OPERATION AND

MAINTENANCE MANUAL
HMK 640 WL
WHEEL LOADER

SERIAL NUMBERS K1020001 and UP

HİDROMEK 2021

WARNING

This manual must be kept inside operator's cab. Operators and

maintenance personnel must read this manual before operating
and/or maintaining the machine. Ensure to observe all safety
related procedures and instructions.

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

Publication No: L227201401 Rev No: 00

Date of publication: 26.11.2021 Original Instructions
ii
 TABLE OF CONTENTS

1. INTRODUCTION ............................................................................................................................................1
1.1. GENERAL INFORMATION ......................................................................................................................1
1.2. CE DECLARATION OF CONFORMITY AND EMC DIRECTIVE ............................................................2
1.3. BEFORE STARTING OPERATION AND MAINTENANCE .....................................................................2
1.4. SAFETY INFORMATION .........................................................................................................................3
1.5. INTENDED USE OF MACHINE ..............................................................................................................4
1.6. VISIBILITY FROM OPERATOR'S SEAT .................................................................................................4
1.7. NECESSARY INFORMATION .................................................................................................................4
1.8. LOCATION OF SERVICE METER ..........................................................................................................5
1.9. TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR INFORMATION .................................................5
2. TECHNICAL SPECIFICATIONS ....................................................................................................................6
2.1. GENERAL AND WORKING DIMENSIONS .............................................................................................6
2.2. NOISE AND VIBRATION ...................................................................................................................... 11
3. WORK SAFETY........................................................................................................................................... 12
3.1. SAFETY LABELS .................................................................................................................................. 12
3.2. PRECAUTIONS DURING OPERATION AND MAINTENANCE ........................................................... 20
3.3. PRECAUTIONS DURING OPERATION ............................................................................................... 27
3.4. PRECAUTIONS FOR MAINTENANCE ................................................................................................ 39
4. OPERATION ................................................................................................................................................ 49
4.1. GETTING TO KNOW OUR MACHINE ................................................................................................. 49
4.2. EXPLANATION OF CONTROLS AND GAUGES ................................................................................. 53
4.3. OPERATION ......................................................................................................................................... 83
4.4. TRANSPORTATION ........................................................................................................................... 120
4.5. COLD WEATHER OPERATION ......................................................................................................... 124
4.6. LONG-TERM STORAGE .................................................................................................................... 125
4.7. INSTRUCTIONS ON WITHDRAWAL FROM USE AND UTILIZATION ............................................. 126
4.8. TROUBLESHOOTING ........................................................................................................................ 127
4.9. ENGINE PROBLEMS ......................................................................................................................... 135
5. MAINTENANCE ......................................................................................................................................... 138
5.1. MAINTENANCE RULES ..................................................................................................................... 138
5.2. OIL, FUEL, COOLANT ........................................................................................................................ 140
5.3. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS ..................................................... 147
5.4. PERIODICAL INSPECTION AND MAINTENANCE LIST ................................................................... 148
5.5. PERIODICAL INSPECTION AND MAINTENANCE PROCEDURES ................................................. 151
6. COMMUNICATION INFORMATION ......................................................................................................... 200
6.1. PLANTS AND AFTER SALES SERVICES ......................................................................................... 200

iii
WARRANTY CONDITIONS
During warranty period of the machine, all the
failures related to material or workmanship defects
will be repaired by Hidromek (or authorized
dealers) free of charge. During warranty period, if
the machine is used out of its intended purpose, if
it is modified without prior written consent of
Hidromek, if periodical maintenance is not duly
conducted by Hidromek (or authorized dealers),
and if original spare parts or wear parts
recommended by Hidromek are not used, warranty
conditions will be null and void.
Main parts and components of the machine such
as buckets, lifting arms etc. are designed and
manufactured for certain applications. If machine is
used out of its intended purpose, performance of
such parts and components cannot be guaranteed.
Warranty certificate is valid only for the machine it
belongs to. For their claims during warranty period,
customers will be requested to provide warranty
certificate and periodical maintenance invoices
issued by authorized service dealers.
Failures happening when the machine is used by
unauthorized people without an operator's license
will be out of warranty coverage.
Periodical replacement parts, wear parts and/or
materials such as oil, fuel, antifreeze, filtres, linings
and etc. are not under warranty coverage. Glasses,
mirrors, pins & bushings, V-belts, teeth, electric
cables, bulbs, lamps, turning lamps and parts
made of elastic materials such as rubber and
plastic are not under warranty coverage.
Warranty claims related to tires and diesel engine
will be evaluated by their manufacturer according
to their own warranty policy and their decision will
be final.
Repair and maintenance of radio/cassette player/
CD player and similar devices will be made by their
suppliers through their service dealers.
Any kind of failures and/or damages originating
because of hitting, collision, dropping, rolling, tilting
the machine or operating or parking the machine in
improper conditions will be out of warranty
coverage.
iv
It is the customer’s responsibility to follow
machine's operation hours and periodical
maintenance time and request service from
Hidromek. If maintenance cannot be conducted in
time and machine continues to operate as such,
possible defects or damages will not be under
warranty coverage.
For the service works to be done under warranty,
customer has to deliver the machine to Hidromek
Authorized Service or Dealer. In case repair or
maintenance of machine is not allowed for some
reason or repair or maintenance is delayed and
defective machine continues to operate, possible
defects or damages will not be under warranty
coverage. In case machine fails during warranty
period, the time spent for repair will be added to
warranty period.
Hidromek's responsibility is limited to repairing the
machine within a reasonable time. Customer
cannot raise any claim for the time spent for repair
and for the time machine is away from work.
Hidromek is free to decide to replace failed parts
partially or fully or to reuse them after the repair.
Replaced parts are Hidromek's property. Lost or
missing parts are out of warranty coverage.
Performance of Hidromek labeled original parts,
which are designed for Hidromek machines, cannot
be assured when they are installed on another
equipment.
Works which are not covered within warranty even
during warranty period will be charged according
to current Hidromek parts and labor rates.
All the warranty claims during warranty period will
be submitted in written to authorized Hidromek
Services, Hidromek Branch Offices or Hidromek
After Sales Service Department. If failure under
warranty needs to be fixed at Hidromek workshop
or at any Hidromek Authorized Service or Dealers,
transportation costs will be customers liability and
will not be under warranty coverage.

1. INTRODUCTION
1.1. GENERAL INFORMATION
Thank you for your decision to buy Hidromek
Wheel Loader.
With their performance, Hidromek Wheel Loaders
are highly efficient, functional, economical and user
friendly machines.
With its experience over 38 years, in addition to its
highly advanced production facilities, Hidromek
meets necessary testing and quality control
requirements to assure high level of reliability and
safety of its products.
This Operation and Maintenance Manual contains
information about safety, operation, transportation,
repair and maintenance which is aimed to help the
owners and operators of the machine for efficient
and safe operation. Moreover, this manual
provides work plan for safe and proper operation of
the machine. Safety related items are explained in
details in Operation Safety Section of this Manual.
You must read and study this manual carefully and
fully understand the operation, lubrication,
maintenance and repair methods before operating
this machine.
This manual also explains procedures for effective,
economical usage and maintenance of Hidromek
Wheel Loaders and hints to increase the efficiency
of the operator.
Keep this manual always inside operators cab in
good condition. When the machine is handed over
to another party for any reason, this manual should
always accompany the machine.
WARNING
Careless or improper operation of this machine
may cause serious injuries.
Mechanics and operators must read this
manual carefully before operating or performing
lubrication, maintenance and repair on this
machine.
Keep this manual in the storage area inside the
operator’s compartment so that all personnel
handling the machine can read it periodically.
Read this manual repeatedly and study until you
become familiar with controls and operations of
the machine.
If this manual is lost or damaged, please ask a
new one from your HIDROMEK Branch Office
or Hidromek Authorized Service or Dealer.
This manual should always be kept on the
machine.
The safety, operation, maintenance and repair
information given in this manual is limited to the
specified intended usage of the machine.
Our dealer network is always ready to provide our
customers with the necessary support including
original Hidromek spare parts. In order to keep your
warranty valid, all spare parts must be supplied
from Hidromek dealers. When ordering parts, you
will be requested to inform your machine's model
and serial number in addition to full description of
required parts. In order to find your machine serial
numbers easily, you are recommended to write
such data in advance in "1.9 TABLE TO ENTER
SERIAL NO. AND DISTRIBUTOR" section.
Hidromek warranty conditions are explained in the
previous pages and also included in the Warranty
Manual delivered with the machine in details.
Before starting to operate your machine, you are
requested to read the warranty conditions and
follow them.
Special equipment and attachments are not
included in operation instructions.
Continuing improvements and advancement of
product design may have caused changes on your
machine which are not included in this publication.
To reflect such changes, manuals are revised from
time to time.
Some photographs or illustrations in this
publication may not reflect details or attachments
available on your machine. Guards and covers may
have been removed for illustrative purposes.
Without any obligation to revise this manual, based
on continuous improvement policy, Hidromek
reserves the right to change or improve material,
design or construction of any part. Hidromek is not
obliged to apply design changes or improved or
modified parts and components to the machines
previously sold to the customers.
WARNING
To be familiar with your machine, before starting
operation you must read and fully understand the
contents of this Manual.
Failure to follow this Manual may result in serious
accidents.
NOTE
This manual is copyrighted with all rights reserved.
No part of this manual may be copied, in whole or
in part, without a written consent from HIDROMEK.
1
1.2. CE DECLARATION OF CONFORMITY AND
EMC DIRECTIVE
This machine complies with “Health and Safety
Requirements” as per European Union Machinery
Directive 2006_42_EC. That is why it is entitled to
bear CE marking of EU.
CE marking also shows conformity to EU EMC
(Electromagnetic Compatibility) Directive
(2004/108/ EC).
Declaration of conformity must be kept with the
machine and in case machine is sold to third parties
it must be handed over as well.
This declaration covers Hidromek attachments as
well. If an unauthorized modification is applied or
an unapproved attachment or part is used, this
declaration will be invalidated and a new
declaration has to be issued. The User will be
responsible for the consequences.
Work safety should always be the priority and
machine must be used as explained in this manual
in OPERATION section. Only Hidromek approved
attachments or parts must be used on this Fig 1.1. Storage location of Operation and Maintenance
machine. Manual

1.3. BEFORE STARTING OPERATION AND
MAINTENANCE
This manual gives details of the operation and
methods for inspection and maintenance of this
machine that must be obeyed in order to use the
machine safely. Most of the accidents are caused
by the failure to follow basic safety rules for the
operation and maintenance of machines.
You must read, understand and follow all
precautions and warnings in this manual before
starting to perform an operation and maintenance
on the machine. Failure to do so may result in
serious injuries or even death.
Manufacturer -Hidromek- cannot predict every
circumstance that might involve a potential hazard
when operating and/or maintaining the machine.
Therefore, the safety messages in this manual and
on the machine may not include all potential safety
precautions. If you carry out any operation,
inspection or maintenance under conditions which
are not described in this manual, understand that it
is your responsibility to take the necessary
precautions to ensure safety. In no event should
you or others engage in the prohibited uses or
actions described in this manual. Improper
operation and maintenance of the machine can be
hazardous and could result in serious injuries or
even death.
If you sell the machine, be sure to give this
Operation and Maintenance Manual to the new
owner along with the machine.
Always keep this Operation and Maintenance
Manual in the location shown on the figure (behind
the cover on left rear side of operator's seat) so that
all relevant personnel can read it at any time.
If this manual is lost or damaged, contact your
Hidromek dealer immediately for its replacement.
Hidromek dealer will need some information about
the machine such as engine serial number and
chassis serial number. This information should be
registered in advance in section "TABLE TO
ENTER SERIAL NO. AND DISTRIBUTOR".
This manual uses the international units (SI) for
units of measurement. For reference, units that
were used in the past are given in parentheses ( ).
The explanations, values, and illustrations in this
manual have been prepared based on the latest
information available at the date of its publication.
Continuing improvements in the design of this
machine may lead to additional changes that are
not reflected in this manual. Consult your Hidromek
dealer for the latest available information
concerning your machine or with questions
regarding information contained in this manual.
• The numbers in circles in the illustrations
correspond to the numbers in parentheses ( ) in the
text. (For example:1→ (1))
Hidromek delivers machines that comply with all
applicable regulations and standards of the country
where the machines are shipped. If the machine is
purchased in another country, it may lack certain
standards that are necessary to be used in your
country. If there are any questions about whether
your product complies with the applicable
standards and regulations of your country, consult
your Hidromek dealer before operating the
machine.

2
1.4. SAFETY INFORMATION
To enable you to use the machine safely, and to
prevent any injury to operators, service personnel
or other people around the operation site, the
precautions and warnings included in this manual
and the safety signs attached on the machine must
always be strictly observed.
To identify and emphasize important safety
messages given in this manual and on the machine
labels, the following signal words are used.
These Signal Words identify important safety
messages on machines, in manuals, and
elsewhere. When you see ‘’Danger’’, be alert to the
risk of a personal injury or death. Follow the
instructions in the safety message.

