

Symptom

Possible Cause

Remedy

Fuel system is failure.

Engine running is unstable.

Water or air is in fuel system.

Bleed air or remove water.

Engine control system is failure.

No coolant.

Replenish.

Front of radiator is clogged with dust.

Clean with soft brush.

Sub tank cap is not tightened properly.

Tighten securely or change sub tank cap.

Coolant is fouled.

Clean inside of radiator and change coolant.

Engine overheats.

Oil is in coolant.

Oil pressure does not rise.

Thermostat is failure.

Change thermostat.

Engine oil viscosity is not correct.

Change with oil of correct viscosity.

Engine oil level is not sufficient.

Replenish.

Inside of engine is failure.

Meter, lamp or switch is failure.

Hunting in oil pressure.

Engine oil is too much.

Make correct oil level.

Air cleaner is clogged.

Clean element.

Fuel filter is clogged.

Remove water and change element.

Pre-fuel filter is clogged.

Clean element.

Strainer is clogged.

Engine control system is failure.

Engine has no power.

Engine is failure.

Exhaust system is clogged.

Fuel system is failure.

Type of fuel is not correct.

Electromagnetic type fuel pump is failure.

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5.10. HYDRAULIC SYSTEM 5.10.1. HYDRAULIC PUMP Symptom Insufficient output of the pump

Abnormal noises and vibrations

Extreme decrease of pump delivery flow and nonincrease of delivery pressure

Possible Cause

Remedy

Malfunction of controller

Fix or replace

Cavitation (Remarks: Low boost pressure, air leakage at suction pipe, increased suction resistance)

Check working oil for emulsion

Damage in piston shoe

Replace the piston shoe, plate, etc.,

Cracking of the cylinder

Replace the cylinder

Wrong installation of the pump

Correct installation

Hunting of the regulator

Repair the regulator

Regulator failure

Repair regulator

Seizure or damage inside the pump

Replace damaged part

Wrong fitting of the regulator piping

Correct

5.10.2. TRAVELING, SWINGING AND ATTACHMENT WORKING Symptom

Attachment, swing and traveling are impossible

Insufficient power on attachment, swing and traveling

Only one side of the levers not work or the power is weak

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Possible Cause

Remedy

Pump malfunction

Fix or replace

Insufficient operation oil

Refill

Damage on suction pipe or hose

Fix or replace

Gear pump malfunction

Fix or replace

Selection valve malfunction

Fix or replace

Malfunction due to the pump worn out

Replace

Decreased pressure setting of main relief valve

Adjust

Insufficient operation oil

Refill

Oil tank strainer blocked by foreign matters

Clean

Air intrusion during suction

Tighten

Bad control valve

Fix or replace

Loosened connecting parts

Tighten

Damage on O-Ring on connecting parts

Replace

Malfunction of the pump

Fix or replace

Symptom

Possible Cause

Remedy

Spool of control valve damaged

Replace

A foreign material on spool

Fix or replace

Damage on piping or hoses

Fix or replace

Loosened connecting parts

Tighten

Damage on O-Ring on connecting parts

Replace

Malfunction of motor or cylinder

Replace

Malfunction of traveling or swing reduction gear

Replace

Center joint trouble

Fix or replace

Travel motor trouble

Fix or replace

Parking brake trouble

Fix or replace

Contamination on oil cooler

Clean

Insufficient tension on engine fan

Adjust

Loose plug

Tighten properly

‘O-ring’ damage

Replace

Control lever cannot be operated

Pilot control valve trouble

Fix or replace

Control lever span too much

Pilot control valve trouble

Fix or replace

The control lever inclined on side

Loose bolt of pilot control valve

Tighten more

Only one function cannot be done.

Travel problem on both sides Travel problem on one side

High operating oil temperature

The low pressure hose leaks

5.10.3. HYDRAULIC CYLINDERS Symptom Cylinder does not work or the power is weak

The drifts while the machine is stopping

Possible Cause

Remedy

Damaged oil seal

Replace oil seals or hydraulic cylinder

Oil leaking due to cylinder rod failure

Replace rod or hydraulic cylinder

Damaged or worn out piston seal

Fix or replace

Abnormal wear of control valve spool

Replace

Malfunction of main or overload relief valve

Fix or replace

147

5.11. ELECTRIC SYSTEM Symptom

Possible Cause

The lamp fades out or blinks while the engine is running The battery recharge warning lamp doesn’t work The alternator abnormal sound

generates

an

Starter motor doesn’t work while the key is ON The Bendix pinion of starter motor is faulty The starter can’t start the engine

The starter motor stops before the engine is started Engine oil pressure warning lamp doesn’t light up when engine is stopped Battery recharge warning lamp does not light up when engine is stopped. (Key is ON)

Remedy

A terminal is loose or wire disconnected

Inspect, replace if necessary

Loose belt tension

Adjust

Alternator trouble

Inspect, replace if necessary

Wire disconnection

Inspect, replace if necessary

Alternator trouble

Replace

Wire disconnection

Replace

Battery discharge

Recharge

Starter motor trouble

Replace

Battery discharged

Recharge

Battery discharged

Recharge

Starter motor trouble

Replace

Wire problem

Inspect, replace if necessary

Battery discharge

Recharge

Monitor trouble

Replace

Wire disconnection

Inspect, replace if necessary

Pressure switch trouble

Replace

Monitor trouble

Replace

Wire problem

Inspect, replace if necessary

5.12. OTHER TROUBLES Symptom

Swing is not smooth

148

Possible Cause

Remedy

Air entering (to brake valve of motor)

Remove air

Wear on swing gear

Repair or replace

Damage on swing bearings or balls

Repair or replace

Lack of grease

Refill

6. MAINTENANCE 6.1. CAUTIONS IN MAINTENANCE All the inspection and maintenance information specified in the manual must be strictly observed.

Park the machine on level and firm ground, then perform inspection and maintenance.

WARNING Select a place with flat and firm ground for performing maintenance. It would be very dangerous if the engine started to move.

Make sure to stop the engine and pull out the starter key.

When performing works with the electrical system, make sure to disconnect the negative (-) battery terminal.

Do not perform work near an open flame or other heat sources.

Each part on the engine is hot immediately after driving. Be careful not to get burned. Perform inspection when the engine has cooled down.

Replacement of each oil and oil filter should be performed when each oil has cooled down sufficiently. Performing work when they are still hot can cause burn injury.

When performing a maintenance work on the fuel line or fuel filter, remove the fuel cap. Since the fuel system is under high pressure, the fuel may overspill unless the pressure is relieved, and the spilled fuel may be ignited, possibly leading to a fire.

Do not leave the engine running in a poorly ventilated indoor place. This could cause carbon monoxide poisoning.

CAUTION Use only appropriate tools.

Do not leave the removed parts or tools on the engine. They may damage the equipment if they are caught in the belts or other moving components.

When replacing, take sufficient care so that filth or foreign matter does not attach to the removed component.

Dirty water, dirt and other impurities seriously impair the effectiveness of the oil, and damage the parts, so take sufficient care not to let filth or foreign matter mix into the oil while adding or replacing.

Confirm that all systems and components are normal after performing the work.

6.1.1. HIDROMEK GENUINE SPARE PARTS When replacing the parts, use only genuine spare parts supplied by HIDROMEK. 6.1.2. WINDOW WASHER FLUID Use the washer fluid for cars.

6.1.3. OIL AND GREASE Use clean oil and grease and check if the container is broken. Be careful to keep lubricants contaminant free.

6.1.4. NEVER MIX OILS Never use different type of oil when changing or adding oil. Never mix different types or brands of oils, even they are recommended by Hidromek.

6.1.5. CHECK HOUR METER Check the hour meter every day to determine if any periodic maintenance is required.

6.1.6. KEEP THE MACHINE CLEAN Keep the machine clean to find defects easily.

Especially, keep grease fittings, breather, and oil level gauge (oil sight gauge) clean to prevent contamination.

6.1.7. CAUTIONS FOR HOT OIL AND WATER Draining oil or water and replacing filter immediately after stopping the machine is very dangerous. Wait until the temperature is considerably reduced. If the oil is cold, warm up the oil (about 20°C - 40°C), and then drain it.

6.1.8. CHECK FILTER When replacing oil and/or filter, check the drained oil and used filter for contamination of metal particles or other foreign materials.

6.1.9. CAUTIONS WHEN ADDING OIL If oil filler port has a strainer, fill oil without removing it.

6.1.10. KEEP CONTAMINATION AWAY Inspect and replace oil in a place as clean as possible to protect the components from contamination.

6.1.11. ATTACH WARNING TAG In case of draining oil or water, attach a warning tag on the control lever or starter switch to prevent risk of operation by others.

6.1.12. OBSERVE ALL WARNINGS AND CAUTIONS Observe the caution depicted on the plate attached to the machine and caution in this manual thoroughly and work safely.

6.1.13. PRECAUTIONS WHEN WELDING Disconnect the main power (Turn the starter switch to OFF position and also turn the battery master switch to CUT OFF position.)

Never use 200V or more continuously.

Attach the work piece ground clamp within 1 m of the welding point (as close to welding spot as possible).

Be careful that seals or bearings are not in the electrical path between the welding point and the ground clamp.

Avoid setting the ground clamp on fastening pin of attachment or hydraulic cylinder.

149

Wear protective clothing, goggles, and gloves to make sure your body is insulated from the work piece.

6.1.14. PRECAUTIONS ON FIRE Use non-flammable solution or light oil to clean the parts. When using light oil, do not expose it to open flame.

6.1.15. CLEANING MACHINED SURFACES When dismantling parts installed with an O-Ring, gasket and seal, clean the surface and replace them with new ones. Ensure the O-Ring, seal or gasket, etc. are properly installed.

6.1.16. PRECAUTIONS WHEN WASHING THE MACHINE Never let water or steam contact electronic parts or connectors.

Never let water contact controllers and instrument panel in the operator’s cab.

Never let high-pressure water contact radiator and oil cooler.

6.1.17. CHECK BEFORE AND AFTER WORK When working on a swampy ground, a shore, under water and snow, check the tightening condition of each plug. After finishing work, wash the machine to check for cracks, damage and loose bolts and nuts. Grease each part sufficiently after finishing work. In case of working under water frequently, replace travel motor oil often regardless of working time, because the oil may be diluted if water gets in it.

6.1.18. PRECAUTIONS DURING WORK IN DUSTY CONDITIONS When working in dusty environments, check the following.

Clean the radiator and oil cooler core (fin) often to prevent it from being clogged Clean the electronic parts, especially starter motor, alternator, to protect them from dust.

6.1.19. DISCARDED PARTS, OILS AND OTHER LIQUIDS Discarded parts, oil, grease and fluids could have an adverse effect on the environment. It is difficult to dispose of these properly, so have a Hidromek Authorized Service handle all inspections and replacements.

When replacing each oil, filter, or coolant, prepare a pan and drain them into the pan.

Disposal and treatment of replaced each component, oil, filter or coolant must be conducted in accordance with the specified procedure.

150

6.1.20. HIDROMEK RECOMMENDED OILS AND GREASE Periodical adding and replacement of oils and greases are very essential to maintain the engine performance and to prevent failures.

For Hidromek recommended greases and oils, their quality and performance are guaranteed by Hidromek.

For maintenance and service, use of Hidromek recommended greases and oils is recommended.

Refer to “Chapter 6.2. Oil, Fuel, Coolant and Diesel Exhaust Fluid” for recommended type of fluids.

6.1.21. OIL Oil used in the engine or hydraulic system is always subject to severe operational conditions (e.g. high temperature, high pressure) over time. Be sure that you use specified type of oil according to work condition described in this manual. Always replace the oil according to specified maintenance schedule even if it is not deteriorated.

Contamination in oil will negatively affect the performance and service life of the components.

Keep oil clean and in good condition, prevent contamination during maintenance.

Machine breakdowns are almost always caused by contamination. Especially, when storing or filling the oil, ensure the containers, funnels etc. are clean.

DO NOT mix different brands of oil.

Refill the oil to the specified level. Excessive or insufficient oil may cause a breakdown.

If air gets in the circuit, hydraulic oil becomes misty.

Contact Hidromek Authorized Service to pinpoint and root out the cause.

When replacing oil, make sure to replace the related filters as well.

Check the condition of the machine and get the oil analyzed periodically.

Contact Hidromek Authorized Service.

When the machine is delivered, it is filled with hydraulic oil type ISOVG46.

6.1.22. FUEL The fuel pump is a high pressure and precision component machined with fine tolerances. If the fuel is contaminated with water or dust, it will cause component failure.

When storing or filling fuel, pay attention to avoid contamination.

Make sure to use correct type of fuel specified in this manual. In lower temperatures, the fuel gels or solidifies, therefore it is crucial to use fuel that best suits the ambient temperature.

After finishing work, refill the fuel tank fully to prevent accumulation of water as the air is condensed in the fuel tank.

Before starting the engine or 10 minutes after refilling the fuel, drain the sediment and water from the fuel tank. Drain the water separator daily.

6.1.23. COOLANT Never use well, river, sea or waste water in the cooling system since the cooling system can be clogged and damaged. See Part 6.2.5 for quality of water to be used.

When using antifreeze solution, observe the cautions specified in this manual and shown on the container.

When the machine is delivered, the coolant contains 50% antifreeze and %50 water. This antifreeze solution minimizes corrosion, rusting, scaling and formation of sludge in the cooling system. See Part 6.2.5 for life expectancy.

The mixing ratio of antifreeze solution depends on outside temperature. See Part 6.2.5 for mixing ratios per temperature.

Should an overheat situation arise, never stop the engine immediately. Cool it down at low idle and stop, then refill the coolant. See Part 6.2.5 for warning.

Use an antifreeze solution throughout all seasons to lower the freezing point and raise the boiling point which will minimize failures such as overheating, pitting of liners, water pump leakage and clogging of radiators.

6.1.24. GREASE Grease should be used to prevent the rotating parts and the connection parts from wear, seizure and noise.

It is not necessary to replenish the grease nipples which are not specified in periodical maintenance section. These grease nipples are for overhauling or for replacement of grease. After using the machine for a long time, if the machine does not work smoothly, refill the grease.

After filling the grease, clean overflowing grease thoroughly. Especially, be careful to clean the rotating parts on which sand and dust might deposit.

6.1.25. STORING OIL AND FUEL Always comply with regulations governing safe handling and storage of fuel and oil.

If stored outdoors, protect the drums and other containers from external conditions i.e. direct sun beam, rain, snow, sand etc., by storing them under an open sided shelter.

If kept outdoors with no protection, position (tilt) the drums so that water and debris cannot accumulate on the top, or cover with a waterproof tarp.

Also turn the drum to put the plugs on a horizontal plane to prevent moisture and impurities being drawn in as the drum expands and contracts.

Avoid deterioration of product quality due to longterm storage: use them on a first-in/first-out basis.

6.1.26. DIESEL EXHAUST FLUID (DEF/AdBlue®) DEF/AdBlue® is a clear, colorless, and harmless aqueous solution. It is normal for DEF/AdBlue® to emit an odor in some circumstances.

DEF/AdBlue® is harmless to the human body even if touched, however, it may cause inflammation in rare circumstances depending on its constitution.

In such cases, take the following actions.

In the case of contact with skin, wash off with water.

Failure to do so may result in irritation for those with sensitive skin.

In case of accidental ingestion, drink one or two glasses of water or milk and consult your physician immediately.

In the case of contact with eyes, immediately wash out with large amount of water for at least 15 minutes and consult your physician.

Storing DEF/AdBlue® Seal the DEF/AdBlue® container to prevent evaporation and store it indoors or in places that are well ventilated and not exposed to direct sunlight.

When stored, the expiration date of DEF/AdBlue® varies depending on the temperature of the storage location. Contact your Hidromek Authorized Service for details.

Storage temperature 10°C (50°F) 25°C (77°F) 30°C (86°F) 35°C (95°F)

Maximum period 36 months 18 months 12 months 6 months

storage

DEF/AdBlue® may deteriorate significantly if stored at 35°C or above.

Even if frozen, DEF/AdBlue® retains the same quality as when thawed and is usable as is.

When storing or carrying DEF/AdBlue®, use the container in which the DEF/AdBlue® was contained when purchased. If not, use a dedicated polyethylene tank (PE) or stainless steel container that is free from any adhesion of foreign materials such as water or dust.

Disposing of DEF/AdBlue® Do not dispose of DEF/AdBlue® or its empty containers into lakes, seas, rivers, or other such places.

Dispose of in an appropriate way complying with local legal requirements.

151

6.1.27. FILTERS Filters are very important parts to protect oil, fuel and air circuits against impurities. Replace them periodically according to this manual. The periods of filter replacement given in this manual are for recommendations. Operating conditions of the machine may require the filter elements to be replaced more or less often than the service periods recommended in this manual.

Never reuse the filter (cartridge type), When replacing the oil filter, check whether the consumed filter has metal particles on it. If any are found, contact Hidromek Authorized Service.

Please obtain genuine filters from HIDROMEK. 6.1.28. ELECTRONIC PARTS Damaged insulation, accumulation of dirt and water on electronic parts and components may cause electric leakage and lead to machine malfunction.

