Transcript
DUMPER HP2500
AND ACCESSORIES INTERCHANGEABLE MANUAL USE AND MAINTENANCE Valid from serial number 33.
MUHP250020307
INDEX CHAPTER
1 1.1 1.2 1.3 1.4 1.5
INTRODUCTION ...................................................................................Page 04 Summary chart........................................................................................Page 05 Understanding and learning safety informationa .............................Page 06 Authorised uses ......................................................................................Page 07 Unauthorised uses ..................................................................................Page 07 Identification data...................................................................................Page 08
CHAPTER
2 2.1 2.2 2.3 2.4 2.5 2.6 2.6.1 2.6.2 2.6.3 2.6.4 2.6.5 2.6.6 2.7 2.8
SAFETY REGULATIONS .....................................................................Page 09 Safety warnings (stickers)......................................................................Page 09 Placing safety warnings .........................................................................Page 09 Noise plates ............................................................................................Page 10 Other pictograms located on the machine ..........................................Page 11 General warning .....................................................................................Page 12 - 14 Precautions when working ...................................................................Page 15 Precautions when starting the machine ..............................................Page 15 Precautions when driving .....................................................................Page 15 Precautions when transporting loads..................................................Page 15 Parking and stopping on slopes ...........................................................Page 16 Transporting the machine......................................................................Page 16 - 17 Using rubber tracks ................................................................................Page 17 - 18 Maintenance precautions.......................................................................Page 18 - 19 Battery ......................................................................................................Page 20
CHAPTER
3 3.1 3.2 3.2.1 3.2.2 3.2.3 3.3 3.3.1 3.3.2 3.3.3 3.4 3.5
DESCRIPTION AND USE OF THE DUMPER ..................................Page 21 Terminology ............................................................................................Page 21 Operating instructions ...........................................................................Page 22 Driving position and controls: fixed undercarriage .........................Page 22 Driving position and controls: extendable carriage .........................Page 22 Operating board......................................................................................Page 23 - 25 Moving the machine...............................................................................Page 26 Operating crawler...................................................................................Page 26 Operating shift change gear ..................................................................Page 27 Operating extendable carriage.............................................................Page 27 Flat battery ..............................................................................................Page 28 Starting with cables ................................................................................Page 28
CHAPTER
4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.7.1 4.7.2 4.7.3 4.7.4 4.7.5 4.7.6 4.8 4.8.1 4.8.2 4.8.3 4.8.4 4.8.5 4.8.6
MAINTENANCE....................................................................................Page 29 Preparing the machine for maintenance .............................................Page 29 Engine hour meter ..................................................................................Page 29 Safe maintenance ....................................................................................Page 29 Access to the engine ...............................................................................Page 30 Screws and nuts torque.........................................................................Page 31 Recommended fluids and lubricants...................................................Page 31 - 32 Engine maintenance ...............................................................................Page 33 Engine oil ................................................................................................Page 33 Engine oil filter........................................................................................Page 34 Maintenance of the engine oil filter .....................................................Page 34 - 35 Replacing the gasoil filter ......................................................................Page 35 - 36 Removing the air from the air system .................................................Page 36 Decanter cleaning and water draining ................................................Page 37 - 38 Rubber track maintenance.....................................................................Page 39 Checking track tension...........................................................................Page 39 Operations to loosen or tighten track ..................................................Page 39 Checking rubber tracks..........................................................................Page 40 - 41 Replacing rubber tracks .........................................................................Page 41 Removing rubber track ..........................................................................Page 42 Fitting rubber track.................................................................................Page 42
1
CHAPTER
5 5.1 5.1.1 5.1.2 5.2
HYDRAULIC SYSTEM ..........................................................................Page 43 Checking hydraulic oil...........................................................................Page 43 Replacing hydraulic oil ..........................................................................Page 43 Replacing hydraulic oil filter cartridge ...............................................Page 43 Hydraulic system diagram ...................................................................Page 44 - 45
CHAPTER
6 6.1 6.2 6.3 6.4
COOLING SYSTEM ...............................................................................Page 46 Checking coolant level ...........................................................................Page 46 Changing coolant ...................................................................................Page 46 External cleaning of the radiator ..........................................................Page 47 Checking fan belt tensioning ...............................................................Page 47
CHAPTER
7 7.1
ELECTRICAL SYSTEM..........................................................................Page 48 - 50 Electric system diagram.........................................................................Page 51 - 53
CHAPTER
8 8.1 8.2
STORAGE AND REMOVAL OF THE MACHINE...................................Page 54 Storage of the machine...........................................................................Page 54 Removing the machine after storage ...................................................Page 54
CHAPTER
9 9.1
TECHNICAL SPECIFICATIONS ........................................................Page 55 Technical specifications..........................................................................Page 56
CHAPTER
10 10.1 10.2
TROUBLE SHOOTING .........................................................................Page 57 Engine.......................................................................................................Page 58 - 60 Hydraulic system....................................................................................Page 61 - 64
CHAPTER
11
APPENDIX ..............................................................................................Page 65
CHAPTER
12
INTERCHANGEABLE KITS FOR MINIDUMPER HP2500...................Page 70
CHAPTER
12.1 12.1.1 12.1.2 12.1.3
TRACK KIT ..............................................................................................Page 70 Connecting the track kit to the machine..............................................Page 70 Terminology .............................................................................................Page 70 Technical specifications ...........................................................................Page 71
CHAPTER
12.2 12.2.1
12.2.6 12.2.7 12.2.8 12.2.9
SELF LOADING LIFTING BUILDING KIT .....................................Page 72 CONNECTING SELF LOADING LIFTING BUILDING KIT TO THE MACHINE ...............................................................................Page 72 TERMINOLOGY ....................................................................................Page 73 DRIVER’S SEAT AND CONTROLS ....................................................Page 74 CONTROLS DESCRIPTION ................................................................Page 74 Operating precaution .............................................................................Page 76 12.2.5.1 General use of the minidumper.............................................Page 76 12.2.5.2 Use of the hi tip self loading dumper bed.............................Page 76 12.2.5.3 Use of the self loading bucket (only on hi tip dumper with self loading system)..............................Page 76 12.2.5.4 Never work in dangerous areas..............................................Page 77 12.2.5.5 LIFTING MEMBERS MAINTENANCE................................Page 77 Greasing points ......................................................................................Page 78 Storage of the machine ..........................................................................Page 78 Technical specifications .........................................................................Page 79 Hydraulic system diagram ...................................................................Page 80
12.3 12.3.1 12.3.2 12.3.3 12.3.4 12.3.5
ROTATING BUILDING KIT...................................................................Page 82 Connecting rotating building kit to the machine...............................Page 82 Terminology .............................................................................................Page 83 Driver’s seat and controls ......................................................................Page 84 Description of the controls......................................................................Page 84 Greasing points .......................................................................................Page 85
12.2.2 12.2.3 12.2.4 12.2.5
CHAPTER
2
12.3.6 12.3.7 12.3.8
Storage of the machine...........................................................................Page 86 Technical specifications..........................................................................Page 87 Hydraulic system diagram....................................................................Page 88
CHAPTER
12.4 12.4.1 12.4.2 12.4.3 12.4.4 12.4.5 12.4.6 12.4.7 12.4.8
SELF-LOADING BUILDING KIT..........................................................Page 90 Connecting the self loading kit to the machine .........................................Page 90 Terminology .............................................................................................Page 91 Driver’s seat and controls ......................................................................Page 92 Description of the controls......................................................................Page 92 Greasing points .......................................................................................Page 94 Storage of the machine...........................................................................Page 94 Technical specifications..........................................................................Page 95 Hydraulic system diagram....................................................................Page 96
CHAPTER
12.5 12.5.1 12.5.2 12.5.3 12.5.4 12.5.5 12.5.6 12.5.7 12.5.8
BUILDING KIT ........................................................................................Page 98 Connecting the building kit to the machine ...............................Page 98 Terminology .............................................................................................Page 99 Driver’s seat and controls........................................................................Page 100 Description of the controls......................................................................Page 100 Greasing points .......................................................................................Page 101 Technical specifications..........................................................................Page 101 Technical specifications..........................................................................Page 102 Hydraulic system diagram....................................................................Page 103
CHAPTER
12.6 FM1300 FORKLIFT KIT ..........................................................................Page 105 12.6.1 EC Declaration of conformity ...............................................................Page 105 12.6.2 Identification data...................................................................................Page 106 12.6.3 Safety standards......................................................................................Page 107 12.6.3.1 Safety warnings (labels) .........................................................................Page 107 12.6.3.2 General precautions ...............................................................................Page 111 12.6.3.3 Precautions to be taken before starting the engine............................Page 111 12.6.4 Nomenclature..........................................................................................Page 112 12.6.5 Connecting the FM1300 forklift kit to the minidumper....................Page 113 12.6.6 Precautions for use .................................................................................Page 116 12.6.6.1 General use of the minidumper............................................................Page 116 12.6.6.2 Use of the forklift kit ..............................................................................Page 116 12.6.6.3 Do not work in dangerous areas ..........................................................Page 118 12.6.7 Manoeuvring the machine ....................................................................Page 119 12.6.7.1 Precautions when working ...................................................................Page 119 12.6.8 Driving position and controls ...............................................................Page 120 12.6.9 Handling the machine............................................................................Page 121 12.6.9.1 Undercarriage operation .......................................................................Page 121 12.6.9.2 Moving the forklift forwards ................................................................Page 122 12.6.9.3 Tilting the forks.......................................................................................Page 122 12.6.9.4 Second travel speed................................................................................Page 123 12.6.9.5 Fork lift control lever..............................................................................Page 123 12.6.9.6 Handling the load...................................................................................Page 124 12.6.9.7 Lifting points ...........................................................................................Page 125 12.6.10 Routine maintenance..............................................................................Page 127 12.6.10.1 Prepare the machine for routine maintenance ...................................Page 127 12.6.10.2 Greasing points .......................................................................................Page 127 12.6.10.3 Maintenance on the lifting mechanisms..............................................Page 128 12.6.10.4 Storing the machine................................................................................Page 128 12.6.11 Technical specifications .........................................................................Page 129 12.6.11.1 Technical data..........................................................................................Page 129 12.6.11.2 Hydraulic system diagram....................................................................Page 130 12.6.11.2.1 Key to the hydraulic system diagram...............................Page 130 12.6.11.3 Electrical system diagram......................................................................Page 131 12.6.11.3.1 Key to the electrical system diagram ................................Page 131
3
INTRODUCTION
• This manual gives the customer all the information on the machine and its safety rules as well as operating and maintenance instructions to get the most out of the machine, keeping it efficient in time. • The operator’s manual is an integral part of the machine and it must always be kept with it until its final discarding. • This manual must always be on board of the machine and of easy access for quick consultation. • This manual must be given to operators.
CAREFULLY READ THIS MANUAL BEFORE STARTING, OPERATING, MAINTAINING, REFUELLING OR DOING ANY OPERATIONS ON THE MACHINE.
• You can request a copy of this manual to Hinowa S.p.A if it were lost or damaged. • The form enclosed into the manual must be filled in; all the features data of the machine must always be supplied to the Dealer or to Hinowa Spa if needed or when ordering spare parts. • We remind you that our after sales service is always at your complete disposal to help you keep your Dumper in a perfect operating order. Even after the warrantee has expired, our After Sales Service will remain at your disposal to ensure the service you might need and to supply you with ORIGINAL SPARE PARTS, which are the only ones guaranteeing a perfect quality replacement. Wherever your country or your working place are, our AFTER SALES service will supply you with useful information or repairs.
CAUTION • Being compact and easy to manoeuvre, any improper use and maintenance of the Dumper have risks and can cause serious damage or even death to people. THE MACHINE OPERATOR MUST BE A PROPERLY TRAINED PERSON AND HAVE EXPERIENCE IN OPERATING MACHINES BEFORE STARTING ANY JOBS.
4
INTRODUCTION
1.1
SUMMARY CHART
SERIAL N° ....................................................
DUMPER MOD. ........................................
ENGINE MAKE ....................................................
SERIAL N° ........................................
DEALER DATA .......................................................................................................................... NAME
................................................................................................................................ ................................................................................................................................
ADDRESS
................................................................................................................................ ................................................................................................................................ ................................................................................................................................
PERSON TO CONTACT ......................................................................................................................
NOTES: .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... ....................................................................................................................................................................
5
INTRODUCTION
1.2
UNDERSTANDING AND LEARNING SAFETY INFORMATION
To avoid accidents, read, understand and follow all precautions and warnings included in this manual before starting work or carrying out any maintenance operations. This is a safety -warning signal. Take care when you see this sign on the machine or on this manual, as there is a potential danger of bodily injury. Take the necessary precautions and follow safety operating procedure. Words DANGER and CAUTION are used along with the warning and safety signs. The word DANGER indicates the most serious risks, which could cause serious injuries or even death if danger is not avoided. It can also cause damage to the machine. The word CAUTION indicates potentially dangerous situations that, if ignored, can cause light damages or bodily injury. This wording can also be used for dangerous situations causing damage to the machine. You can find this sign in situations in which the machine life could be shortened if the necessary measures are not taken.
FOLLOW SAFETY INSTRUCTIONS Carefully read the meaning of all safety messages in this manual and safety signs on the machine. Check that the safety signs are in proper working condition, replacing the damaged and missing ones. Make sure that the new equipment bears correct signs when replacing new parts or tools. Learn the correct way to operate the machine and the controls. Never allow anyone to operate the machine without instructions. Keep the machine in good operational conditions. Unauthorised alterations on the machine could interfere with the working and/or safety and life of the machine itself.
6
DANGER
CAUTION
IMPORTANT
INTRODUCTION
1.3
AUTHORISED USES
The Dumper Hinowa described here accurately in this manual can only be used by properly trained people.