DANGER
This signal word indicates a close hazardous
situation which, if not avoided, will result in death or
a serious injury.

WARNING
This signal word indicates a potentially hazardous
situation which, if not avoided, could result in death
or a serious injury.

CAUTION
This signal word indicates a potentially hazardous
situation which, if not avoided, may result in a
minor or moderate injury.
In addition to above, following signal words are
used to alert you that the instructions must be
followed to avoid damage to the machine.

NOTE
This signal word indicates that the machine may be
damaged or the service life may be reduced if the
precaution is not followed.

3
1.5. INTENDED USE OF MACHINE 1.7.1. PRODUCT IDENTIFICATION NUMBER
Hidromek has designed and manufactured this (PIN)/MACHINE SERIAL NO. PLATE
machine to be used mainly for the following works: Located on the front chassis, facing the operator on
• Digging work left bell crank (1).

• Leveling work The design and content of the nameplate may differ
from country to country.
• Pushing work
• Loading work
For details of the operating procedures, see section
"WORK POSSIBLE USING WHEEL LOADER".
1.5.1. FRONT/REAR, LEFT/RIGHT DIRECTIONS
OF MACHINE

Fig 1.3

1.7.2. AB/EPA REGULATION, ENGINE SERIAL

NUMBER PLATE
Located on RH side of cylinder block, above engine
control module (MCM) when viewed from fan side.

Fig 1.2

In this manual, the directions of the machine (front,

rear, left, right) are determined according to the
view from the operator's seat in the direction of Fig 1.4
travel (front) of the machine.
1.6. VISIBILITY FROM OPERATOR'S SEAT
This machine complies with the visibility standard
ISO 5006.
1.7. NECESSARY INFORMATION
When requesting service or ordering spare parts,
please inform your Hidromek Authorized Service or
Dealer of the following items.

Fig 1.5

EPA: Environmental Protection Agency, U.S.A.

4
1.8. LOCATION OF SERVICE METER
Located on left rear side of the operator's seat, next
to the storage compartment (1).

Fig 1.6

1.9. TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR INFORMATION

Machine Serial Number (PIN)

Engine Serial Number

Transmission Serial Number

Front Axle Serial Number

Rear Axle Serial Number

Dealer’s Name

Address

Service Repr.

Telephone / Fax

5
2. TECHNICAL SPECIFICATIONS
2.1. GENERAL AND WORKING DIMENSIONS

Fig 2.1

Fig 2.2

6
TECHNICAL SPECIFICATIONS

1. Wheelbase 3500 mm

2. Center line of rear axle to edge of counterweight 2325 mm

3. Center line of rear axle to hitch 1750 mm

4. Ground clearance with 26.5R25 (L3) tires 530 mm

5. Height to center line of axle 820 mm

6. Height to top of hood 2880 mm

7. Height to top of exhaust pipe 3470 mm

8. Reaching angle 30°

9. Hinge pin height, carry position 270 mm

10. Tilt back on ground 40°

11. Bucket width 3300 mm

12. Height to top of ROPS 3530 mm

13. Overall length 8950 mm

14. Reaching distance with 26.5R25 (L3) tires 1330 mm

15. Dumping height 2920 mm

16. Bucket pin height 4400 mm

18. Dumping angle 46°

7
TECHNICAL SPECIFICATIONS
ENGINE FRONT AXLE

Manufacturer MTU Axle rating 24,706

Model OM 470.907 Static load rating 50.000 kg

Type Electronic diesel engine Dynamic load rating 28.000 kg

Maximum power 242 kW, 325 HP @1800 rpm Oscillation --

Maximum torque 1600 Nm @1300 rpm Traction 4WD

Aspiration system Turbocharging with charge air Weight 1.800 kg

cooler (air/air)
Differentail lock ratio %100
Combustion system Four stroke direct injection
REAR AXLE
Nmb of cylinders 6
Axle rating 24,666
Cyl arrangement Vertical in-line
Static load rating 44.000 kg
Bore x stroke 125x145 mm
Dynamic load rating 25.000 kg
Displacement 10,7 liters
Oscillation ±13°
Cooling system Coolant recirculation cooling
Traction 4WD
Exhaust emission EU Stage 3a
Weight 1.200 kg
Lubrication system Gear pump
Differential lock ratio %0
Weight 950 kg
HYDRAULIC SYSTEM
TRANSMISSION
Type Closed center load system

Manufacturer ZF Pump type Piston type Piston type

Tandem pump
Type 5WG260 Pump
100 cc 100cc + 45 cc
displacement

Torque converter W370 Pump 190 lt/min

flow@1900rpm 190 lt/min +
85,5 lt/min
Torque converter ratio 2,19 Weight 45 Kg 75 kg
System LS relief 230+4 bar
Torque lock - pressure
Steering LS 190+4 bar
Gear forward-reverse 5-3 relief pressure
Load sensing 26 bar
pressure
Gear selection Powershift
Pilot pressure 35 bar
Break valve Max 80
Max. allowable transmission 80-85°C Operating
oil temperature Temperature Main Control
Min 20
Valve

Weight 830 Kg

8
TECHNICAL SPECIFICATIONS TIPOVER LOAD
HYDRAULIC CYLINDERS
When machine is in straight 19.270 kg
Piston Rod Dia Stroke Nmbr of position
Dia Cylinders
Lift cylinder 160 100 862 2 When machine is in articulated 17.015 kg
Tilt cylinder 130 85 624 2 position
Steering
100 50 428 2 LOADER BUCKET CAPACITY
cylinder

FILTERS Part no Declared Width Bucket capacity

bucket
capacity (mm) (ISO 7546) (m3)
Pilot filter 5 µm
Struck/Heaped/Rated
Return filter 10µm
L225300000 Std bucket: 3300 3,64 0,55 4,2
Leakage filter 10µm 4.0 m3

PERFORMANCE L225306100 Std bucket: 3300 3,52 0,45 4

LOADER BREAKOUT FORCE 4.0 m3

Loader breakout force 195.905 N OPERATING WEIGHT

Lifting capacity at maximum height 7,842 kg Weight 26480 kg *

AXLE RATING * Operating weight includes: 4.0 m³ bucket, air

conditioner, 75kg operator, full fuel tank
Front axle load in travel position 13.180 kg TRAVEL SPEED

Rear axle load in travel position 13.000 kg Transmission 5WG260

LIFTING CAPACITY
Number of gears 5 Forward / 3 Reverse

Gear selection Automatic

Direction Gear Travel speed (km/h)

Forward 1 7
2 12,13
3 19,34
4 27,6
5 40
Reverse 1 7
2 12
3 27
TIRES
BRAND FRONT REAR
Bridgestone 26.5 R25 VJT L3 65±1 psi 60±1 psi
Fig 2.3 Bridgestone 26.5 R25 MS VSNT
68±1 psi 60±1 psi
T/L L4 DE2
Bucket at maximum height, max 6.830 kg Michelin 26.5 R25 XHA2 L3 65±1 psi 55±1 psi
lifting capacity at bucket center of Michelin 26.5 R25 X-MINE D2 L5 75±1 psi 65±1 psi
gravity

9
TECHNICAL SPECIFICATIONS
OPERATOR'S CAB EQUIPMENT LIST

Closed type, steel construction, adjustable

steering wheel, pockets, cool box, air conditioning Standard Equipment
and ventilating system, roof shelf, parking brake,
cd player, one piece rear window, cleanable RTD
interior roof lining, FOPS and ROPS certified Automatic Transmission
Double Brake Pedal
REFILL CAPACITIES
Differential Lock
Cooling system 50 lt

Loader Bucket
Fuel tank 400 lt
Standard Bucket
Engine, total 35 lt Rock Bucket

Transmission 32 lt
Optional Equipment
Rear axle 42 lt CD player
Forklift Fixture
Front axle 61 lt
Automatic Lubrication
Hydraulic system (refill) 135 lt

Hydraulic system (total) 200 lt

SPECIFICATIONS OF ELECTRIC AND

ELECTRONIC CONTROL SYSTEM

Starting motor 24V / 7 kW

Alternator 24V / 100A

Battery Quantity 2

Voltage 12 V

Rating 180 Ah

Power (cca) 1100

10
TECHNICAL SPECIFICATIONS

2.2. NOISE AND VIBRATION

Noise

Noise level inside operator's cab According to ISO 6396 standard 72 dB (A)

Noise level outside the machine According to ISO 6395 and 2000/14/EC standards 108 dB (A)

Vibration
Vibration tests of HMK640WL have been conducted according to EN 1032+A1:2008 standard.
Declared vibration values as per EN 12096 are:
Whole body vibration

Measured vibration value, a 0,751 m/s2

Uncertainty, K 0,13 m/s2

Vibration transmitted to hands

For HMK640WL Wheel Loaders vibration transmitted to hands is lower than 2,5 m/s².

CAUTION

In order to minimize the vibrations affecting the operator:

Check the operator's seat adjustments before starting to operate the machine and set weight and height
adjustments according to the weight and height of the operator.
Provide operation surface as level as possible. Use attachments only recommended by Hidromek.

11
3. WORK SAFETY

WARNING

While operating the machine or performing repair

and maintenance on the machine, strictly follow
the instructions given in this manual.

3.1. SAFETY LABELS

The following safety labels are used on this
machine. Be sure to read and fully understand the
correct position and content of these safety labels.
To make sure that the contents of these safety
labels can be read properly and they are in the
correct place, always keep them clean. When
cleaning them, use soap and water. Do not use
organic solvents or gasoline. These may cause the
safety labels to peel off.
If the safety labels are damaged or lost, or cannot
be read, replace them immediately with new parts.
For details of the part numbers, see this manual or
check on the actual label, and order the new part
from your Hidromek dealer.
There are also other labels in addition to safety
labels. Handle these labels in the same manner.

12
3.1.1. LOCATIONS OF SAFETY LABELS

Fig 3.1

13
3.1.2. EXPLANATION OF SAFETY LABELS
4. Emergency Exit
1. Do not approach the fuel filling area with fire
In case of an emergency, break right side window
Do not approach the fuel filling area with open with the hammer inside cab and escape from the
flame or fire. Do not smoke. machine.
Part number: L227000200 Part number: L227000500

Fig 3.2
Fig 3.5
2. Do not stand under the equipment
5. Battery Disconnect Switch
Attachment may fall down and there is crushing
hazard. Keep away when the attachment is lifted, In case of an emergency, while you are out of the
and do not stand under. machine, cut off electric circuit with the switch
behind this cover.
Part number: L227000300
Part number: L227000700

Fig 3.3

3. Lifting point
Lift the machine from these points.
Fig 3.6
Part number: L227000400
6. Wire connection point
Use these points to tie ropes or steel ropes to fix
the machine.
Part number: L227000800

Fig 3.4

Fig 3.7

14
7. Transmission maintenance manual 10. Pressurized systems
Before servicing transmission, read related section There is high pressure at these points, be careful
of Operation and Maintenance Manual. while opening.
Part number: L227000900 Part number: L227001200

Fig 3.8

8. Hydraulic oil refill point Fig 3.11

Fill hydraulic oil through this point. Part number:
L227001000
11. Operation and Maintenance Manual
Before starting operation, maintenance, assembly,
disassembly and transportation works, please read
and understand Operation and Maintenance
Manual.
Part number: L227001400

Fig 3.9
Fig 3.12
9. Lifting point
12. Cabin tilting
Use these points to lift the machine.
Before tilting the cab, please read related section
Part number: L227001100
of Operation and Maintenance Manual.
Part number: L227001600

Fig 3.13

Fig 3.10

15
13. Starting with booster cables 16. Hydraulic oil level

Before starting engine with booster cables, please Hydraulic oil level is checked at this point.
read related section of Operation and Maintenance Part number: L227002000
Manual.
Part number: L227001700

Fig 3.17

17. Attachment label

Gives information about the attachment mounted
on the machine.
Part number: L227002100

Fig 3.14

14. Transmission connectors

Shows pressure gauge connectors on
transmission.
Part number: L227001800 Fig 3.18

18. Electromagnetic hazard

Related to electromagnetic fields, please read
warnings in Operation and Maintenance Manual.
Part number: L227002200

Fig 3.15

15. Drain point

Indicates oil drain point.
Part number: L227001900

Fig 3.16

Fig 3.19

16
19. Drier 22. Hot surfaces
Please refer to section "INSPECTION AND Soon after the machine is stopped, some parts are
MAINTENANCE OF AIR CONDITIONER" for drier. still very hot. Before touching these parts, wait for
them to cool down.
Part number: L227002300
Part number: L227002600

Fig 3.20
Fig 3.23
20. Diesel Exhaust Fluid/Adblue® Warning
(It is available on machines with EU Stage4 23. Articulation caution
engines) If you enter articulation area, there is a risk of being
Do not fill fuel through Adblue® tank refill cap by crashed and other serious injuries. Keep away from
mistake, fill only Adblue® at this point. the moving machine.