This is very dangerous and must be avoided.

Check the fan belt tension, belt damage and the electrolyte level.

Never disconnect or dismantle electronic parts from the machine.

Never use, on the machine, electronic components other than those specified and/or approved by HIDROMEK. Be careful not to wet the electronic parts when washing the machine, and close the cab windows on rainy days to protect electronic components.

The controller of control system may malfunction due to electromagnetic interference. If you have to use a portable phone, consult with Hidromek.

When working ashore, keep the electronic parts dry to protect them from corrosion.

When installing electronic equipment like an air conditioner/heater, connect them to their own power connector.

Never connect the optional component power supply circuit directly to starter switch, battery relay, etc.

DO NOT use electric lamp or other high voltage electric devices when troubleshooting on electronic components and systems. Otherwise you will damage them. USE ONLY multimeter and similar accurate electronic measuring instrument designed for this purpose.

6.1.29. HYDRAULIC SYSTEM The hydraulic components are hot during and soon after working. Also these parts are under high pressure during work and even after the machine is shut off, therefore be careful and observe the followings when performing maintenance and checks on the hydraulic system.

Lower the bucket to the ground level, and release all pressure in the attachment circuits.

Stop the engine before performing any maintenance and service on the machine.

Allow oil to cool down.

There is always internal pressure in the hydraulic circuit. Never supply oil or drain oil, and never maintain or check the machine before eliminating the internal pressure. Also, when you loosen the 152

plug and hose connectors, loosen them slowly with extreme care and keep them aside.

6.1.29.1. RELEASING INTERNAL PRESSURE IN MAIN CIRCUIT After stopping the engine, turn the start switch to ON position, then move the right and left control levers forward/backward, left/right, respectively several times to release the internal pressure in the main circuit.

6.1.29.2. RELEASING PRESSURE IN TANK AND RETURN CIRCUIT 1. Remove air breather plastic cap (1) of the pressure relief valve on the hydraulic tank.

2. Press the pressure relief valve (2) to release pressure in the hydraulic tank.

Check the hydraulic oil level, and replace the filter and hydraulic oil.

When removing the high-pressure hoses, check whether the O-ring is damaged. If any damage is found, replace it with a new one.

After replacing the hydraulic oil filter element and cleaning the strainer, oil repairing / replacing the hydraulic units, or dismantling the hydraulic oil piping, bleed the air from the hydraulic oil circuit.

The hydraulic accumulators contain nitrogen gas and hydraulic oil under high pressure; so handle with care to avoid an accident.

Handling of the accumulator  Refer to “2.1.20.

Handling of Accumulator.”

6.2. OIL, FUEL, COOLANT AND DIESEL EXHAUST FLUID 6.2.1. CAPACITIES OF OIL, FUEL, COOLANT AND DIESEL EXHAUST FLUID Use products with the following specification or better. Do not mix different brands and qualities of oils.

CAPACITY LOCATION

OIL TYPE 210 series

Engine Oil Pan

Engine Oil

21 L

Water pump

Grease

As required

Swing Reduction Gear

5L

Front Axle Differential

14.6 L

Rear Axle Differential

Gear Oil

Front/Rear Axle Planet Gear

18 L 2*2,5 L (Each)

Transmission

2,9 L

Hydraulic Oil Tank

Hydraulic Oil

159 L (replacement) 318 L (system)

Fuel Tank

Diesel Fuel

345 L

Pins and Bushings

Grease

Radiator

Antifreeze and water mix *

As required 30 L

* See Chapter "6.2.5. Coolant" for mixing ratios according to temperature.

153

Oil viscosity by temperature (C) Oil Type

Isuzu 4HK1 Engine Oil

-30

-20

-10

0

20

30

40

50

30

40

50

SAE 10W-40

Oil Type

Oil viscosity by temperature (C)

-30

-20

-10

0

10

20

SAE 90, API GL5

Swing Reduction Gear

Oil viscosity by temperature (C)

Oil Type

Use at outside temperatures above

Viscosity Grades

Transmission Oil

10

Hydraulic section

Mechanical section

SAE 5W-30, 5W-40

-35 °C

-40 °C

SAE 10W-30, 10W-40

-30 °C

-35 °C

SAE 15W-30, 15W-40

-25 °C

-30 °C

SAE 20W-20

-20 °C

-25 °C

SAE 20W-40

-20 °C

--

SAE 30

-5 °C

-10 °C

Oil Type

Oil viscosity by temperature (C) -30

-20

-10

0

10

20

30

40

50

30

40

50

ISO VG 32 Hydraulic Oil

ISO VG 46 ISO VG 68 Oil viscosity by temperature (C)

Oil Type Front Axle Joint

-30

-20

-10

0

NLGI No. 1, LS, EP, ISO VG 460

Swing Unit Reduction Gear Grease Water Pump Grease

NLGI No. 2, LS, AW, EP

Swing Ring Gear Grease * NLGI No. 2, LS, AW, EP Pins and Bushings Grease NLGI No. 2, AW, EP, High Performance

154

10

20

Oil viscosity by temperature (C) Fluid Type

-30

-20

-10

0

10

20

30

40

50

30

40

50

Long Life Coolant

Antifreeze and Water Mix **

Oil viscosity by temperature (C) Fluid Type

-30

-20

-10

0

10

20

ASTM D975 NO.1 Diesel Fuel ASTM D975 NO.2

* ** SAE ISO NLGI ASTM API

: : : : : : :

Refers to lubricants that are used in filling at the factory See Chapter "6.2.5. Coolant" for mixing ratios according to temperature.

Society of Automotive Engineers International Organization for Standardization National Lubrication Grease Institute American Society of Testing and Material American Petroleum Institute

155

6.2.2. RECOMMENDED LUBRICATION OIL Engine Oil

Performance

Transmission Oil ZF TE-ML 07 : 07D Engine oil in accordance with specification: - API CD/CE/CF-4/CF/CG-4/CH-4/CI-4/CI-4 Plus/CJ-4 - API SF/SG/SH/SJ/SL/SM - ACEA-categories A/B/E

API CJ-4 ACEA E6, E9 JASO DH-2

Viscosity

SAE 10W-40

SAE 15W-40

Petrol Ofisi

Maximus HD 10W-40

Turbo Dizel Extra 15W/40

Mobil

Delvac XHP ESP 10W-40

Mobil Delvac MX 15W/40

Shell

Rimula R6 LM 10W-40

Shell Rimula R3 X 15W40

Castrol

Enduron Global 10W-40 VECTON Long Drain 10W-40

Castrol CRB Turbomax 15W-40 BP Super V Turbo 15W/40 Vanellus Super V Turbo 15W-40

BP

Hydraulic Oil

Gear Oil (Swing Reduction Unit)

Gear Oil (Axles)

Performance

DIN51524, PART-II

API GL5 MIL-L 2105D

ZF TE-ML 05 : 05C

Viscosity

ISO VG 46

SAE 90

SAE 90

Petrol Ofisi

Hydro Oil HD 46

Universal Keban EP SAE 90

Mobil

Mobil DTE 25

Mobilube HD 80W-90

Mobilube LS 85W-90

Shell

Tellus S2 M46

Shell Spirax S2 A 80W90

Spirax S3 ALS 80W-90

Castrol

Hyspin AWS 46

Energear HYPO SAE 80W-90 Axle EPX 80W-90

Axle Z Limited Slip 90

Performance

Grease

Antifreeze Solution

NLGI

Ethylene Glycol Base, Extended Life

Viscosity

NO.2 (High Performance)

NO.2

NO.1 1/2

-

Petrol Ofisi

Carius EP 320 Ultra Gres CS2

Süper Gres EP2

Carius EP 146

Extended Life Coolant

Mobil

Mobilgrease Xhp Mine

Mobilux EP2

Mobilith SHC 460

Mobil Antifiriz

Shell

Gadus S2 V220AD 2

Gadus S2 V220 2

Albida SDM 1

-

Castrol

Pyroplex Blue

Spheerol EPL 2

-

Radicool SF

BP

Pro Cool

CAUTION • The engine oil has a significant impact on the performance and service life of the engine, and fuel economy, so it is recommended to use the recommended oil specified by Hidromek. Any failure or accident which arises from use of inappropriate engine oil is excluded from the coverage of warranty.

• The engine oil has the following important functions: - Prevents each part of the engine from wearing.

- Cools down each part of the engine.

- Cleans each part of the engine.

- Maintains airtightness of the combustion chambers and prevents rust generation. Replace the engine oil periodically.

CAUTION Using fuel other than extra-low-sulfur diesel fuel (with sulfur content of 15 ppm or lower) may have a harmful effect on the engine and the exhaust gas purification device (urea SCR system), possibility resulting in a breakdown. If a wrong type of fuel is filled in, drain it completely. It is dangerous to start the engine with the wrong type of fuel filled in because doing so may cause a fire or engine damage.

Open the fuel cap slowly. If the cap is opened quickly, the fuel may spurt out.

Engine warranty is not applicable if any fuel except extra low sulfur diesel is used.

156

CAUTION Engine oil lubricates and cools the engine interior components. The quality of the oil is degraded and the quantity of oil is reduced by evaporation, exhaust and combustion during the engine's operation. Continually using the same oil without checking the level or without replenishing and changing it could cause seizure or damage to the engine. Add or change the oil when the quality of the oil has degraded or the quantity is reduced, even if that occurs before expiration of the specified intervals in the maintenance schedule, which will differ depending on the conditions of use.

Fuel gradually gets mixed with the engine oil, causing the engine oil to become thin. Make sure to replace the engine oil at the specified intervals.

WARNING Engine life and engine oil life will be affected by the quality and cleanliness of the fuel used. Make sure you know the quality of the fuel you are buying. If you are not sure, USE MINIMAL INTERVAL for oil change as specified below.

CAUTION It is the responsibility of the user to monitor the actual condition of the engine oil. Perform maintenance (oil, fuel and air filters) according to the Maintenance Section (6.4) and follow recommendations made therein. It is extremely important to pay attention to type of fuel used and to CLEANLINESS.

157

6.2.3. RECOMMENDED FUEL Use correct type of fuel that is recommended in this manual.

CAUTION • Using fuel other than extra-low-sulfur diesel fuel (with a sulfur content of 10 ppm or lower for Japan and Europe, 15 ppm or lower for America) may have a harmful effect on the engine and the exhaust gas purification device (urea SCR), possibly resulting in a breakdown. If a wrong type of fuel is filled in, drain it completely. It is dangerous to start the engine with the wrong type of fuel filled in because doing so may cause a fire or engine damage.

• Any failure which arises from use of fuel other than extra-low-sulfur diesel fuel is excluded from the coverage of warranty.

• Open the fuel cap slowly. If the cap is opened quickly, the fuel may spurt out.

CAUTION • For fuel of diesel engine, the following characteristics are required.

Use a type of extra-low-sulfur diesel fuel designated for general diesel vehicles that is compliant with the following standards: Japanese Industrial Standards (JIS) K2204, American Society for Testing and Materials (ASTM) D975 No. 1-D S15 and No. 2-D S15, British Standards (BS) EN590, Deutsche Industrie Normen (DIN) EN590, Canada General Standards Board (CGSB) CGSB-3.517 - No fine dust is contained.

- Appropriate degree of viscosity is provided.

- High in cetane value.

- Good low-temperature fluidity.

- Low sulfur content.

- Low carbon residue.

• Be sure to use extra-low-sulfur diesel fuel. Adding of or mixing with inferior fuel, water remover, other fuel additives, gasoline, heating oil, heavy oil or alcoholic fuel for use may cause a sliding failure of the fuel lubricating portions in the fuel filter and injector, and have harmful effects on each part of the engine which may result in an engine failure.

158

NOTE • The specifications of diesel fuel vary depending on the season and the region.

WARNING • Be sure to place the starter switch in the "OFF" position to shut down the engine before refueling the machine because refueling while the engine is running may cause a fire.

• When refueling, putting any flame nearby is strictly prohibited. Do not place a lighted cigarette or something similar nearby which may result in a fire.

• When refueling, take care not to spill the fuel. If any fuel is spilled, carefully wipe it away. Leaving as it is may cause the spilled fuel to be ignited, resulting in a fire.

Also, the cloths, papers, etc. used for wiping are easily ignitable. Dispose of them properly as flammable waste.

• When the fuel cap is not securely closed, the fuel may leak and cause a fire while driving.

CAUTION • When dust or water mixes into the fuel, this may lead to an engine failure or accident. When adding the fuel to the fuel tank, take care not to let dust or water enter in the tank. When refilling directly from a drum can out of necessity, particularly be cautious to prevent foreign matters from entering into the tank.

• Add sufficient amount of fuel to the fuel tank, and periodically open the drain plug located at the bottom part of the tank to remove the sediments (dust and moisture) deposited at the bottom.

6.2.4. DIESEL EXHAUST FLUID (DEF/AdBlue®) Use DEF/AdBlue® specified by Hidromek.

Use DEF/AdBlue® compliant with the following standards: JIS (Japanese Industrial Standards) K2247 standard defined for AUS 32, ISO (International Organization for Standardization) 22241 standard defined for AUS 32, the API (American Petroleum Institute) standards.

The mixing ratio is determined according to the temperature, however to get minimum protection, at least 30% per volume is needed. When mixing antifreeze into coolant, determine the mixing ratio considering the lowest temperature expected. Set the freezing point at 10º C lower than the expected lowest temperature. Check the mixing ratio of antifreeze solution with the Baumé scale.

The lowest temp.(˚C)

DEF/AdBlue® is a clear, colorless liquid. Do not use if there is color, as the DEF/AdBlue® may have deteriorated or been altered.

-15

-24

-35

Antifreeze

0,33

0,4

0,5

Water

0,77

0,6

0,5

Mixing volume (L) *

6.2.5. COOLANT WARNING Use distilled water in the radiator. Do not use water from a well, river, sea, or brackish and waste water otherwise the cooling system may be damaged.

If you add coolant to the system, use coolant in the same concentration with the coolant in the system.

When refilling coolant, flush out the system with distilled water.

Never mix different brands and different classes antifreeze. For example never mix standard life ethylene glycol antifreeze with extended life ethylene glycol antifreeze. If they are mixed, the protection level will be reduced.

Values given in the table are water and antifreeze volumes in 1 liter of coolant. Multiply the values with the coolant capacity of your machine to calculate the total amount of water and antifreeze.

Eg: For protection of 39 liters coolant to -24 C. Volume of antifreeze is 39 x 0,4 = 15,6 L and volume of water is 39 x 0,6 = 23,4 L.

Replace the engine coolant periodically. When only water is used as coolant, it can cause a serious damage in the cooling system because of lower freezing point, lower boiling point, and unfavorable corrosive properties. Therefore, add antifreeze when preparing coolant.

If it is not possible to have distilled water, the coolant water quality should comply with the following requirements.

Material

Amount

Total solids

340 ppm

Total hardness (maximum CaCO3)

170 ppm

Chloride

40 ppm

Sulfate

100 ppm

pH

6.5 - 8

159

6.3. PERIODIC PARTS

REPLACEMENT

OF

MAIN

To assure operational and working safety the user must perform maintenance of the machine and its components periodically as specified in the manual. Main parts and components listed in the following section must be replaced in their specified periods to secure max. safety and performance.

As the characteristics of these material deteriorate or the main parts wear out over time, it is hard to judge their condition just by periodical checks.

Therefore, they should be replaced with the new ones at specified intervals, even though there are no apparent extraordinary abnormalities.

However, whenever any abnormality is found, replace them immediately. Also when you are replacing the hoses, if any damage is found on the hose clamps, replace the clamps as well.

Regularly, check hydraulic oil hoses in addition to the periodical replaced pads, if any abnormality is found, tighten or replace them.

When replacing the hoses, also replace O-Rings and gaskets.

For replacement of main parts, HİDROMEK dealer service centers.

contact

Check the hydraulic oil hoses and fuel hoses periodically as follows: Description

Checking items

Before working

Leakage from connector of fuel, hydraulic oil hoses.

Monthly checking

Frequently checking

160

Leakage from connector of fuel, hydraulic oil hoses.

Damage of fuel hoses, hydraulic oil hoses (cracks, wear, falling-off).

Leakage from connector of fuel, hydraulic oil hoses. Blistering, twisting, aging, cracking and wear damage of fuel, and oil hoses.

6.4. INSPECTION AND MAINTENANCE LIST 10 h 50 h 250 h 500 h 1000 h 1500 h 2000 h daily weekly monthly 3months 6months annually

ISUZU Engine

Areas to be serviced Check engine oil level and contamination

●

Check oil leak

●

"Engine oil pressure is low" warning light

●

Oil pressure warning light

●

Check fuel leak

●

Drain sediment and water from fuel filters

●

Check coolant level Check abnormal discoloration contamination of coolant Check coolant leak

● and

● ●

Radiator cap installation condition

●

Inspect the fan belt. Replace if necessary.