1.4
UNAUTHORISED USES
WARNING The company Hinowa cannot always foresee all the potentially dangerous circumstances when using and maintaining the machine. If you follow all the instructions and operations allowed for this machine, you can be sure that the operator and the people nearby can operate safely and without any risk of damaging the machine. Please contact us in case of doubt about safety procedures. Beside the indications given in the following chapter regarding rules for preventing accident and on safety procedures, you must avoid the following uses: -
Machine operated by unskilled people Operating the machine for lifting people Transporting containers of toxic or high risk products Operating the machine for the towing of other equipment.
7
INTRODUCTION
1.5
IDENTIFICATION DATA
IDENTIFICATION OF THE DUMPER The Hinowa Dumpers described in this present manual are CE marked as they meet with the assimilated EEC regulations.
The plate with the CE marking and the machine identification data are on the distributor support.
ENGINE IDENTIFICATION
The mounted engine identification number is printed on the plate placed on the engine itself.
KIT IDENTIFICATION
Even the kit coupled to the dumper carries a plate reporting the supplier’s data.
8
SAFETY REGULATIONS
2
SAFETY REGULATIONS
2.1
SAFETY WARNINGS (STICKERS)
Read the safety messages on this manual and the safety signs on the machine. Check that the safety signs are in proper condition and replace damaged or missing ones. Make sure that when replacing components or new equipment they carry the proper safety signs. Learn the correct way to operate the machine and controls. Never allow unauthorised or unskilled people to operate the machine and/or do its maintenance.
2.2
PLACING SAFETY WARNINGS
• MACHINE IN MOVEMENT Never come close to the machine in movement and keep out of its working range.
9
SAFETY REGULATIONS
2.3
NOISE PLATES
EXTERNAL NOISE This figure indicates the external noise level of the machine and refers to the noise heard by people near the working site.
10
SAFETY REGULATIONS
2.4
OTHER PICTOGRAMS LOCATED ON THE MACHINE
HYDRAULIC OIL FILTER
HYDRAULIC OIL LEVEL
HYDRAULIC OIL
FUEL
LIFTING POINTS
11
SAFETY REGULATIONS
2.5
GENERAL WARNING
CLOTHING AND PROTECTIVE WEAR Avoid wearing loose clothes, rings, watches, long hair, belts, shoes, ties, bracelets and anything that could get entangled inside the rotating parts. Do not wear clothes stained with oil or fuel, as they can be flammable. When operating the machine or doing maintenance work, wear a protection helmet, safety glasses and safety shoes, a mask, gloves and noise protection earmuffs. UNAUTHORISED ALTERATIONS It is absolutely forbidden to do any alterations on the machine which could damage its working or its safety. Hinowa declines any responsibility for injury or damage caused by unauthorised alterations. SAFETY VALVES Never alter or/and tamper with the safety valves and the controls in the hydraulic system. Hinowa declines any responsibility for injury to people, damage to things and to the machine when the hydraulic valve standard gauging have been tampered with.
GETTING IN AND OUT THE MACHINE • Get into the machine without clinging onto the servo controls. • When getting on and off the machine always keep three anchoring or supporting points using the proper handles and footboards. • Always do on and off manoeuvres with care. • Clean any oil or debris properly from handles and footboards.
12
SAFETY REGULATIONS
FIRE PREVENTION Keep the engine compartment clean; remove any pieces of wood, paper and other flammable products; clean any fuel, oil or flammable fluid leaks properly, as they can be potential fire risks. Petrol is extremely flammable and explosive under certain conditions. Refuel in a well-ventilated place and when the engine is off. Never smoke or cause sparks in the refuelling place or the fuel storage place. Never fill the tank too much. After refuelling, make sure that the cap is closed safely and properly. Make sure that there is no fuel leak when refuelling. Petrol fumes or possible leaks might catch fire. Make sure that the area is dry before starting the engine. The exhaust pipe gets overheated during work and remains hot even after the engine has been turned off. Take care not to touch the exhaust pipe when it is hot.
FIRE EXTINGUISHER AND FIRST AID KIT
Regularly check the first aid kit and make sure that there are fire extinguishers on the working area. It is essential to know how to use both properly. Both the coolant and the oil inside the engine and the hydraulic system reach very high temperatures. Before checking the levels and doing any maintenance work where there are fluids at high temperature, turn off the engine and wait until it has cooled down. Before doing any maintenance in the presence of hot oil or hot coolant, put on gloves, glasses and heavy clothing. To remove the radiator cap first let the system cool down, then unscrew the cap slowly and wait until the pressure discharges and finally remove the cap.
13
SAFETY REGULATIONS
WARNING AGAINST DAMAGES CAUSED BY THE WORKING MACHINE Avoid staying in the working range of the machine when it is operating.
WARNING REGARDING THE OPTIONAL KIT Only use equipment authorised by Hinowa and after carefully reading its relative operator’s manual. Hinowa declines any responsibility for damages to the machine, to people and things and if unauthorised equipment has been used.
PRECAUTIONS TO TAKE BEFORE STARTING THE ENGINE Before starting the engine, carefully check the conditions of the working ground to find any possible irregularities, which might make working dangerous. Always take care of people entering on the working area of the machine.
14
SAFETY REGULATIONS
2.6
PRECAUTIONS WHEN WORKING
DANGER PERICOLO 2.6.1 PRECAUTIONS WHEN STARTING THE MACHINE Before starting, walk around the machine and carefully inspect it. Warn people nearby when about to start the machine. Never allow anyone to climb onto the machine.
2.6.2 PRECAUTIONS WHEN DRIVING To avoid possible accidents and loss of control, never climb onto the carriage. Place yourself behind it and take a good grip of the handle. Keep children or animals away from the working area to avoid injuries due to contact with the machine. NEVER USE THE MINIDUMPER AT NIGHT
2.6.3 PRECAUTIONS WHEN TRANSPORTING LOADS Make sure that the load is secured, that it does not come out of the carriage outline and obstruct the operator’s visibility. In order to avoid tipping over, make sure not to change directions of transport carriage when going up slopes. Never make the carriage go up slopes with an inclination over 25° or going down slopes with an inclination over 25°. Take care when reversing with the carriage, as there are higher risks of falling of skidding. When going up steep slopes, always drive at minimum speed. Never reverse when going down slopes.
15
SAFETY REGULATIONS
2.6.4
PARKING AND STOPPING ON SLOPES
CAUTION: parking and stopping on slopes is very dangerous. If parking or stopping on a slope cannot be avoided take the following precautions: 1. If the engine races on a slope, put all the levers in the neutral position and then start the engine again. 2. When stopping on a slope, even for a short time, put blocks under the downward tracks. 3. Before trying to start on a slope, make sure that the engine and the hydraulic oil are properly warmed up. Otherwise, the slow moving of the machine on a steep hill could cause problems.
2.6.5
TRANSPORTING THE MACHINE
LOADING THE MACHINE ON A LOW BED TRUCK. Always load and unload on flat and solid ground. CAUTION: Always remember to use a ramp or a loading platform to load/unload. 1. The ramps must be strong enough to bear the weight of the machine. Make sure that the inclination of the ramps is not under 15°. 2. The loading platforms must be large and resistant enough and have a suitable slant so that the machine can travel on them. 3. Before loading the machine, thoroughly clean the ramp and the bed. Ramps or beds dirty with oil, mud or ice and be slippery and dangerous.
INCLINATION LOWER THAN 15° INCLINAZIONE INFERIORE A 15°
CAUTION: during cold weather warm up the engine properly before loading/unloading.
16
SAFETY REGULATIONS
CAUTION: 1. Avoid steering when going up and down ramps, as it can be extremely dangerous. If you have to steer, first go back to the ground or the low bed, change direction and start driving again. 2. Never move any other lever than the gear lever when going up and down the ramp otherwise the machine might become unbalanced. 3. There is a bump at the end of the ramp at the beginning of the bed. Take care when crossing it. 4. Drive the machine slowly up the ramp. 5. The mid-line of the machine must be on the mid-line of the trailer. IMPORTANT: fasten chains or cables to the machine frame. Never put chains or cables against hydraulic tubes. 6. Put wedges in front and behind the tracks. 7. Fix every corner of the machine and the front tool to the trailer with a chain or a cable equipped with a proper load fastener. During transport, turn the fuel valve onto the OFF position and make sure that the engine is flat to avoid oil leaks. Petrol fumes or possible leaks could take fire.
PRECAUTIONS
WHEN TRANSPORTING THE MACHINE WITH RUBBER TRACKS
When transporting a machine on rubber tracks remember to fix the frame of the right and left track properly to the truck bed using metallic cables or soft guards. Never allow metallic cables to come in contact with the rubber tracks.
2.6.6
USING RUBBER TRACKS
Avoid the following situations when working with an undercarriage on rubber tracks: 1. Never manoeuvre on hard, stony and irregular surfaces like, for example, riverbed rocks), gravel etc. 2. Never keep rubber tracks under direct sunlight for more than 3 months. 3. Try to avoid as much as possible steering on asphalt or cement, as you would cause excessive wear of the skids. Avoid also steering on asphalt roads when their temperature exceeds 60°C, as this could not only cause damage to the skids by also to the tarmac. 4. Manoeuvring with a loose track on an irregular surface can cause the detaching of the skid and/or damages to the rubber track. 5. The rubber tracks are meant to be used on soft and not hard and abrasive surfaces like sand, stones, minerals etc. Using rubber tracks on these surfaces could cause early wear
17
SAFETY REGULATIONS
6. 7. 8. 8.
and deformation. Try to avoid that the rubber track comes in contact with sharp concrete edges etc. Fuels or synthetic oils must never come in contact with the rubber track. If it happens clean it immediately. Avoid using the rubber track along the sea as salty air and salt in general corrode the adhesion between the tyre and the inner metal core. L’uso del cingolo in gomma in zone litoranee marine dovrebbe essere evitato, perché l’aria salina o il salino in genere corrode l’adesione fra la gomma e l’anima metallica interna.
2.7
MAINTENANCE PRECAUTIONS
TOOLS The tools placed inside their bag must always come along with the machine. After using the tools they must be properly cleaned and put back inside their container.
EQUIPMENT The stored equipment can fall and cause serious injury and even death. To move optional kits use lifting cables and hooks in good condition. Store safely equipment and accessories to prevent them from falling. Keep children and people away from the storage area.
USING THE ENGINE DURING MAINTENANCE Only do maintenance with the engine on when it is absolutely necessary and keep a person at the driver’s seat to stop the engine each time it is necessary. PRECAUTIONS TO TAKE WHEN HANDLING HIGH PRESSURE OIL The liquid that comes out under pressure can penetrate your skin and cause serious injury.
18
SAFETY REGULATIONS
Avoid danger by zeroing the pressure before removing the hydraulic tubes or other tubes. Tighten all the connectors before pressurising. Use a piece of cardboard to look for leaks. Protect your hands and body against high-pressure liquids and always wear safety glasses and gloves. In case of accident, immediately contact a doctor. If the liquid is injected under the skin it must be surgically removed within few hours otherwise this could cause serious pathologies.
BELT AND COOLING FAN Take care when coming close to moving or rotating parts (fan blade or fan belt) as they could cause serious health hazard to people.
DISPOSING OF WASTE MATERIAL Discard liquids according to current environmental regulations in order to avoid severe damage to environment. Inform yourselves about current regulations before discarding any liquid. Only use proper containers when discarding liquids. Never use containers meant for food or drinks as it might induce someone to drink from it. NEVER POUR lubricants on the ground, in sewer, canals, ponds or streams. Always observe current environmental regulations when discarding oil, fuel, coolant, batteries and other harmful discard.
19
SAFETY REGULATIONS
2.8
BATTERY
PREVENTING DANGER DERIVING FROM THE BATTERY Before doing any maintenance jobs on the electrical system, stop the machine by turning the ignition key OFF and disconnect the battery. The acid contained is extremely corrosive for clothes and dangerous for the operator’s eyes and skin. In case of contact, wash the interested area with water and see a doctor. If swallowed, drink antacids and call immediately for a doctor. When the electrolyte is frozen, the battery could explode if there are any attempts to load it or if the battery is connected to another load to start the machine. Always wear heavy gloves and safety glasses when working on the battery. Never cause sparks and avoid smoking near the battery as it produces easily flammable hydrogen. The terminals must never be inverted and must always be properly tightened to avoid sparks.
20
DESCRIPTION AND USE OF THE DUMPER
3
DESCRIPTION AND USE OF THE DUMPER
3.1 TERMINOLOGY To help you understand all the safety and instruction warning as well as the operating and maintenance instructions of the minidumper HP 2500, you will find all the names of the machine main parts below:
14
15
16
17
8 9
7
12
13 4
5
3
2
1
11
18
19
10
6
KEY 1 2 3 4 5 6 7 8 9 10
-
Track tensioner sprocket Rubber crawler frame Roller Traction reduction unit Sprocket Rubber track Hydraulic oil tank Hydraulic distributor Fuel tank Engine
11 12 13 14 15 16 17 18 19
-
Water separator Footboard Hydraulic pump Battery Roll bar Radiator Air filter Gas-oil filter Engine oil filter
21
DESCRIPTION AND USE OF THE DUMPER
3.2
OPERATING INSTRUCTIONS
3.2.1 DRIVING POSITION AND CONTROLS
A E
A B E F G
22
B
- Lever translation movement left - Lever translation movement right - Lever to tilt or rotate the skip (optional) - Lever to control the skip (optional) - Hi-tip master lever (optional)
C
G
F
D
C - 2 speed lever D - Accelerator control
DESCRIPTION AND USE OF THE DUMPER
3.2.2 OPERATING BOARD 8
1
9
10
3
2
5
4
6
7
1 - ELECTRIC SYSTEM FUSE BOX
2 - ELECTRIC SYSTEM SWITCH AND START/STOP IGNITION SWITCH
AT E H
OFF
ON
START
- HEAT position Pre-heating sparkling plugs - OFF position No live circuit (key can be pulled out) - ON position Ready for engine ignition; signals and control gauges working; Live miscellaneous users. - START position Engine start The key automatically returns into ON position.