Part number: L227002400 Part number: L227002700

Fig 3.21

21. Rotating Fan

Keep away from rotating parts such as fan and fan
belt.
Part number: L227002500 Fig 3.24

Fig 3.22

17
24. Hot oil or coolant 26. Air filter
Burn or scalding hazard from spurting hot water or For cleaning and replacement procedure of air
oil if radiator or hydraulic tank is uncapped while filter, please read related section of Operation and
being hot. Maintenance Manual.
Part number: L227002900 Part number: L227003100

Fig 3.27
Fig 3.25

25. Don't step on this surface 27. While traveling reverse

İndicates surfaces which may not support your There is a risk of a SERIOUS INJURY and DEATH,
weight. therefore observe the following before moving the
Part number: L227003000 machine and/or attachments:
- Honk the horn to warn people within
surrounding area.
- Make sure that there is nobody on the
machine or nearby.
- If visibility is poor, appoint a signalman.
Even if the machine is equipped with a backing up
alarm and mirrors, follow the instructions above.
Part number: L227003200

Fig 3.26

Fig 3.28

18
28. Noise level around the machine (LwA) 31. Cabin safety pin
Indicates machine noise power level around the After tilting the operator's cab, in order to prevent it
machine tested according to EU standards. from dropping or moving unintentionally, apply the
safety pin.
Part number: L227003500
Part number: L227003800

Fig 3.32

Fig 3.29 32. Crushing hazard

29. Noise level inside operator’s cabin (LpA)
Indicates machine noise power level inside the
cabin tested according to EU standards.
Part number: L227003600
When you enter the articulation area, there is a risk
of being crushed or other serious injuries. Keep
away from the moving machine.
Part number: L227003900

Fig 3.30

Fig 3.33
30. Engine oil refill
İndicates engine oil refill point.
Part number: L227003700

Fig 3.31

19
3.2. PRECAUTIONS DURING OPERATION AND 3.2.2.3. USE TIGHT-FITTED CLOTHES AND
MAINTENANCE PROTECTIVE EQUIPMENT
Mistakes during operation, inspection and/or
maintenance of the machine can result in serious
personal injuries or even death. Before carrying out
operation, inspection and/or maintenance, make
sure that you always read this manual and the
safety labels on the machine carefully and obey the
warnings.

3.2.1. PRECAUTIONS BEFORE OPERATION

3.2.1.1. WORK SAFETY
Only well trained and authorized personnel can
operate and conduct maintenance of this machine.
Follow all safety precautions, and instructions in
this manual when operating or performing
inspection or maintenance on the machine
If you are not feeling well, or if you are under the
influence of alcohol or medication, your ability to
safely operate or repair your machine can be
severely impaired, putting yourself and everyone
else on your job site in danger.
Fig 3.34
Do not wear loose clothes or any accessories. If
these catch on the control levers or protruding
parts, there is the danger that it can cause the
machine to move unexpectedly.
Always wear a hard hat and safety shoes. If the
nature of the work requires it, wear safety glasses,
a mask, gloves, ear plugs, and a safety belt when
operating or maintaining the machine.

When working with another operator or with the
person responsible from worksite traffic, discuss
the contents of the operation beforehand and use
the determined signals when carrying out the
operation.
3.2.1.2. BE FAMILIAR WITH YOUR MACHINE
Before operating the machine, read this manual
carefully. If there are any places in this manual
which you do not understand, ask the person in
charge of safety to give an explanation.
3.2.2. PREPARATIONS FOR SAFE OPERATION
3.2.2.1. PRECAUTIONS FOR SAFETY-RELATED
EQUIPMENT
Make sure that all guards, covers and mirrors are
in their proper position. Have guards and covers
repaired immediately if they are damaged.
Understand the method of use of safety features
and try to use them properly
Never remove any safety features such as guards,
covers and etc. Always keep them in good and
operating condition.
3.2.2.2. CHECKING THE MACHINE
Check the machine before starting operations. If
any abnormality is found, do not operate the
machine until repairs of the problem location have
been completed.
If you have long hair and it hangs out from your
hard hat, there is a hazard that it can get caught up
in the machine, so tie your hair up and be careful
not to let it get caught.
Before starting operation, always check that all
protective equipment and devices are functioning
properly.
3.2.2.4. ALWAYS KEEP THE MACHINE CLEAN
Fig 3.35
If you get on or off the machine or carry out
inspection and maintenance when the machine is
dirty with mud or oil, there is a hazard that you will
slip and fall. Wipe off any mud or oil on the
machine. Always keep the machine clean.
If water gets into the electrical system, there is a
hazard that it will cause malfunctions or
misoperation. If there is any misoperation, there is
danger that the machine may move unexpectedly
and cause serious personal injuries or death.
When washing the machine with water or steam,
do not allow water or steam to come into direct
contact with electrical components.

20
3.2.2.5. PRECAUTIONS INSIDE OPERATOR'S 3.2.2.7. IN CASE OF A PROBLEM
COMPARTMENT
If you face any problem in the machine during
When entering the operator's compartment, always operation and/or maintenance (noise, vibration,
remove all mud and oil from the bottom of your smell, incorrect gauges, smoke, oil leakage, etc., or
shoes. any abnormal display on the warning devices or
monitor), report to the person in charge and have
If you operate the pedal with mud or oil affixed to
the necessary action taken. Do not operate the
your shoes, your foot may slip and this may cause
machine until the problem has been solved.
a serious accident.
Do not leave tools or spare parts lying around
inside the operator's compartment. If tools or parts
get into the control devices, they can obstruct
operation and cause the machine to move
unexpectedly, resulting in serious personal injuries
or even death.
Do not stick suction pads to the window glass.
Suction pads act as a lens and may cause fire.
Do not use a mobile phone when driving or
operating the machine. This may lead to mistakes
in operation, which could cause serious accidents.
Never bring any flammable or explosive items into
the operator's compartment.
3.2.2.6. KEEP FIRE EXTINGUISHER AND FIRST
AID KIT INSIDE CAB

Fig 3.36

Always follow the instructions below to be prepared

for an action in case of any injury or fire.
Be sure that fire extinguishers have been provided
and read the labels to make sure that you know
how to use them in case of an emergency.
Do not neglect periodic inspections and
maintenance to ensure that the fire extinguisher is
always ready to be used.
Provide a fully furnished first aid kit in the storage
compartment.
Carry out periodic checks and add missing or
expired contents if necessary.

21

3.2.3. FIRE PREVENTION
3.2.3.1. ACTIONS TO BE TAKEN IN CASE OF
FIRE
Turn the start switch OFF and stop the engine.
Get off the machine by using the handrails and
steps.
Do not jump off the machine. There is the danger
of falling and suffering from a serious injury.
3.2.3.2. PRECAUTIONS TO PREVENT FIRE
Fig 3.37
Fire caused by fuel, oil, antifreeze or window
washer fluid
Do not bring any flame or fire close to flammable
substances such as fuel, oil, and antifreeze or
window washer fluid. There is the danger that they
can catch fire. To prevent fire, always observe the
following:
• Do not smoke or use open flame near fuel or
other flammable substances.
• Stop the engine before supplying fuel.
• Do not leave the machine when supplying fuel or
oil.
• Tighten all fuel and oil caps securely.
• Be careful not to spill fuel on overheated surfaces
or on parts of the electrical system.
• After supplying fuel or oil, wipe up any spilled fuel
or oil.
• Put greasy rags and other flammable materials
into a safe container to maintain safety at the
workplace.
• When washing parts with oil, use non- flammable
oil.
• Do not use diesel oil or gasoline. There is a
danger of catching fire.
22
• Do not weld or use a cutting torch to cut any pipes
or tubes that contain flammable liquids.
• Keep oil and fuel in well ventilated areas and do
not allow any unauthorized person to enter.
• When carrying out grinding or welding work on
the machine, move any flammable materials to a
safe place before starting.
Fire caused by accumulation of flammable
material.
• Remove any dry leaves, chips, pieces of paper,
coal dust or any other flammable materials
accumulated or affixed around the engine,
exhaust manifold, muffler or battery or inside
the undercovers.
Fire starting from electric wiring
• Short circuits in the electrical system can cause
fire. To prevent fire, always observe the
following.
• Keep all electric wiring connections clean and
securely tightened.
• Check the wiring every day for looseness or
damage. Tighten any loose connectors or
wiring clamps. Repair or replace any damaged
wiring.
Fire originating from piping
Check that all the hose and tube clamps, guards,
and cushions are securely fixed in position. If they
are loose, they may vibrate during operation and
rub against other parts. There is the risk of
damaging hoses and causing high-pressure oil to
spurt out, leading to fire, and serious personal
injuries or death.
Explosion caused by lighting equipment
When checking fuel, oil, battery electrolyte, or
coolant, always use lighting with anti-explosion
specifications.
When taking the electrical power for the lighting
from the machine itself, follow the instructions in
this manual.
3.2.4. PRECAUTIONS WHEN GETTING ON OR
OFF MACHINE
3.2.4.1. USE HANDRAILS AND STEPS WHEN
GETTING ON OR OFF MACHINE
To prevent an injury caused by slipping or falling off
the machine, always do the following.
Fig 3.38
Use the handrails and steps marked by arrows in
the diagram when getting on or off the machine.
Fig 3.39
Always face the machine and maintain at least
three-point contact (both feet and one hand, or both
hands and one foot) with the handrail and steps to
ensure that you support yourself.
Fig 3.40
Before getting on or off the machine, check the
handrails and steps, and if there is any oil, grease,
or mud on them, wipe them off immediately. In
addition, repair any damage and tighten any loose
bolts.
Do not grip the control levers and work equipment
lock lever when getting on or off the machine.
Never climb on the engine hood or covers where
there are no non-slip pads.
Never use the steps at the rear of the machine or
at the side of the cab to get on top of the tire.
Do not get on or off the machine while holding tools
or parts in your hand.
Fig 3.41
(1) is the emergency escape step.
Use this when escaping from the machine in case
of fire or other emergencies. Do not use it in normal
situations.
3.2.4.2. DO NOT JUMP ON OR OFF MACHINE
Never jump on or off the machine. Never get on or
off a moving machine.
If the machine starts to move when there is no
operator on the machine, do not jump on the
machine to try to stop it.
23
3.2.4.3. PEOPLE NOT ALLOWED ON 3.2.4.7. PRECAUTIONS WHEN LEAVING THE
ATTACHMENTS OPERATOR'S SEAT
Never let anyone ride on work equipment or other
attachments. There is a hazard of falling and
suffering from serious personal injuries or death.
3.2.4.4. WHEN LEAVING THE MACHINE
If the proper procedures are not observed when
leaving the machine, the machine may suddenly
move off by itself and this may lead to serious
personal injuries or death. Always do the following
before leaving the machine. Fig 3.44
Before leaving the machine, always lower the work
equipment completely to the ground, apply safety Before leaving the operator's seat, when adjusting
lock (3) and FNR lock (2) and turn parking brake the position of the seat, always lower the work
button (1) ON and then stop the engine. In addition, equipment completely to the ground, apply safety
lock all parts, always take the key with you, and lock (3) and FNR lock (2) and turn parking brake
leave it in the specified place. button (1) ON and stop the engine.
If above locks are not applied and control levers are
activated by mistake, the machine can suddenly
move and cause serious personal injuries or
death.

Fig 3.42

3.2.4.5. EMERGENCY EXIT FROM OPERATOR'S

CAB
On machines with a cab, a door is installed on the
left side and an emergency escape door is installed
on the right side. If the door on the left side does
not open, escape from the emergency door on the
right side.
3.2.4.6. CLEANING CAB WINDOWS
Always keep the cab windows clean to ensure
good visibility when operating.
When cleaning the windscreen, stand on the
ground and use commercial cleaning fixtures and if
necessary some cleaning detergent. Fig 3.45

Fig 3.43

Fig 3.46

24

3.2.4.8. BE CAREFUL IN ARTICULATING
PORTION
Clearance at the articulating portion may change
any time.
If somehow you get caught in clearance area, you
will suffer from serious personal injuries or death.
Do not allow anyone to come inside the articulation
range.
The clearance in the area around the work
equipment changes according to the movement of
the link. If you get caught, you will suffer from
serious personal injuries or death. Do not allow
anyone to come close to any rotating or
extending/retracting portion.
If the protective structure is welded, or holes are
drilled in it, or it is modified in any other way, its
strength may drop. Consult your Hidromek dealer
before carrying out any modifications.
If the protective structure is damaged or deformed
by falling objects or by rolling over, its strength will
be reduced and it will not be able to fulfill its function
properly. In such cases, always contact your
Hidromek dealer for advice on the method of repair.
Even if the protective structure is installed, always
fasten your seat belt properly when operating the
machine.
If you do not fasten your seatbelt properly, it may
not display its protective function.
ROPS structure is tested according to ISO
3471:2008 standard and complies with the values
specified in this standard.