●

Inspect using coolant temperature gauge or instrument panel (75 ~ 90°C)

●

Clean the intercooler and radiator exterior

●

Inspect the cooling system and perform maintenance

●

Inspect the functionality of radiator cap



Engine startability and abnormal noises

●

Check exhaust color

●

Inspect the engine failures from instrument panel

●

●

(1)

Replace fuel filter elements

●

(2)

Change engine oil

●

(3)

Change engine oil filter

●

(3)

Inspect and clean the supply pump strainer

●

(2)

Clean electromagnetic pump filter

●

(2)

Check and adjust engine valve clearance



Measure the compression pressure



PCV blow-by oil separator inspection

PCV blow-by oil separator filter replacement Inspecting and cleaning the injector Inspect and clean the EGR valve

●

Inspect and clean the EGR cooler

●

Inspecting and replacing the fuel pipe and coolant pipe Inspect the turbocharger (if necessary clean the blower)

Hydraulic System

Notes

●

Check hydraulic tank level

●

Clean the breather of hydraulic tank

●

Change return filter element

■

●

Change pilot filter element

■

●

 (Every 2500 hours) (4JJ1 engine only)  (Every 2500 hours) (4JJ1 engine only)  (Every 4500 hours)  (Every 4500 hours)  (Every 4500 hours)  (Every 24 months)  (Every 4500 hours)

161

Areas to be serviced

10 h 50 h 250 h 500 h 1000 h 1500 h 2000 h daily weekly monthly 3months 6months annually

Hydraulic breaker return line filter element

Replace filter every 250 hydraulic breaker operating hours (4) ●

Clean suction filter element Replace hydraulic oil

Upper Frame Lower Frame Attachment Electrical Cooling System

● ●

(4)



(5)

●

Change the filter of hydraulic tank breather Hydraulic hoses & assemblies

●

Walk around / visual inspection

●

Check fuel level

●

Grease swing gear bearing

●

Remove sediment from fuel tank

●

Grease swing unit reduction gear

■

Replace swing unit reduction gear oil

■

Check and if necessary grease swing ring gear

●

Walk around / visual inspection

●

Check tires for correct pressure and damage

●

Grease dozer blade pins

●

Grease outrigger pins

●

Grease front axle pin

●

● ●

Replace front and rear axle differential oil

■

●

Replace front and rear axle planetary gear oil

■

●

Replace transmission oil

■

●

Check front and rear axle differential oil level

●

Check front and rear axle planetary gear oil level

●

Grease steering joint and axle joint housing

●

Grease front / rear shaft

●

Walk around / visual inspection

●

Grease attachment pins Check shim clearance and adjust if necessary

●

Check and if necessary change bucket teeth

●

Walk around / visual inspection

●

Check electric wire

●

Check battery electrolyte level

Notes

(6)

●

Check antifreeze density

●

Check and clean cooling units fin

●

Clean cooling system Change Long Life Coolant every 2 years (7) Replace coolant

162

Areas to be serviced

10 h 50 h 250 h 500 h 1000 h 1500 h 2000 h daily weekly monthly 3months 6months annually

Check brakes

● ■

Other

Change braking system filter

●

Adjust tension of air condition belt

●

Check air condition refrigerant

●

Inspect the air filter case against cracking and replace it if necessary

Notes

●

Replace air filter outer element

●

(8)

Replace air filter inner element

●

(8)

Replace air conditioner internal and external filters

●: Routine inspection and maintenance ■: First inspection and maintenance : Contact Authorized HIDROMEK Service (1): See "Chapter 5. Troubleshooting".

(2): Replacement interval may change depending on fuel consumption and fuel quality.

(3): Replacement interval may change depending on engine oil type and fuel quality. See Chapter 6.2. "Oil, Fuel, Coolant And Diesel Exhaust Fluid" for more information.

(4): The use of hydraulic breaker decreases hydraulic oil replacement interval. In this case, replace the hydraulic oil every 1000 hours and hydraulic return filter every 500 hours of operation.

For more information about oil and filter life refer to chapter "8.7.3. Hydraulic Breaker".

Replace the hydraulic breaker return filter according to hydraulic breaker operating hours.

(5): Hose assemblies will eventually age, harden, wear and deteriorate under thermal cycling and compression set. Periodically inspect, at intervals not exceeding 4 years, all hose assemblies for damage, crack, flattening, blistering and crushing.

Replace if any of the above-mentioned is found.

●

(9)

(6): If the machine works in water or mud, do not wait for the given periodic maintenance schedule time and refill new grease to the submerged parts in a shorter period of time. Grease attachments like bucket pins and remove the old grease completely.

(7): See Chapter 6.2. "Oil, Fuel, Coolant And Diesel Exhaust Fluid" for coolant properties.

(8): Replace the air filter outer element when the "air cleaner clogged" indicator comes on the instrument panel.

(9): Shorten the inspection / cleaning and replacement intervals to 250 hours if the machine is used particularly in a dusty environment.

IMPORTANT The inspection and maintenance list is provided only for normal operating conditions. It may be necessary to change the inspection and maintenance interval depending on operator and operating conditions including excessive dust, water, humidity and temperature. Please read maintenance suggestions for specific operating conditions given in this manual and consult your Hidromek dealer.

WARNING The hydraulic hoses bear extreme pressure. Any minor defect may cause hydraulic oil to eject in streams and cause heavy injury. In such a case, immediately consult your doctor.

163

6.5. EVERY 10 HOURS (BEFORE STARTING) 6.5.1. WALK-AROUND INSPECTION (VISUAL INSPECTION) Before starting the engine, visually check bolts and nuts for tightness, oil, fuel or coolant circuits for leakage, damaged lines, and loose connections, and check attachment or hydraulic system for abnormality.

WARNING Dust around the engine and leakage of oil or fuel may cause fire. Keep the parts clean. Check thoroughly, if any abnormality is found, be sure to repair them. If it is impossible, contact the authorized HIDROMEK dealer.

Inspect for the following items before starting the engine every day: 1. Inspect components that showed abnormalities during previous operation.

2. Check battery fluid level. Looseness and corrosion in terminal section of battery.

3. Check engine oil level and contamination.

4. Check coolant level.

5. Remove water from fuel. Drain the water in fuel filter water separators.

6. Inspect of presence or absence of engine failure indication.

7. Check fan belt tension and damage.

8. Check the attachments, cylinders, and hoses for damage, wear and clearance. If any abnormality is found, repair them.

9. Check for dust around the engine and radiator.

If any abnormality exists, remove dust from the engine and the radiator.

10. Check for coolant and oil leakages while the engine is running. Repair if any abnormality exists.

11. Check for leakage in the hydraulic system, hydraulic tank and hose connections. If any abnormality exists, repair the parts.

12. Check the undercarriage for damage, wear, looseness of bolts and leakage. If any abnormality exists, repair it. Check pressure of tires and inflate them to proper value.

13. Check the guardrails and steps for damage and bolts for tightness. If there is any damage, repair them and fasten the bolts.

14. Check the gauges and monitor for damage and bolts for tightness. Check the gauges and instrument panel in the operator’s cab for damage, if any abnormality exists, replace it.

Keep the surface of them clean.

15. Check rear view mirrors and replace if there is any damage. Keep the surface of the mirrors clean and adjust the angle for the best view.

16. Check for the seat belts and its mounting hardware, replace them if damaged.

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6.5.2. INSPECTING ENGINE STARTABILITY AND ABNORMAL NOISE Operate the starter switch to start the engine. At this time, confirm that the engine is started quickly and also there is no abnormal noise.

6.5.3. INSPECTING CONDITION OF THE ENGINE AT LOW SPEEDS AND DURING ACCELERATION 1. Operate the starter switch to start the engine, and warm up the engine.

2. Confirm that the engine is running smoothly at the idling speed within the range of normal idling speeds.

However, the following condition should be excluded.

When the coolant temperature is low.

3. Confirm that the engine speed increases smoothly and there is no knocking when accelerating gradually by operating the accelerator. *: Inspection items that should be performed at an appropriate period determined based on the operation hours, driving conditions, etc. are indicated.

6.5.4. COOLANT LEVEL CHECK Coolant reservoir tank has its own cover on the engine hood. It could be reached by opening the cover with its key.

NOTES Stop the engine before checking the coolant level and wait until it cools down. Coolant expands with temperature thus when the engine is hot, coolant level seems to be higher.

WARNING Do not perform any maintenance while the engine is running. Right after operating the engine, the coolant is very hot. Never open the radiator cap immediately after shut-down. Wait until it cools down, and then open the cap slowly to release the internal pressure. Hot vapor or boiling water may burst out and cause a burn. When removing the cap of the radiator or reserve tank, use a thick cloth to cover the cap and loosen it gradually.

If the coolant level is abnormally low, there may be a leakage in the system. In this case, contact Hidromek Authorized Service and get checked the cooling system.

CORRECT

Inspect the radiator and radiator hose for a crack, damage and water leakage. Also, check whether a stain of water leakage is left on the ground surface where the machine is set. When a crack, damage or water leakage is found, contact a Hidromek Authorized Service.

INCORRECT

WARNING Use without fixing the water leakage can cause engine seizure.

Use specified amount of antifreeze-water mixture as coolant in all seasons.

Check the coolant level in the reservoir tank after the engine is cooled down. Fill the coolant reservoir tank to the maximum level.

When an overheating problem occurs in your engine, refer to the Chapter "Troubleshooting" before adding coolant to the system.

WARNING The coolant is toxic and must not be ingested. If the coolant is mistakenly ingested, immediately vomit it and seek prompt medical attention.

When the coolant gets in your eyes, rinse it off immediately with a large amount of water for 15 minutes or longer. Also, if still an abnormality such as irritation is felt, seek medical attention.

When the coolant gets on your skin, rinse it off using a soap with a large amount of water. Also, if an abnormality is observed, seek medical attention.

The coolant is flammable. Keep flames away from it. Also, the coolant could catch fire if it comes in contact with a hot surface, such as the exhaust manifold. Pay attention to prevent this from happening.

Coolant reservoir cover

Coolant reservoir cap

Coolant gauge

Coolant and water specifications, mixing ratios Refer to  Chapter 6.2 "Oil, Fuel, Coolant and Diesel Exhaust Fluid”.

filling

level

165

6.5.5. CHECKING ENGINE OIL LEVEL CAUTION When the engine oil level is above the "FULL" mark of the oil level gauge, it may cause an engine failure.

NOTE Perform inspection on a level surface before starting the engine.

Oil level cannot be measured accurately while the engine is running.

When the engine has been running, wait for 10 20 minutes after stopping the engine and then check the oil level.

1. Pull out the oil level gauge and wipe off the attached oil.

2. Reinsert the oil level gauge fully and then gently pull it out. When the oil level is between the "FULL" and "ADD" marks, the oil level is appropriate.

At this time, also check for oil contamination and stickiness.

1. Oil level gauge Isuzu 4HK1

3. If the oil level is insufficient, add the oil up to the "FULL" mark.

4. Reinstall the oil level gauge after checking the oil level.

CAUTION When inserting the oil level gauge, be careful not to bend it. Otherwise, the oil level gauge may be deformed.

Take care not to use excessive force when inserting the oil level gauge. If the oil level gauge is long, do not hold the grip and try to forcefully insert, but instead hold an area around the guide tube to insert.

CAUTION Insert the oil level gauge until the grip part touches the guide tube. A gap between them may let water enter the engine causing a malfunction.

A. Grip part B. Guide tube C. Gap

166

Engine oil  Refer to Chapter 6.2.

6.5.5.1. FILLING ENGINE OIL WARNING When filling oil, pay attention not to spill it. If you spill oil on engine or equipment, wipe it properly.

This could lead to fire and a personal injury and / or equipment damage.

Do not leave a flammable item such as a cloth or cotton work glove on the engine. Such items may trigger a fire.

CAUTION Prevent dirt from entering the engine oil filler port when adding oil. If foreign matter mixes with the oil, it could damage the engine.

2. Oil filling cap CAUTION When the oil is added rapidly through a funnel attached to the filler port, the oil inside the head cover may overflow from the breather. Add the oil gently.

When the oil is added as much as exceeding the "FULL" position, this may cause an engine malfunction. Wait for 10 - 20 minutes after the oil is added, and make sure to check the oil level using the oil level gauge.

Isuzu 4HK1

CAUTION Be careful not to spill engine oil onto the fan belt during refilling, as doing so may damage the fan belt or cause accidents.

When the engine oil level is less than "FULL" mark, remove the supply inlet oil filling cap, pull out the oil level gauge, and add engine oil up to "FULL" mark.

After adding the oil, securely install the oil filling cap and the oil level gauge.

167

6.5.6. FUEL LEVEL CHECK WARNING Add fuel or oil in a well-ventilated area.

Before adding fuel or oil, stop the engine, keep away all sources of fire and do not smoke.

Wipe up spilled fuel or oil immediately.

Tighten the caps on containers for fuel or oil securely.

1. Get in the operator's cab.

2. Insert the key to starter switch.

3. Turn on the starter switch.

4. After the instrument panel turns on, check the fuel level gauge on the instrument panel main screen.

IMPORTANT If breather holes of fuel tank cap are clogged, it prevents fuel flow to engine. Clean holes periodically.

Keep your fuel tanks full after the operation. A full tank minimizes the condensation of water.

5. Use the fuel transfer pump, located in the tool box, to add fuel.

Refer to "Chapter 6.15.1. Filling Fuel (Fuel Transfer Pump)" for more information about fuel filling procedure.

168

6.5.7. HYDRAULIC OIL LEVEL CHECK WARNING Add fuel or oil in a well-ventilated area.

Before adding fuel or oil, stop the engine, keep away all sources of fire and do not smoke..

Wipe up spilled fuel or oil immediately.

Tighten the caps on containers for fuel or oil securely.

Figure. Pump door

1. Park the machine on a hard and level ground.

2. Position the machine as follows to check hydraulic oil level: 

Extend the bucket cylinder completely, and retract the arm cylinder completely.



Lower the boom to the ground completely.



Stop the engine.



Turn starter switch to ON position.



Move the left and right control levers in full course in all directions to relieve internal pressure in hydraulic circuits.

3. Open the pump door located at the right hand side of the machine. Hydraulic oil level gauge is located on the front wall of pump compartment.

Check the hydraulic oil level through the gauge. 

If the oil level is in the center of the gauge, it is correct.



If the level is low, open the cover of the hydraulic tank and add hydraulic oil.



Hydraulic oil  Refer to "Chapter 6.2. Oil, Fuel, Coolant and Diesel Exhaust Fluid".

IMPORTANT Be careful not to refill the hydraulic oil above the correct level. If the current oil level exceeds the required oil level, the hydraulic oil may overflow or cause damage to the hydraulic circuit.

Figure. Position of hydraulic oil level gauge

Figure. Correct hydraulic oil level

Figure. Position of hydraulic oil tank

169

6.5.8. ELECTRIC WIRE CHECK WARNING If the fuses are repeatedly blown or the traces of short circuit are found, find the cause and repair it.

Check the fuses or electric wires for damaged or short circuit. Check the terminals for looseness.

Tighten the loosened terminal securely. Especially, inspect the wiring to and from the following components:   

6.5.10. CHECKING AND CHANGING THE BUCKET TEETH Change the bucket teeth before the adaptors wear away.

When changing the bucket teeth, always lower the bucket to the ground, position it to the safest posture for working, stop the engine and lock the safety locking system securely.

Place a block under the bucket, then lower the bucket keeping it horizontal. Stop the engine and lock the safety locking system.

Battery Start motor Alternator

Contact Hidromek Authorized Dealer or Service station in case of a problem.

6.5.9. CLEANING THE FILTER OF HYDRAULIC TANK BREATHER In dusty working environments, the dust will be collected around the hydraulic tank breather.

Clean the surrounding of the hydraulic tank breather regularly so air flow of the hydraulic tank will not be blocked.

WARNING Before removing locking pins, always wear eye protection!

Drive out pin (2) using a hammer and punch. Be careful not to damage the lock washer (3). Use a round bar with a smaller diameter than the pin as a punch.

Clean the surface of adapter (4), insert a new lock washer (3) in the correct place, and install a new tooth (1).

Drive pin (2) into the pin groove, through lock washer (3) until the pin is flush with the teeth.

170

6.5.11. FAN BELT Fan belt has the function of transferring the engine rotational force to the auxiliary equipment and enabling operation of each mechanism.

When replacing the fan belt, it is recommended to use the "Hidromek genuine parts".

If a low quality and unapproved belt is used, it may cause problems like abnormal engine noise, halt of the engine unexpectedly and insufficient battery charging because of rapid belt wear or belt rupture.

Too loose or too tight V-belts will cause problems like a squeaking noise, engine overheating, insufficient battery charging, alternator malfunction and water pump malfunction. The tension of the belts must be adjusted correctly.

WARNING Before performing any controls, check if the engine is stopped. Otherwise your hands, clothes, hair or feet may be caught in the rotating parts or linkages of the engine and it may result in a serious damage or even death.

If any of the V-belts is found to be damaged, have it replaced immediately at your HIDROMEK Authorized Service or Dealer. Damaged belts are detrimental to the engine, especially when they are broken.

Keep the V-belts free of oil and grease. Contact with these substances can cause the belts to slip and may shorten their service life.