Starting engine Turn key from OFF to HEAT position. Once the spark plugs have heated (light 9 is on), turn key into START position and release key back to ON position. Stopping engine Turn key into OFF position and then pull it out.
23
DESCRIPTION AND USE OF THE DUMPER
3 - HOUR COUNTER There are 5 digits on the hour counter: the black digits show the working hours and the red ones (the last ones on the right) the tenths of hours.
4 - INDICATOR (red) ON: THE BATTERY IS NOT RECHARGING PROPERLY If everything works properly, the indicator comes on when the electric system ignition key is turned on and it goes off once the engine has started. Improper working can be when: - the indicator stays on when the engine is running: check alternator and tension on the alternator belt; - the indicator stays off both when the engine is on or off: check the indicator lamp and the protective fuse. If you cannot identify the cause, contact a specialist.
5 - SEGNALATORE (ROSSO): INSUFFICIENTE PRESSIONE DELL’OLIO DI LUBRIFICAZIONE DEL MOTORE L’accensione della spia segnala pressione insufficiente dell’olio che può essere causata da: - regime minimo del motore troppo basso; - insufficiente livello dell’olio; - impiego dell’olio di viscosità non adatta alla temperatura stagionale; - anomalie di funzionamento del circuito. AVVERTENZA: anche quando tutto è normale, il segnalatore può accendersi se il motore è molto caldo ed a basso regime.
6 - INDICATOR (red) ON: OVERHEATING OF THE ENGINE COOLING WATER Overheating can be due to: - lack of water in the radiator; - deposits in the cooling circuit (remove through washing); - the fan drive belt is slipping; - defective thermostats; - cooling circuit not working properly.
24
DESCRIPTION AND USE OF THE DUMPER
7 - INDICATOR (yellow) ON: FUEL WARNING If the light comes on, this means there is about 5 L fuel left in the tank.
8 - 12 V SOCKET
9 - SPARK PLUG PRE-HEATING RESISTANCE When the key is on HEAT, the resistance becomes incandescent meaning the engine must start.
10 - HORN SWITCH (OPTIONAL)
25
DESCRIPTION AND USE OF THE DUMPER
3.3
MOVING THE MACHINE
3.3.1 OPERATING CRAWLER
Shift in straight line Move both joysticks forward to go in a straight line. Pull both joysticks backward to reverse.
Steering leftward and rightward To turn right: move left joystick forward. To turn left: move left joystick forward.
Steering on axle Move one joystick forward and the other one backward.
26
DESCRIPTION AND USE OF THE DUMPER
3.3.2
OPERATING SHIFT CHANGE GEAR
To change the translation speed of the undercarriage move the handle indicated in the picture.
27
DESCRIPTION AND USE OF THE DUMPER
3.4
FLAT BATTERY
DANGER Follow the indications at point PREVENTING DANGERS DERIVING FROM BATTERY • Remove the battery and disconnect the terminals taking care to remove the earth one first (-). • Install the battery and connect the terminals taking care to install the positive one first (+).
3.5
STARTING WITH CABLES
DANGER • When starting the engine with another machine, connect the battery parallel (+ with + and – with - ). • Avoid contact between the positive (+) and the negative (-) cable. • When starting the engine with auxiliary cables, always wear safety glasses. • Avoid contact between the two machines concerned by the starting operations as this causes sparks that could cause hydrogen explosions of the batteries. • Once the cables are detached, make sure that they do not touch each other or touch parts of the machine to avoid explosions. • The cables and pincers must be in good condition and proportionate to the current load to transfer. • Make sure it is a 12 V starting battery. • Make sure that the pincers cannot detach themselves from the battery terminals. CONNECTING CABLES 1. Turn the ignition key to OFF. 2. Connect the positive (+) poles of the two batteries between each other. 3. Connect the loaded cable of the negative terminal (-) of the battery to the earth block of the machine to start. 4. Start the engine of the machine that is working properly and bring it to a high rpm. 5. Start the machine engine that could not start following the indications at point START OF THE ENGINE. REMOVING CABLES Once the engine has started, remove the cables of the two batteries doing the opposite operation to the one described at the previous point.
28
MAINTENANCE
4
MAINTENANCE
4.1
PREPARING THE MACHINE FOR MAINTENANCE
1. Park the machine on a flat and solid surface. 2. If the machine has just undergone a strong working load, run the engine without the load at low speed for about three minutes to cool it down. 3. Turn the ignition key to OFF. Remove the ignition key. Never do any maintenance or regulating jobs when the engine is running if not specified in the manual. In that case, never leave the machine unattended.
DANGER 4. If it is necessary to keep the engine on, guide the exhaust toward the outside. Avoid leaks of exhaust fumes that could happen unexpectedly. The exhaust system must be properly sealed. 5. Before doing any jobs put on the machine a clearly visible “DO NOT OPERATE” sign on the operating board.
4.2
ENGINE HOUR METER
Use the hour meter to establish when your machine needs regular maintenance. The recommended maintenance periods are based on normal usage. Severe conditions will require more frequent maintenance (contact your dealer).
4.3
SAFE MAINTENANCE
WARNING These instructions are necessary to carry out the required machine maintenance safely. Not observing these instructions can cause serious injuries or even death.
29
MAINTENANCE
4.4
ACCESS TO THE ENGINE
To have access to the engine do the following: 1) Unlock the side handles situated on the distributor support. 2) Remove the engine hood from the machina. 3) Put the engine hood on the ground or on a flat surface. 4) Carry on with maintenance. 2 4 3
1
• TANK AND FUEL
WARNING When refuelling, check that there is no water in the fuel drum. If you finish the fuel before refuelling or you have to replace the fuel filter you must remove the air from the fuel system.
• HYDRAULIC SYSTEM AND TRANSMISSION
WARNING Taking care of the engine is of essential importance for the life of the machine. Daily check the level of the oil and its level of contamination. It is important to check that there is no air in the circuit each time there is a change of oil or when the filter cartridge is replaced. Removing the air is done by running the machine empty or at low rpm.
30
MAINTENANCE
4.5
SCREWS AND NUTS TORQUE WARNING
During maintenance, it is important to tighten the screws and nuts properly according to the torque prescribed in these charts. Not observing these indications can cause extremely serious accidents. STANDARD TORQUE
Thread diameter (mm)
Pitch (mm)
Spanner dimensions (mm)
10.9
8.8 kgm
Nm
kgm
Nm
6 8 10 12 14
1 1,25 1,5 1,75 2
10 13 17 19 22
0,96±0,1 2,3±0,2 4,6±0,5 7,8±0,8 12,5±1
9,5±1 23±2 45±4,9 77±8 122±13
1,3±0,15 3,2±0,3 6,5±0,6 11±1 17,5±2
13,5±1,5 32,2±3,5 63±6,5 108±11 172±18
16 18 20 22 24
2 2,5 2,5 2,5 3
24 27 30 32 36
19,5±2 27±3 38±4 52±6 66±7
191±21 262±28 372±40 511±57 644±70
27±3 37±4 53±6 73±8 92±10
268±29 366±36 524±57 719±80 905±98
27
3
41
96±10
945±100
135±15
1329±140
* Nm (Newton meter) Nm = 0,102 kgm
4.6
RECOMMENDED FLUIDS AND LUBRICANTS
WARNING Always follow warnings and operating instructions when handling lubricants like grease oil or other chemical products. Use proper containers. Discard fluids and filters responsibly according to current regulations. When doing maintenance, keep heat sources away, do not smoke or use free flames. Always use safety goggles and rubber protective gloves.
31
MAINTENANCE
• RECOMMENDED OIL AND LUBRICANTS
Trade Marca mark
Hydraulic Olio idraulico oil
ESSO
NUTO H 46
CALTEX
SIRIUS H 46
AGIP
OSO H 46
IP
HYDRUS H 46
Engine oil Olio motore -15°/+40° -15°/+40°
Traction Olio reducer oil riduttore trazione
TD 15W40
SIGMA TURBO 15W40 TARUS TURBO 15W40
Grease Grasso
EP 150
BEACON 2
WRP 150
EP 2
BLASIA 150
GR MUEP 2
MELLANA 150
GREP 2
• FUEL TANK The fuel tank situated at the front of the engine compartment on the right side, has a 21-litre capacity. The fuel is gasoil.
• COOLING SYSTEM The engine cooling system has antifreeze for an outdoor temperature up to –15°C. Consult the table below for different ambient temperatures. The machine is delivered with CALTEX POLAR ANTIFREEZE or ESSO ANTIFREEZE.
OUTDOOR TEMPERATURE C° AMOUNT OR ANTIFREEZE (L) AMOUNT OF WATER (L)
32
-5
-10
-15
-20
-25
1,3
1,6
1,9
2,3
2,7
4,7
4,4
4,1
3,7
3,3
MAINTENANCE
4.7
ENGINE MAINTENANCE
*First replacement/change
4.7.1
ENGINE OIL
CHECKING OIL LEVEL Before starting the machine check the engine oil every day and every 8 working hour. Do the checking when the engine is off and cold, and the machine is on a flat surface. Open the engine hood, remove the gauge (A) and after cleaning it with a clean cloth, put it back completely into its seat and then take it out. If the oil level is close to or lower than the minimum sign on the gauge, top it up through the filling cap (B) using the oil indicated on the table .
C
A
B
CHANGING ENGINE OIL Oil change must always be done when the engine is off and cold. Take a container of suitable capacity. Open the engine hood and unscrew the drain plug (C). As the oil comes out loosen the filling cap (B). Once the oil has completely come out, put back the drain plug (C) and put some new oil using the oil recommended on the table. Check that the oil level touches the maximum sign on the gauge (A). Close the filling cap (B).
33
MAINTENANCE
4.7.2
ENGINE OIL FILTER
REPLACEMENT This operation must be done when the engine is off and cold. Open the engine hood. After removing all the engine oil follow the instructions at point “ENGINE OIL REPLACEMENT”. Remove the filter cartridge (A) using a filter spanner (after the first 50 hours). Do the subsequent replacements every 200 hours. Clean with a clean cloth the sealing surface at the base of the used oil filter. Lubricate the gasket of the new cartridge. Fit a new filtering cartridge tightening the cartridge by hand without using a spanner. Fill with the recommended type and amount of oil following the instructions on the table. Start the engine and check that the filter does not leak. After two minutes, turn off the engine and check the oil level.
A
4.7.3 MAINTENANCE OF THE ENGINE OIL FILTER
Turn off the engine before doing maintenance on the air filter. Each time you do maintenance on the air filter make sure that all the flexible tubes are in good condition and that the clamps are properly tightened. It is recommended to replace the safety cartridge each time you replace the filtering element. Replace the filtering element after the fifth cleaning operation or anyhow after one working year. The operations for the maintenance of the filtering element are the following: • Open the engine hood. • Loosen the clamps (A) situated on the filter cover (B). Remove the cover.
34
A
B
MAINTENANCE
• Remove the filtering element (C ). • Check that the dirty filtering element has not been damaged. • Blow compressed air into the filter inside outward keeping the air nozzle at a distance of at least 30 cm and with a 2-3 bar maximum pressure. • Clean the inside of the filter box with a clean cloth. • Put back the filtering element pushing it until the end of its course. • Fit back the cover in such a way the word “TOP” is towards the top.
C
4.7.4 REPLACING THE GASOIL FILTER
DANGER Before replacing the filter, cool down the engine. During replacement, carefully clean any oil leaks to avoid slipping or accidents.
IMPORTANT Discard gasoil according to current environmental regulations. Never pour it on the ground or in a sewer. A C Discard the filter according to current environmental regulations. Do the following operations to replace the gasoil filter: a) Open and remove the engine hood. b) Turn the fuel stopcock (A) until its complete closure. c) After cleaning with a clean cloth the area around the filter, unscrew the ring nut that holds the sump (B) with a band spanner turning anti-clockwise. d) Remove the sump and the filter. e) Using a clean cloth, clean the gasket seat on the filter body (C). B
35
MAINTENANCE
f) Lubricate with a bit of oil or a bit of grease the gasket of the new filter and the sump gasket. g) Insert the new filter into the sump and fit back the sump on the filter body tightening it by hand. h) Turn the fuel stopcock (A) to its complete opening and then proceed with removing the air out of the fuel system.
4.7.5 REMOVING THE AIR FROM THE AIR SYSTEM
IMPORTANT Removing the air from the fuel system is done when the fuel tank is empty, when the system components are removed for maintenance and when the machine is stopped for long periods. Do the following operations to remove the air: a) Make sure that the gasoil filter is completely full and then loosen the screws (A) located on the injection pump. b) Pump up with the lever (B) of the fuel system pump (C). c) When the fuel starts coming out of the screws without air, stop pumping and tighten the screw. A
C
B
36
MAINTENANCE
4.7.6 DECANTER CLEANING AND WATER DRAINING
DANGER Cool the engine before doing any maintenance on the decanter. Remove carefully any gas oil leaks during maintenance to avoid slipping or accidents.
IMPORTANT Discard gas oil according to current regulations. Never pour it on the ground or in a sewer. A) CLEANING DECANTER Cleaning the decanter has to be done when needed. Do the following operations: a) Open the engine hood. b) Turn the fuel stopcock (E) to its complete closure. C A c) After cleaning the area around the decanter (A) with a clean cloth, unscrew the ring nut that holds the sump (B) with a band spanner turning anti-clockwise. d) Remove the sump containing the filter. e) Clean the inside of the sump and filter with gasoil. f) Lubricate the sump gasket with a bit of oil or grease and fit it back inside with the clean filter tightening the ring nut by hand.