Fig 3.47

3.2.5. PRECAUTIONS RELATED TO

PROTECTIVE STRUCTURES
The operator's compartment is equipped with
ROPS and FOPS structure to protect the operator
by absorbing the impact energy. If the machine
weight (mass) exceeds the certified value (shown
on the ROLL-OVER PROTECTIVE STRUCTURE
(ROPS) CERTIFICATION plate), ROPS will not be
able to function properly. Do not increase machine
weight beyond the certified value by modifying the
machine or by installing attachments to the
machine. Also, if the function of the protective
equipment is weakened, the protective equipment
will not be able to protect the operator, and the
operator may face an injury or death. Always
observe the following.
Fig 3.49

Fig 3.48

If the machine is equipped with a protective

structure as described above, do not remove this
structure from the machine, and do not carry out
operations without it.

25
3.2.6. UNAUTHORIZED MODIFICATIONS
Hidromek will not be responsible for any injuries,
accidents, product failures or other property
damages resulting from modifications made
without written authorization from Hidromek.
Any modification made without authorization from
Hidromek can create hazards. Before a
modification, consult your Hidromek dealer.

3.2.7. PRECAUTIONS RELATED TO

ATTACHMENTS AND OPTIONS
Any injuries, accidents, product failures or other
property damages resulting from the use of
attachments or parts not authorized by Hidromek
will not be the responsibility of Hidromek.
When installing optional parts or attachments,
there may be problems with safety or legal
restrictions or regulations. Therefore, contact your
Hidromek dealer for advice.
When installing and using optional attachments,
read the instruction manual for the attachment, and
the general information related to attachments in
this manual.

3.2.8. PRECAUTIONS WHEN RUNNING ENGINE

INDOORS

Fig 3.50

The engine exhaust gas contains substances that

may seriously damage your health or even cause
death. Start or operate the engine in a place where
there is good ventilation. If the engine or machine
must be operated inside a building or underground
where the ventilation is poor, take measures to
ensure that the engine exhaust gas is removed and
that sufficient amount of fresh air is brought in.

26

3.3. PRECAUTIONS DURING OPERATION
3.3.1. PRECAUTIONS ON JOBSITE
3.3.1.1. INVESTIGATE AND CONFIRM JOBSITE
CONDITIONS
On jobsites, there are always hidden dangers that
may cause a personal injury or even death. Before
starting operations, always check the following
items to confirm that there is no danger on the
jobsite.
When carrying out operations near combustible
materials such as thatched roofs, dry leaves or dry
grass, there is a hazard of fire, so be careful when
operating.
Fig 3.51
Check the terrain and condition of the ground on
the worksite, and determine the safest method of
operation. Do not operate where there is a hazard
of landslides or falling rocks.
It is possible that water lines, gas lines, or high-
voltage electrical lines are buried under the
worksite. Contact each utility company and identify
their locations. Be careful not to sever or damage
any of these lines and try to keep away from them.
Take necessary measures to prevent any
unauthorized person from entering worksite.
In particular, if you need to operate on a road,
protect pedestrians and cars by designating a
person for worksite traffic or by installing fences
around the worksite.
When traveling or operating in water or on soft
ground, check the water depth, speed of the
current, bedrock, and shape of the ground
beforehand and avoid any place that will obstruct
travel.
Maintain the travel route on the jobsite so that there
is no obstruction to travel.
3.3.1.2. WORKING ON LOOSE GROUND
Avoid traveling or operating your machine too close
to the edge of cliffs, overhangs, and deep ditches.
The ground may be weak in such areas. If the
ground should collapse under the weight or
vibration of the machine, there is a hazard that the
machine may fall or tip over. Remember that the
soil after heavy rain or blasting or after earthquakes
is weak in these areas.
When working on embankments or near excavated
ditches, there is a hazard that the weight and
vibration of the machine will cause the soil to
collapse. Before starting operations, take steps to
ensure that the ground is safe and to prevent the
machine from rolling over or falling.
3.3.1.3. KEEP SAFE DISTANCE TO HIGH-
VOLTAGE CABLES
Do not travel or operate the machine near electric
cables. There is a hazard of an electric shock,
which can cause a serious personal injury or death.
On jobsites where the machine may go close to
electric cables, always observe the following.
Before starting work near electric cables, inform the
local power company of the work to be performed,
and ask them to take the necessary actions.
Fig 3.52
Voltage of Cables Safe Distance
100V, 200V 2 m and up
6.000V 2 m and up
22.000V 3 m and up
65.000V 4 m and up
150.000V 5 m and up
190.000V 6 m and up
260.000V 7 m and up
260.000V and up 11 m and up
Even going close to high-voltage cables can cause
an electric shock, which may cause serious burns
or even death. Always maintain a safe distance
(see the table above) between the machine and the
electric cables. Check with the local power
company about safe operating procedures before
starting operations.
27
To prepare for any possible emergencies, wear Make sure that all workers understand the meaning
rubber shoes and gloves. Lay a rubber sheet on top of all signals and signs before starting work.
of the seat, and be careful not to touch the chassis
3.3.1.6. BEWARE OF ASBESTOS DUST
with any exposed part of your body.
Asbestos dust in the air can cause lung cancer if it
Appoint a signalman to give warnings if the
is inhaled. There is a danger of inhaling asbestos
machine approaches too close the electric cables.
when working on jobsites handling demolition work
When carrying out operations near high voltage or handling industrial waste. Always observe the
cables, do not let anyone near the machine. following.
If the machine should come too close or touch the
electric cable, to prevent an electric shock, the
operator should not leave the operator's
compartment until it has been confirmed that the
electricity has been shut off. Also, do not let anyone
near the machine
3.3.1.4. ENSURE GOOD VISIBILITY
This machine is equipped with mirrors to ensure
good visibility, but even then there are places that
cannot be seen from the operator's seat, so be
careful when operating.
When traveling or carrying out operations in places
with poor visibility, it is impossible to check for
obstacles in the area around the machine and to Fig 3.53
check the condition of the jobsite. This leads to
dangers of serious personal injuries or death. Water the area to keep down the dust. Do not use
When traveling or carrying out operations in places compressed air.
with poor visibility, always observe the following.
If there is the danger that there may be asbestos
Position a signalman if there are areas where the dust in the air, always operate the machine in an
visibility is not good. upwind position, and make sure that all workers
Only one signalman should give signals. operate on the upwind side.

When working in dark places, turn on the working All workers should use anti-dust masks.
lamp and front lamps installed to the machine, and Do not allow other persons to approach during the
set up additional lighting in the work area if operation.
necessary.
Always observe the rules and regulations for the
If there is poor visibility because of mist, snow, work site and environmental standards.
rain, or dust, stop operations temporarily.
Asbestos is not used on this machine, but non-
When checking the mirrors installed to the original parts may contain asbestos, therefore
machine, remove all dirt and adjust the angle of the always use genuine Hidromek parts.
mirrors to ensure good visibility.
3.3.1.5. CHECKING SIGNALMAN'S SIGNALS
Set up signs to inform of road shoulders and soft
ground. If the visibility is not good, position a
signalman if necessary. Operators should pay
careful attention to the signs and follow the
instructions from the signalman.
Only one signalman should give signals.

28

3.3.1.7. STARTING ENGINEWARNING TAG
Fig 3.54
If there is any "DANGER!”, “DO NOT OPERATE!"
or a similar warning tag, it means that someone is
carrying out an inspection and/or maintenance on
the machine. If the warning sign is ignored and the
machine is operated, the person carrying out the
inspection or maintenance may be caught in the
rotating parts or moving parts and suffer from
serious personal injuries or death. Do not start the
engine or touch the levers when you see such a
notice or warning.
3.3.1.8. BEFORE STARTING ENGINE
Carry out the following checks before starting the
engine at the beginning of the day's work to ensure
that there is no problem with the operation of the
machine. If this inspection is not carried out
properly, problems may occur during the operation
of the machine, and there is the danger that this
may lead to serious personal injuries or death.
Remove all the dirt on the surfaces of the windows
of operator’s cab to ensure a good view.
"WALK-AROUND CHECK" must be done.
Remove all the dirt on the surfaces of head lamps,
working lamps, and rear combination lamps, and
check that they light up correctly.
Check the coolant level, fuel level, and oil level in
engine oil pan, check if there is clogging in the air
cleaner, and check whether electric wiring is
damaged or not.
Check that there is no mud or dust accumulated
around the movable parts of the accelerator pedal
or brake pedal, and check that the pedals work
properly.
Adjust the operator's seat to a position that it is
easy to carry out operations, and check that there
is no damage or wear on the seat belt or mounting
clamps.
Check that the gauges work properly, check the
angle of the mirrors, and check that the control
levers are all in their Neutral position.
Before starting up the engine, check that the work
equipment control lever lock button is in LOCK
position.
Adjust the mirrors so that the rear of the machine
can be seen clearly from the operator's seat. See
section "ADJUSTING MIRRORS".
Check that there are no persons or obstacles on,
under, or around the machine.
Check that the parking brake button is in ON
position.
Check that frame lock lever is securely fixed in
FREE (F) position.
Fig 3.55
WARNING
Check that there is no obstacle and noone around
the machine. Sound the horn to warn people
nearby before starting the engine.
3.3.1.9. WHEN STARTING ENGINE
Start and operate the machine only while seated in
operator's seat.
When starting the engine, honk the horn as a
warning.
Do not allow anyone apart from the operator to ride
on the machine or inside the cabin.
Do not attempt to start the engine by short-
circuiting the engine starting circuit. This may
cause fire, a serious injury or death.
Check that the backup alarm (alarm buzzer when
machine travels in reverse) works properly.
3.3.1.10. PRECAUTIONS IN COLD WEATHER
Carry out the warming-up operation thoroughly. If
the machine is not thoroughly warmed up before
the control levers are operated, the reaction of the
machine will be slow, and this may lead to
unexpected accidents.
If the battery electrolyte is frozen, do not charge the
battery or start the engine with a different power
source. This will cause the battery to explode.
Before charging the battery or starting the engine
with a different power source, wait for battery
29
electrolyte to melt and check that there is no
leakage of electrolyte before starting.
3.3.1.11. STARTING WITH BOOSTER CABLES
If any mistake is made in the method of connecting
the booster cables, it may cause the battery to
explode, so always do the following:
Always wear safety goggles and rubber gloves
when starting the engine with booster cables.
When connecting a machine working properly to a
machine with a problem by using booster cables,
always be careful that both of the machines have
the same battery voltage. Fig 3.57
When you use booster cables, carry out the
starting operation with two workers (one worker When removing the booster cables, be careful not
sitting in the operator's seat and the other working to let the booster cable clips touch one another or
with the battery). to let the clips touch the machine.

When doing this, do not allow the two machines to For details of the starting procedure when using
touch one another. booster cables, see "STARTING ENGINE WITH
BOOSTER CABLE" in the OPERATION section.
When connecting booster cables, turn the starting
switch to OFF position on both of the machines. If
the starting switch is IN position, the machine will
move when the power is connected.
Be sure to connect the positive (+) cable first when
installing the booster cables.
Disconnect the negative (-) cable (ground side) first
when removing them.

Fig 3.56

30
3.3.2. OPERATION
3.3.2.1. CHECKS BEFORE OPERATION
If the checks before starting are not carried out
properly, the machine will be unable to display its
full performance, and it may lead to a serious
personal injury or death.
When carrying out the checks, move the machine
to a wide area where there are no obstructions, and
pay careful attention to the surrounding area. Do
not allow anyone near the machine.
Fig 3.58
Always wear the seatbelt. There is the danger that
you may be thrown out of the operator's seat and
suffer from a serious injury when the brakes are
applied suddenly.
Check the operation of travel, steering and brake
systems, and work equipment control system.
Fig 3.59
Check for any problem with the sound of the
machine, vibration, heat, smell, or gauge and
check also that there is no leakage of oil or fuel.
Fig 3.60
If there is a problem, fix it immediately.
Before driving the machine or starting operations,
check that frame lock bar (1) is securely fixed in
FREE position.
3.3.2.2. PRECAUTIONS WHEN TRAVELING IN
FORWARD OR REVERSE
Lock the cab door and windows securely when
they are either open or closed. Do not allow anyone
apart from the operator to ride on the machine. If
there are any persons in the area around the
machine, they may be hit by the machine or have
a crush injury, and this will lead to serious personal
injuries or death.
Always observe the following before traveling.
Always operate the machine only when seated.
Before moving off, check again that there is no
person or obstruction in the surrounding area.
Before moving, honk the horn to warn people in the
surrounding area.
Check that the backup alarm (alarm buzzer when
machine travels in reverse) works properly.
If there is an area in the rear of the machine which
cannot be seen, position a signalman.
Always be sure to carry out the above precautions
even when the machine is equipped with mirrors.
31

3.3.2.3. PRECAUTIONS WHEN TRAVELING
Never turn the starting switch to OFF position
while traveling. It is dangerous if the engine stops
when the machine is traveling, because steering
becomes hard. This will cause the steering wheel
to malfunction and may lead to serious personal
injuries or death. If the engine stops, push the
brake pedal immediately and stop the machine.
When traveling or operating, always keep a safe
distance from people, structures, or other
machines to avoid coming into contact with them.
When traveling on flat ground, keep the work
equipment at a height of (A) 70 - 90 cm above the
ground. If the work equipment is too close to the
ground surface, the work equipment may contact
the ground and cause the machine to tip over.
When operating in tunnels, under bridges, under
electric wires, or other places where the height is
limited, operate slowly and be extremely careful not
to let the machine body or work equipment hit
anything.
If you drive the machine at high speed continuously
for a long time, the tires will overheat and the
internal pressure will become abnormally high. This
may cause the tires to burst. If a tire bursts, it
produces a large destructive force, and this may
cause serious injuries or death.
Before traveling long distances, please consult
your Hidromek dealer.
When the machine is traveling on flat ground or
down a slope, NEVER set the drive control lever to
Neutral position. Always set it to the proper
transmission speed range. If the transmission is in
neutral, the engine brakes will not work and the
steering will become hard, so this creates a
dangerous situation which causes damage on the
transmission or other parts of the power train, and
this can lead to serious personal injuries or death.