When replacement is necessary, replace both Vbelts at the same time.

CAUTION If the fan belt is too tight, the alternator bearings may be damaged, causing an engine failure or an accident.

If the fan belt is too loose, it may slip or be damaged which will cause abnormal noises and vibrations, overheating, or charging failures those may result in an engine failure or an accident.

6.5.11.1. CHECKING FAN BELT TENSION Follow the procedure below to inspect the fan belt: 1) Press the center of the belt (between the alternator pulley and idle pulley) with a force of 98 N (approx. 10 kgf) and measure the maximum deflection. If the belt tension is correct maximum deflection should be in accordance with the table below: Engine

Max. deflection

Isuzu 4HK1

6 - 8 mm

Isuzu 4HK1

Vibration frequency 210 Hz

2) Inspect the belts. If necessary re-adjust the tightness. Replace them if any damage is found.

WARNING For safety, before inspecting fan belt, make sure that the engine is stopped and is not going to be operated during the inspection. Remove the starter key from the machine. Hang a "DO NOT OPERATE" sign on the front panel of the operator's cab.

171

6.5.11.2. ADJUSTING FAN BELT TENSION Adjust fan belt tension when the belt slackness is greater than specified amount and when the belts are replaced. Belt tension adjustment is made by pivoting the alternator on the alternator mounting bolt.

1. Loosen mounting bolt (1) of alternator and the locknuts (3).

2. Adjust the belt tension with adjusting bolts (2) of the alternator and secure the alternator within specified range.

3. Tighten the loosened mounting bolt (1) and the locknuts (3) securely.

Tightening torques Engine

Locknut

Mounting bolt

Isuzu 4HK1

76 Nm (7.7 kgfm)

127 Nm (12.9 kgfm)

4. After the adjustment, operate the engine 5 minutes at low idle speed and recheck the belt tension. If necessary re-adjust the belt tension.

CAUTION Belt tension may vary slightly after the alternator is fixed. Therefore, recheck the belt tension after tightening the bolts.

CAUTION If any belt is found cracked or damaged as a result of inspection, it must be replaced as soon as possible. Have the replacement done by your dealer as it involves disassembly of the engine.

CAUTION Initial stretching takes place in any new belt after installation. Also, to fit the belt well in the pulley groove, adjust the belt following the adjustment procedure below regardless of new installation or tension adjustment.

Adjust the belt alignment and belt tension in accordance with the specified procedure.

Start the engine and allow it to idle for at least 5 minutes in order to run-in the belt.

Stop the engine, and again adjust the belt tension to the standard value.

172

1. Lock nut 2. Adjusting bolt 3. Mounting bolt Isuzu 4HK1

6.5.12. GREASING ATTACHMENT PINS 1) In manual refilling, lower the attachment to the ground as illustrated, and stop the engine.

2) Refill the grease through the grease fittings using a hand or power grease gun.

3) After refilling grease, clean off the overflow grease.

(8) Connecting pin of arm and bucket (2 points) (9) Connecting pin of arm and link (2 Points)

CAUTION If the machine has worked in water, immediately refill new grease to the submerged parts like the bucket pins to remove the old grease, regardless of the grease refilling cycle time after the work.

(1) Boom cylinder mounting pin (2 points)

(10) Connecting pin of connecting rod and link (2 points) (11) Bucket cylinder rod end pin (1 point) (12) Connecting pin of bucket and connecting rod (1 point)

(2) Boom mounting pin (3 points) (3) Boom cylinder rod end pin (2 points) (4) Arm cylinder mounting pin (1 point)

(5) Connecting pin of boom and arm (2 points) (6) Arm cylinder rod end pin (1 point) (7) Bucket cylinder mounting pin (1 point)

If machine is equipped with optional automatic greasing system, points shown in figure below will be greased automatically:

173

6.5.13. CHECK TIRES FOR PRESSURE AND DAMAGE

CORRECT

Check all tires to make sure that they are properly inflated and are not damaged. Make sure that all excess mud, stone, etc. has been removed from the tires.

6.5.14. CHECK THE BRAKE Always check service brake performance before starting.

Emergency Braking: At a service brake failure, the braking effect of the hydrostatic drive is also additionally acting. This braking is not adjustable and cannot be influenced by the operator.

BRAKE SYSTEM TEST PROCEDURE • Start the engine and select power mode “P”.

• Run the engine for about 5-10 minutes to warmup and stop the engine.

• Turn the ignition key to “ON” position without starting engine.

• "Brake pressure low" warning light must not come ON. In this mode press the brake pedal fully and release. Repeat the process several times with some waiting periods between pedal operations.

Pedal must be pressed at least 3 times before the "brake pressure low" warning light comes ON. If not, the accumulator may be faulty. Do not move the machine and call Hidromek Authorized Service for help.

WARNING Do not operate a machine whose brakes are faulty.

All maintenance and repair works on the brake system must be performed only by an authorized Hidromek service.

174

6.5.15. DRAINING SEDIMENT AND WATER FROM FUEL FILTERS Three kinds of fuel filter are mounted on the machine.

A. Main fuel filter B. Fuel pre-filter C. Primary fuel pre-filter All filters have a water separation feature. Drain contents of filters before level rings reach the lower part of filter elements.

CAUTION The water separator contains fuel in addition.

When draining the contents of the water separator, wipe up any fuel that splashes on the surrounding area. If not cleaned adequately, it could cause a fire.

WARNING The water separator contains fuel in addition.

When draining the contents of the water separator, wipe up any fuel that splashes on the surrounding area. If not cleaned adequately, it could cause a fire.

DRAINING WATER FROM THE MAIN AND THE PRE-FILTERS 1. Place a tray below pre-filter.

2. Loosen the air bleeder plug and the drain plug.

3. Drain water and sediments until the level ring touches bottom of the case.

4. Tighten the air bleeder plug and the drain plug.

5. In cold weather water may be frozen. Wait until ice melts, then drain the water.

6. Check if there is any leakage and repair it.

Air bleeder plug tightening torque / ISUZU 7.9 to 11.7 Nm (0.8 to 1.2 kgfm) WARNING The entry of air into the fuel system will cause engine starting difficult or engine malfunction. After each servicing such as draining fuel tank, fuel filters, changing filter elements, be sure to conduct air bleeding procedure as told in chapter "6.15.7.

Bleeding Fuel System".

175

6.6. EVERY 50 HOURS (WEEKLY SERVICE) Perform the 10-hours maintenance before starting this maintenance.

6.6.1. GREASING SWING GEAR BEARING (3 POINT) 1. Lower the work attachments to the ground.

2. Pump new grease 1 or 2 times through the grease nipple using a hand power grease gun.

3. After refilling the grease, wipe off the overflow grease completely.

NOTE Do not pump to much grease.

The dust seals are not capable to hold grease under pressure.

WARNING Swing only when no one is in the swinging zone.

IMPORTANT Gearing and bearings of the swing ring must be inspected and re-greased at shorter intervals compared to those specified in the servicing plan under the following conditions :  Excessive temperature  High moisture levels  Exposure to dust and dirt  Marked temperature fluctuations  Continuous swinging 6.6.2. REMOVING SEDIMENT FROM THE FUEL TANK 1) Perform it before starting the machine.

2) Put a container under the drain hose (2).

3) Open drain valve (1) and remove the sediment from the fuel tank. Be careful not to be soaked with the drained fuel.

4) As fuel without water starts to pour out, close drain valve (1) tightly.

IMPORTANT When cleaning the fuel tank, never trichloroethylene.

use

1. Drain valve 2. Drain hose

176

6.6.3. GREASING DOZER BLADE PINS (12 POINTS) Check grease filling of dozer blade pins, determined in the following, if necessary renew.

Dozer Cylinder Pins (4 point) Dozer Upper Connection Pins (4 point) Dozer Lower Connection Pins (4 point)

6.6.4. GREASING OUTRIGGER PINS (8 POINTS) Check grease filling of outrigger pins, determined in the following, if necessary renew.

Outrigger Cylinder Pins (4 point) Outrigger Joint Pins (4 point)

6.6.5. GREASING FRONT AXLE PIN (1 POINT) Check grease filling of front axle pin (A), if necessary renew.

177

6.7. FIRST 250 HOURS Perform the 10, 50-hours maintenances before starting this maintenance.

6.7.1. REPLACING RETURN FILTER ELEMENT OF HYDRAULIC OIL WARNING Before removing cover (3), release the internal pressure of the tank.

1) Release the internal pressure of the tank through air bleeder (1).

2) Loosen the bolts (2) (6 pieces) and remove cover (3). Be careful, since the cover is preloaded by spring (4).

3) Remove O-Ring (5), spring (4) and bypass valve (6), and then pull out element (7).

4) Check and clean the dismantled parts thoroughly.

Replace them if they are worn or damaged.

5) Install a new filter element (7).

6) Install bypass valve (6), spring (4) and O-ring (5).

7) When mounting cover (3), fasten the bolts while pressing the cover.

WARNING If the O-ring (5) is damaged, replace it with a new one.

8) Install the cover.

6.7.2. CHANGING PILOT FILTER ELEMENT

9) To bleed the air, See Chapter 6.15.8. Bleeding Hydraulic System”. Start the engine and run it at low idle speed for 10 minutes.

Place a container under the filter, remove the filter bowl, and replace the inner element.

10) Stop the engine.

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6.7.3. GREASING GEAR

SWING

UNIT

REDUCTION

Park the machine on a firm, level ground, lower the front attachment and stop the engine.

Remove the air drain cap (1) and inject proper amount of grease into the grease feed port (2) by using grease gun.

Reassemble the air drain cap (1). In case of refilling grease without removing the air drain cap, the oil seal may be damaged by internal pressure. It is necessary to refill grease only after removing the air drain cap.

6.7.4. REPLACING SWING UNIT REDUCTION GEAR OIL WARNING Immediately after operating the machine, the oil is hot. Allow the oil to cool.

Prepare a container with enough capacity to collect the drained oil.

Dismantle the main control valve cover mounted on the upper frame.

Put the container under the drain plug (3) of swing driving case to collect the drained oil.

Remove the drain plug (3). After draining the oil, install plug.

Withdraw the oil level gauge (1), and refill the oil to the proper level through the oil feed hole (2).

Oil specification  Refer to Chapter 6.2. "Oil, Fuel, Coolant And Diesel Exhaust Fluid".

Withdraw the oil level gauge, and wipe it with a clean cloth. Insert the oil level gauge again to check the level.

If oil level is on the 2/3 of the gauge (1), it’s normal.

If the oil is below the proper level, refill the oil to the proper level.

If the oil is above the proper level, loosen the drain plug (3), and drain the oil to adjust to the proper level. Then fasten the drain plug (3) and check the oil level again.

Correct Level Correct Level

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6.7.5. REPLACING FRONT AND REAR AXLE DIFFERENTIAL OIL 

Park the machine on a hard and level ground.



Lower the attachment on the ground.



Stop the engine. Remove the starter key.



Clean dust around the plugs.



Place a suitable container under the drain plug.



Remove the oil filling plug (A), then remove the oil drain plug (B).



Completely drain the oil.



Install the drain plug with a new O-ring and tighten it with a torque of 50 Nm.



Fill oil to the proper level.

For recommended oil specifications refer to Chapter 6.2. Oil, Fuel, Coolant And Diesel Exhaust Fluid.

A. Oil filling / check plug B. Drain plug Figure. Front axle

A. Oil filling / check plug B. Drain plug Figure. Rear axle



Install the filling plug with a new O-ring and tighten it to a torque of 50 Nm.



Check oil level after some minutes and fill up to the specified level, until level remains constant.

6.7.6. REPLACING FRONT AND REAR AXLE PLANETARY GEAR OIL 

Park the machine on a hard and level ground.



Lower the attachment on the ground.



Stop the engine. Remove the starter key.

C. Oil drain/filling plug



Clean dust around the plug (C).

Figure. Front axle



Turn tire, until plug completely comes to the lower position.



Open plug and drain the oil completely.



Rotate tire 90° and adjust the drain/filling hole horizontally to the ground.



Pour oil into wheel hub until oil overflows from the hole.

For recommended oils refer to Chapter 6.2. Oil, Fuel, Coolant And Diesel Exhaust Fluid.



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Install the plug (C) with a new O-ring and tighten it to a torque of 50 Nm.

C. Oil drain/filling plug Figure. Rear axle

6.7.7. REPLACING TRANSMISSION OIL The oil change must be carried out as follows: 

Park the machine on a hard and level ground.



Lower the attachment on the ground.



Stop the engine. Remove the starter key.



At operating temperature of the transmission and horizontally standing vehicle, open the oil drain plug (F) with O-Ring and drain the used oil.



Clean oil drain plug and sealing surface on the housing and install it again along with new ORing.



Loosen oil filling plug and clean sealing surface on the housing.



Fill in oil. For recommended oils refer to Chapter 6.2. Oil, Fuel, Coolant And Diesel Exhaust Fluid.



Check oil level after about 2 minutes and replenish oil once again if necessary.



Install oil filling plug (E) with new O-Ring and screw it in.



At the initial filling and after repairs has to be considered that some cavities are not yet filled with oil. Due to these cavities, the oil capacity to be filled in at the initial filling is greater than at the later oil changes during the maintenance service, so that the oil level must be checked once again after a driving time of approx. 5 min.



A deviation of ± 3 mm to the oil level plug is permitted.

E. Oil filling plug F. Oil drain plug

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6.8. EVERY 250 HOURS (MONTHLY SERVICE)

DRAINING SWING RING GEAR GREASE

Perform the every 10 hours and every 50 hours maintenances before starting this maintenance.

6.8.1. CHECKING SWING RING GEAR GREASE WARNING Lower the bucket to the ground to drain the grease at the easiest position, and lock the safety locking system.

1) After starting the engine, swing the upper frame, and lower the attachment to the ground; stop the engine, and lock the safety locking system.

WARNING Swing only when no one is in the swinging area.

2) Loosen two bolts and remove the grease filling cover.

1) Put a container under the grease drain port, located below the fill port, loosen two bolts and remove the cover to drain all the grease.

2) Be careful not to be soaked with the drained grease.

3) After the grease is completely drained, install cover.

Prepare a container with enough capacity before draining the grease.

FILLING SWING RING GEAR GREASE

3) Check gearing and pinion for damage.

4) Check grease filling:  All tooth faces must be covered with a thin grease film.  If the grease film is not ok add 0.5 kg grease.  If the grease looks contaminated or contains water or mud then drain grease and replace with new grease.

1) Loosen the two bolts of the grease feed port in front of upper frame, remove the cover, and refill the proper amount of grease.

2) Install the feed port cover.

IMPORTANT Gearing and bearings of the swing ring must be inspected and re-greased at shorter intervals than specified in the servicing plan in the event of:  Excessive heat  High moisture levels  Exposure to dust and dirt  Marked temperature fluctuations  Continuous swinging

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6.8.2. CHECKING LEVEL

BATTERY

ELECTROLYTE

Check level before starting the machine.

WARNING Battery gas (hydrogen) is flammable. Do not expose to sources of fire such as open flame, cigarettes, or sparks.

If battery electrolyte is splashed onto clothes or skin immediately flush with clean water.

If battery electrolyte is splashed onto eyes, flush with large amounts of clean water and consult a doctor.

Open the cover of the battery box at right side of the machine.

Loosen cap (1). If the level of electrolyte is below the specified level (above 10-12 mm from the plate), refill to the proper level.

Clean the ventilators of battery caps, and tighten it securely.  To prevent the battery from freezing, add distilled water at the beginning of the day’s work and ensure the charging system is fully operational.

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6.9. EVERY 250 HOURS HYDRAULIC BREAKER HOURS 6.9.1. CHANGING HYDRAULIC BREAKER RETURN LINE FILTER 1) Stop the engine.

2) Release the trapped hydraulic pressure from the hydraulic tank breather.

3) Place a container with enough capacity.

4) Remove oil drain plug.

5) Rotate and remove the filter element with span.

6) Before installing the new filter element, replace the old O-rings and gaskets with new ones.

7) Install the new element.

1. Filter element 2. Plug 3. Filter repair kit 3.1 O-ring 3.2 Thrust ring 3.3 O-ring 3.4 Gasket 3.5 O-ring 3.6 Oil drain plug

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6.10. EVERY 500 HOURS (3 - MONTH SERVICE) Perform the 10, 50 and 250 hour maintenance before starting this maintenance.

6.10.1. CHANGING FUEL FILTER ELEMENTS WARNING Keep away from open flames.

After replacing the filter element, wipe up any spilled fuel. Also, make sure there is no fuel leakage from the filter. Leaking fuel will cause fire.

To avoid damaging the element, be careful not to over tighten the element assembly.

CAUTION The fuel filter element may be clogged faster depending on the amount of dust particles in the fuel. Therefore, the element may need to be changed much earlier than 500 hours. If the low engine output or engine stall failure is encountered, changing fuel filter element may solve the problem.

CAUTION Figure shows the valve positions for engine operation. When any fuel filter replacement is to be done, pay attention to valve positions explained in the procedure below.