IMPORTANT Also fit the spring and the red plastic ring properly inside the sump.
D
B E
g) Turn the fuel stopcock (E) to its complete closure and then proceed with removing the air. B) REMOVING THE AIR FROM THE DECANTER a) Loosen the air screws (C) until the fuel comes out without air and then tighten the screw. b) Loosen the air screw (D) until the fuel comes out without air and then tighten the screw.
37
MAINTENANCE
C) DRAINING WATER FROM THE DECANTER
When the red plastic ring situated inside the decanter sump comes up it means that there is water inside the decanter. Do the following operations to drain water: a) Turn the fuel stopcock to its complete closure. b) After cleaning the area around the decanter with a clean cloth, unscrew the ring nut that holds the sump with a band spanner turning anti-clockwise. c) Remove the sump and drain the water inside it. d) Clean the inside of the sump and the filter with gasoil. e) Lubricate the sump gasket with a bit of oil or grease and put it back tightening the ring nut by hand. f) If necessary, remove the air as indicated at point REMOVING THE AIR FROM THE DECANTER.
38
MAINTENANCE
4.8
RUBBER TRACK MAINTENANCE
4.8.1
CHECKING TRACK TENSION
Park the machine on a solid and flat surface. Lift machine safety and put stable blocks under the crawler frame to support it. Measure distance A from the roller bottom to the rubber track rigid inner part. The track tension is correct if measurement A is between 10 and 15 mm. If the track tension is not within the above mentioned measurements, not too loose nor too tight, follow the instructions given in the following paragraph.
A
4.8.2
OPERATIONS TO LOOSEN OR TIGHTEN TRACK
The grease contained in the hydraulic track is under pressure. Therefore never loosen greasing valve 1 for more than one turn. If the valve is too loose, it might get expelled under the grease pressure, exposing the operator to risk. Never loosen grease nipple 2. Remove any mud or gravel jammed between the sprocket and the track links before loosening them. 1. 2.
2 3. 4.
1
5.
Remove screws and plate 3 to have access to regulation To loosen track, slowly unscrew valve 1 anti clockwise for no more than one turn. One turn of valve 1 is sufficient to loosen track. If the grease does not start draining, make the track turn slowly. Once the right tension is obtained, turn valve 1 clockwise and then tighten it. Clean any grease leaks. To stretch a track, put a grease gun inside grease nipple 2 and add grease until the track deflection is within specifications.
DANGER! There is something wrong if the track remains stretched once valve 1 has been turned anticlockwise or loose after having put grease in grease nipple 2. In any case, never try to remove tracks or dismantle the track tension cylinder, as the high pressure of the grease inside the track is very dangerous.
39
MAINTENANCE
4.8.3 CHECKING RUBBER TRACKS ENGRAVED THREAD SCULTURA
The rubber track structure is shown in the drawing beside. The steel ropes and the metal core are buried in rubber. The engraved threads are meant to give stability when moving on soft soil. They are situated in the lower part of the support to the ground. The wheel guides, situated inside the track, prevent the track from coming out of the guide rollers.
CAUSES OF DAMAGES
STEEL CORDE ROPES D'ACCIAIO
SPROCKET FORO RUOTA HOLE WHEEL DENTATA METAL CORE ANIMA METALLICA
A) Steel ropes breakage An excessive tension causes the breaking of the steel ropes under the following conditions: - When there is an excess of stones and foreign material between the track and the crawler frame; - When the track comes out of its guide; - When there is strong friction like quick changes of direction. B) Wear and tear of metallic cores As in the case of the a.m. breakage of steel ropes, an excessive stress might cause the bending or the breaking of the metallic cores, which can also be caused by the following: - Improper contact between sprocket and track; - Rotation of the inner rollers - Working in sandy soil.
WORN PARTS PARTI USURATE
C) Parting of the metallic cores The metallic core acts as rubber adhesive between itself and the steel ropes. Parting can be caused by excessive stress like the breakage of the ropes, as a result of the following: - the metallic cores have been wound up by the worn sprocket as shown. If the sprocket shows wear and abrasion, replace it as soon as possible. In case of breakage as per paragraphs A-B-C, it is necessary to replace the track as this could interfere with proper working. D) Abrasion and fatigue cracks 1. The cracks at the base of the thread are the result of fatigue rubber bending caused by the sprocket and the track tensioner as shown in photo 4 in the appendix.
40
CRACK
SIDE LATO RUOTA
MAINTENANCE
2. 3.
The cracks and the curves on the rubber edge are due to manoeuvring the track where there are concrete kerbs and sharp edges. The cracks and abrasions on the rubber of the roller guide slides are caused by fatigue due to the compression of the rubber under the wheel weight combined to working in sandy soil, or repeated sharp changes of direction as indicated in photo 6-8-9 in the appendix. The conditions for possible damage indicated in paragraph D point 1, 2, 3 are not to be considered deadly for the track and even if there is a gradual or progressive damage, the track will continue to work. If the damage indicated at point 3 worsens, this will expose the metallic cores. If this exposition is more than half the track circumference, it is time to replace it. However you can still use it.
E) Cracks due to external factors The cracks on the track outer surface (the one in contact with the ground) are very often due to contacts with gravel, sharp stones, sharp material such as metal plates, nails, glass, which can cause cuts as shown in photo 10 in the appendix. From the point of view of rubber property this cannot be avoided although it depends from working conditions. The cracks on the circumference outer surface and on the rubber edge come from the contact the track has with the crawler body or with concrete sharp edges as shown in photos 12 and 13 in the appendix. The crack increases quite slowly. Even if it does not look good, the track can still be used in hard working conditions.
4.8.4
2
1
REPLACING RUBBER TRACKS
The grease inside the hydraulic track is under pressure. Therefore never loosen grease nipple valve 1 for more than one turn; otherwise it might be expelled under the pressure of the grease, putting the operator at risk. Never loosen grease nipple 2. In case of gravel or mud jammed between the sprocket and the track link, remove them before loosening.
41
MAINTENANCE
4.8.5
REMOVING RUBBER TRACK 52
1. Park the machine on a solid and flat surface, lift it and support it safely. 2. Remove screws and take off plate 3 to have access to regulation.
02
02
BH
19
3
3. To loosen track, slowly unscrew valve 1 anti-clockwise for no more than one turn. One turn of valve 1 is sufficient to loosen track. 4. If the grease starts coming out, make the track turn.
5
52 02 02 BH 19
5. Insert 3 steel tubes (4) inside the track, in the space between the rollers. Rotate drive wheel backward (5), so that the steel tubes move along with the track and mesh with the track tensioner sprocket. Apply force (6) sideways to run the track and lift it from the track tensioner sprocket.
4.8.6
4
FITTING RUBBER TRACK
1. Make sure that all the safety conditions are met when the machine is lifted to fit track.
6
7
52
02
02
BH
19
2. Check that the grease inside the hydraulic cylinder has been removed. 3. Mesh the track links with the sprocket and place the other end of the track on the track tensioning sprocket. 4. Rotate driving wheel backward (7) pushing the track shoes inside the frame (8). 5. Using a steel tube, position track and rotate driving wheel again. 6. Make sure the track links are properly meshed onto the sprocket and the track-tensioning sprocket. 7. Adjust track tension (see paragraph 4.8.2 - “Operations to loosen/stretch track”). 8. Place rubber crawler on the ground.
42
8
HYDRAULIC SYSTEM
B
5
HYDRAULIC SYSTEM
5.1
CHECKING HYDRAULIC OIL
To check hydraulic oil, place the machine on a flat surface and check if the oil level is half way the visual indicator (A). If not, top up though the filling cap (B).
5.1.1 A
C
REPLACING HYDRAULIC OIL
Do the following to completely replace the hydraulic oil: - Open the filling cap (B); - Unscrew the drain plug (C) in the lower part of the tank; - Drain completely the oil contained inside the tank. Carefully clean the tank before filling the tank. Tighten the drain plug and fill the tank through the topping up cap (B) avoiding mixing different oil. Use mineral oil with anti-wear additives like HLP (DIN 51524) or HM (ISO 6743/4) with ISO VG46 viscosity. The recommended filtering must be absolute 10 µ or ß10 75.
5.1.2 REPLACING HYDRAULIC OIL FILTER CARTRIDGE
D
F
E
The hydraulic oil filter is situated in the upper part of the hydraulic oil filter. To replace the cartridge you only need to loosen the filter cap (D) and extract the cartridge itself (E) slowly with a slight traction upward to avoid oil leaks. After replacing the cartridge with a new one, pushing it to its seat until the end of its course check the condition of the gasket (F) situated under the filter cap (D). Then lubricate with a bit of oil and tighten the cap again.
43
HYDRAULIC SYSTEM
5.2 HYDRAULIC SYSTEM
MA1
7
MA1
7 A
A R/G
B
T1,T2
T1,T2
Ps
MB1
Ps
6
B3
A4 B4
B6 A6
150 Bar
4 M
1
2 bar
YANMAR 3TNE74 2800 Giri/min P=20.7 HP Taratura(vuoto)=2600 rpm 4 bar
S
3
5
Autoc.
Soll-Rot
15 Bar
Cingolo Dx
P1
2ª Velocita'
150 Bar
Cingolo Sx
Ribaltamento
150 Bar
P3 P2
POMPA CASAPPA P14+14+6.3 cm3/giro Pressione pist.=210bar Pressione ingr.=180bar
2
44
R/G
B
MB1
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM DIAGRAM KEY
1. Diesel engine Yanmar 3TNE74 2. Variable displacement triple pump 3. Hydraulic oil filter 4. Filter 5. Water-oil exchanger 6. Distributor 7. Reduction gear drive
45
COOLING SYSTEM
6
COOLING SYSTEM
6.1
CHECKING COOLANT LEVEL
A
The check is to be run when the engine is off and cool. Remove radiator plug (A) carefully and check that water comes up the overflow tubes. If the water level in the radiator is below the minimum, top up with fresh water and antifreeze, as per table. Never add dirty water since it could clog up the cooling system. NOTE: RUN THIS CHECK DAILY.
6.2
CHANGING COOLANT
To completely change coolant, drain it out by opening drain plug (B) and carefully remove the filling cap (A). Close again the drain plug (B) and fill the radiator with a suitable mixture of water and antifreeze, according to the table.
B
A
B
46
COOLING SYSTEM
6.3
EXTERNAL CLEANING OF THE RADIATOR
Each time it is necessary, clean the external part of the radiator to encourage the heat exchange compromised by dirt and dust. To clean, use compressed air aiming the air stream from inside to outside of the engine compartment. When working in dusty places, and in particular at high temperatures, clean the radiator more frequently.
6.4
CHECKING FAN BELT TENSIONING
Turn off the engine before putting your hands close to the belt. Check daily the tension of the radiator fan belt pushing it by hand towards the indicated area. If the arrow goes over 10±12 proceed with the tensioning. To loosen the belt, first loosen the screw that locks the alternator (A) on the engine rod (B ). Do the tensioning and tighten the screw. If the belt is worn, replace it.
B 10 ¸ 12 mm
A
47
ELECTRICAL SYSTEM
7
ELECTRICAL SYSTEM
This machine is equipped with a 12 V electrical system composed of one cabin line and one frame line connected between each other by two waterproof connectors fixed inside the frame. The components of the system that might require operator’s maintenance are: 1. Battery 2. Fuses 3. Relays 4. Tension regulator
1) BATTERY With regard to the dangers deriving from the battery follow the instructions at points PREVENTING DANGERS DERIVING FROM THE BATTERY, OPERATING AT LOW TEMPERATURES, FLAT BATTERY AND STARTING WITH CABLES.
IMPORTANT • Clean the outside of the battery with sodium bicarbonate or ammoniac and water. • Spray the terminals with a special protective anti-oxidation substance.
2) FUSES 2a) DASHBOARD LINE FUSES The fuses protect the electrical circuit and are situated in a box on the dashboard.
IMPORTANT Before removing a fuse, cut off power in the circuit by disconnecting the battery. Make sure that the new fuse is of the correct value.
48
ELECTRICAL SYSTEM
POSITION IN THE FUSE BOX
COLOR
CIRCUI PROTECTED PART
1
RED
Socket
10
2
RED
Engine stop
10
3
RED
Regulator
10
4
RED
Indicators
10
5
RED
Solenoid valve
10
6
RED
Horn
10
CAPACITy (A)
The rest of the components that compose the electric system are fixed to the distributor support and can be easily reached by removing the front chain case.
2b) ENGINE LINE FUSES 1 CAPACITy (A)
COLOR
CIRCUIT PROTECTED PART
80
YELLOW OVERALL FEEDING
40
ORANGE
50
RED
POS. 1
ENGINE PRE-WARMING
2
OVERALL START
3
2 3
49
ELECTRICAL SYSTEM
3) RELAYS, DIODES AND TIMERS 4 POS.
1
DESCRIPTION
1
ENGINE PREWARMING RELAY
2
ENGINE PREWARMING RELAY (H0008)
3
ENGINE STOP RELAY
4
ENGINE STOP TIMER (H00015)
5
DIODES N.B.: The other diode is inside the engine compartment near the engine solenoid
2
3
5
A 4) TENSION REGULATOR
The tension regulator (A) is under the front chain case of the distributor support, fixed in the lower right part.