Fig 3.61

If it is necessary to operate the work equipment

control lever, stop the machine first, then operate
the control lever.
Avoid traveling over obstacle. If the machine has to
travel over an obstacle, keep the work equipment
close to the ground and travel at low speed. There
is a great possibility of the machine’s tipping over
to the left or right than tipping over to the front or
rear. Therefore, do not travel over obstacles which
make the machine tilt strongly to the left or right
sides.
When traveling on rough ground, travel at low
speed and avoid abrupt turns and changing the
direction of the machine abruptly. The machine
may tip over. The work equipment may hit the
ground surface and cause the machine to lose its
balance which can damage the machine or
structures in the area.
When using the machine, to prevent personal
injuries caused by the damage of work equipment
or by the machine’s tipping over due to
overloading, do not exceed the permitted
performance of the machine and/or the maximum
permitted load determined for the machine.
When passing over bridges or structures, first
check that the structure is strong enough to
support the weight of the machine.

32

3.3.2.4. TRAVELING ON SLOPES
To prevent the machine from tipping over or sliding
to the side, always do the following.
Keep the work equipment at a height of (A) 20 - 30
cm (8 - 12 in) above ground to enable the machine
to stop for an emergency.
Fig 3.62
Fig 3.63
Always travel straight up or down a slope. Traveling
at an angle or across the slope is extremely
dangerous.
Fig 3.64
Do not turn on slopes or travel across slopes.
Always go down to a flat place to change the
position of the machine, then travel on to the slope
again.
Travel on grass, fallen leaves, or wet steel plates at
low speed.
Even on slight slopes there is a danger of sliding.
If the engine stops, depress the brake pedal
immediately, lower the bucket to the ground, and
apply the parking brake to stop the machine.
When traveling downhill, never shift the gear or
place the transmission in neutral. It is dangerous
not to use the braking force of the engine. Always
place the transmission in a low gear before starting
to travel downhill.
When traveling downhill, travel slowly. If
necessary, use the braking force of the engine
together with the brake pedal to control the travel
speed.
When traveling up or down hills with a loaded
bucket, always travel with the bucket facing uphill.
If the machine travels with the bucket facing
downhill, the machine may tip over.
DANGER
When traveling down the slope, do not lower the
bucket on the ground instantaneously, otherwise
machine may tip over.
3.3.2.5. USING BRAKES
When the machine is traveling, do not rest your foot
on the brake pedal. If you travel with your foot
resting on the pedal, the brake will always be
applied, and this will cause the brakes to overheat
and fail.
Do not depress the brake pedal repeatedly if not
necessary.
When traveling downhill, use the brake pedal to
slow down the machine.
33
3.3.2.6. PRECAUTIONS WHEN OPERATING
When using the machine, to prevent personal
injuries caused by the damage of work equipment
or by the machine’s tipping over due to
overloading, do not exceed the permitted
performance of the machine and/or the maximum
permitted load determined for the machine.
If the engine cannot be started again after it has
stopped, immediately operate the work equipment
control levers to lower the work equipment to the
ground. (After the engine stops, the accumulator
allows the work equipment to be operated for a
limited time.).
Be careful not to approach too close the edge of
cliffs. When making embankments or landfills, or
when dropping soil over a cliff, dump one pile, then
use the next pile of soil to push the first pile.
The load on the machine suddenly becomes lighter
when the soil is pushed over a cliff or when the
machine reaches the top of a slope. When this
happens, there is the danger that the travel speed
will suddenly increase, so be sure to reduce the
speed.
When the bucket is fully loaded, never start, turn,
or stop the machine suddenly. There is the danger
that the machine can tip over or tilt to the side.
Fig 3.65
34
When handling unstable loads, such as round or
cylindrical objects, or rolled metal sheets, if the
work equipment is raised very high, there is the
danger that the load may fall on top of the
operator's compartment and cause serious injuries
or death.
Fig 3.66
When handling unstable loads, be careful not to
raise the work equipment too high or tip the bucket
back too much.
If the work equipment is suddenly lowered or
suddenly stopped, the reaction may cause the
machine to tip over. Particularly when carrying a
load, be sure to operate the work equipment
carefully.
When operating in tunnels, under bridges, under
electric wires,or other places where the height is
limited, be extremely careful not to let the machine
body or work equipment hit anything.
To prevent accidents caused by hitting other
objects, always operate the machine at a speed
which is safe for operation, particular in confined
areas, indoors, and in places where there are other
machines.
Fig 3.67
3.3.2.7. PROHIBITED OPERATIONS
If the machine rolls over or falls, or the ground at
the working point collapses, it may lead to serious
personal injuries or death. Always observe the
following precautions:
Do not excavate under overhangs. Overhangs can
collapse on the machine.
Fig 3.68
When digging, never thrust the bucket into a load
at an angle. This will bring an excessive load to
bear on the machine and will reduce the service life
of the machine.
It is dangerous to apply drive force when
excavating a rock face. In addition, an excessive
load will be brought to bear on the machine and this
will damage the machine.
Never carry out digging operations on a downhill
slope. Excessive load will be brought on the
machine and this will damage the machine.
Do not use the bucket or lift arm as a crane. There
is the danger that the machine can tip over and that
the load can fall.
Do not pass the bucket over the head of other
workers or over the operator's seat of dump trucks
or other hauling equipment. The load may spill or
the bucket may hit the dump truck and cause
serious personal injuries or death.
Fig 3.69
3.3.2.8. TRAVELING ON SNOW-COVERED OR
FROZEN SURFACES
Snow-covered or frozen surfaces are slippery, so
be extremely careful when traveling or operating
the machine, and do not operate the levers
suddenly. Even a slight slope may cause the
machine to slip, so be particularly careful when
working on slopes.
On frozen ground surfaces, the ground becomes
soft when the temperature rises, and this may
cause the machine to tip over or sink in the ground.
When traveling on snow-covered roads, always
use tire chains. Install snow chains on all 4 tires.
When tire chains are installed, do not drive the
machine faster than 20kph.
If the machine enters an area where there is deep
snow, it may tip over or become buried in snow. Be
careful not to leave the road shoulder or to get
trapped in snow.
When clearing snow, the road shoulders and
objects (if there are any) placed along the road are
covered with snow and cannot be seen. There is a
hazard of the machine’s tipping over or hitting
covered objects, so always carry out operations
carefully.
When traveling on snow-covered slopes, never
apply the foot brake suddenly. Reduce the speed
and use the engine as a brake while applying the
foot brake intermittently (depress the brake
intermittently several times). If necessary, lower the
work equipment to the ground to stop the machine.
35
3.3.2.9. PARKING MACHINE
Park the machine on firm and level ground.
Select a place where there is no hazard of
landslides, falling rocks, or floods.
Lower the work equipment completely on the
ground.

Fig 3.72
Fig 3.70

Apply control lever lock (3) and FNR lever lock (2) If it is necessary to park the machine on a slope,
and turn parking brake button (1) ON and then stop set blocks under the wheels to prevent the machine
the engine. from moving.

Fig 3.73

Fig 3.71

Always close the operator's cab door, and use the

key to lock all the equipment in order to prevent any
unauthorized person from using the machine.
Always remove the key, take it with you, and leave
it in the specified place.

36

3.3.3. TRANSPORTATION OF MACHINE
When the machine is transported on a trailer, there
is a danger of serious personal injuries or death
during transportation. Always do as follows:
Always check the machine dimensions carefully.
Depending on the work equipment installed, the
machine weight, transportation height, and overall
length may differ.
After receiving road permit, check beforehand that
all bridges and other structures on the
transportation route are strong enough to withstand
the combined weight of the transporter and the
machine being transported.
The machine can be divided into parts for
transportation, so when transporting the machine,
please contact your Hidromek dealer to have the
work carried out.
Lock the frame with the frame lock bar to prevent
the machine from articulating.
Fit chains to the front frame and the rear frame to
hold the machine securely in position.
For details of the procedure for transporting the
machine, see "TRANSPORTATION" section.
3.3.3.1. LOADING AND UNLOADING
Run the engine at low idling and drive the machine
slowly at low speed.
Never correct your steering direction on the ramps.
If necessary, drive off the ramps, correct the
direction, then go on the ramps again.
When loading or unloading on an embankment or
a platform, make sure that it has the suitable width,
strength, and grade.
For machines equipped with a cab, always lock the
door after the machine is boarded a trailer. If this is
not done, the door can suddenly open during
transportation.
Fix the front and back chassis by using a steel rope
or chain.
Refer to "TRANSPORTATION" section.

Fig 3.74

When loading or unloading the machine, improper

operation may cause the machine to tip over or
slide to sides, so be extremely careful. Always do
as follows.
Perform loading and unloading on firm and level
ground only. Maintain a safe distance from the
edges of the road or cliff.
Always use ramps of adequate strength. Be sure
that the ramps are wide, long, and thick enough to
provide a safe loading slope. Take suitable steps to
prevent the ramps from moving out of position or
coming off.
Be sure the ramp surface is clean and free of
grease, oil, ice and loose materials. Remove dirt
from the tire of the machine. On rainy days, in
particular, be extremely careful since the ramp
surface is slippery.

37
3.3.4. TOWING MACHINE
3.3.4.1. PRECAUTIONS WHEN TOWING
MACHINE
Always use the correct towing equipment and
towing method. Any mistake in the selection of the
wire rope or towing bar or in the method of towing
a machine may lead to serious personal injuries or
death.
For details of the procedure for towing, see the
"METHOD OF TOWING MACHINE" section.
Always confirm that the wire rope or drawbar used
for towing has ample strength for the weight of the
machine being towed.

Fig 3.75

Never use a wire rope which has cut strands (A),

reduced diameter (B), or kinks (C). There is the
danger that the rope may break during the towing
operation.
Always wear leather gloves when handling wire
rope.
Never tow a machine on a slope.
During the towing operation, never stand between
the towing machine and the machine being towed.

38
3.4. PRECAUTIONS FOR MAINTENANCE
3.4.1. PRECAUTIONS BEFORE STARTING
INSPECTION AND MAINTENANCE
3.4.1.1. DISPLAY WARNING TAG DURING
INSPECTION AND MAINTENANCE
If there is any "DANGER! Do NOT operate!"
warning tag displayed, it means that someone is
carrying out inspection or maintenance of the
machine. If the warning sign is ignored and the
machine is operated, there is the danger that the
person carrying out inspection or maintenance may
be caught in the rotating parts or moving parts and
suffer from serious personal injuries or death. Do
not start the engine or touch the levers.
If necessary, put up signs around the machine also.
When not using this warning tag, keep it in the
toolbox.
If there is no toolbox, keep it in the pocket for the
Operation and Maintenance Manual.
Fig 3.76
Fig 3.77
3.4.1.2. KEEP WORKPLACE CLEAN AND TIDY
Do not leave hammers or other tools lying around
in the work place. Wipe up all grease, oil, or other
substances that will cause you to slip. Always keep
the work place clean and tidy to enable you to carry
out operations safely. If the work place is not kept
clean and tidy, there is the danger that you will trip,
slip, or fall over and injure yourself.
3.4.1.3. SELECT SUITABLE PLACE FOR
INSPECTION AND MAINTENANCE
Stop the machine on firm and level ground.
Select a safe place where there is no hazard of
landslides, falling rocks, or floods.
3.4.1.4. ONLY AUTHORIZED PERSONNEL
Do not allow any unauthorized personnel into the
area when servicing the machine. If necessary,
employ a guard.
3.4.1.5. APPOINT LEADER WHEN WORKING AS
A TEAM
When repairing the machine or when removing and
installing the work equipment as a team, appoint a
leader and follow his instructions during the
operation.
39

3.4.1.6. STOP ENGINE BEFORE CARRYING
OUT INSPECTION AND MAINTENANCE
pressure in the hydraulic circuit. Apply control lever
lock (3) and FNR lever lock (2).
After releasing the pressure in the hydraulic circuit,
turn the starting switch to OFF position

Fig 3.78

Lower the work equipment completely to the

ground and stop the engine before performing any
inspection and maintenance.