Figure. HMK 210W filter assembly Condition of Valves Activity situation Engine in operation

Valve 1

Valve 2

Valve 3

OPEN

OPEN

CLOSED

While changing filters

CLOSED

CLOSED

CLOSED

While bleeding the air

OPEN

CLOSED

CLOSED

While flushing the fuel line

OPEN

CLOSED

OPEN

While replacing the fuel filters, fuel line cleaning system protects the fuel line system from contamination. During the fuel filter replacement, follow the steps given below: 1. Park the machine in a suitable place complying with the safety rules.

2. Turn starter key to the “OFF” position.

3. Close Valve 1 (coming from the fuel tank). And Valve 2 (feeding the engine) 4. Place a suitable container under the filters and under the main filter drain hose in order to avoid spillage.

5. Replace the fuel filter elements with the new ones.

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6. Open Valve 1 (coming from the fuel tank).

1. Air bleeding plug 2. Filter body 3. Filter element 4. Float 5. O-ring 6. Element case 7. O-ring 8. Drain plug

7. Open the Air Bleeding Plug on the main fuel filter.

Turn the key starter switch to the "ON" position. Fuel transfer pump starts operating. Meanwhile, turn the handle of the hand pump to unlock it and manipulate the hand pump to speed up bleeding the air out.

Continue the process until bubble free fuel comes out from the drain hose. Turn the key starter switch to the "OFF" position and tighten the Air Bleeding Plug. Take the handle of the hand pump back to its original place and fix it.

NOTE If bleeding process does not complete in 5 minutes, do not keep the starter key at “ON” position. Otherwise the pump can be damaged.

Take the starter key to “OFF” position.

8. Open valve 3 (flowing towards to the fuel tank), turn the key starter switch to the "ON" position and re-operate the fuel transfer pump. Let the fuel transfer pump run for 30 seconds, so contaminants can be filtered. After 30 seconds is over, turn the key starter switch to the "OFF" position.

9. Then open Valve 2 (feeding the engine) and close Valve 3 (flowing towards the fuel tank).

10. Finally, be sure that the positions of the valves are as given below Valve 1 (coming from the fuel tank): OPEN Valve 2 (feeding the engine): OPEN Valve 3 (flowing towards the fuel tank): CLOSED 11. Start the engine, and check If there is any fuel leakage.

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Figure. Fuel Filter Assembly

6.10.2. REPLACING ENGINE OIL AND OIL FILTER The engine oil provides engine cooling and flushes out the filth inside the engine. The engine oil has a significant impact on the performance and service life of the engine and fuel economy, so only use recommended oil in your engine.

Check if there is any oil leakage around the oil filter or the drain plug.

1. One-touch type drain plug (Isuzu 4HK1) CAUTION Do not perform abrupt engine idling, which may cause an engine failure.

2. Oil filling cap Isuzu 4HK1 1. Clean around the oil filling cap so that foreign matter does not enter into the engine. Remove the oil filling cap.

2. Place a container under the drain plug and the oil filter.

3. Loosen the cap of the oil drain plug to remove it.

Tightly attach the oil drain hose to the oil drain plug all the way to the end to drain the oil.

4. When the oil is completely drained out, disconnect the oil drain hose, and wipe off the oil attached to the drain plug.

5. Securely tighten the cap of the oil drain plug.

(Tighten the cap lightly until it is seated, and then tighten it further for approx. 60° - 90°) CAUTION Make sure to wipe off any dirt on the drain plug before installing it.

1. Oil level gauge

8. Stop the engine. Wait for 20 to 30 minutes and then re-check the engine oil level using the oil level gauge.

WARNING During inspection and service, injuries may occur due to hot engine body, coolant or engine oil. For safety, conduct service work after the engine is stopped and cools down sufficiently.

It is very dangerous to inspect and service the rotating parts. For safety, conduct service work after the engine is stopped. Also, make sure that it does not start during work.

Periodically replacing engine oil and engine oil filter will affect the performance and the service life of the engine.

For oil specifications refer to "Chapter 6.2. Oil, Fuel, Coolant and Diesel Exhaust Fluid Chapter".

When the oil filter is clogged, “FILTER CLOGGED 1” warning is indicated on the instrument panel. In such a case, replace the filter regardless of the specified replacement schedule.

WARNING While adding oil, be careful not to spill any oil.

Clean up spilled oil with a workshop rag, Otherwise it could catch fire.

Do not leave flammable items such as clothes and work gloves in the engine compartment.

Such items could catch fire. Also, do not leave any of the tools.

Right after operating the machine the engine oil temperature is high. Before replacing the engine oil wait for the oil to cool down and be careful not to get burned.

Isuzu 4HK1 6. Remove the oil level gauge and carefully fill engine oil through the oil filler.

7. Install the oil level gauge and the filler cap. After refueling wait for 5 minutes before starting the engine. Start the engine and run it at idle speed.

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CAUTION When replacing the engine oil, also replace the engine oil filter.

Do not perform abrupt engine idling, which may cause an engine failure.

Check the engine oil level using the oil level gauge. Do not fill oil above the "FULL" mark on the oil level gauge, because adding too much oil may cause an engine malfunction.

Do not let the oil level falls below the "ADD" mark on the oil level gauge, because the engine may be damaged if the oil level falls.

Disposal and treatment of the drained oil must be conducted in accordance with the specified procedure.

6.10.3. REPLACING THE OIL FILTER The engine oil filter has the function of removing the dirt, dust and other impurities mixed into the engine oil. The engine filter has a significant impact on the performance and service life of the engine, so use of the "Hidromek genuine parts" is recommended.

CAUTION When replacing the engine oil filter, it is recommended to use a Hidromek genuine oil filter. An unapproved oil filter may cause an engine damage. Replace the engine oil and the oil filter at the same time.

Disposal and treatment of the waste oil and the oil filter must be conducted in accordance with the specified procedure.

1.

Clean around the oil filling cap so that foreign matter does not enter into the engine. Remove the oil filling cap.

2.

Place a container under the oil pan and the oil filter.

3.

Remove the oil pan drain plug and drain the oil.

4.

Use the special oil filter wrench to remove the filter.

5.

Apply a thin layer of clean engine oil to the gasket before installing the filter.

6.

Install the new filter. Screw the filter until the gasket comes in contact with the seal surface, and then tighten it by one full turn using the special oil filter wrench.

7.

Confirm that the engine oil drain plug is securely tightened.

CAUTION When installing the oil filter, make sure that the gasket does not get caught at the rim. This could cause oil leakage.

Any dirt on the drain plug should be wiped off before installing it.

Do not perform abrupt engine idling, which may cause an engine failure.

After replacement of the filter, perform a test for the engine and confirm that there is no oil leakage around.

1. Oil filter Figure. Location of the engine oil filter

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8. Install the oil level gauge and the filler cap. After refueling wait for 5 minutes before starting the engine. Start the engine and run it at idle speed.

Check if there is any oil leakage around the oil filter or the drain plug.

9. Stop the engine. Wait for 20 to 30 minutes and then re-check the engine oil level using the oil level gauge.

1. Filter body 2. Gasket 3. Filter CAUTION Prevent dust particles from entering through filler port during replacement. Entry of dust particles may cause engine damage or accident.

Filling the engine oil above the “Max” marking or below the “Min” marking on the oil level gauge may cause engine damage or accident.

Drain the engine oil to the “Max” marking if the oil level is above “Max” marking. Also, add engine oil to the “Max” marking if the oil level is below the “Min” marking.

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6.10.4. CLEANING SUPPLY PUMP STRAINER The strainer is incorporated in the supply pump inlet side joint bolt. Clean the strainer with compressed air and rinse it in a container filled with fuel.

6.10.5. CLEANING ELECTROMAGNETIC PUMP FILTER CAUTION When the filter is removed, make sure to replace the gasket and clean the magnet portion inside the cover.

1. Remove the wirings attached on the pump cover.

Rotate the cover with a wrench and remove it.

CAUTION When removing since the fuel present inside the pump, use a container or something to receive the fuel does not splash on the engine. Also, be cautious of fire.

1. Strainer 2. Joint bolt Figure. ISUZU 4HK1

2. Remove the filter and the gasket, and replace or clean them.

CAUTION Do not disassemble the piston and its parts locating at the inside center of the electromagnetic pump.

When removing the gasket, hold the outer part of the gasket with your fingers and pull it out.

Clean the filter with clean diesel fuel, and blow off the dirt and other impurities using high-pressured air. Then, install the filter and install a new gasket.

3. Install the cover. When installing, use a wrench and fully tighten it until the filter is properly seated.

CAUTION After the cover has been installed, make sure to check the airtightness.

The interval of replacement or cleaning should be shortened depending on the status of fuel management and refuel.

Bolt Tightening Torque 4HK1

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14,6 ~ 24.6 N (1.5 - 2.5 kgf.m)

6.10.6. CHECKING ANTIFREEZE DENSITY Check the density of anti-freeze. Use ethylene glycol antifreeze mixed with quality water at a ratio of 50:50 to provide protection against freezing at temperatures down to -37°C. Use a high quality tester and follow the manufacturer’s instructions to obtain an accurate reading.

6.10.7. CHECKING AND CLEANING RADIATOR, OIL COOLER AND CONDENSER FIN WARNING Compressed air, steam or water can cause personnel injury. Wear safety goggles or a facemask.  Do not use steam to clean the air condenser.

Coolant specification  Refer to Chapter 6.2. "Oil, Fuel, Coolant And Diesel Exhaust Fluid".

After opening the engine hood and the left side door of the machine, loosen the wing bolt and remove the mesh in front of oil and water coolers.

Blow away any mud, dust and leaves stucked on the radiator fin and oil cooler fin with compressed air.

Also clean the mesh. Clean the condenser fin of the air conditioner; water may be used instead of the compressed air.

Check the rubber hose for signs of wear or crack. If damaged, replace it. Check the hose clamp for looseness.

IMPORTANT When using the compressed air, keep the nozzle at some distance from the fins to prevent any damage. If the fin is damaged, this may cause leakage or overheating.

Under dusty environment conditions, check it every day regardless of its maintenance interval.

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6.10.8. CHECKING FRONT/REAR DIFFERENTIAL OIL LEVEL

AXLE

 Clean dust around the oil check plug (A).  Remove the oil check plug (A).  Check the oil level in the axle. Oil level should be at the lower point of the hole.

Figure. Front axle

 If the level is low, add oil and top up the level until oil overflows.  Install the plug and tighten it to 50 Nm.  Wait for 5 minutes and check the level again.

Figure. Rear axle

6.10.9. CHECKING FRONT/REAR PLANETARY GEAR OIL LEVEL

AXLE



Clean dust around the bolt.



Turn tire and bring the oil filling plug (B) to a horizontal position with the ground.



Remove the oil filling plug (B).



Check the oil level in the planetary gear. Oil level should be at the lower point of the hole.



If the level is low, add oil and top up the level until oil overflows.



Install the plug and tighten it to 50 Nm.



Wait for 5 minutes and check the level again.

B. Oil drain/filling plug Figure. Front axle

B. Oil drain/filling plug Figure. Rear axle

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6.10.10. GREASING AXLE JOINT HOUSING

Grease from grease nipples shown in figure.

For recommended grease refer to Chapter 6.2. Oil, Fuel, Coolant And Diesel Exhaust Fluid.

6.10.11. GREASING FRONT / REAR SHAFT Check grease filling on nipple A and B, if necessary renew.

6.10.12. GREASING SWING UNIT REDUCTION GEAR Greasing  Refer to Chapter 6.7.3. Greasing Swing Unit Reduction Gear.

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6.11. EVERY 1000 HOURS (6 MONTHS SERVICE) Perform the 10, 50 250 and 500 hours maintenances before starting this maintenance.

6.11.1. REPLACING SWING UNIT REDUCTION GEAR OIL Replacing oil  Refer to Chapter 6.7.4. Replacing Swing Unit Reduction Gear Oil. 6.11.2. CHANGING PILOT FILTER ELEMENT For changing pilot filter element, see Chapter 6.7.2.

Changing Pilot Filter Element.

6.11.3. CHANGING RETURN FILTER ELEMENT OF HYDRAULIC OIL For replacing return filter element of hydraulic oil, see Chapter 6.7.1. Replacing Return Filter Element Of Hydraulic Oil. 6.11.4. ENGINE VALVE CLEARANCE CHECK This check must be performed by a HİDROMEK Authorized Service.

6.11.5. STARTER AND ALTERNATOR CHECK AND CLEANING This check must be performed by a HİDROMEK Authorized Service.

6.11.6. CYLINDER COMPRESSION CHECK This check must be performed by a HİDROMEK Authorized Service.

6.11.7. ADJUSTMENT OF TENSION OF THE AIR CONDITIONER BELT IMPORTANT If the tension of the belt is not correct: The performance of compressor is reduced and the belt and compressor may be damaged.

Frictional sound (halt) is generated. Adjust the Vbelt tension. If torn away, replace it.

Therefore, check the tension of the air condition belt should any of these abnormalities are found.

Press the center of belt between pulleys with force of 10 kg. If it can be depressed about 7-10 mm, belt tension is normal.

Id tension is to be adjusted, loosen the nut of the idler pulley, and adjust the belt tension with adjusting bolt.

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6.11.8. REPLACING THE FILTER OF HYDRAULIC TANK BREATHER In dusty working environments, the hydraulic tank breather will become blocked after a short period of time.

Follow the steps below to replace the filter element of hydraulic tank breather:

1. Remove air breather plastic cap (1) on the air relief valve of the breather.

2. Press the relief valve (2) to release the pressure in hydraulic tank.

3. Remove nut (3), washer (4) and disassemble breather cover (5).

4. Now, remove breather filter element (6).

5. Clean the cover and surrounding and do not let any dirt enter into the hydraulic system.

6. Install new filter (6).

7. Re-mount breather cover and tighten nut to fix it.

8. Install washer and air breather plastic cap to secure the pressure relief valve.

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6.12. EVERY 2000 HOURS (ANNUALLY) SERVICE Perform the 10, 50, 250, 500 and 1000 hours maintenances before starting this maintenance.

6.12.1. REPLACING OIL AND CLEANING OR REPLACING SUCTION FILTER ELEMENT OF HYDRAULIC TANK WARNING Stop the engine before performing any maintenance and service on the machine.

Immediately after stopping the machine, the oil is hot. Allow the oil to cool down. Before removing the drain plug and the suction filter element cover, release the internal pressure of the tank.

12. Fill the hydraulic tank to the proper level through oil filling port (12).

Check the hydraulic oil level through the gauge on side of hydraulic tank. The centerline on the oil level gauge is the correct level.

Follow the procedure in “Chapter 6.5.10. Hydraulic Oil Level Check” to check oil level in tank.

For oil specifications refer to "Chapter 6.2. Oil, Fuel, Coolant and Diesel Exhaust Fluid".

When the machine is delivered from the factory, the hydraulic system is filled with “ISO VG46” grade oil.

Prepare a container with proper capacity to collect the drained oil.

1. Swing the upper frame so that the drain plug at the bottom of the hydraulic tank is located between the left and right tracks.

2. Retract the arm and bucket cylinder to its full stroke, and lower the bucket to the ground.

3. Lock the safety locking system and stop the engine.

4. Release the internal pressure of the tank through the air breather (1).

5. Remove the bolt (2) and washer (3).

6. Remove the bolt (5), then remove the filter element cover (6), the O-Ring (7) and the filter element (8).

If the suction filter element (8) is damaged, replace it with a new one.

7. Put a container under the drain plug (9) to collect the drained oil. Remove the drain plug (9) and drain the oil.

13. Bleed the hydraulic system.

8. Replace the O-Ring (10) on the drain plug (9).

After draining the oil, tighten the drain plug (9).

  

Tightening torque of the drain plug is 18 kgf.m.

CAUTION When removing drain plug (9), be careful not to be soaked with the drained oil.

9. Remove the suction flange (15) and replace the O-ring (14).

10. Clean the removed parts and assemble the parts in reverse order.

11. Remove the plug (11) and filling plug (12) on the return filter cover (13).

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Hydraulic system needs to be bled after below situations: After replacing the hydraulic oil After replacing the return filter element After cleaning/replacing the suction filter element (8).

For more information refer to “Chapter 6.15.8.

Bleeding Hydraulic System”.

14. Check the hydraulic oil level through the gauge on side of hydraulic tank.

6.12.2. REPLACING FRONT AND REAR AXLE DIFFERENTIAL OIL For replacing front and rear axle differential oil, see Chapter 6.7.5. Replacing Front and Rear Axle Differential Oil. 6.12.3. REPLACING FRONT AND REAR AXLE PLANETARY GEAR OIL For replacing front and rear axle planetary gear oil, see 6.7.6. Replacing Front and Rear Axle Planetary Gear Oil. 6.12.4. REPLACING TRANSMISSION OIL For replacing transmission oil, see Chapter 6.7.7.

Replacing Transmission Oil.

6.13. EVERY TWO YEARS OF SERVICE 6.13.1. CLEANING COOLING SYSTEM REPLACING COOLANT

AND

WARNING Inspection, filling or replacement of the coolant should be performed after the engine is sufficiently cooled down. Allow the engine to cool down.