50
ELECTRICAL SYSTEM
F3
F1
H1
10A
X19
10A
F6
10A
C1
S1
M-N1
B-R2.5
R6
I
-
-
X9
X9
B-N1
I
X11
X11
1
X4
2
5
5
X2
X4
X1
C1
2
X2
B-N1
N1
6
X2
A4
N1
N1
A4
H2 S2
F2
10A
R4
30
2.1 2.1
C-N1
19
2
S1
N2.5
A4
50
A4 N1
N1
15
M6
58
B-N1
0 1 P
A4
ELECTRIC SYSTEM DIAGRAM
M6
7.1
K2
CENTRALINA. CANDELETTE
87 30
3
4
1
X14
1
X13
-
X15
I
1
X15
2
3
4
X12 X12 X12 X12
6
X1
R-V1
B2.5
2
2
X20
2
X18
M6
l
X3
FG1 FG2 FG3 80A
TEMP.ARR. MOTORE
87 30
R2.5
R6 R4
1
X7 X7 X7 X7
L-N2.5
R2.5
4
X2
B-N1
N1
6
M-N1
5
M1
4
87a
85
B-R1 1
X8 X8 X8 X8
86
A-R1
87a
85
A-B1
86
R-V1
K1
C-N1
HA1
40A
50A
-
X3
1
5
6
1
X10
Y3
R1
U1
2
X10
3
X10
N1
4
N1
3
N2.5
A2.5
2
M4
N2.5
1
S1
X6 X6 X6 X6 X6 X6
N2.5
G
I
X16
A2.5
-
X16
N1
M
G2
N2.5
N35
X17 50
B-R1 B-R2.5
R4
R2.5
30
12Vcc
1
M1
B-R1
G1
X18
R-N2.5 R35
R6
X20
1
31
2.1
51
ELECTRICAL SYSTEM
F5
Z-B1
R-G1
H4
F4
10A
B1 X1
3
X1
1
X2
X2
V-B1
X1
7
B1
9
N1
X1
4
Z-B1
8
S3
S5 t
1.5
52
31
S4 p
N1
80
H5
B-V1
H3
10A
17
A4
17
B1
A4
N1
A4 N1
N1
1.5 1.5
P1 S
-
hi +
ELECTRICAL SYSTEM
KEY F1 F2 F3 F4 F5 F6 FG1 FG2 FG3 G1 G2 H1 H2 H3 H4 H K1 K2 M1 P1 R1 S1 S2 S3 S4 S5 U1 X19 Y3 X1 X10 X11 X12 X13 X14 X15 X16 X17 X18 X2 X20 X3 X4 X5 X6 X7 X8 X9
COLOUR WIRE KEY 10A socket fuse A LIGHT BLUE 10A engine stop fuse B WHITE Fuse + 15 10A regulator C ORANGE 10A pilot light fuse G YELLOW 10A solenoid valve fuse H GREY 10 A horn fuse L DARK BLUE 80A overall fuse M BROWN 40A glow plug overall fuse N BLACK R RED Overall fuse + 30 50A S PINK Battery V GREEN Alternator Z PURPLE Battery pilot light Glow plug pilot light NOTE: The bicolour wires are indicated with the Low fuel warning light following initials: Water temperature light Oil warning light G/V= YELLOW/GREEN (transversal colours) Start relay G-V= YELLOW-GREEN (longitudinal colours) Glow plug gear case Starter Hour meter Glow plugs Starting panel Horn pushbutton Fuel level sensor Engine oil pressure Water temperature maximum Voltage regulator Socket Engine stop solenoid valve Solenoid valve-dashboard line 9 way connector mark Engine line 3 way-connector 90° engine line 2 way-connector Engine line 4 way-connector Engine line 1 way connector Engine line 1 way connector 90° engine line 2 way connector 90° engine line 2 way connector Engine line 1 way connector Engine line 2 way connector Engine line-dashboard line 7 way connector mark Engine line 2 way connector 90° engine line-dashboard line 2 way-connector Engine line-dashboard line 2 way connector Dashboard line 3 way connector Engine line 6 way connector Engine line 4 way connector Engine line 6 way connector 90° engine line 2 way connector
53
STORAGE AND REMOVAL OF THE MACHINE
8
STORAGE AND REMOVAL OF THE MACHINE
8.1
STORAGE OF THE MACHINE STORE THE MACHINE IN A DRY AND COVERED PLACE. IF STORED OUTSIDEM COVER IT WITH A PLASTIC SHEET.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
8.2
Thoroughly clean the machine Check the machine. Repair worn or damaged parts. Fit new ones if necessary. Clean all the filtering elements of the air filter Lubricate all the greasing points Change the engine oil and the engine oil filter Drain the cooling system and leave the drain plug open Clean and change the air filter cartridge if necessary Put blocks under the tracks. Oil the pins of the track links (except the rubber tracks). Wash the machine Remove the battery and put it in a dry place after discharging it. Paint all the parts that require it to avoid rust.
REMOVING THE MACHINE AFTER STORAGE
CAUTION! Turn on the engine only in a well-ventilated place Before starting the machine after more than 30 days of inactivity do the following important operations: 1. Do the refuelling 2. Remove the air and drain the water from the fuel system 3. Check and if necessary top up the level of the engine oil 4. Close the radiator drain plug and fill the cooling system. 5. Start the engine and after two or three minutes turn it off and check levels, 6. Check the condition of the fan belt 7. Check and if necessary top up the level of the hydraulic oil 8. Move all the hydraulic parts several times 9. Check carefully the whole system before operating the machine at full load.
54
TECHNICAL SPECIFICATIONS
9
TECHNICAL SPECIFICATIONS
Weight..........................................................................................................................................1250 kg YANMAR engine technical data Idling calibration rating ........................................................................................................2500 rpm Max gross HP ..........................................................................................17,7 kW /24 HP a 3600 rpm Electrical starter ..........................................................................................................................12 Volt Gas-oil tank ......................................................................................................................................23 lt Hydraulic system Pump, quantity and type ....................................2 variable displacement pumps + 1 gears pump Capacity..........................................................................................................................34+34+15 l/min Operating pressure ....................................................................................................................230 bar Traverse speed....................................................................................................................1a - 2,6 km/h ..............................................................................................................................................2a - 4,7 km/h Hydraulic oil tank ............................................................................................................................23 lt Carriage Track width ................................................................................................................................250 mm Wheel base................................................................................................................................1370 mm Carriage length ........................................................................................................................1850 mm Noise level (ISO 5131) YANMAR................................................................................................96 dB Frame Max length................................................................................................................................2180 mm Width ........................................................................................................................................1300 mm Max height at levers ................................................................................................................1670 mm at roll-bar ..............................................................................................................2420 mm
55
TECHNICAL SPECIFICATIONS
9.1
TECHNICAL SPECIFICATIONS
N.B : Dimensions in mm.
56
TROUBLE SHOOTING
10
TROUBLE SHOOTING
In order to get the carriage to operate in the best way, never dismantle it unless it is absolutely necessary. If the following instructions to identify breakdowns are not enough to bring back the carriage to its proper working conditions, contact an authorised Hinowa dealer.
The engine does not start: • Is the quality of the fuel good enough? • Is there enough oil in the engine?
57
TROUBLE SHOOTING
10.1 ENGINE PROBLEM
CAUSE
SOLUTIONS
The engine does not start or is hard to start
Wrong fuel
Use right fuel
Discharged battery
Recharge or install a new one
Glow plug supply line or glow plugs broken
Repair or install new glow plug
The ignition circuit is resistant
Clean and tighten battery and starter contacts
Wrong motor oil
Use right oil
Water, dirt and air impurities in diesel fuel and/or clogged gas-oil filter
Remove impurities from system. Replace gas-oil filter
Dirty injectors working properly
Contact you authorised dealer for injector servicing
Engine runs unevenly or stop
58
or
not
Out of fuel
Fill the fuel tank
Low motor oil level
Add oil to proper level
Clogged up gas-oil filter
Install new filter
Water, dirt or air inside gasoil system
Remove air from gas-oil system. Clean tank
Clogged up filters or dirty or defective injectors
Contact your authorised dealer for injector servicing
TROUBLE SHOOTING
PROBLEMI
Overheated engine
Low motor oil pressure
Exhaust fumes are black of grey
CAUSE
SOLUTIONS
Out of fuel
Fill up fuel tank
Accelerator wire out of place
Contact your authorised dealer
Wrong oil
Use right oil
Engine too hot
Check and repair valves. Consult engine manual.
Lack of coolant
Check coolant level
Defective radiator plug
Install new plug
Clogged up radiator fins
Clean radiator
Clogged up air filter
Clean air filter
Loose or defective belt
Stretch or install new belt
Lack of oil
Top up to right level
Clogged up oil filter
Install new oil filter
Oil leaks
Identify leaks
Engine temperature too high
Check cooling system
Wrong fuel
Use right fuel
Pump injectors not properly synchronised
Contact your authorised dealer
Dirty or defective injectors
Contact your authorised dealer
59
TROUBLE SHOOTING
PROBLEM
CAUSE
SOLUTIONS
Exhaust fume is white
Wrong fuel
Use right fuel
Cold engine
Run engine until it warms up
Dirty or defective injectors
Contact your authorised dealer
Loose or corroded terminal
Clean and tighten them
Loose or defective alternator belt
Stretch it and install a new one
Alternator does not charge
Contact your authorised dealer
Loose or corroded contacts
Clean and tighten them
Wrong motor oil
Use right oil
Defective ignition key
Replace it
Alternator not working properly
Replace alternator
Broken cables
Check and repair them
Broken fuse
Replace fuse
Sensors not working properly
Replace sensors
Broken wires
Check and repair them
Battery does not charge
Starter not working or running slowly
Alternator indicator stays on when engine is running
Panel indicators working
60
not
TROUBLE SHOOTING
10.2 HYDRAULIC SYSTEM PROBLEM
CAUSE
SOLUTIONS
Hydraulic movements too slow
Cold oil
Warm up system up to usual working temperature
Wrong oil
Use right oil
Engine rpm too low
Contact your authorised dealer
Broken pump
Contact your authorised dealer
Wrong oil
Use right oil
Clogged up filter
Replace filter
Broken pump
Contact your authorised dealer
Clogged up radiator or oil cooler
Clean and straighten fins
Defective oil cooler
Contact your authorised dealer
Defective exhaust valve
Contact your authorised dealer
Dirty oil
Replace oil
Air sucked from tank to pump
Find out and eliminate defect
Wrong oil
Use right oil
Water in oil
Change oil
Oil level too high or too low
Bring oil to proper level
Oil temperature too high
Oil is foaming
61
TROUBLE SHOOTING
PROBLEMI
CAUSE
SOLUZIONI
Low or no oil pressure
Wrong oil
Use right oil
Lack of oil in system
Fill up with right oil
Faulty max pressare valve
Contact your authorised dealer
Broken hydraulic pump
Contact your authorised dealer
Lack of oil
Add oil
Linea aspirazione danneggiata
Riparate la linea di aspirazione
Broken pump
Contact your authorised dealer
Exhaust pressure regulated too low
Contact your authorised dealer
Hydraulic oil level too low
Add oil
Exhaust valve not working properly
Contact your authorised dealer
Damaged hoses or connectors
Repair or replace them
Loose connectors
Tighten them
Broken hydraulic pump
Contact your authorised dealer
No movements at all (noisy pump)
Lack of power in movements
Left and right joysticks not working
62
TROUBLE SHOOTING
PROBLEM
Only one working
joystick
is
One cylinder not working or with low power
A reduction unit not working
Irregular traverse movements
CAUSE
SOLUTIONS
Damaged hoses or connectors
Repair or replace them
Loose connectors
Tighten them
Damaged oil seals
Repair or replace them
Oil leaks caused by a damaged cylinder rod
Repair or replace it
Damaged hydraulic circuit
Repair or replace it
Damaged reduction unit
Contact your authorised dealer
Damaged hydraulic circuit
Repair or replace it
Too tight or too loose track
Adjust tension
Lower pump performance
Contact your authorised dealer
Lower engine performance
Contact your authorised dealer
Deformed carriage frame
Repair or replace it
Stones or debris between track links
Remove them
Control valves not working properly
Contact your authorised dealer
63
TROUBLE SHOOTING
PROBLEM
CAUSE
SOLUTIONS
Improper rotation movements
Lower pump performance
Contact your authorised dealer
Damaged rotation engine
Contact your authorised dealer
Broken rotation reduction unit
Contact your authorised dealer
Damaged fifth wheel
Contact your authorised dealer
No grease
Put grease
Control valves not working properly
Contact your authorised dealer
Uneven rotation
64
APPENDIX
11
APPENDIX
PHOTO N. 1 STEEL ROPES THAT HAVE BEEN CUT
PHOTO N. 2 ABRASED AND BROKEN STEEL CORES
PHOTO N. 3 STEEL CORE PARTING
65
APPENDIX
PHOTO N. 4 BREAKING OF ENGRAVED THREAD BASE CAUSED BY RUBBER BENDING (CURVING) UNDER PRESSURE
PHOTO N. 5 BREAKING OF TYRE OUTER PART UNDERNEATH STEEL CORE EDGE
PHOTO Nr. 6 BREAKING OF TYRE INNER PART ON THE STEEL CORE SIDE.
66
APPENDIX
PHOTO N. 7 ABRASED ENGRAVED THREAD
PHOTO N. 8 RUBBER ABRASED BY DRIVING WHEELS (FIRST STAGE)
PHOTO N. 9 RUBBER ABRASED BY DRIVING WHEELS (FINAL STAGE)
67
APPENDIX
PHOTO N. 10 CUT FROM SHARP MATERIAL ON TYRE OUTER PART
PHOTO N. 11 BREAKING AND ABRASION ON TYRE OUTER PART CAUSED BY HARD SOIL CONDITIONS
PHOTO N. 12 CUT ON EDGE OF TYRE INNER PART CAUSED BY SHARP MATERIAL OR SHARP EDGES
68
APPENDIX
PHOTO N. 13 BREAKING OF TYRE INNER PART CAUSED BY CONTACT WITH CRAWLER FRAME
69
TRACK KIT
12 INTERCHANGEABLE KITS FOR MINIDUMPER HP2500 12.1) 12.2) 12.3) 12.4) 12.5) 12.6)
TRACK KIT SELF LOADING LIFTING BUILDING KIT ROTATING BUILDING KIT SELF-LOADING BUILDING KIT BUILDING KIT FM1300 FORKLIFT KIT
12.1) TRACK KIT
12.1.1 CONNECTING THE TRACK KIT TO THE MACHINE B A
The track kit is fixed with 18 screws (A) to the holes at the dumper base and with two screws at the head (B).