Fig 3.81

Turn parking brake button (1) ON to apply the

parking brake, put blocks in front of and behind the
tires to prevent the machine from moving.

Fig 3.79
Fig 3.82

Set frame lock bar to lock position (L) to lock the

front and rear frames.

Fig 3.80

After stopping the engine, turn the starting switch

to ON position, operate work equipment control
levers fully in the RAISE and LOWER directions 2
or 3 times to release the remaining

40
3.4.1.7. ENGAGE TWO WORKERS FOR
MAINTENANCE WHEN ENGINE IS RUNNING
To prevent personal injuries, do not carry out
maintenance while the engine is running. If
maintenance must be carried out when the engine
is running, carry out the operation with at least two
workers and do as follows.
One worker must always sit in the operator's seat
and be ready to stop the engine at any time. All
workers must maintain contact with each other.

Fig 3.85

Be careful not to touch the control levers or steering

Fig 3.83
When carrying out operations near the fan, fan belt,
or other rotating parts, there is a hazard of being
caught in the parts, so be careful not to come close.
Never drop or insert tools or other objects into the
fan, fan belt, or other rotating parts. There is the
danger that they may be broken and thrown up in
the air causing damage.
Lower the work equipment completely to the
ground, then apply control lever lock (3) and FNR
lever lock (2) to prevent the machine from moving.
equipment. If the control levers must be operated,
always give a signal to your partner and have your
partner withdraw to a safe place.
3.4.1.8. INSTALLING, REMOVING OR STORING
ATTACHMENTS
Appoint a leader before starting removal or
installation operations for attachments.
Place attachments that have been removed from
the machine in a stable condition so that they do
not fall. And take steps to prevent unauthorized
persons from entering the storage area.

Fig 3.86

Fig 3.84

Turn parking brake button (1) ON to apply the

parking brake, and put blocks in front of and behind
the tires to prevent the machine from moving.

41
3.4.1.9. PRECAUTIONS WHEN WORKING AT
HIGH PLACES
When working at high places, use a step ladder or
other stand to ensure that the work can be carried
out safely.
DANGER
3.4.1.10. PRECAUTIONS WHEN WORKING The boom should not be left raised without being
UNDER MACHINE OR WORK EQUIPMENT hanged to a hoisting crane or being supported by
Make sure the hoists or jacks you use are in good a proper stand and the boom safety lock
condition and strong enough to handle the weight installed. Do not stand under the bucket or boom
of the component. Never use jacks at places where while the boom is raised. Unexpected dropping of
the machine is damaged, bent, or twisted. Never the boom could result in death or heavy injuries
use frayed, twisted or pinched wire ropes. Never by crushing.
use bent or distorted hooks.

Fig 3.87 3.4.1.11. PROPER TOOLS

Use only the tools suitable for the task and be sure
to use the tools correctly. Using damaged,
If the work equipment or component are not deformed, or low quality tools, or making improper
supported, there is the hazard that they may come use of the tools may cause serious personal
down and that this may lead to serious personal injuries.
injuries or death. Never use supports which are
made up of concrete. They can collapse under
even light loads.
If work needs to be done to the front chassis
(maintenance or repairs) the boom must be
pressed safely onto the floor and all the other safety
precautions must be taken.
If the loader boom has been secured safely by a
crane that has enough capacity or balanced and
supported by a proper carrier, the boom safety bar
can be used as a secondary safety tool. Otherwise
it should not be used and nobody should go under
the boom. Fig 3.88

42
3.4.2. PRECAUTIONS FOR INSPECTION AND
MAINTENANCE
3.4.2.1. PRECAUTIONS WHEN WELDING
Welding operations must always be carried out by
a qualified welder and in a place equipped with
proper equipment. There is a hazard of gas, fire, or
electrocution when carrying out welding, so never
allow any unqualified personnel to carry out
welding.
3.4.2.2. HANDLING BATTERY
Before inspecting or handling the battery, always
turn the starting switch to OFF position.
Danger of battery exploding
When the battery is being charged, hydrogen gas
which is flammable and explosive. In addition, the
battery electrolyte includes dilute sulphuric acid.
Any mistake in handling may cause serious
personal injuries, explosion, or fire, so always
observe the following.
Fig 3.90
Do not use or charge the battery if the battery
electrolyte is below the LOWER LEVEL mark. This
will cause explosion. Always carry out periodic
inspection of the battery electrolyte level, add
distilled water to the UPPER LEVEL mark.
Do not smoke close to battery or approach it with
any flame.
Hydrogen gas is generated when the battery is
being charged, so remove the battery from the
machine, take it to a well-ventilated place, remove
the battery caps, then carry out the charging.
After charging, tighten the battery caps securely.
Danger from dilute sulphuric acid
When the battery is being charged, flammable
hydrogen gas is generated and it may explode.
In addition, the battery electrolyte includes diluted
sulphuric acid. Any mistake in handling may cause
serious personal injuries, explosion, or fire, so
always observe the following.
Fig 3.91
When handling the battery, always wear protective
goggles and rubber gloves.
If battery electrolyte gets into your eyes,
immediately wash your eyes with large amounts of
fresh water. Contact a physician as quickly as
possible.
If battery electrolyte gets on your clothes or skin,
wash them immediately with large amounts of
water.
Removing battery cables
Before repairing the electrical system or carrying
out electric welding, turn the starting switch OFF.
Wait for approx. 1 minute, then remove the
negative (-) battery cable.
Danger of sparks
There is the hazard that sparks will be generated,
so always observe the following.
Do not let tools or other metal objects contact the
battery cables. Do not leave tools or parts on the
battery.
When removing the battery cables, remove the
ground cable (negative (-) cable) first. When
installing, connect the positive (+) cable first, then
connect the ground.
Tighten the battery cable terminals securely and fix
the battery firmly in its place.
3.4.2.3. PRECAUTIONS WHEN USING HAMMER
When using a hammer, pins may come out of their
position or metal particles may be scattered. This
may lead to serious personal injuries or death.
Always do as follows.
When hammering pins or bucket teeth, metal
pieces may scatter and injure people in the
surrounding area. Always check that there is no
one in the surrounding area.
If hard metal parts such as pins, bucket teeth,
cutting edges, or bearings are hammered, there is
the hazard that pieces might be scattered and
cause serious personal injuries or death. Always
wear safety glasses and gloves.
43
If a pin is hit with a strong force, it may come out its
position and injure people in the surrounding area.
Do not allow anyone to enter the surrounding area.
Fig 3.92
3.4.2.4. PRECAUTIONS WITH HIGH-
TEMPERATURE COOLANT
To prevent burns from boiling water or steam
spurting out when checking or draining coolant,
wait for the coolant to cool down to a temperature
that the radiator cap can be touched by hand. Then
loosen the cap slowly to release the pressure
inside the radiator, and remove the cap.
Fig 3.93
3.4.2.5. PRECAUTIONS WITH HIGH-
TEMPERATURE OIL
To prevent burns from hot oil spurting out or from
touching high-temperature parts when checking or
draining oil, wait for the oil to cool down to a
temperature that the cap or plug can be touched by
hand. Then loosen the cap or plug slowly to release
the internal pressure and remove the cap or plug.
44
Fig 3.94
3.4.2.6. PRECAUTIONS WITH HIGH-PRESSURE
OIL
The hydraulic system is always under internal
pressure. In addition, fuel piping is also under
internal pressure when the engine is running and
immediately after the engine is stopped. When
carrying out inspection or replacement of the piping
or hoses, check that the internal pressure in the
circuit has been released. If this is not done, it may
lead to serious personal injuries or death. Always
do as follows.
Do not carry out inspection or replacement work
with the circuit under pressure.
Always release the pressure before starting. For
details, see "STOP ENGINE BEFORE CARRYING
OUT INSPECTION AND MAINTENANCE".
If there is any leakage from the piping or hoses, the
surrounding area will be wet, so check for cracks in
the piping and hoses and for swelling in the hoses.
When carrying out an inspection, wear safety
glasses and leather gloves.
Fig 3.95
High-pressure oil leaking from small holes may
penetrate your skin or cause loss of sight if it
contacts your eyes directly, which are extremely
dangerous. In such cases, wash your skin or eyes
with plenty of clean water, and consult a physician
at once.
3.4.2.7. PRECAUTIONS WITH HIGH-PRESSURE
FUEL
When the engine is running, high-pressure is
generated in the engine fuel piping. When carrying
out inspection or maintenance of the fuel piping
system, stop the engine and wait for at least 5
minutes to allow the internal pressure to go down
before starting the operation.
3.4.2.8. HANDLING HIGH-PRESSURE HOSES
AND PIPING
If oil or fuel leaks from high-pressure hoses or
piping, it may cause fire or failure, and lead to
serious personal injuries or death. If the hose or
piping mounts are loose, stop operations and
tighten them to the specified torque.
If any damaged or deformed hoses or piping are
found, please consult your Hidromek dealer.
Replace the hose if any of the following problems
are found.
Damaged hose or deformed hydraulic fitting.
Frayed or cut covering or exposed reinforcement
wire layer. Covering swollen in some places.
Twisted or crushed hoses.
Foreign material embedded in covering.
3.4.2.9. NOISE LEVEL
When carrying out maintenance of the engine, due
to being exposed to noise for long periods of time,
wear ear covers or ear plugs while working.
If the noise from the machine is too loud, it may
cause temporary or permanent hearing loss.
3.4.2.10. HYDRAULIC ACCUMULATOR
This machine is equipped with a hydraulic
accumulator. When there is engine failure, it is
possible to operate the work equipment control
lever in the LOWER direction for a short time to
allow the work equipment to go down under its own
weight.
Before stopping the engine, apply work equipment
lock lever and FNR lever to LOCK position and turn
the parking brake button ON.
The accumulator is charged with high-pressure
nitrogen gas. If the accumulator is handled
mistakenly, it may cause an explosion that could
lead to serious personal injuries or death. For this
reason, always observe the following precautions:
Fig 3.96
Do not disassemble the accumulator.
Do not approach the accumulator with flame or
dispose it in fire.
Do not make holes in it, weld it, or use a cutting
torch.
Do not hit, roll or strike the accumulator.
When disposing the accumulator, the gas must be
released. Please contact your Hidromek dealer to
have this work performed.
3.4.2.11. PRECAUTIONS WITH COMPRESSED
AIR
When carrying out cleaning with compressed air,
there is the hazard of serious personal injuries
caused by flying dust or particles.
When using compressed air to clean the filter
element or radiator, wear safety glasses, an anti-
dust mask, gloves, and other protective equipment.
3.4.2.12. MAINTENANCE OF AIR CONDITIONER
If air conditioner refrigerant gets into your eyes, it
may cause loss of sight and if it contacts your skin,
it may cause frostbite. Never loosen any parts of
the cooling circuit without taking the necessary
precautions.
3.4.2.13. DISPOSAL OF WASTE MATERIALS
To prevent pollution, pay careful attention to the
method of disposing waste materials and dispose
them according to environmental regulations in the
area.
Always put oil drained from your machine in
containers having adequate capacities. Never
drain oil directly onto the ground or dump into the
sewage system, rivers, seas, or lakes.
You must comply with the laws and regulations in
the area when disposing harmful materials such as
oil, fuel, coolant, solvent, filters, and batteries.
45
Fig 3.97

3.4.2.14. PARTS CONTAINING MERCURY

Upon request, High Intensity Discharge Lamps
which contain mercury might have been installed
on your machine. These parts must be re-used,
recycled or disposed according to the related local
regulations and laws.
3.4.2.15. WINDOW WASHER FLUID
Methyl alcohol based washer liquid may irritate
your eyes, so do not use it.
Use ethyl alcohol based washer liquid.
3.4.2.16. PERIODIC REPLACEMENT OF
SAFETY- CRITICAL PARTS
For using the machine safely for an extended
period of time, replace safety-critical parts like
hoses and seat belts periodically.
For the details of replacement of safety-critical
parts: See "PERIODIC REPLACEMENT OF
SAFETY CRITICAL PARTS" section.
The material of these components naturally
undergoes changes over time, and repeated use
causes deterioration, wear, and fatigue. As a result,
there is the hazard that these components may fail
and cause serious personal injuries or death. It is
difficult to judge the remaining life of these
components by their look or by observing their
performance, so always replace them periodically.
Replace or repair safety-critical parts if any defect
is found, even when they have not reached the
specified replacement time.