Do not loosen or remove the radiator cap or the reservoir cap while the coolant temperature is still high. Hot vapor or boiling water may burst out and cause a burn.

When the engine has cooled down sufficiently and the coolant temperature has dropped down, cover the cap with a cloth, etc. and loosen it slowly to release the internal pressure, then remove it.

WARNING Tie up long hair and do not wear loose clothing or dangling jewelry. Do not place your hands or tools near any rotating parts. You may get caught by the rotating parts and serious injury or death could result.

CAUTION The water which is mixed with the long-life coolant (LLC) has to be tap water (soft water), not well water or river water.

Use distilled water in the radiator. Do not use water from a well, river, sea and waste water since the cooling system can be damaged.

If you add coolant to the system, use coolant in the same concentration with the coolant in the system.

When refilling coolant, flush out the system with distilled water.

Never mix different brands and different classes of antifreeze. For example, never mix standard life ethylene glycol antifreeze with extended life ethylene glycol antifreeze. If they are mixed, the protection level will be reduced.

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See "Chapter 6.2. Oil, Fuel, Coolant and Diesel Exhaust Fluid" for more information about Coolant and Water Specifications and their mixing ratios.

WARNING The antifreeze is flammable, keep away from flames.

WARNING When removing the drain plug, be careful not to be soaked with the coolant.

WARNING The coolant is toxic and must not be ingested. If the coolant is mistakenly ingested, immediately vomit it and seek prompt medical attention.

When the coolant gets in your eyes, rinse it off immediately with a large amount of water for 15 minutes or longer. Also, if still an abnormality such as irritation is felt, seek medical attention.

When the coolant gets on your skin, rinse it off using a soap with a large amount of water. Also, if an abnormality is observed, seek medical attention.

The coolant is flammable. Keep flames away from it. Also, the coolant could catch fire if it comes in contact with a hot surface, such as the exhaust manifold. Pay attention to prevent this from happening.

CAUTION Replace the coolant periodically.

Failure to periodically replace the engine coolant may cause rust due to engine coolant deterioration, possibly resulting in water leakage, clogging of the radiator or heater core, or failure of the urea SCR system.

CAUTION Do not use the long-life coolant at any concentration other than the one specified.

When the long-life coolant concentration is 60% or higher, overheating is likely to occur, while when it is 30% or lower, the anti-corrosion function is not provided sufficiently.

Using the long-life coolant at any concentration other than the one specified may reduce the antifreezing performance, and the coolant may freeze. Adjust the concentration of the coolant depending on the situation.

If the coolant level decreases rapidly, consult Hidromek Authorized Service for an inspection or repair.

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6.13.1.1. CHANGING COOLANT While changing coolant, flush the cooling system with clean water and drain all of the water after flushing. Also, clean the radiator, radiator cap, and intercooler.

Draining the Cooling System 1. Remove the radiator cap (C).

2. Remove the coolant drain plug (D) of radiator and drain the coolant.

3. Loosen and remove the air bleeding plug (E) on the EGR cooler.

A. Coolant level gauge B. Coolant reservoir filling cap CAUTION After the coolant is drained, do not start the engine. If there is no water in the radiator, it could cause engine seizure.

Hand tighten the drain plug of the radiator.

Tightening with pliers or some other tool could damage it.

Disposal and treatment of the drained coolant must be conducted in accordance with the specified procedure.

E. Air bleeding plug (4HK1)

4. Remove the filling cap of the coolant reservoir.

5. Remove the coolant drain plug of engine located on the right side of the cylinder block, and drain the coolant inside the engine block.

Follow the procedure below to change the coolant: 1. Park the machine on a hard and flat ground.

2. Lower the bucket to the ground. Stop the engine and remove the starter key. Disconnect the battery. Allow engine coolant to cool down to avoid burning.

3. Open the engine hood.

4. Place an appropriate container under the radiator and engine to collect the coolant that will be drained.

F. Coolant drain plug of the engine (Isuzu 4HK1) 6. Install the coolant drain plug of the radiator and the coolant drain plug of the engine.

7. Install the air bleeding plug on the EGR cooler.

C. Radiator cap D. Coolant drain plug of radiator

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Cleaning the Coolant System

Filling the Cooling System

If the cooling system circuit is contaminated due to sludge particles or scaling, cooling efficiency will be lowered. Periodically clean the cooling circuit.

WARNING Pay attention to prevent overflowed coolant not to splash onto the exhaust system components.

The coolant may catch fire, so make sure to wipe it off completely.

Preferably, add hot water into the radiator which has suitable properties as recommended in Chapter 6.2.

1. Fill the radiator with tap water up to the top of the opening.

2. Check and clean the radiator cap. Replace the cap if it is damaged.

3. Firmly close the radiator cap.

4. Fill the reservoir tank with tap water up to the "MAX" line.

5. Close the cap of the reservoir tank.

6. Start the engine and run at idle speed for 20 minutes, and then stop the engine, wait until it cools down sufficiently, and drain the water. If the water is dirty, repeat this flushing procedure until the coolant appears totally clean.

E. Air bleeding plug (4HK1) 1. Mix antifreeze and water in a container. For more information about Long Life Coolant specifications refer to "Chapter 6.2. Oil, Fuel, Coolant and Diesel Exhaust Fluid”.

2. Loosen air bleeding plugs on the water pipe and on the EGR cooler. Then fill Long Life Coolant slowly from the radiator inlet. To avoid air intrusion to the cooling system, the Long Life Coolant should be filled slowly.

CAUTION When the air bleeding plug of the water pipe and EGR cooler has been loosened, make sure to replace the packing with a new one.

NOTE It is not necessary to bleed air from the EGR cooler if the vehicle is equipped with a pressurized reserve tank.

3. Once Long Life Coolant starts to overflow from the air bleeding plugs on the water pipe and EGR cooler, wait until no more air is coming out and then tighten the bleeding plugs.

4HK1 Air bleeding plug tightening torque 24.5 - 30.5 N·m (2.5 - 3.1 kgf·m) 4. Fill the radiator with Long Life Coolant to the top of the filler opening.

5. While manually pressing the radiator upper hose several times to bleed any air from within the hose, add an amount of Long Life Coolant equivalent to the amount in which the coolant level has dropped so that the coolant level is up to the brim of the radiator filler neck.

6. Repeat Step 5 until the coolant level no longer decreases.

200

7. Firmly close the radiator cap.

8. Fill the reservoir tank with the Long Life Coolant up to the "MAX" line and close the cap of the reservoir tank.

9. Bleed the air from the coolant piping of the urea SCR dosing module. Remove the coolant piping connected to one side of the dosing module and check if any coolant is overflowing before reconnecting.

10. Completely wipe up any coolant that has overflowed.

11. Idle the engine for 5 minutes and then stop the engine.

12. After making sure that the coolant has cooled down, remove the radiator cap, and if the coolant level has lowered, add the coolant up to the radiator filler opening. If the coolant level is abnormally low, check for coolant leaks.

Cleaning the Radiator Exterior When radiator fins are clogged with filth such as dirt and dry grass, it may interrupt the air flow and cause overheat of the engine cooling system.

Periodically check if the radiator is clogged and when it is clogged clean the radiator fin with steam or pressured water.

If the front of the radiator is clogged with mud or dirt, wash it and ensure that air can flow through the radiator core without obstruction.

CAUTION Take care to prevent the spilled coolant from getting into the exhaust system and its components. If you spill coolant, wipe it properly, or this could lead to a fire.

13. Firmly close the radiator cap.

14. Start and warm up the engine. Bleed any air from inside the heater circuit. Set the temperature and blower speed to their maximum. Also, warm the engine by accelerating the engine speed to around 1,500rpm or more until the engine coolant temperature gauge stabilizes.

15. Touch the upper hose with the engine running and check whether it has become warm. If it has not become warm, return to Step 14.

16. Idle the engine for 5 minutes and then stop the engine.

NOTE When the engine has cooled down, the inside of the radiator will be at a negative pressure and coolant will automatically be supplied to the radiator side from the reserve tank.

17. Remove the radiator cap after confirming that the engine coolant has cooled down and add coolant up to the radiator filler neck if the coolant level has decreased. If it has decreased significantly, inspect for engine coolant leakage.

When leakage is found, contact Hidromek Authorized Service.

18. Firmly close the radiator cap.

19. Fill the reservoir tank with Long Life Coolant up to the "MAX" line, and close the cap of the reservoir tank.

CAUTION If the coolant in the reservoir tank has decreased the next morning, add engine coolant up to the "MAX" line.

201

Checking Coolant Level To release the air in the coolant system, operate the engine about 10~15 minutes at a low idle speed and wait for the coolant temperature reach to proper degree (90~95°C).

Turn on the heater during this warm up.

Stop the engine and wait the engine to cool down until 40 °C. Check the coolant level in the coolant reservoir after the engine is cooled down. Fill the coolant reservoir to the maximum level.

6.14. EVERY 4500 HOURS 6.14.1. INSPECTING AND CLEANING THE INJECTOR This maintenance should be performed by Hidromek Authorized Service.

6.14.2. INSPECTING AND CLEANING THE EGR VALVE This maintenance should be performed by Hidromek Authorized Service.

6.14.3. INSPECTING AND CLEANING THE EGR COOLER This maintenance should be performed by Hidromek Authorized Service.

6.14.4. INSPECTING THE TURBOCHARGER (IF NECESSARY CLEAN THE BLOWER) This maintenance should be performed by Hidromek Authorized Service.

6.14.5. INSPECTING THE UREA SCR SYSTEM This maintenance should be performed by Hidromek Authorized Service.

A. Coolant level gauge B. Coolant reservoir filling cap

202

Strainer

6.15. WHEN REQUIRED 6.15.1. FILLING FUEL (FUEL TRANSFER PUMP) IMPORTANT Stop the engine when refueling.

Do not run fuel transfer pump dry for more than 30 seconds, since excessive wear and damage may occur.

Be careful not to block the pump exit by closing the valve or with a folded hose.

Check the pump strainer frequently. Do not run the pump with a clogged strainer to prevent cavitation. Dirt will cause overheating and damage the pump.

Keep pump away from water and rain.

Maximum operation time is 25 minutes, do not exceed. Usage of pump over recommended operation time will cause heating and pump damage.

Cap Check valve A cap and a strainer are installed at the end of the suction line hose to prevent any foreign materials to enter the pump and the fuel tank.

The pump is used to transfer fuel to the fuel tank.

To transfer fuel into the fuel tank:    

Turn the cap at the end of the hose to counter clockwise to open the holes on the cap.

Dip the suction hose into the fuel source tank to transfer fuel into the fuel tank.

Open the valve.

Turn pump switch to “ON” position.

NOTE Pump refueling capacity is 35 l/min. Be careful not to overfill the fuel tank.

The pump is installed inside the tool box.

Figure. Red pin near fuel tank cap   

1. Fuel transfer pump 2. On/off switch 3. Hose

 

When fuel level in the tank becomes full, the red pin floats up.

Turn switch to “OFF” position when refueling is completed.

Take suction hose out from the fuel source tank and run pump for 2 or 3 seconds to drain remaining fuel from suction hose.

Close the valve.

To prevent any foreign materials from entering the hose, turn the cap to clockwise direction and tighten. This will close the fuel holes on the cap.

Keep the strainer and the hose clean.

203

6.15.2. REPLACING AIR CONDITIONER FILTERS Air conditioner filters are used to prevent foreign materials and smell from coming inside the vehicle and provides a pleasant atmosphere.

If not replaced for a long period, the filters will be blocked by foreign materials and the air flow will extremely decrease. The blower motor may make noise, and bad odor come in through the discharge ports. Check for existence of any of these signs and if necessary clean or replace the filters.

Filters should be frequently checked and replaced depending on the area, device and work site environment where air pollution is serious and dust or smoke is largely generated due to bad road condition.

The air conditioner unit has two types of filters.

1. External filter 2. Internal filter External filter: It filters dirt and dust particles outside. If it is clogged, clean it by using pressurized air (below 2 kgf/cm 2, 28 psi). If not well cleaned or damaged, use a new filter.

Internal filter: It filters dust particles in the air which is circulated inside the operator’s cab. Check if it is clogged, clean it using pressurized air (below 2 kgf/cm2, 28 psi) or water. If it is still dirty, or damaged then replace it with the new one.

Do not change the orientation of the filters!

IMPORTANT When water is used to clean a mesh filter, ensure that it is completely dry before installing.

WARNING All service and inspection of air conditioning system should be performed while the starter switch is in OFF position.

If using compressed air to clean the element, make sure you wear safety glasses.

204

6.15.3. REPLACING OR IF NECESSARY CLEANING AIR FILTER OUTER ELEMENT CAUTION Never clean or replace the air cleaner while the engine is running.

When cleaning the element with compressed air, wear goggles.

Never start the engine without air cleaner or with a damaged air cleaner.

Shorten the inspection/cleaning and replacement intervals if the engine is used particularly in a dusty environment.

Do not clean and reuse the inner element.

6.15.3.1. CHECKING AIR FILTER

WARNING Do not remove the inner element except for replacement.

Clean the element with compressed air. Make sure the air pressure does not exceed 150 kPa (1.5 bar).

Never attempt to clean the element by knocking it against another object or by striking it.

If the element blackened by oily soot, replace it with a new one irrespective of the specified replacement interval.

Make sure the elements are fitted in securely. If they are not fitted securely, dust or other foreign materials may be sucked into the engine and prevent a normal operation.

Figure. Air filter is clogged warning light When the signal on the instrument panel comes on, it means the air filter is clogged. Replace the outer element. HIDROMEK does not recommend cleaning the outer element, but if it is necessary to clean it consider the following information.

1. Cover 2. Protection cap 3. O-ring 4. Cover 5. Marking

6. Vacuum valve 7. Outer element (main element) 8. Inner element (safety element) 9. Body

Figure. Air filter

205

6.15.3.2. CLEANING OUTER ELEMENT Remove the element.

Clean the dust bowl.

Check the level of contamination in the element, and then clean the element.

When all parts are cleaned, assemble them in the reverse order of the disassembly procedure.

Blow clean compressed air form inside of the element 150 kPa (1.5 bar) towards the pleats. Do not blow air closer than 25 mm.

6.15.3.3. REPLACING ELEMENT

AIR

FILTER

INNER

CAUTION Shorten the inspection/cleaning and replacement intervals if the engine is used particularly in a dusty environment.

Do not clean and reuse the inner element.

Replace the outer and inner elements at the same time.

Hold a light source inside the element and inspect the filter media.

Replace the element if the filter paper has small holes, badly abraded areas, or any other damage or if the seal is damaged.

206

6.15.4. BLEEDING FUEL SYSTEM If the engine has stalled due to running out of fuel or the fuel filter has been replaced or draining water from the fuel filters then air gets in the fuel system.

If air enters into the fuel system, it may cause engine starting difficulty or engine malfunction.

Therefore, air in the fuel system needs to be bled before starting the engine.

After Starting the Engine

WARNING There is a risk of fire. Do not smoke or use a lighter or other open flame and stop the engine before bleeding the fuel system.

11. Slowly increase the engine speed and keep this for three minutes.

CAUTION If fuel spills on the exhaust pipe, wipe it up completely. Spilled fuel may start fire due to heat generated by the engine.

When bleeding the fuel system, be careful not to get hurt by the parts in the work area that have sharp edges.

13. Return to idling speed.

INFORMATION During air bleeding operation, fuel will come out the bleeding plug. To prevent fuel from spilling over the surrounding parts, install a hose in the air bleeding plug to collect spillage in a container.

Use a transparent hose so air bubbles inside the fuel could be seen through the hose.

8. Start the engine, but do not raise the engine speed on machine side.

9. If the engine does not start at this time, repeat the procedure from Step 4.

10. After starting, maintain the idle speed for 5 seconds.

12. Operate the engine speed to maximum on the machine side. (Repeat this operation several times)

CAUTION If the air bleeding work is insufficient then it could lead to faults in the engine. Therefore, the procedures after starting the engine should always be implemented.

Air bleeding plug tightening torque 7,9 to 11,7 Nm (0,8 to 1,2 kgf.m)

Before Starting the Engine 1. Install a hose to the air bleeding plug (1) on the fuel filter. Fit a tray below the fuel main filter.

2. Turn the starter switch to "ON" position to activate the electromagnetic pump.

3. Loosen the bleeding plug adequately and operate the hand pump (2) until the fuel comes out.

4. Tighten the bleeding plug, and operate the hand pump until the fuel filter is filled with fuel (10 times or more).

5. After waiting for approximately a minute, loosen the plug and bleed out the air in the fuel filter. (This work must be repeated a minimum of three times until no more air comes out from the plug).

1. Air bleeding plug 2. Hand pump 3. Cartridge 4. Float 5. Drain plug

6. Tighten the plug firmly and wipe the fuel in the surrounding area.

7. Operate the hand pump (10 to 15 times) till it is filled with fuel and then send fuel to the engine.

WARNING Check the filter case for fuel leakage. Spilled fuel can cause fire.

Start the engine and check the fuel system for leakage. Pay attention to safety as leakage causes fire.