12.1.2 TERMINOLOGY
1
KEY 1 - Track base
70
TRACK KIT
12.1.3 TECHNICAL SPECIFICATIONS
N.B.: dimensions in mm.
71
SELF LOADING LIFTING BUILDING KIT
12.2 SELF LOADING LIFTING BUILDING KIT
12.2.1 CONNECTING SELF LOADING LIFTING BUILDING KIT TO THE MACHINE
The self-loading hi-tip kit has to be positioned on the machine exclusively by learned operators, allowed by Hinowa to make this operation. The operation must be made in an authorized workshop. Place the self-loading building lifting kit (A) on the dumper base (B). Fix the kit to the base holes (A) with 10 screws (C) and 2 screws at the head (D).
A
D
C B
The self-loading lifting building kit is equipped with a hydraulic system independent from the dumper to which it must be fixed. Connect the hydraulic tubes (A) situated on the dumper base coming from the distributor to the union blocks (B) situated on the kit. Also connect the tubes (D) coming from the dumper distributor to the block on the lifting cylinder (C).
C
A
D
72
B
SELF LOADING LIFTING BUILDING KIT
12.2.2 TERMINOLOGY To make easier reading of safety warnings, operating instructions and maintenance of the self-loading kit we give below the names of the different assembled components: 2 3
4
1
5
6
7
8
KEY 1) 2) 3) 4) 5) 6) 7) 8)
Self-loading building dump box Bucket Arm Self loading cylinders Dumping cylinder Dump box support Lifting cylinder Dump box support guide
73
SELF LOADING LIFTING BUILDING KIT
12.2.3 DRIVER’S SEAT AND CONTROLS 1
1. 2. 3. 4. 5. 6. 7.
2
3
7
4
5
Carriage left shift control joystick Dump box lifting joystick Carriage right translation control joystick Dump box control joystick Bucket control joystick Accelerator control joystick 2 speed switch
12.2.4 CONTROLS DESCRIPTION DUMPING CONTROL You carry out the dumping by moving forward the dumping joystick, situated on the dumper driving seat (fig1) You put back the dump box in a horizontal position by pulling back the joystick. fig. 1
74
6
SELF LOADING LIFTING BUILDING KIT
LIFTING DUMP BOX CONTROL You lift the dump box by moving backward the dump box lifting joystick situated on the dumper driver's seat (fig.2). If you pull forward the joystick you bring back the dump box on the ground.
fig. 2
BUCKET CONTROL You lower the bucket if you move the bucket control joystick situated on the dumper driver's seat (fig.3). You lift the bucket if you pull the lever back. fig. 3
75
SELF LOADING LIFTING BUILDING KIT
12.2.5 OPERATING PRECAUTION
PERICOLO 12.2.5.1 General use of the minidumper Please refer to the maintenance and operating catalogue HP2500 generico della macchina. 12.2.5.2 Use of the hi tip self loading dumper bed Keep all extraneous persons away from the working area and the area of the machine movements. Control the hi tip ONLY from the control position. Make sure that the work site terrain is strong enough to firmly support the machine. When you work near to an excavation keep the machine with its engine to the rear. The lifting of the dumper bed has to be made only when the machine is stopped and on a flat surface. IT IS ABSOLUTE FORBIDDEN TO TRANSLATE WHILE THE DUMPER IS LIFTED. When the tip is a self loading one the lifting of the dumper has to be made with the supporting arms of the bucket in a vertical position.The movement of the self loading bucket with the lifted dumper is not allowed. It is not allowed the switching of the hydraulic self-loading/hi tip switch while the dumper is lifted. Be careful to the turnover when working on frozen terrain. A rise in temperature can cause the terrain to soften. Before using the hi tip system make sure that the sliding zone and the dumper bed support is clear of rubbles or other that can obstruct the movement.
12.2.5.3 Use of the self loading bucket (only on hi tip dumper with self loading system) Keep all extraneous persons away from the work zone and the area of machine movement. Make sure the work site terrain is strong enough to firmly support the machine. When you work near an excavation keep the machine with its engines to the rear. Be careful when working on frozen terrain. A rise in temperature can cause the terrain to soften and tip the excavator over. Use the shovel only to load the bin. Do not use it as a jackhammer or a splitting blade.
12.2.5.4 Never work in dangerous areas The special shape and design of the shovel loader makes it impossible to equip it with guards that protect against falling materials and against the risks that come from tipping over. Never work in sites where there is danger of objects falling from above. Always comply with operating instructions to avoid the risk of tipping over.
76
SELF LOADING LIFTING BUILDING KIT
12.2.5.5 LIFTING MEMBERS MAINTENANCE The carriage lifting on the hi tip and self-loading hi tip is carried out by a chain. Such chain has to be greased periodically (we advise once in a month) and it depends on the usage conditions. It is necessary to frequently control the chain allowance and its wear and tear, checking the connecting pins’ conditions of the chain and the pins connecting to the fixed part. You have to measure the wheel-base of the pins settling the chain and check that it does not exceed the 2% of the nominal wheel-base. The check can easily be made in this way: - Close completely the lifting cylinder, leaning the undercarriage against the base of the machine. - Open the dumper tilting cylinder to free the access zone to the chain.
ATTENTION - Measure the wheel-base of 34 links of the chain (distance between pin to pin). The measure must not exceed mm 655. - If the measure exceeds this limit change immediatly the chain. We advise a monthly check. A daily check of the cleaning of the dumper slides is recommended.
77
SELF LOADING LIFTING BUILDING KIT
12.2.6 GREASING POINTS
3 2
1
4
5
12.2.7 STORAGE OF THE MACHINE Beside the points described at pag.54 (chapter 8) in the standard Dumper HP2500, do the following operations: • Put the machine with the lowered dump box and bucket on the ground. • Lubricate with hydraulic oil or with grease, the overhanging part of the cylinders rod.
78
SELF LOADING LIFTING BUILDING KIT
480
535
1250
1500 1670
1900
2420
12.2.8 TECHNICAL SPECIFICATIONS
800 1300
250
1370 1850 2795 3560
415
1300
250
N.B.: dimensions in mm. TECHNICAL SPECIFICATIONS - Dump box capacity ..................................................................................................1,03 m3
79
SELF LOADING LIFTING BUILDING KIT
12.2.9 HYDRAULIC SYSTEM DIAGRAM
MA1
7
8
RIBALTAMENTO
SOLLEVAM.
MA1
9
A
A R/G
B
R/G
B
T1,T2
T1,T2
Ps
MB1
Ps
6
A1
B1
A2
B2
B3
A4 B4 B5
A5
B6 A6
150 Bar
4 2 bar
YANMAR 3TNE74 2800 Giri/min P=20.7 HP Taratura(vuoto)=2600 rpm 4 bar
S 3
5
Autoc.
1
Soll-Rot
M
15 Bar
2
POMPA CASAPPA 14+14+6.3 cm3/giro Pressione pist.=210bar Pressione ingr.=180bar
2» Velocita
150 Bar
P1
Cingolo Dx
Cingolo Sx
Ribaltamento
150 Bar
P3 P2
80
AUTOCARICANTE
7
MB1
10
SELF LOADING LIFTING BUILDING KIT
KEY 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Yanmar 3TNE74 Diesel engine Variable displacement triple pump Hydraulic oil filter Filter Water-oil exchanger Distributor Reduction gear drive Tilting cylinder Lifting cylinder Self-loading cylinder
81
ROTATING BUILDING KIT
12.3 ROTATING BUILDING KIT 12.3.1 CONNECTING ROTATING BUILDING KIT TO THE MACHINE The rotating building kit has to be positioned on the machine exclusively by learned operators, allowed by Hinowa to make this operation. The operation must be made in an authorized workshop. Place the rotating building kit (A) on the dumper base (B). Fix the kit to the base holes (B) with 10 screws (C) and with 2 screws (D) at the head.
D
C
B
A
Connect the hydraulic tubes (A), coming from the distributor situated on the dumper base, directly to the dumping cylinder (B) and to the kit rotating engine (C).
A
B
C
A
82
ROTATING BUILDING KIT
12.3.2 TERMINOLOGY
To make it easier to read the safety, operating and maintenance of the self-loading kit, we give below the names of the assembled components:
1 2
5
3 4
KEY 1) 2) 3) 4) 5)
Building dump box Dumping cylinder Rotating dump box support Rotating engine Kit base
83
ROTATING BUILDING KIT
12.3.3 DRIVER’S SEAT AND CONTROLS
1 1. 2. 3. 4. 5. 6.
2
3
4
5
Carriage left translation control joystick Dump box rotation control joystick Carriage right translation control joystick 2 speed switch Dumping control joystick Accelerator control joystick
12.3.4 DESCRIPTION OF THE CONTROLS
DUMP BOX ROTATING CONTROL You rotate the dump box to the left ( fig.A) if you move the dump box joystick forward situated on the dumper driver’s seat. You rotate the dump box to the right (fig.B) if you pull the joystick backward. fig. A
84
fig. B
6
ROTATING BUILDING KIT
DUMPING CONTROL You do the dumping if you move the dumping joystick forward situated on the dumper driver’s seat (fig.C). You put back the dump box horizontally if you pull the joystick backward.
fig. C
12.3.5 GREASING POINTS
1
2
3
85
ROTATING BUILDING KIT
12.3.6 STORAGE OF THE MACHINE
Beside the points described at pag.54 (chapter 8) in the Dumper HP2500 standard operating and maintenance manual, do the following operations: • Place the machine with the bucket horizontally. • Lubricate with oil or grease the overhanging part of the dumping cylinder rod.
86
ROTATING BUILDING KIT
250
800 1300
250
535
480
650
1450
1500 1670
2420
12.3.7 TECHNICAL SPECIFICATIONS
1370 525
1850 2790
415
90°
90°
N.B.: Dimensions in mm.
TECHNICAL SPECIFICATIONS -
Dump box capacity ..............................................................................................1,03 m3
87
ROTATING BUILDING KIT
12.3.8 HYDRAULIC SYSTEM DIAGRAM
MA1
7
8
RIBALTAMENTO
ROTAZIONE
MA1
9
7
A
A R/G
B
T1,T2
T1,T2
Ps
MB1
Ps
6
B2
A2
B3
A4 B4 B5
A5
B6 A6
150 Bar
4 2 bar
YANMAR 3TNE74 2800 Giri/min P=20.7 HP Taratura(vuoto)=2600 rpm 4 bar
S
3
5
Autoc.
1
Soll-Rot
M
15 Bar
POMPA CASAPPA 3 14+14+6.3 cm /giro Pressione pist.=210bar Pressione ingr.=180bar
2» Velocita
150 Bar
P1
Cingolo Dx
Cingolo Sx
Ribaltamento
150 Bar
P3 P2
2
88
R/G
B
MB1
ROTATING BUILDING KIT
KEY 1. 2. 3. 4. 5. 6.
Yanmar 3TNE74 Diesel engine Variable displacement triple pump Hydraulic oil filter Filter Water-oil exchanger Distributor
7. 8. 9.
Reduction gear drive Tilting cylinder Slew motor
89
SELF-LOADING BUILDING KIT
12.4 SELF-LOADING BUILDING KIT 12.4.1 CONNECTING THE SELF LOADING KIT TO THE MACHINE The self-loading building kit has to be positioned on the machine exclusively by learned operators, allowed by Hinowa to make this operation. The operation must be made in an authorized workshop. Place the self-loading kit (A) to the dumper base (B). Fix the kit with 16 screws (C) to the dumper base holes (A) and with 2 screws (D) at the head.
A
B
C
D
The self-loading building kit is equipped with a hydraulic system independent from the one on the dumper on which it must be fixed. Connect the hydraulic tubes, coming from the distributor situated on the dumper base, to the flexible tubes (A) situated on the kit. A
90
SELF-LOADING BUILDING KIT
12.4.2 TERMINOLOGY To make it easier to read the safety, operating and maintenance instructions of the kit, you will find below the various assembled components:
2 6
1
3
4 5 KEY 1) 2) 3) 4) 5) 6)
Self loading building dump box Bucket Arm Self loading cylinders Self loading dump box support Dump box dumping cylinder
91
SELF-LOADING BUILDING KIT
12.4.3 DRIVER’S SEAT AND CONTROLS 1
1. 2. 3. 4. 5. 6.
2
3
4
Carriage left translation control joystick Carriage dumping control joystick Carriage right translation control joystick Optional (extension) control joystick, if planned Bucket control joystick Accelerator control joystick
12.4.4 DESCRIPTION OF THE CONTROLS DUMPING CONTROL You do the dumping if you move the dumping joystick forward situated on the dumper driver’s seat (fig.A). You put back the dump box horizontally if you pull back the joystick.
fig. A
92
5
6
SELF-LOADING BUILDING KIT
BUCKET CONTROL You lower the bucket if you move the bucket control joystick forward situated on the dumper driver’s seat. You lift the bucket if you pull the joystick backward (fig.B).
fig. B
93
SELF-LOADING BUILDING KIT
12.4.5 GREASING POINTS
3 2
1
4
5
12.4.6 STORAGE OF THE MACHINE Beside the points described at pag.54 (chapter 8) in the standard HP2500 dumper operating and maintenance manual, do the following operations: • Place the machine with the dump box horizontally; • Lubricate with oil or grease the overhanging part of the cylinders rod.
94
SELF-LOADING BUILDING KIT
250
800
535
400
480
1250
1500 1670
2075
2420
12.4.7 TECHNICAL SPECIFICATIONS
1370
250
1850 2180
1300
335
2600
1300
3370
N.B.: dimensions in mm.