46
 If the tire pressure is continuously reducing or if the
3.4.3. TIRES tire does not fit on the rim properly, please contact
your Hidromek Dealer to investigate the reason.
3.4.3.1. HANDLING TIRES
If the tire does not fit on the rim properly, the rim
Any mistakes made while maintaining tires or rims can come out of position while the tire is inflated.
may cause the tire to explode, or cause the rim to To ensure safety, place a guard around the tire and
be out of position causing serious personal injuries do not work in front of the rim but work on the tread
or death. side of the tire.
Do not adjust tire pressure right after a shift-end or
right after a high speed travel
Wait for the tires to cool down.
Do not perform welding next to tires, or approach
the tires with open fire.
Before dismounting the rim, completely bleed the
air inside the tire.
Before dismounting tires from the machine for
repair, first release the inner pressure by bleeding
air inside, then remove the tire.
Fig 3.98

Fig 3.99

To maintain safety, always do as follows.

Maintenance, disassembly, repair, and assembly
of the tires and rims require special equipment and
special technology, so always ask for help from
your Hidromek dealer.
Always use the tires specified by Hidromek and
maintain the specified inflation pressure.
For the suitable tire inflation pressure: see
"HANDLING TIRES" section.
When pumping up the tires, check that no other
person is standing near the tire, and install an air
chuck with a clip on the air valve.

While inflating the tire, check the inflation pressure

occasionally so it will not be over the specified
pressure.

47
3.4.3.2. STORING TIRES
Tires for construction equipment are extremely
heavy. It may lead to serious personal injuries or
death if they are not handled properly. To maintain
safety, always do as follows.

Fig 3.100

Fig 3.101

As a basic rule, store the tires in a warehouse

where unauthorized persons cannot enter.
If the tires must be stored outside, always erect a
fence and put up "No Entry" signs.
Stand the tire on level ground at an angle (A) of 60°
- 70° and fit blocks (1) securely so the tire cannot
roll/fall over if it is hit.
Do not lay the tire on its side. This will deform the
tire.
If the tire rolls over, do not attempt to stop it. Get
out of the way quickly.

48
4. OPERATION

WARNING

Before reading this section, please make sure that you read and fully understand SAFETY section.

4.1. GETTING TO KNOW OUR MACHINE

4.1.1. GENERAL VIEW OF MACHINE

1. Bucket 6. Rear view mirrors

2. Bell crank 7. Side working lamp
3. Bucket cylinder 8. Head lamp
4. Lift arm 9. Rear wheel
5. Front working lamps 10. Front wheel

Fig 4.1

49
4.1.2. REAR VIEW

1. Rear working lamps

2. Rear view camera
3. Combination lamps
4. Towing Pin
5. Back-up alarm

Fig 4.2

50
4.1.3. RIGHT SIDE VIEW

1. Batteries
2. Cabin tilting pump
3. Automatic lubrication (if available)
4. Step
Fig 4.3

4.1.4. LEFT SIDE VIEW

5. Engine hood tilt button & Battery switch

Fig 4.4

51
4.1.5. GENERAL VIEW OF CONTROLS AND GAUGES

1. Monitor Panel 7. Switches

2. Opera 8. Steering wheel
3. Control levers 9. Right brake pedal
4. FNR (Directional) lever 10. Left brake pedal
5. Wiper lever 11. Accelerator pedal
6. Side Panel (Radio/Air Con/Lighting/Camera) 12. Starting switch

Fig 4.5

52
4.2. EXPLANATION OF CONTROLS AND GAUGES
4.2.1.1. MONITOR PANEL

1. "Differential Lock Applied" warning lamp 3. TIPSHIFT warning lamp

When differential lock is applied, this warning lamp When machine FNR (Forward/Reverse) lever is
turn on. shifted to TIPSHIFT switch, this warning lamp turns
on.

2. Confortable Drive Control (CDC) warning

lamp
4. Parking Brake warning lamp
When necessary conditions are provided and CDC
is applied, this warning lamp turns on. For details, When parking brake is applied, this warning lamp
refer to "5.2.1.2. Opera" section explanations about turns on.
"Comfortable Drive Control".

53
 10. Machine speed
5. "Work Safety Lock is Applied" warning
lamp Indicates machine speed as km/h.

When work equipment control levers are locked,

this warning lamp turns on.

11. Selected gear and direction indicator

6. "Battery is Not Charging" warning lamp
Indicates selected direction ( Forward (F) / Neutral
If there is trouble in the battery charge system,
warning alarm activates and this red light turns on. (N) / Reverse (R) ) and currently active gear.
Normally, when starting switch is turned ON, this
light turns on as well and it turns off a few seconds
after the engine is started.

12. Engine Speed Indicator

7. "Rear View Mirror Heater is ON" warning
lamp Indicates engine speed as rpm.
When coil heater of rear view mirror is applied, this
warning lamp turns on.

8. Engine Cooling Water Temperature Gauge

13. Transmission Oil Temperature Gauge
Indicates engine cooling water temperature.
Indicates transmission oil temperature.

14. "Transmission Oil Temperature is High"

9. "Engine Water Temperature is High"
warning lamp
warning lamp
When transmission oil temperature exceeds
When engine cooling water temperature exceeds
110°C,
110°C, this warning lamp lights up in red.
this warning lamp lights up in red.

54
 "Stop Engine", "LIM" and
"Defective Emission System" CAUTION lamps
start flashing.

15. Diesel Exhaust Fluid (DEF) (Adblue®) Level
Gauge
(It is available on machines with EU Stage4
engines)
Shows the level of Diesel Exhaust Fluid (Adblue®).
Low Level Status of Adblue®/DEF
If Adblue®/DEF level drops to 10%, on the main
monitor "Adblue®/DEF level is low" CAUTION
message is displayed. In this case, Adblue®/DEF
should be added until it reaches the proper level as
soon as possible.
If CAUTION message is neglected and if Adblue®/
DEF level drops further, engine torque and engine
speed may be limited by the control unit. Engine
torque can be dropped up to 20% of maximum
torque with no change in engine speed. Engine
speed can be limited with the idle speed only.
After Adblue®/DEF tank is filled up, failure
disappears and engine continues to run with full
power again. If control unit cannot detect any other
failure during system check, "Defective Emission
System" CAUTION lamp turns off. However, to
complete the system check, engine may need to be
stopped and restarted several times, to be kept
running for a few hours or the machine may need
to be driven properly.
16. "High Beam is ON" warning light
When high beam is activated, this warning light
turns on.

When the Adblue®/DEF fluid level 17. "Low Beam is ON" warning light
starts to drop, and approx. 7.5% remains, first "Fill
Adblue®/ DEF" When low beam is activated, this warning light
turns on.
and "LIM" CAUTION lamps turns on
and
"Defective Emission System" CAUTION
lamps starts to flash.
If Adblue®/DEF level drops further, and approx. 5%
remains, "Fill Adblue®/DEF" CAUTION lamp
18. "Working Lamps are ON" warning light
continues to light and at the same time When one of the working lamps is activated, this
warning light turns on.
"LIM" light and Defective Emission System"
CAUTION lamp flashes
If Adblue®/DEF level drops further, and approx.
2.5% remains, "Fill Adblue®/DEF" CAUTION and

"Stop Engine" CAUTION lamps turn on

and at the same time "LIM"
and "Defective Emission System" CAUTION lamp
flashes.
If Adblue®/DEF level comes down and approx.
19. "Rotary Lamp is ON" warning light
When rotary lamp on top of the operator's cab is
activated, this warning light turns on.

0% remains, "Fill Adblue®/DEF"

CAUTION lamp continues to light and at the same
time

55
20. Fuel Level Gauge
25. Failure warning lamp
Indicates fuel level in the fuel tank.
If any failure occurs on the machine, this warning
lamp turns on.

21. "Failure in Emission System" warning lamp

If a failure occurs in the emission system, this 26. "Engine Oil Pressure Low" warning lamp
warning lamp turns on (failure code is displayed on When engine oil level is lower than specified, this
the screen). warning lamp turns on.

22. LIM warning lamp

27. "Air Filter is Clogged" warning lamp
Engine torque and speed may be limited by the
When air filter is clogged, this warning lamp turns
engine control unit due to a failure. In such a case,
on.
LIM warning lamp turns on. Failure code and the
explanation are displayed on the screen.

28. "Water in Fuel Filter" warning lamp

23. "Stop Engine" warning lamp If excessive amount of water is accumulated in fuel
filter, this warning lamp turns on.
If a serious engine failure occurs, this warning lamp
turns on. If it turns on, stop the machine and engine
immediately. Contact Hidromek dealer for service
and do not start or operate the machine until the
problem is fixed.

29. "Transmission Oil Pressure Low" warning

lamp
When pressure in transmission line drops below
the specified value, this warning lamp turns on.
24. "Check Engine" warning lamp
When a failure occurs in diesel engine, this yellow
lamp lights up.

30. "Hydraulic Oil Temperature High" warning

lamp
When hydraulic oil temperature exceeds 95°C, this
warning lamp turns on.

56
4.2.1.2. OPERA PANEL

Fig 4.6

57
1. Volume Control Knob
Used for volume control while media or radio is on.
Volume may be increased or decreased by just
turning the knob. To increase the volume turn the
knob to right. To decrease the volume turn the knob
to left.
Mute (turning the volume off): When the knob is
pressed, volume is temporarily turned off. When
pressed again, previous sound level comes back.
2. "Park / Lamp" Key
Used for lighting parking lamps and headlamps in
short beam.
Parking lamps can be turned on while the starting
switch is turned to OFF or ON position. Short beam
function works only while starting switch is turned
ON.
When the knob is pressed once, parking lamps
turns on. Upper pilot lamp next to knob lights up.
When the knob is pressed twice both parking lamps
and short beam headlights turn on. Upper and
lower pilot lamps next to knob light up.
When the knob is pressed three times, parking
lamps and short beam headlights turn off. Upper
and lower pilot lamps next to knob also turn off.
3. Hazard Lamp Key
Even if the starting switch is in OFF position, when
this key is pressed, color of the key turns to red and
hazard lamps (all turning signals) flash on and off.
Whenever there is a problem on the machine or
when an emergency stop is required, operate these
hazard lamps. Press the key again to turn it off.
58
4. Transmission Power Mode Adjustment
Knob (Automatic Powershift)
When the knob is fully turned to left, 4 lights on the
left turn on and low power (LOW) mode activates.
In this mode, shifting up is realized at low engine
speed. Suitable for travel.
When the knob is at midpoint, 4 lights in the middle
turn on and normal power (MID) mode activates. In
this mode, shifting up is realized at a little higher
engine speed than the low power mode. This mode
is suitable for V-type loading operation.
When the knob is fully turned to right, 4 lights on
the right turn on and high power (HIGH) mode
activates. In this mode, shifting up is realized at
high engine speed. This mode is suitable for uphill
operations.
5. Menu Search and Confirmation Knob
When you enter the menu of side panel, by turning
this knob to right or left, you can surf among the
titles of the menu.
After deciding on the title you want to select, press
this knob to confirm.
6. Back (Cancel) Key
Press this key to exit from the current menu or to
return to the previous menu.
7. Home Key
While inside the menu, press this key to return to
the main screen.

8. Lift Arm Automatic Lowering Key
Each time the machine is started, bucket automatic
positioning function is set to the standard position
adjusted for the bucket leveling operation.
To change bucket automatic positioning set point,
move the bucket to the position in which you want

The function of lift arm automatic lowering key is to adjust and then keep the bucket automatic
disabled when the engine is not running. positioning key pressed for a few seconds.

When you press lift arm automatic lowering key

once, the function is activated and the lamp on the
right hand side of the key lights up. When the key
is pressed again, the function is de-activated and
the lamp on the right hand side of the key turns off.
11. Floating Mode Key
To set lift arm position automatically, lower the lift
arm to the position in which you want to set and Floating function is disabled when the engine is not
then keep lift arm lowering key pressed for a few running.
seconds. This position will be stored in the memory
To activate the floating mode, press the key once.
and the lamp on the left hand side of the key lights
When floating mode is activated, the lamp on the
up. When it is deactivated, the lamp will turn off.
key lights up. To de-activate floating mode, press
the key again. When floating mode is disabled,
lamp on the key turns off.

9. Lift Arm Automatic Raising Key

The function of lift arm automatic raising key is
disabled when the engine is not running. 12. Automatic Shift-Down (Kick Down) Key

When you press the lift arm automatic raising key
once, the function is activated and the lamp on the
key lights up. When the key is pressed again, the
function is de-activated and the lamp on the key
turns off.
To set lift arm position automatically, raise the lift
arm to the position in which you want to set and
then keep the lift arm raising key pressed for a few
seconds. This position will be stored in the memory
and the lamp on the key lights up. When it is
deactivated, the lamp will turn off.
The function of automatic shift-down function key is
disabled when the engine is not running.
To enable automatic shift-down function, press
this key once. When automatic shift-down function
is enabled, the lamp on the key lights up.
With this function, to increase the drawbar pull in
digging operations, transmission is shifted from the
2nd gear to the 1st gear.
To disable automatic shift-down function, press the
key once again. When the automatic shift-down
function is disabled, the lamp on the key turns off.