207

6.15.5. BLEEDING HYDRAULIC SYSTEM Hydraulic system should be bled after replacement of hydraulic cylinders or any other part of the hydraulic circuit or changing hydraulic oil.

Set a low engine speed and follow the procedure below: 1. Operate each cylinder 100 mm forward and backward. Repeat this 4 or 5 times.

2. Operate each cylinder at full stroke. Repeat it 34 times.

6.15.6. CHECKING AIR CONDITIONER REFRIGERANT AMOUNT If the cooling or heating effect of the air conditioner is poor, there may be lack of refrigerant (gas).

Contact Hidromek dealer for inspection and repair.

6.15.7. REPLACEMENT OF THE FUEL PIPING When the fuel injection pipes (high-pressure piping) are removed, do not reuse them again.

Because they have metal to metal contact sealing.

If they are reused, the seal surface may be shifted which will cause fuel leakage. Also due to very high pressure in the fuel piping, fuel jet could cause damage or death.

ISUZU 4HK1

208

7. SPECIFICATIONS 7.1. TECHNICAL SPECIFICATIONS OF HMK 210 W-4

NORMAL BOOM DIMENSIONS, mm BOOM LENGTH, m

5.60 (Mono boom)

ARM LENGTH, m

2.40

BUCKET CAPACITY, m3

2.92 0.90

A

Wheel base

2,850

B

Tread

1,914

C

Distance between rotation axis and front axle

1,500

C'

Maximum distance between front axle and dozer

1,140

D

Distance between rotation axis and rear axle

1,350

D'

Maximum distance between rear axle and outrigger

1,166

E

Upper structure ground clearance

1,290

F

Distance between rotation axis to counterweight

2,855

F'

Counterweight rotating radius

2,890

G

Overall width of upper structure

2,500

H

Overall height of operator's cab

3,220

I

Outrigger ground clearance

370

I’

Tire width (loaded)

335

J

Dozer width

2,500

J'

Tread width

2,500

K

Overall width of outrigger

3,800

L

Depth of outrigger

130

M

Ground clearance of dozer blade

340

N

Depth of dozer blade

135

O

Overall traveling length

9,590

9,610

P

Overall shipping length

9,480

9,550

Q

Overall boom traveling height

3,610

3,690

R

Overall boom shipping height

3,330

3,450

209

TECHNICAL SPECIFICATIONS OF HMK 210 W-4

ARTICULATED BOOM DIMENSIONS, mm BOOM LENGTH, m ARM LENGTH, m

5.50 (Articulated boom) 2.40

BUCKET CAPACITY, m3

2.92 0.90

A

Wheel base

2,850

B

Tread

1,914

C

Distance between rotation axis and front axle

1,500

C'

Maximum distance between front axle and dozer

1,140

D

Distance between rotation axis and rear axle

1,350

D'

Maximum distance between rear axle and outrigger

1,166

E

Upper structure ground clearance

1,290

F

Distance between rotation axis to counterweight

2,855

F'

Counterweight rotating radius

2,890

G

Overall width of upper structure

2,500

H

Overall height of operator's cab

3,220

I

Outrigger ground clearance

370

I’

Tire width (loaded)

335

J

Dozer width

2,500

J'

Tread width

2,500

K

Overall width of outrigger

3,800

L

Depth of outrigger

130

M

Ground clearance of dozer blade

340

N

Depth of dozer blade

135

O

Overall traveling length

7,570

7,570

P

Overall shipping length

9,510

9,520

Q

Overall boom traveling height

4,000

4,630

R

Overall boom shipping height

3,250

3,280

210

TECHNICAL SPECIFICATIONS OF HMK 210 W-4 SPECIFICATIONS AND PERFORMANCE BOOM LENGTH, mm ARM LENGTH, mm

5,60 2,40

2,92

ISO

SAE

BUCKET CAPACITY, m3

FORCES, (kgf)

5,5 (2p) 2,40

2,92

0,90

0,90

Bucket Digging Force

13,400

13,400

13,400

13,400

Bucket Digging Force, Power Boost

14,200

14,200

14,200

14,200

Arm Breakout Force

11,600

10,200

11,600

10,200

Arm Breakout Force, Power Boost

12,200

10,700

12,200

10,700

Bucket Digging Force

15,000

15,100

15,000

15,100

Bucket Digging Force, Power Boost

15,900

15,900

15,900

15,900

Arm Breakout Force

11,900

10,400

11,900

10,400

Arm Breakout Force, Power Boost

12,600

11,000

12,600

11,000

BOOM LENGTH, mm

5.60 (Mono Boom)

5.5 (Articulated Boom)

ARM LENGTH, mm

2.40

2.40

BUCKET CAPACITY, m3

0.90

0.90

Operating weight, kg

22,100

22,450

PERFORMANCE Swing Speed Travel Speed

12,6 rpm 1. speed

30 km/h

2. speed

7,5 km/h

Gradeability

31° (60%)

Maximum traction force

11400 kgf

211

TECHNICAL SPECIFICATIONS OF HMK 210 W-4 ENGINE Manufacturer

ISUZU

Model

AR-4HK1X

Emission class

97/68 EC, TIER-4 (StageIV)

Type

4 cylinder, vertical inline, water cooled, direct injection, overhead camshaft, with turbocharger

Gross Power (SAE J1995)

128.4 kW @ 2000 rpm 172.2 HP @ 2000 rpm

Net Power (SAE J1349)

120.7 kW @ 2000 rpm 161.8 HP @ 2000 rpm

Maximum torque

670 Nm, 1600 rpm

Number of cylinder

4

Bore x Stroke

Ø115 mm x 125 mm

Total displacement

5193 cc

ELECTRICAL SYSTEM Alternator

Starter motor

Battery

Voltage

24 V

Current

50 A

Voltage

24 V

Power

5 kW

Type

Maintenance free

Capacity

100 Ah

Voltage

2 x 12 V

HYDRAULIC SYSTEM

Main pump

Pilot pump

Main control valve

212

Flow rate

2 x 233 L / min

Displacement

2 x 117 cc/rev

Function Type Type

Full horsepower control Axial piston pump with variable displacement and swash plate Gear pump

Flow rate

20 L / min

Displacement

10 cc/rev

Type

7 Spool-Monoblock pilot operated

TECHNICAL SPECIFICATIONS OF HMK 210 W-4 TRAVEL SYSTEM

Travel Motor

Type

Variable displacement, pressure control

Displacement (Minimum / Maximum)

74,5 (min1) cc/rev / 160 (max) cc/rev 88 (min2) cc/rev / 160 (max) cc/rev

Counterbalance valve

Exists

Type

2 stage

Reduction (1.Gear/2.Gear)

4.869 / 1.196

Oscillation

± 8°

Total Reduction Ratio

16

Tire Pressure

109±1

Transmission

Axle

Tires

10.00-20 16PR NB-38

Q’ty

8

Wheel nut tightening torque

55  5 kgf

BRAKE SYSTEM Full hydraulic, front and rear brake hydraulic independent from each other

Type Service brake

Type

Gear pump

Displacement

8 cc/rev

Brake pump

Parking brake

Integrated to the transmission, Hydraulic disc type

Type

STEERING SYSTEM Type

Gear pump

Displacement

23 cc/rev

Steering unit

Type

Open Center, non reaction

Steering cylinder

Function

Controls wheels of the front axle

Steering pump

Oscillation angle of the front axle

±8˚

Minimum turning radius

7400 mm

213

TECHNICAL SPECIFICATIONS OF HMK 210 W-4 SWING SYSTEM Type

Fixed displacement, swash plate type axial piston motor integrated with super schock absorbing valve

Displacement

151 cc/rev

Brake

Hydraulic multi disc type, automatically activated

Swing reduction gear

Type

2 stage, planet type

Swing gear

Type

Bearing, annular gear

Swing motor

HYDRAULIC CYLINDERS Main Boom (Mono Boom)

Boom 1 (Articulated Boom)

Boom 2 (Articulated Boom)

Q’ty

2

Bore x Rod x Stroke

120 mm x 85 mm x 1300 mm

Q’ty

2

Bore x Rod x Stroke

125 mm x 85 mm x 1060 mm

Q’ty

1

Bore x Rod x Stroke

170 mm x 105 mm x 680 mm

Q’ty

1

Bore x Rod x Stroke

135 mm x 95 mm x 1520 mm

Q’ty

1

Bore x Rod x Stroke

120 mm x 85 mm x 1060 mm

Arm

Bucket

PRESSURE SETTINGS Hydraulic system

350 kgf/cm2

Powerboost

370 kgf/cm2

Swing system

305 kgf/cm2

Travel system

350 kgf/cm2

Pilot control system

40 kgf/cm2

Dozer

280 kgf/cm2

CONTROLS Travel

Hydrauic steering wheel Throttle and brake foot pedals

Attachment and swing

2 hydraulic joystick

Engine

Electrical and mechanical

214

TECHNICAL SPECIFICATIONS OF HMK 210 W-4 OPERATOR'S CAB Length

1854 mm

Height

1681 mm

Width

1000 mm ROPS: ISO 12117-2:2008

Safety FOPS : Level I / ISO 10262 High capacity automatic air conditioner is standard equipment. Fan speed, air temperature and vents can be selected on manual control. Heating system is created to distribute air in the best way.

Heating and ventilation

Front

Window

Fully-open, laminated safety glass Left

Sliding open, tempered safety glass

Right

Fixed, tempered safety glass

Side

Rear

Fixed, tempered safety glass

Function

Air suspended weight adjustment, lateral suspension, reclining, seat and seat base fore-aft adjustment, seat pan depth and angle adjustment, 4 position seat height adjustment, headrest height and angle adjustment Reclining

Rear: 70

Horizontal (Seat)

80 mm

Horizontal (Seat Base)

50 mm

Suspension stroke

50 mm

Seat Adjust

215

TECHNICAL SPECIFICATIONS OF HMK 210 W-4 WORKING RANGE (NORMAL BOOM)

WORKING DIMENSIONS, mm BOOM LENGTH, m

5.60 (Mono boom)

ARM LENGTH, m BUCKET CAPACITY, m

3

2.40

2.92

0.90

0.82

S

Maximum digging reach

9,400

9,790

T

Maximum reach at ground level

9,170

9,570

U

Maximum digging depth

5,770

6,290

V

Maximum digging height

9,960

10,020

W

Maximum dumping height

7,170

7,280

X

Maximum vertical digging depth

4,430

4,620

Y

Minimum swing radius

3,080

3,050

Z

Maximum digging depth on 2440 mm horizontal plane

5,560

6,100

3,360

2,840

W' Minimum dumping height * Standard 216

TECHNICAL SPECIFICATIONS OF HMK 210 W-4 WORKING RANGE (ARTICULATED BOOM)

WORKING DIMENSIONS, mm BOOM LENGTH, m

5.5 (Articulated boom)

ARM LENGTH, m

2.40

2.92

BUCKET CAPACITY, m3

0.90

0.82

S

Maximum digging reach

9,460

9,910

T

Maximum reach at ground level

9,240

9,700

U

Maximum digging depth

5,740

6,240

V

Maximum digging height

10,360

10,560

W

Maximum dumping height

7,460

7,690

X

Maximum vertical digging depth

4,630

5,000

Y

Minimum swing radius

3,230

3,130

Z

Maximum digging depth on 2440 mm horizontal plane

5,640

6,150

3,360

2,800

W' Minimum dumping height * Standard

217

TECHNICAL SPECIFICATIONS OF HMK 210 W-4 SOUND AND VIBRATION LEVELS Sound Level Sound pressure level (LpA) inside the cab and sound power level (LwA) around the machine comply with 2000/14/EC. Sound pressure level (LpA) inside the cab: ....... dB (tested based on ISO 6396) Sound power level (LwA) around the machine: ....... dB (tested based on ISO 6395) Vibration Level Declared vibration emission values in accordance with EN 12096 are as in the following.

Hand/arm vibration emission value is less than ...... m/s2.

Whole body vibration emission value is less than ....... m/s2.

Hand/arm and whole body vibration emission values are determined in accordance with EN 1032:2008.

Seat vibration level is determined in accordance with EN ISO 7096.

WARNING Vibration levels change with various operating conditions such as working mode, structure of ground, speed etc. Do the following tips to minimize the level of vibration emission and to reduce risks.

Adjust the operator’s seat according to the operator’s weight.

Make sure that the suspension on various systems of the machine such as the cabin, the tire, the seat are maintained regularly.

Check the hydraulic system and the linkages regularly.

To the extent possible, do not steer, brake, accelerate, shift gears too suddenly; operate the attachments or load the bucket smoothly.

Slow down when traveling on a rough terrain.

218

TECHNICAL SPECIFICATIONS OF HMK 210 W-4 LIFTING CAPACITY WARNING Do not exceed the capacity given on the table of lifting capacities posted on the Cabin window.

For a safe operation, be sure that the working ground is level and has adequate supporting surface. Do not lift maximum loads given on lifting capacity table when working on non-level, soft and sandy terrain.

Otherwise serious accidents may occur.

See the precautions for security given in the Parts 7.7 and 12.13.

Lifting capacities comply with SAE J1097 and ISO 10567.

The load point is the load tying point on the bucket.

Lifting capacity do not exceed 87% of hydraulic capacity or %75 of tipping capacity.

Bucket weight is excluded in given loads. (*) Load is limited by hydraulic capacity rather than tipping capacity.

Lifting capacities are to be considered for a machine working on a level and firm supporting ground.

MONO BOOM

Boom: 5.6 m, Arm 2.4 m, Bucket 0.9 m 3, Front dozer and rear outrigger, Counterweight: 3800 kg : Front attachment is on the forward position. : Front attachment is turned to the side position.

219

TECHNICAL SPECIFICATIONS OF HMK 210 W-4 Boom: 5.6 m, Arm 2.92 m, Bucket 0.9 m 3, Front dozer and rear outrigger, Counterweight: 3800 kg : Front attachment is on the forward position. : Front attachment is turned to the side position.

ARTICULATED BOOM

Boom: 5.5 m, Arm 2.4 m, Bucket 0.9 m 3, Front dozer and rear outrigger, Counterweight: 3800 kg : Front attachment is on the forward position. : Front attachment is turned to the side position.

220

TECHNICAL SPECIFICATIONS OF HMK 210 W-4 Boom: 5.5 m, Arm 2.92 m, Bucket 0.9 m 3, Front dozer and rear outrigger, Counterweight: 3800 kg : Front attachment is on the forward position. : Front attachment is turned to the side position.

221

8. EQUIPMENT AND ATTACHMENTS 8.1. GENERAL PRECAUTIONS Please use attachments that are supplied or recommended by HİDROMEK. Otherwise the performance and service life of the machine may be affected and safety related problems may arise.

If you want to use any other attachment that is not specified in this manual, contact your authorized HİDROMEK dealer or Hidromek Services.

Otherwise, possible problems regarding safety and/or performance will be considered as the users own responsibility.

8.2. CAUTION WHEN FITTING THE WORKING EQUIPMENT WARNING A long-length attachment will reduce the stability of the machine, so when swinging it on a slope, it may overturn due to unbalance.

The following operations are very dangerous.

Never perform the following: Do not descend with raised equipment.

WARNING Take special care during removing and mounting operations. Make sure to take the following precautions when removing and mounting the work equipment.

Removing and mounting the work equipment should be done on a level and firm surface.

When a second person is signaling the operator, both parties must make sure that they understand each other without any doubt.

For heavy objects, use a crane.

Before removing a heavy part, make sure to block it securely. Be careful of the center of gravity for heavy objects.

Support all lifted parts when working.

When removing or mounting the work equipment put it down firmly.

When lifting by a crane or working near lifted attachments, never stand under the lifted object.

Be sure to keep away from the lifted object.

Do not swing on a slope. If such operations have to be carried out, pile soil to make platform on the slope so that the machine can be kept horizontal when operating.

WARNING The crane operation should be done by qualified people who possess an operator license for the equipment he is using. DO NOT let any nonqualified persons to operate it.

Refer to assembly-disassembly instructions or consult an authorized HİDROMEK dealer for the removing and mounting works.

When a heavy attachment is fitted, swing flow becomes large (the distance from swing start position to swing stop position). Pay special attention to working area. Self-lowering may be increased.

Abnormal attached boom or arm can cause serious damage. Contact the authorized HİDROMEK dealer.

In case of being equipped with a long-length attachment, the work scope becomes large. Pay special attention not to hit against other things due to wrong judgment. In this time, keep sufficient distance from other things.

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8.3. SELECTION OF ATTACHMENT There are very important considerations when choosing and using the attachments. So obey the rules that are specified in this part.

Install FOPS (Falling Object Protection Structure) where falling or scattering materials may damage the operator’s cab.

IMPORTANT Select an attachment suitable for the machine.

Attachments that can be used are different from machine to machine. While selecting the attachments, contact your HIDROMEK Authorized Service or Dealer.

8.4. PROTECTION AGAINST FALLING OR FLYING OBJECTS (FOPS) Install protective guards as required by the working conditions where the operator’s cab is subjected to falling or scattering materials.

When operating a breaker, make sure that you close the front window.

During operation, make sure all personnel are out of range of materials, which may fly off.