TECHNICAL SPECIFICATIONS -
Dump box capacity ..............................................................................................1,03 m3
95
SELF-LOADING BUILDING KIT
12.4.8 HYDRAULIC SYSTEM DIAGRAM MA1
7
8
RIBALTAMENTO
AUTOCARICANTE
MA1
9
7
A
A R/G
B
T1,T2
T1,T2
Ps
MB1
Ps
6
B2
A2
B3
A5
A4 B4 B5
B6 A6
175 Bar POMPA CASAPPA\P14+14+6.3 cm3/giro\PPressione pist.=210bar\PPressione ingr.=180bar
4
2 M
1
2 bar
YANMAR 3TNE74\P2800 Giri/min P=20.7 HP\PTaratura(vuoto)=2600 rpm
4 bar
S
3
Autoc.
Soll-Rot
15 Bar
2 Velocita
230 Bar
P1
Cingolo Dx
Cingolo Sx
Ribaltamento
230 Bar
P3 P2
96
R/G
B
5
MB1
SELF-LOADING BUILDING KIT
KEY 1. 2. 3. 4. 5. 6.
Yanmar 3TNE74 Diesel engine Variable displacement triple pump Hydraulic oil filter Filter Water-oil exchanger Distributor
7. 8. 9.
Reduction gear drive Tilting cylinder Self-loading cylinder
97
BUILDING KIT
12.5
BUILDING KIT
12.5.1 CONNECTING THE BUILDING KIT TO THE MACHINE The building kit has to be positioned on the machine exclusively by learned operators, allowed by Hinowa to make this operation. The operation must be made in an authorized workshop. Place the building kit (A) on the dumper base (B). Fix the kit with 14 screws (C) to the holes of the dumper base (A) and with 2 screws at the head (D). A
C
B
D
The building kit is equipped with a hydraulic system independent from the one on the dumper to which it must be fixed. Connect the hydraulic tubes situated on the dumper base (A), coming from the distributor, to the flexible tubes (B) situated on the kit.
B
98
A
BUILDING KIT
12.5.2 TERMINOLOGY To make it easier to read the safety, operating and maintenance instructions of the building kit, you will find below the names of the various components.
1
2
3
KEY 1) 2) 3)
Building dump box Dumping cylinder Dump box support
99
BUILDING KIT
12.5.3 DRIVER’S SEAT AND CONTROLS 2
3
4
1
1. 2. 3. 4. 5.
Carriage left translation control joystick Dumping control joystick Carriage right translation control joystick Optional (extension) control joystick, if planned Accelerator control joystick
12.5.4 DESCRIPTION OF THE CONTROLS DUMPING CONTROL You do the dumping if you move the dumping joystick forward situated on the dumper driver’s seat. You put back the dump box horizontally if you pull the joystick backward (fig.A).
fig. A
100
5
BUILDING KIT
12.5.5 GREASING POINTS
1
2
12.5.6 STORAGE OF THE MACHINE
Beside the points described at pag.54 (chapter 8) in the standard HP2500 dumper operating and maintenance manual, do the following operations: • Place the machine with the dump box horizontally • Lubricate with oil or grease the overhanging part of the cylinders rod.
101
BUILDING KIT
250
800
535
400
480
1250
1500 1670
2075
2420
12.5.7 TECHNICAL SPECIFICATIONS
1370
250
1850
1300
335
2180
1300
2600
N.B.: dimensions in mm.
TECHNICAL SPECIFICATIONS -
102
Dump box capacity ................................................................................................1,03 m3
BUILDING KIT
12.5.8 HYDRAULIC SYSTEM DIAGRAM
MA1
7
8
MA1
7
RIBALTAMENTO
A
A R/G
B
R/G
B
T1,T2
T1,T2
Ps
MB1
Ps
MB1
6
B3
A5
A4 B4 B5
B6 A6
150 Bar
1
Autoc.
M
Soll-Rot
POMPA CASAPPA 14+14+6.3 cm3/giro Pressione pist.=210bar Pressione ingr.=180bar
15 Bar
Cingolo Dx
P1
2» Velocita
150 Bar
Cingolo Sx
Ribaltamento
150 Bar
P3 P2
2
4 2 bar
YANMAR 3TNE74 2800 Giri/min P=20.7 HP Taratura(vuoto)=2600 rpm 4 bar
S
3
5
103
BUILDING KIT
KEY 1. 2. 3. 4. 5. 6. 7. 8.
104
Yanmar 3TNE74 Diesel engine Variable displacement triple pump Hydraulic oil filter Filter Water-oil exchanger Distributor Redutcion gear drive Tilting cylinder
FM1300 FORKLIFT KIT
12.6 FM1300 FORKLIFT KIT 12.6.1 EC DECLARATION OF CONFORMITY
105
FM1300 FORKLIFT KIT
12.6.2 IDENTIFICATION DATA
The FM1300 tilting forklift kit described in this manual is CE marked, being compliant with the European Union harmonised standards as of the date the EC declaration of conformity was issued. The rating plate located at the rear of the platform shows the data identifying the kit; this data will be required when requesting service from Hinowa SpA, so as to identify the exact technical specifications of the kit when repairs are needed.
WARNING ATTENZIONE -
This kit, combined with the HP2500 Minidumper, is suitable for lifting and transporting loads in compliance with the rules described in this manual.
-
Any danger caused due to using the forklift for purposes other than those illustrated in this manual is the user's responsibility.
-
This forklift has been designed for off-road driving, not in enclosed places; check that the ground the machine is working on can support the weight of the forklift.
-
This kit is not suitable for driving on the road and can only be used by authorised personnel, after having read and understood this manual.
-
Do not use the forklift in conditions of poor visibility or at night.
106
FM1300 FORKLIFT KIT
12.6.3 SAFETY STANDARDS This forklift can only be used by authorised personnel, after having read and understood this manual. 12.6.3.1 SAFETY WARNINGS (LABELS) Read the safety messages described in this manual and the safety signs on the machine. Check that the safety signs are in good condition, replacing any missing or damaged signs. Make sure that when replacing any components the correct safety signs are applied. Learn how to operate the machine and use the controls correctly. Do not allow any unauthorised or untrained persons to operate and/or perform maintenance on the machine.
POSITION OF THE SAFETY WARNINGS ON THE KIT 1) This label, located on the hydraulic component protective hood, at the top, indicates that it is prohibited to lift a load when the gradient of the machine from the horizontal is greater than 1°. For this purpose the FM1300 forklift kit has been fitted with a spirit level to check before lifting any weight that the gradient of the machine is within the allowed limits. At the bottom, on the other hand, the correct travel configuration is illustrated; that is, travelling is not allowed with the forks raised and/or extended.
2) This label, located on the distributor protective hood, shows the possible movements that can be performed by operating the corresponding levers on the hydraulic distributor.
107
FM1300 FORKLIFT KIT
3) This label, located on the hydraulic component protective hood, indicates that a maximum load of 1300 kg can be lifted, with a maximum distance of the centre of gravity of the load from the horizontal and vertical of the forks of 500 mm. These maximum limits regarding the capacity and the distance of the centre of gravity from the forks must not be exceeded.
4) This label, located on the hydraulic component protective hood, indicates the correct positioning of the load in the travel configuration: load completely retracted and lowered.
5) This label, located on the hydraulic component protective hood, indicates that the use and maintenance manual must be carefully read before using the machine.
108
FM1300 FORKLIFT KIT
6) This label, located on the lifting guide, indicates to beware and keep a safe distance away from the machine.
7) This label, located on the fork travel guide, indicates that extra care must be paid to the danger of shearing the upper limbs.
8) This label, located on the lifting guide, indicates that it is prohibited to climb onto the forks, and to use the forklift as an aerial work platform.
9) This label, located on the hydraulic component protective hood, indicates that safety equipment such as helmets, glasses, gloves, earmuffs and work shoes must always be worn when using the machine or when performing maintenance operations.
10) This label, located on the lifting guide, indicates that no maintenance operations may be performed with moving parts.
109
FM1300 FORKLIFT KIT
11) This label, located on the lifting guide, indicates the zone to be used for attaching the lifting cables (see par. 12.6.9.7)
DIAGRAM OF LABEL POSITIONS
Note: CHECK THAT LABEL 2 IS IN THE CORRECT POSITION ON THE MACHINE THAT THE FORKLIFT KIT IS BEING INSTALLED ON. ALSO CHECK THAT THE OTHER LABELS ARE PRESENT ON THE FORKLIFT KIT. IF THE LABELS ARE MISSING, CONTACT HINOWA SERVICE.
110
FM1300 FORKLIFT KIT
12.6.3.2 GENERAL PRECAUTIONS Unauthorised modifications It is strictly prohibited to make modifications to the kit that may compromise operation and endanger safety. Hinowa is not liable for any injuries or damage caused by unauthorised modifications. Safety valves It is strictly prohibited to modify and/or tamper with the hydraulic system safety and control valves on the kit. Hinowa is not liable for any damage to people, things and kit when the standard adjustments of the hydraulic valves are tampered with. Prevention against damage caused by the working machine When the machine is working, do not enter within its range of action.
12.6.3.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE Refer to the corresponding section in the use and maintenance manual for the machine that kit is installed on.
WARNING ATTENZIONE As regards the procedure for loading and unloading the forklift from trucks or other means of transport, follow the instruction described in the track use and maintenance manual, and in paragraph 12.6.9.7.
WARNING ATTENZIONE The points and procedures for refuelling the forklift are specified in the track use and maintenance manual.
111
FM1300 FORKLIFT KIT
12.6.4 NOMENCLATURE To assist the understanding of the safety warnings and the operating and maintenance instructions for the FM1300 forklift kit, below are the names of the various assembled components: 2
9
4
8
11
1
10
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
112
FORKS EXTERNAL LIFTING GUIDE MICROSWITCH LIFTING CHAIN FORKLIFT DRIVE ENGINE RACK LIFTING CYLINDER CONTROL POSITION INTERNAL LIFTING GUIDE OPERATOR PLATFORM TILT CYLINDERS
7
3 5
6
FM1300 FORKLIFT KIT
12.6.5 CONNECTING THE FM1300 FORKLIFT KIT TO THE MINIDUMPER Position the adapter above the HP2500 minidumper and fasten using the 8 bolts as shown in the figure. The FM1300 forklift kit, supported by suitably rated chains or cables, is ready to be mechanically fastened to the minidumper (see the attachment procedures and points in par. 12.6.9.7).
Position the FM1300 forklift kit above the HP2500 minidumper, so as to be able to tighten the two bolts at the rear of the kit (see the photo). Then position the first two of the eight bolts that are used to fasten the forklift kit to the adapter previously fastened to the minidumper.
Now hydraulically connect the hoses from the minidumper to those on the kit. The hoses have been suitably numbered, make sure this operation is performed correctly, otherwise any movements of the levers on the distributor will not correspond to the response of the kit as described in paragraph 12.6.8 Driving position and controls.
113
FM1300 FORKLIFT KIT
Then raise the forks so as to release the microswitch that enables horizontal movement (see par. 12.6.4), allowing the forks to be moved forwards or backwards in the special guides and thus fasten the other six bolts that join the platform on the kit to the adapter at the front of the machine. Also connect the electrical system by joining the two connectors, as shown in the figure.
Now position the rear counterweight that also acts as the support platform (after having removed the standard platform, if featured); to move the counterweight, tighten four M8 eyebolts into the four threaded holes, as shown in the figure.
Lift it using suitable equipment, considering that it weighs around 210 kg; secure it using four M16 bolts to the chassis of the HP2500 minidumper.
Then remove the eyebolts and tighten the non-slip platform, as shown in the figure.
114
FM1300 FORKLIFT KIT
Now fasten the second counterweight, which weighs around 130 kg, to the adapter using two M14 bolts, as shown in the figure here to the side.
WARNING ATTENZIONE Never use the forklift for any reason without having first correctly installed both counterweights.
WARNING ATTENZIONE Do not remove the forklift kit from the minidumper without first having removed both counterweights.
WARNING ATTENZIONE Before using the forklift, make sure that the lifting stops are fitted, which limit the height of the load to 1800 mm. The forklift must not be used without the lifting stops, as it may overturn. Risk of death.
The assembly and dismantling of the kit onto/from the machine must be performed by specialist personnel, only after having carefully read and understood the use and maintenance manual. To remove the kit, complete the procedure described above in the reverse order.
115
FM1300 FORKLIFT KIT
12.6.6 PRECAUTIONS FOR USE
12.6.6.1 GENERAL USE OF THE MINIDUMPER Refer to the use and maintenance manual for the track that is used with this kit.
WARNING ATTENZIONE This forklift is not fitted with lighting, and so the forklift must not be used in conditions of poor visibility and at night.
12.6.6.2 USE OF THE FORKLIFT KIT
WARNING ATTENZIONE Before starting the machine check that all the levers on the distributor are in the neutral position.
DANGER PERICOLO Move all people away from the area where the machine works and moves. The FM1300 forklift kit must ONLY BE OPERATED FROM THE CONTROL POSITION (par. 12.6.8). The Hinowa FM1300 forklift kit coupled to the Hinowa HP2500 track is designed for handling palletised objects on sites. The objects moved must have a maximum weight of 900 kg, with a maximum distance of the centre of gravity of the load from the horizontal and vertical plane of the forks of 500 mm. The loads that are handled must be solid and compact, well positioned on standard 1000x1200mm or 800x1200mm pallets, the maximum height of the load being transported must not exceed 1800 mm (check that the centre of gravity of the load being transported is a maximum distance of 500 mm from the horizontal and vertical plane of the forks). The operator must always look in the direction of travel so as to observe the path being followed and avoid accidents. If the goods being transported impede the view, drive in reverse; if this is not possible, a second person, keeping a safe distance, must walk with the forklift; in this case, the driver of the forklift must travel at walking speed and stop the vehicle as soon as visual contact is lost with the reference person; in any case, it is prohibited to drive with
116
FM1300 FORKLIFT KIT
the load lifted. The machine must be loaded and unloaded and the forks moved on solid and level ground, with a maximum slope of 1°, checked using the spirit level installed on the machine. The machine can only be moved with the forks in the driving position (see labels 1 and 4). Make sure that the ground is strong enough to securely support the machine. When working near an excavation, position the machine with the engine at the rear. Beware of overturning when working on frozen ground. The increase in temperature softens the ground, making it unstable. Check that the forklift slide and support zone on the machine is free of debris or other material that may block its movement.