IMPORTANT For protection guards and structures, contact with HIDROMEK Authorized Service or Dealer.

Install protective cage when working with a breaker.

8.5. PROTECTION AGAINST TIPPING AND ROLLING OVER Operator's cab name plate is hanged inside the operator's cab on the left hand side. Check the name plate to find out if the operator's cab has necessary protection against ROPS (Rolling Over Protection System), FOPS (Falling Over Protection System) or TOPS (Tipping Over Protection System).

DANGER During working at construction sites where high risk of rolling over exist, like hillsides or slopes, be sure to have an operator's cab compatible with ROPS. Consult with Hidromek Authorized Service to learn if your operator's cab protection fulfills your machine's operating conditions.

The decal below shows that the operator's cab is compatible with ROPS:

Install falling object guard (FOG) when working at quarries and demolition.

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8.6. HANDLING TIRES 8.6.1. TIRE CHANGING PROCEDURE CAUTION Before changing tires, move safety lock lever to locked position. Place a warning tag on controls so that no one begins to operate machine while tires are being changed.

1. Park machine on secure and level ground able to support weight of machine.

2. Raise the carrier with the dozer blade and stabilizer to lift the tire off the ground.

3. Put blocks under the front axle and the rear axle.

4. Lower bucket to ground.

5. Remove wheel nuts (1) and outer tire assembly (2) from hub (3). Examine nuts and washers for wear and damage. Replace if necessary.

7. Remove inner washers from studs and examine for damage and wear.

8. Examine all parts for excessive wear and damage. Replace all necessary parts.

9. Reassemble parts in following order:     

Inner washer Inner tire Rubber spacer Outer tire Outer washer and wheel nuts

10. Use tightening pattern in figure when tightening wheel nuts.

11. Run machine forward and backward several times to ensure proper assembly and seating of the washers. Retighten wheel nuts to ensure proper torque.

6. Remove rubber spacer (1) and inner tire assembly (2) from hub (3). Examine rubber spacer assembly for wear and damage.

Replace if necessary.

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Refer to Chapter 7. Specifications for tire pressure and wheel nut torque.

8.6.2. TIRE ROTATION The wear differently depends on their positions.

Therefore, change the mounting position periodically as shown.

8.7. HYDRAULIC BREAKER Hydraulic breaker should be compatible with the pressure and flow settings of the excavator’s hydraulic system and it wouldn’t disturb balance of the machine. Use only Hidromek approved hydraulic breakers. Contact Hidromek Authorized Dealer to help you in choosing the right hydraulic breaker.

Press the chisel firmly onto the surface at right angle.

DANGER As it may cause accidents do not operate hydraulic breaker valves when hydraulic system is under pressure.

Before operating hydraulic breaker valves stop the machine and release the pressure in hydraulic lines.

8.7.1. MAINLY AVAILABLE WORKS

When striking, press the chisel firmly onto the surface, and lift the frame about 5 cm. Never raise the machine unnecessarily high.

1) Breaking stone and rock 2) Demolition work 3) Road repairing It is widely used in works such as demolition of building, breaking road surfaces, tunneling work, smashing slag, and breaking or cutting stone.

If the surface is repeatedly struck but it is not broken within 1 minute, move the breaker to break from the end portion.

WARNING If the excavator will be charged in tunneling work, it should have suitable equipment and attachments. In tunneling work hydraulic breaker bracket should be chosen as tunnel type and a Hidromek approved hydraulic breaker should be used. Attachments like boom, arm, hydraulic breaker, hydraulic breaker bracket etc. should only be used after having Hidromek’s written approval or otherwise Hidromek will not be held liable for any failure, loss or damage.

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The striking direction of chisel and the direction of breaker body are a little deviated. Correct the bucket cylinder so that the direction is always aligned.

Pushing the stones and rocks to move them

Do not work by swing force.

Press the chisel properly so blank striking does not occur.

Moving the chisel while striking.

8.7.2. INCORRECT METHODS The following methods are prohibited in order to extend the service life of the machine and to work safely.  Never operate the cylinder to its stroke end, leave about 5 cm.

Striking horizontally, or in upward direction.

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Twisting the chisel to make a hole in the ground.

Hammering with the breaker.

Raising the machine while the bucket cylinder is fully extended.

Do not operate the breaker to the side of the machine as the machine may tip over on a side and reduce undercarriage component life.

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8.7.3. MAINTENANCE FOR HYDRAULIC BREAKER Maintenance for machine operated with hydraulic breaker is different from maintenance for machine operated in normal working conditions, because the viscosity breakdown and contamination of hydraulic oil is faster.

Determine replacement intervals for hydraulic oil, hydraulic oil return filter element and hydraulic breaker return filter element (if exists) according to the following table. Replace the hydraulic breaker return filter element according to hydraulic breaker operating hours.

Hydraulic Oil, Hydraulic Return Filter Element Replacement Intervals 2000

REPLACEMENT INTERVAL (HOURS)

1800 1600

Hydraulic oil

1400 1200

Hydraulic Oil Return Filter Element

1000

1000 800

500

500

600 400

250

250

200 0 0%

20%

40%

60%

80%

100%

HYDRAULİC BREAKER OPERATION RATE (%)

Replace Hydraulic Breaker Return Filter every 250 hydraulic breaker operating hour.

CAUTION If the machine is used particularly in a dusty or dirty environment like tunnel, quarry, etc. replace the hydraulic breaker return filter (if exists) more frequently than stated above. Check the hydraulic oil to determine the filter replacement interval.

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8.8. QUICK COUPLING ATTACHMENT Quick coupling attachment is equipped with a double effect cylinder. Attachment has a fixed and a swivel jaw in order to engage bucket from bucket pins. Swivel jaw can swing in and out in connection with hydraulic cylinder. To fix swivel jaw, it has to be moved to the inside.

8.8.1. MOUNTING THE BUCKET Operate the machine and bucket to such a position that the bucket looks to the cab on a straight ground.

Operate the quick coupling attachment to such a position that fixed jaw engages the first pin of the bucket.

3 Press the quick coupling attachment switch on the right hand side console continuously to open the swivel jaw.

4 4

2

1

Operate the arm by joystick to such a position that swivel jaw engages the second pin of bucket.

As you release your finger from the switch, jaw moves upwards and engages with the bucket pin.

5

5

1. Swivel jaw 2. Fixed jaw 3. Safety pin 4. Bucket pin mount 5. Bucket pins

Reinstall the safety pin to prevent possibility of accidental disengagement of the bucket from the attachment.

8.8.2. DISMOUNTING THE BUCKET Park the machine on a level ground and rest the bucket on the floor.

Remove the safety pin.

Press the switch continuously on the right hand side console. While you are pressing, swivel jaw will move downward and bucket pin will be freed.

CAUTION Be sure that safety pin and hydraulic system work smooth after installation of the bucket. Otherwise bucket may disengage from the attachment and this can cause an accidents.

WARNING Before operating the machine be sure that red safety pin is installed on the quick coupling.

Otherwise it may cause quick coupling hydraulic valve to be damaged.

WARNING Be sure that there is no one in the working area of quick coupling attachment installation and adjusting.

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9. APPENDIX 9.1. HAND SIGNALS USAGE OF HAND SIGNALS Do not begin operation until signals are clearly understood.

If non-standard signals are going to be used, be sure that you and your signal person agree on them beforehand.

The operator shall respond only to operating signals from the appointed signal person, but shall obey a stop signal at any time from anybody. A signal person must be fully qualified by training and experience.

A signal person must be in a sufficiently lighted area so as to be clearly visible to the operator during night time operations.

WHILE OPERATING USE HAND SIGNALS

RAISE LOAD VERTICALLY Turn your face to the operator. With either forearm vertical, index finger pointing up, move hand in small horizontal circle.

LOWER LOAD VERTICALLY Turn your face to the operator. With either arm extended downward, index finger pointing down, move hand in small horizontal circle.

MOVE LOAD IN HORIZONTALLY Turn your face to the operator. With either arm extended, hand raised and open toward direction of movement, move hand in direction of required movement.

MOVE LOAD OUT HORIZONTALLY Turn your face to the operator. With either arm extended, hand raised and open toward direction of movement, move hand in direction of required movement.

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RAISE THE BOOM Turn your face to the operator. With either arm extended horizontally, fingers closed, point thumb upward.

LOWER THE BOOM Turn your face to the operator. With either arm extended horizontally, fingers closed, point thumb downward.

SWING TO LEFT Turn your face to the operator. With either arm extended horizontally, point with index finger to direction of swing rotation.

SWING TO RIGHT Turn your face to the operator. With either arm extended horizontally, point with index finger to direction of swing rotation.

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“ARM” INWARD Turn your face to the operator. With both hands clenched, point thumbs inward.

“ARM” OUTWARD Turn your face to the operator. With both hands clenched, point thumbs outward.

COUNTER ROTATE TO LEFT Turn your face to the operator. Place your right hand on head. Move your left hand in vertical circle indicating forward rotation of other wheel.

COUNTER ROTATE TO RIGHT Turn your face to the operator. Place your left hand on head. Move your right hand in vertical circle indicating forward rotation of other wheel.

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TRAVEL TO FORWARD Turn your face to the operator. Move fists in vertical circle about each other in direction of wheel rotation

TRAVEL TO BACKWARD Turn your face to the operator. Move fists in vertical circle about each other in direction of wheel rotation.

CLOSE BUCKET Turn your face to the operator. Hold one hand closed and stationary. Rotate other hand in small vertical circle with index finger pointing horizontally at closed hand.

OPEN BUCKET Turn your face to the operator. Hold one hand closed and stationary. Rotate other hand in small vertical circle with index finger pointing horizontally at open hand.

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TURN TO LEFT Turn your face to the operator. Raise forearm with closed fist indicating inside of turn. Move other fist in vertical circle indicating direction of wheel rotation.

TURN TO RIGHT Turn your face to the operator. Raise forearm with closed fist indicating inside of turn. Move other fist in vertical circle indicating direction of wheel rotation.

THIS FAR TO GO Turn your face to the operator. With hands raised and open inward, move hands laterally, indicating distance to go.

MOVE SLOWLY Turn your face to the operator. Place one hand motionless in front of hand giving motion signal.

(Raise load slowly as shown.)

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TOP Turn your face to the operator. With either arm extended laterally, hand open downward, move arm back and forth.

EMERGENCY STOP Turn your face to the operator. With either arm extended laterally, hands open downward, move arms back and forth.

STOP ENGINE Turn your face to the operator. Draw thumb or index finger across throat.

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9.2. CONTACTS 9.2.1. FACTORY AND SERVICE DEPARTMENT HEAD OFFICE AND FACTORY Address : Ahi Evran OSB Mahallesi Osmanlı Caddesi No: 1 Sincan/ANKARA TURKEY Phone :+90 312 267 12 60 (20 Lines) Fax :+90 312 267 12 39 Internet : www.hidromek.com.tr E-mail : info@hidromek.com.tr AFTER SALES SERVICES DEPARTMENT : Şehit Osman Avcı Mahallesi No: 479 (İstanbul Yolu 17. km) 06973 Adress Eryaman / ANKARA TURKEY Phone : +90 312 280 87 40 (8 Lines) Fax : +90 312 280 87 48 Spare Parts Fax : +90 312 280 87 49

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10. ALPHABETICAL INDEX

A Accumulator ........................................................ 11 Additional works................................................ 133 Air condition belt ............................................... 204 Air condition filter .............................................. 215 Air filter inner / outer element ........................... 217 Air filter outer element....................................... 216 Anti-freeze density ............................................ 201 Asbestos ............................................................... 9 Automatic/manual mode switch .......................... 95 Axle differential oil ..................................... 191, 207 Axle differential oil level .................................... 202 Axle planetary gear oil .............................. 191, 207 Axle planetary gear oil level .............................. 202 B Backhoe work ................................................... 133 Battery relay ........................................................ 95 Before maintenance............................................ 26 C Cautions during operation................................. 131 Check after stopping the engine ....................... 136 Check the brake................................................ 185 Checking and replacing the bucket teeth ......... 181 Checking battery electrolyte level ..................... 194 Checks after finishing work ............................... 136 Cleaning the breather of hydraulic tank ............ 181 Coolant level ....................................................... 27 Coolant level check ........................................... 174 Cooling system ................................................. 208 Cruise function .................................................. 128

Fuel filter element ............................................ 196 Fuel level check ............................................... 177 Fuel tank sediment removing ........................... 187 Fuel transfer pump ........................................... 213 Fuse / relay box ................................................. 93 G Gas lines ............................................................ 10 Greasing attachment pins ................................ 184 Greasing dozer blade pins ............................... 188 Greasing front axle pin ..................................... 188 Greasing outrigger pins .................................... 188 Greasing shaft .................................................. 203 Greasing steering joint and axle joint housing . 203 Greasing swing gear bearing ........................... 187 Greasing the swing driving case ...................... 190 H High temperature ........................................... 8, 29 High-pressure hoses .......................................... 29 High-pressure oil ................................................ 29 Hydraulic oil return filter element replacing ..... 189, 204 Hydraulic tank level check ............................... 180 I Indicators............................................................ 80 Inspections before starting the engine ............. 107 K Keep the machine clean .................................... 28 L

D Detached attachment.......................................... 27 Ditching work .................................................... 133 Door lock mechanism ....................................... 102 Dozer blade ...................................................... 127 E Electric wire check ............................................ 181 Engine oil filter, replacing.................................. 198 Engine oil level check ....................................... 175 Engine oil, replacing ......................................... 198 Engine valve clearance..................................... 204 Every 10 hour ................................................... 173 Every 1000 hour ............................................... 204 Every 2000 hour ............................................... 206 Every 250 hour ......................................... 193, 195 Every 50 hour ................................................... 187 Every 500 hour ................................................. 196 F Fire ........................................................................ 8 Fire extinguisher ................................................... 9 First 250 hour .................................................... 189 First-aid kit .................................................... 9, 100 Forward travel ................................................... 123

Left lever .......................................................... 126 Levers ................................................................ 88 Lifting ................................................................ 134 Light usage......................................................... 27 Lighter .............................................................. 100 Loading work .................................................... 133 Locking system ................................................ 138 M Mirror adjustment ............................................. 105 Modifications ........................................................ 7 Monthly service ................................................ 193 Moving parts......................................................... 9 Multi-function lever ............................................. 82 O Operating attachments ..................................... 126 Operating dozer blade ..................................... 127 Operating levers ................................................. 88 Operating outriggers ........................................ 127 Operators ............................................................. 7 Outriggers .................................................. 20, 127 P Park mode .......................................................... 84 237

Parking procedure ............................................ 124 Pilot filter element ............................................. 204 Pilot filter element replacing.............................. 189 Prohibitions during operation ............................ 129 Proper tools ........................................................ 26 R Radiator ............................................................ 201 Read manual ...................................................... 26 Replacing bucket .............................................. 135 Replacing the coolant ....................................... 208 Right lever ......................................................... 126 Rotating fan and belt........................................... 30 S Safety devices ...................................................... 7 Safety equipment .................................................. 7 Seat belt ............................................................ 106 Security parts ...................................................... 26 Shovel work ...................................................... 133 Speed selection switch ....................................... 81 Start switch ......................................................... 74 Starting at room temperature warning .............. 108 Starting in cold weather .................................... 109 Starting the engine............................................ 108 Starting the machine ......................................... 123 Steering............................................................... 79 Steering column .................................................. 79

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Stopping the engine ......................................... 136 Swing driving case oil ...................................... 204 Swinging the machine ...................................... 125 T Tire pressure ...................................................... 30 Tires ................................................................... 30 Transmission oil ....................................... 192, 207 Travel direction control ..................................... 125 Travel mode ....................................................... 84 U Under maintenance ............................................ 27 V Visual inspection .............................................. 173 W Warning tag ........................................................ 26 Waste ................................................................. 30 Water separator sediment................................ 186 Weekly service ................................................. 187 Work and travel mode ........................................ 84 Working under the machine ............................... 27 Y Yearly service................................................... 206

NOTES ……………………………………………………………………………………………………………………………… ……………………………………………………………………………………………………………………………… ……………………………………………………………………………………………………………………………… ……………………………………………………………………………………………………………………………… ……………………………………………………………………………………………………………………………… ……………………………………………………………………………………………………………………………… ……………………………………………………………………………………………………………………………… ……………………………………………………………………………………………………………………………… ……………………………………………………………………………………………………………………………… ……………………………………………………………………………………………………………………………… ……………………………………………………………………………………………………………………………… ……………………………………………………………………………………………………………………………… ……………………………………………………………………………………………………………………………… ……………………………………………………………………………………………………………………………… ……………………………………………………………………………………………………………………………… ……………………………………………………………………………………………………………………………… ……………………………………………………………………………………………………………………………… ……………………………………………………………………………………………………………………………… ……………………………………………………………………………………………………………………………… ……………………………………………………………………………………………………………………………… ……………………………………………………………………………………………………………………………… ……………………………………………………………………………………………………………………………… ……………………………………………………………………………………………………………………………… ……………………………………………………………………………………………………………………………… ………………………………………………………………………………………………………………………………

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