The forks must only be raised when the machine has stopped and is on level ground. It is prohibited to drive with the forks lifted and/or the forklift extended.
WARNING ATTENZIONE The forks must not be moved when travelling.
The maximum load that can be lifted is 1300 kg with a maximum distance of the centre of gravity of the load of 500 mm from the horizontal and vertical plane of the forks. These maximum limits regarding the capacity and the distance of the centre of gravity from the forks must not be exceeded.
117
FM1300 FORKLIFT KIT
The correct travel configuration is illustrated here to the side, and involves keeping the load completely lowered and retracted. A device is provided that allows the forklift to travel in second speed only when it is in correct travel configuration (see the figure).
THE
FORKLIFT KIT IS FITTED WITH TWO MICROSWITCHES THAT FORCE THE VEHICLE TO TRAVEL IN FIRST
SPEED WHEN IT IS NOT IN THE TRAVEL CONFIGURATION.
WARNING ATTENZIONE NEVER ACTIVATE
THE LEVERS FOR HANDLING THE LOAD WHEN DRIVING, AS THERE MAY BE A SUDDEN
ACCELERATION OR DECELERATION DUE TO THE MICROSWITCHES THAT FORCE THE VEHICLE TO TRAVEL IN FIRST SPEED WHEN IT IS NOT IN THE TRAVEL CONFIGURATION.
WARNING ATTENZIONE THE
FORKLIFT KIT IS FITTED WITH A MAXIMUM PRESSURE VALVE, LOCATED NEAR THE FORK LIFTING
CYLINDER, SPECIALLY CALIBRATED SO AS TO NOT BE ABLE TO LIFT A LOAD GREATER THAN
1300
KG;
NONETHELESS, THE OPERATOR MUST CHECK THAT THE DISTANCE OF THE CENTRE OF GRAVITY OF THE LOAD IS A MAXIMUM OF
500 MM FROM THE HORIZONTAL AND VERTICAL PLANE OF THE FORKS.
HINOWA DECLINES ALL LIABILITY AND THE WARRANTY IS IMMEDIATELY VOID IF THIS VALVE IS TAMPERED WITH AND/OR THE FORKLIFT IS USED IMPROPERLY.
12.6.6.3 DO NOT WORK IN DANGEROUS AREAS Due to the specific constructional difficulties, the FM1300 forklift kit cannot be fitted with protection against the risks of material falling from above and the risk of overturning.
DANGER PERICOLO Never work in places where there is the danger of objects falling from above, and always refer to the instructions provided in the manual to avoid the risk of overturning. Always wear protective garments (helmet, overalls, gloves, glasses and work shoes).
118
FM1300 FORKLIFT KIT
12.6.7 MANOEUVRING THE MACHINE 12.6.7.1 PRECAUTIONS WHEN WORKING
WARNING ATTENZIONE Before starting the machine check that all the levers on the distributor are in the neutral position.
WARNING ATTENZIONE Always run a safety check of the working area before starting work. Do not forget to adopt the following precautions: (a) Do not manoeuvre in places where there is the danger of falling objects, such as debris, tools, parts of scaffolding being setup or dismantled, etc. (b) Always wear a helmet and protective garments when manoeuvring the machine. Make sure that any other people working near the machine also wear safety garments and helmets. (c) Do not allow other workers to stay nearby when manoeuvring the machine, and always keep other people present at the site in view. POSITION THE MACHINE SAFELY
WARNING ATTENZIONE Make sure that the machine is always on ground that is strong enough to support its weight, especially when working near edges.
WARNING ATTENZIONE This forklift is not fitted with a tow bar; consequently, it cannot be used to tow objects, trailers, etc. nor tow the forklift itself.
RUBBER TRACKS
IMPORTANT IMPORTANTE The rubber tracks are only for use on soft ground, and not on hard and abrasive surfaces such as sand, stones, minerals, etc. Using the rubber tracks on these surfaces may cause deformation and premature wear.
119
FM1300 FORKLIFT KIT
AFTER HAVING FINISHED WORKING 1. 2. 3.
Find a safe and level site to park, where there is no danger of falling rocks or other debris. Turn the machine off and remove the ignition key. Clean the machine thoroughly.
12.6.8 DRIVING POSITION AND CONTROLS A
ABCDEF-
FORKLIFT L TRAVEL CONTROL LEVER TILT FORK CONTROL LEVER FORKLIFT R TRAVEL CONTROL LEVER SECOND SPEED CONTROL LEVER FORK TRAVEL CONTROL LEVER FORK LIFT CONTROL LEVER
G- ACCELERATOR CONTROL
120
B
C
D
E
F
G
FM1300 FORKLIFT KIT
12.6.9 HANDLING THE MACHINE
12.6.9.1 UNDERCARRIAGE OPERATION - Travelling in a straight line Move both levers forwards to travel in a straight line. Pull both levers backwards to travel in reverse.
- Steering to the right or left To turn right, move the left lever forwards. To turn left, move the right lever forwards.
- Turning on the spot Move one lever forwards and the other lever backwards.
121
FM1300 FORKLIFT KIT
12.6.9.2 MOVING THE FORKLIFT FORWARDS Operating the lever as shown, after having installed the tilting forklift kit, moves the forklift forwards. This movement is only allowed if microswitch "I" is not energised. N.B.: This microswitch prevents the forks from moving forwards or backwards if the relative height between the forks and the platform does not ensure there is no risk of collision between the two.
I
Moving the lever backwards returns the forklift back.
12.6.9.3 TILTING THE FORKS Moving the lever indicated in forwards or backwards respectively lowers or raises the tips of the forks.
122
FM1300 FORKLIFT KIT
12.6.9.4 SECOND TRAVEL SPEED To activate the 2nd travel speed of the undercarriage, move the lever to the position as shown. Operate this control only when travelling on level ground.
WARNING ATTENZIONE The forklift kit is fitted with two microswitches that force the vehicle to travel in first speed when it is not in the travel configuration.
12.6.9.5 FORK LIFT CONTROL LEVER The optional control lever, if activated as indicated in the figure, is used to lower the forks; if activated in the opposite direction, it raises the forks.
WARNING ATTENZIONE N.B.: THE LOAD BEING LIFTED MUST NOT EXCEED 1300 KG with a distance of the centre of gravity of 500 mm from the horizontal and vertical plane of the forks.
123
FM1300 FORKLIFT KIT
12.6.9.6 HANDLING THE LOAD Only complete palettes that do not exceed the allowed dimensions can be handled; the load must be compact and uniform, and must not exceed the allowed weight and maximum distance of the centre of gravity. Approach the load to be handled and brake gradually so as to stop the forklift near the load. Extend the forklift, tilt forwards so that the mast is vertical, and lift the forks.
WARNING ATTENZIONE The tilting forwards operation must be performed slowly, to prevent the forklift from overturning or the load sliding off the forks. Travel slowly, making sure not to damage the load or any shelving, and stop smoothly as soon as the heel of the forks support the load. Make sure that the centre of gravity of the load is in the centre of the two forks. Lift the load. Then tilt backwards and fully retract the forks, so that the load is as close as possible to the operator. Check that the path is free and reverse the machine until the lower can be lowered safely, stop smoothly and lower the load until reaching the travel configuration. Now the machine can be driven with care, accelerating and decelerating slowly, making sure to slow down significantly when cornering. Note: when travelling up or down rises the load should remain behind the vehicle; do not travel horizontally across slopes or corner on sloped ground. Avoid parking or standing with the forklift in such areas.
WARNING ATTENZIONE Once work has terminated, at the end of the day or for a break, always remove the keys from the ignition.
124
FM1300 FORKLIFT KIT
12.6.9.7 LIFTING POINTS The forklift must be lifted using suitably rated hoisting equipment, by personnel with sufficient experience in the use such equipment. To determine the correct weight to be lifted, read the rating plates on the minidumper and the forklift kit: WEIGHT TO BE LIFTED = WEIGHT OF THE HP2500 FORKLIFT KIT + WEIGHT OF THE HP2500 MINIDUMPER
Once having determined the correct weight to be lifted and checked that the hoisting slings are suitable for supporting the load, park the machine on a flat area and attach the hoisting slings. To avoid damaging forklift, suitably rated fabric slings should be used.
In addition, a balance bar must be used for lifting, so that the slings that support the forklift are vertical to the points of attachment (see the figure); the points are highlighted in black in the figure: minidumper roll bar and cross bars bolted and welded to the mast of the forklift kit. The length of the slings must be adjusted so that the rubber strips, even when the forklift is lifted, remain parallel to the ground.
Bolted cross bar
Welded cross bar
I f lif-
125
FM1300 FORKLIFT KIT
ting the forklift kit only, the weight to be considered for choosing the hoisting equipment is shown on the kit's rating plate; do not use a balance bar, but rather fasten the fabric slings by wrapping them around the bolted and welded cross bars on the mast of the kit (see the figure).
Bolted cross bar
Welded cross bar
DANGER PERICOLO -
Only use the points specified above and suitably rated equipment for lifting.
-
Never enter underneath the suspended loads. Risk of death.
-
When lifting, make sure that the forklift does not collide against other objects and that no dangerous and uncontrolled movements are caused. If necessary, keep the forklift still using guide ropes, making sure to stay a safe distance away.
126
FM1300 FORKLIFT KIT
12.6.10 ROUTINE MAINTENANCE 12.6.10.1 PREPARE THE MACHINE FOR ROUTINE MAINTENANCE
IMPORTANTE Before starting the maintenance procedure, complete the following operations: 1. Park the machine on level ground; 2. Position the forks on the platform; 3. Run the engine at low speed and without the machine loaded for 3 minutes; 4. Turn the ignition key OFF. Remove the ignition key if possible. If maintenance must be performed with the engine on, never leave the machine unsupervised; 5. Before starting work on the machine, place the "DO NOT OPERATE" sign in a visible position; 6. If during maintenance the forks need to be raised, the fork lifting cylinder must be locked mechanically. 12.6.10.2 GREASING POINTS 5
2
6
3 1 7
4 1 2 3 4 5 6 7
Fork support Lifting chain External lifting guide Travel guide Internal lifting guide Forklift bearings Lifting chain locking comb
127
FM1300 FORKLIFT KIT
12.6.10.3 MAINTENANCE ON THE LIFTING MECHANISMS The forklift on the FM1300 forklift kit is raised using a chain mechanism. The chain should be greased periodically (recommended once a month), depending on the operating conditions. The play and wear of the chain should be checked frequently, together with the condition of the chain coupling pins and the coupling pins to the fixed part. Measure the distance between the pins making up the chain and check that this does not exceed 2% of the rated value of 25.4 mm. On a practical ground, proceed as follows: - Completely retract the forks and fully close the lifting cylinder, resting the forks on the ground. - Measure the distance between the pins on 34 links in the chain. The total measurement must not exceed 880 mm (34*25.4=863.6 863.6+2%=880 mm). - If the measurement exceeds this limit, immediately replace the chain. This check must be performed every month. Every month also check the tightness of the nut and the lock nut that secure the lifting chain locking comb. Every day check the presence and the correct positioning of the safety pins on the pin that connects the lifting chain to the comb. Every day check that the sliding guide is clean and visually inspect the forks to check for any deformations (in this case, immediately replace both forks). Check that the fork stops (1) are positioned and working correctly. Check that the side stops (2) that prevent the forks from coming out are in place and are positioned correctly.
12.6.10.4 STORING THE MACHINE In addition to the points on storing the machine in the manual for the track used with this kit, the following operations are required: - position the machine with the forks completely retracted and lowered; - protect the exposed cylinder rods with hydraulic oil.
128
FM1300 FORKLIFT KIT
12.6.11 TECHNICAL SPECIFICATIONS 12.6.11.1 TECHNICAL DATA
42°
545 1210 1650
1800
3017
2°
2141
3°
Working capacity....................................................................................................................1300 kg Max allowable distance of the centre of gravity of the load............................................500 mm Operating weight of the FM1300 forklift kit ......................................................................1050 kg Operating weight, excluding the operator (kit + HP2500) ..............................................2300 kg Class 2b forklift (width) ........................................................................................................900 mm Maximum lifting height......................................................................................................1800 mm
250
800 1300
250
2491
3510
1850 2033 3140
129
FM1300 FORKLIFT KIT
12.6.11.2 HYDRAULIC SYSTEM DIAGRAM
12.6.11.2.1 KEY TO THE HYDRAULIC SYSTEM DIAGRAM 1. Raise 2. Travel 3. Valve 4. Valve
130
5. Forklift drive engine 6. Lifting cylinder 7. Tilt 8. Tilt cylinders
FM1300 FORKLIFT KIT
12.6.11.3 ELECTRICAL SYSTEM DIAGRAM
12.6.11.3.1 KEY TO THE ELECTRICAL SYSTEM DIAGRAM X1 X2 X3 S1 S2
Dashboard line connector Microswitch 1 connector Microswitch 2 connector Microswitch 1 Microswitch 2
131
Legal and administrative seat HINOWA S.p.A. I - 37054 NOGARA (VR) via Fontana Tel. +39 0442 539100 Fax +39 0442 539075
[email protected] - marketing:
[email protected] www.hinowa.com