10. Bucket Automatic Positioning Key

The function of bucket automatic positioning key is
disabled when the engine is not running.
When you press bucket automatic positioning key
once, the function is activated and the lamp on the
right hand side of the key lights up. When the key
is pressed again, the function is de-activated and
the lamp on the right hand side of the key turns off.

59
13. Comfortable Drive Control (CDC) Key 16. CAUTION Key

Comfortable drive mode does not function if the It is activated when the starting switch is turned ON.
engine is not running. Also, when CDC valve is out Failures and warnings are displayed on the side
of order, comfortable drive valve cannot be panel for a while.
activated.
When this key is pressed, failures and warnings
In shiftdown (kickdown) operation, comfortable screen is continuously displayed on the side panel.
drive function can be activated, but comfortable When the key is pressed again, it is deactivated.
drive valve cannot be activated.
When comfortable drive key is pressed once,
comfortable drive function activates and the lamp
on the key lights up. Comfortable drive function
activates if the machine travel speed is more than
6 km/h forward or 4 km/h in reverse direction.
When comfortable drive key is pressed again, CDC 17. Air Conditioner Key
function will be disabled, the lamp on the key turns
off and comfortable drive valve cannot be It functions when the starting switch is turned ON.
activated.
When this key is pressed, air conditioner screen on
the side panel is displayed.

14. INFO (İnformation) Key

18. Rear View Camera Key
If the engine is running, INFO function is not active.
This key is used to display the rear view camera on
INFO function is used to receive information about the side panel. Press it again to deactivate.
the functions of other keys on the machine.
When INFO key is pressed once, INFO function
activates, the functions of other keys on the
machine are temporarily disabled and the lamp on
the key lights up. While the INFO key is active,
press the key of any function which you need to
19. Beacon Lamp Key
know, information about the function of that key will
be displayed on the side panel. It functions when the starting switch is turned ON.
When you press INFO key again, the function will When you press this key, rotary lamp at the top of
be disabled and the lamp on the key turns off. the operator's cabin lights up together with the light
on the key. When the key is pressed again, rotary
lamp and key light both turn off.

15. "Engine Start / Stop" Button

This knob is used to start and to stop the engine.
After turning the starting switch "ON", keep this
botton pressed to start the engine. If you press this
knob again while the engine is running, the engine
will be stopped.

60
 23. Media Key
20. Rear Wiper Key
Operates only when the starting swich is turned
ON.
When this key is pressed, media screen is
If the wiper motor is defective, it does not function. displayed on the side panel.
When rear wiper key is kept pressed for several
seconds, rear wiper washer activates and
continues to spray as long as the key is kept
pressed and the lamp on the right hand side of the
key lights up. When it is released, window washer 24. SRC key
stops and the lamp turns off.
Each time this key is pressed, Media, AUX and
When rear wiper key is pressed, rear wiper motor Radio screens are displaced on the side panel.
activates. Lamp on the left side of the key lights up.
When the key is pressed again, rear wiper motor
stops and lamp on the left side turns off.

21. Radio Station Forward Search / Right

Direction Key
While radio is operating, increases frequency
value searching automatically for a radio station
and stops on the nearest station.
It is also used as a right direction key while scrolling
through the menu.

22. Radio Station Reverse Search / Left

Direction Key
While radio is operating, decreases frequency
value searching automatically for a radio station
and stops on the nearest station.
It is also used as a left direction key while scrolling
through the menu.

61
4.2.2. RIGHT CONSOLE
Fig 4.7
1. Lift arm control lever
2. Bucket control lever
3. TIPSHIFT switch
4. TIPSHIFT activation button
1. Lift Arm Control Lever
Lift arm control lever has 4 positions: Raise, hold,
lower and float.
2. Bucket Control Lever
Bucket control lever has 3 positions: Tilt, hold
and dump.
3. TIPSHIFT (Forward-Reverse (FNR)
Direction Selecting) Button
To enable TIPSHIFT function, set the gearshift
lever and TIPSHIFT switch to neutral position and
press TIPSHIFT activation button (4). When
TIPSHIFT is activated, the lamp on the monitor
panel lights up.
While TIPSHIFT switch is in forward position, FNR
shifts to FORWARD, while TIPSHIFT switch is in
reverse position, FNR shifts to REVERSE and
while TIPSHIFT switch is in the middle, FNR shifts
to NEUTRAL.
4. TIPSHIFT Activation Button
When this button is pressed, TIPSHIFT on the side
console is activated. When TIPSHIFT is active,
CAUTION lamp on the monitor panel lights up.
5. Differential Lock Button
When this button is kept pressed, differential lock
is applied and will be ON as long as the button is
kept pressed. When differential lock is applied, light
62
5. Manual differential lock button
6. Horn button
7. N/A
8. Kick-down button
on the monitor panel lights up.
NOTICE
This function must be activated only when the
machine is going to be operated on slippery
ground.
Actuate Manual Differential Lock only when front
and rear frames are on line and machine is going
to travel straight. Do not turn the machine when
Manual Differential Lock is applied.
6. Horn Button
Horn sounds as long as it is kept pressed.
7. N/A
This button has no function.
8. Kickdown Button
When this button (8) is pressed, transmission shifts
down. When the button (8) is pressed again
transmission shifts up. Use this function when you
need to increase the drawbar pull in digging
operations.
To cancel the kickdown function, set the gear shift
lever or TIPSHIFT switch (if enabled) to REVERSE
or NEUTRAL position.
When the starting switch is turned OFF, kickdown
function is cancelled.
4.2.3. FNR (DIRECTIONAL) LEVER 4.2.4. WIPER LEVER

Fig 4.9

When “0” is aligned with the arrow, the wiper does

Fig 4.8
1. Direction set (FNR):
FORWARD: (F) position: Push the lever forward.
NEUTRAL: (N) position: Bring the lever to midpoint.
REVERSE: (R) position: Pull the lever backwards.
2. Speed range set:
not function. When the symbol above ‘’0’’ is aligned
with the arrow, wiper operates intermittently.
When “1” is aligned with the arrow, wiper operates
at low-speed. When “2” is aligned with the arrow,
wiper operates at high-speed.
When arm is pushed up, washer liquid is sprayed
out. When arm is pulled down, high beams
activate.

This lever (2) changes the speed range of the When arm is pushed forward, left turn signal works.
transmission. Set the desired speed range by When it is pulled back, right turn signal works.
turning the lever.
Depending on the selected speed range, gears
to be activated vary.
1. When gear shift lever is in the 1st, it is fixed in the
1st.
2. When gear shift lever is in the 2nd, it is fixed in
the 2nd.
3. When gear shift lever is in the 3rd, depending on
the machine speed, the 2nd or 3rd speed is selected
automatically by the machine control unit.
4. When gear shift lever is in the 4th, depending on
the machine speed, the 2nd, 3rd, 4th or 5th gear is
selected automatically by the machine control unit.

CAUTION

Gear shifted by the gearshift lever is not the active

gear. Active gear is determined by the machine
control unit, depending on the machine speed and
travel conditions.

3. FNR (Directional) lever lock:

Enables or disables FNR lever to select Forward/
Neutral/Reverse directions.

63
4.2.5. SIDE PANEL 1. Working lamps key
Inside the side panel, a special computer with 8" When this key is pressed, working lamps screen is
touchscreen is fitted. displayed. To turn the working lamps on, tap the
selected working lamp on the screen, and the
selected working lamp will light up. To turn the
working lamps off, tap the selected working lamp
on the screen, the selected working lamp will go off.

Fig 4.10

1. Working lamps key

2. Air conditioner key
Fig 4.11
3. Media key
1. Working lamps key
4. Radio key
5. Main menu key
6. Rear view camera key
7. Menu key
8. Back key

64
2. Air conditioner Key 3. Media Key

When this key is pressed, air conditioner screen is When this key is pressed, if a device complying
displayed. The functions of the air conditioner key with the screen is connected to USB inlet, music in
are explained below: the files in this device can be played. For USB
device, function of the keys are as follows:

Fig 4.12
Fig 4.13
2. A/C key
3. Media key
9. Temperature decrease key
15. Music player key
10. Temperature increase key
16. Video player key
11. Fan speed decrease key
17. Photograph display key
12. Fan speed increase key
13. Aircon ON/OFF key
14. Fresh air intake key

65
4. Radio Key 5. Main Menu Key
When this key is pressed, radio screen is
displayed.

Fig 4.15

When this key is pressed, main menu screen is

displayed.

6. Rear View Camera Key

Fig 4.16

When this key is pressed, rear view camera screen

is displayed.

7. Menu Key
To enter the menu, press menu key (7).
Fig 4.14

4. Radio key
18. Volume increase
19. Volume decrease
20. Station search left Fig 4.17
21. Active station
22. Station search right 8. Back Key
When this key is pressed, the current screen is
closed and the previous screen is displayed.

Fig 4.18

66
4.2.5.1. MENUS OPERATION HOURS SCREEN
To enter the menu, press menu key (7) below the
screen.

Fig 4.19

To scroll through the menus, tap the right or left

direction keys on the screen. On the upper part of
the active menu screen, the symbol of the screen
is displayed. Symbols of the menu screens taking
place on the right and left hand sides of the active
menu screen are displayed on right and left of the
active menu symbol.

Following items are available on this menu:

Fig 4.20
1. Operating hours screen
2. Maintenance information screen
On this screen, following information is displayed:
3. Engine screen
4. Transmission screen User’s operation hours : 0000:00
5. Hydraulics screen
Starting key-ON hours : 0000:00
6. Axle & Brakes screen
7. Electrics screen Working hours : 0000:00
8. Adjustments screen
Engine Idling hours : 0000:00
9. Machine information screen
Loader working hours : 0000:00

900-1100 rpm running ours : 0000:00

1100-1300 rpm running hours : 0000:00

67
MAINTENANCE INFO SCREEN ENGINE SCREEN

Fig 4.21 Fig 4.22

Following information is displayed on this screen: Following information is displayed on this screen:
Engine oil change 500 hours 1. Fan reverse function
Engine oil filter change 500 hours 2. Engine speed (rpm)
Engine fuel filters change (fuel pre- 500 hours 3. Engine fan speed (rpm)
filter, Main fuel filter)
Air filter change 12 month 4. Coolant temperature (low/normal/high)
Engine coolant change 24 month 5. Engine oil pressure (low/normal/high)
AdBlue® filter change 24 month 6. Engine oil level (low/normal/high)
(It is available on machines with EU
Stage4 engines) 7. Air filter (normal/clogged)
Transmission oil change 1000 hours
Transmission oil filter change 1000 hours
Hydraulic tank breather element 500 hours
change
Hydraulic oil return line filter change 1000 hours
Hydraulic oil pilot line filter change 1000 hours
Hydraulic oil leakage line filter 1000 hours
change
Hydraulic oil filter change 2000 hours
Hydraulic oil change 2000 hours
Front axle oil change 1000 hours
Rear axle oil change 1000 hours
Aircon filter change 1000 hours

68
FAN REVERSING ADJUSTMENT TRANSMISSION SCREEN

Fig 4.24
Fig 4.23

By pressing sub-key of fan reversing on the engine
screen, fan reversing function can be adjusted.
Fan reversing function can be adjusted manually
or automatically.
To reverse the fan manually, keep manual key
pressed.
Following information is displayed on this screen:
1. Transmission oil temperature (low/normal/high)
2. Transmission oil level (low/normal/high)
3. Transmission oil pressure (low/normal/high)
4. Transmission oil filter (normal/clogged)

To reverse the fan automatically, press automatic

key. After actuating automatic reversing mode,
select one of the periods "rare, normal, often"
suitable to your working condition.

69
HYDRAULICS SCREEN AXLE & BRAKES SCREEN

Fig 4.25 Fig 4.26

Following information is displayed on this screen:
1. Hydraulic oil temperature (low/normal/high)
2. Hydraulic oil level (low/normal/high)
3. Hydraulic oil pressure (low/normal/high)
4. Hydraulic oil filter (normal/clogged)
5. Comfortable drive control (ON/OFF)
6. Floating system (ON/OFF)
7. Bucket Automatic Positioning (ON/OFF)
Following information is displayed on this screen:
1. Brake pressure (low/normal/high)
2. Front axle oil temperature (low/normal/high
3. Rear axle oil temperature (low/normal/high)
4. Parking brake status (ON/OFF)

70
ELECTRICS SCREEN MACHINE INFORMATION SCREEN

Fig 4.29
Fig 4.27
Following information is displayed on this screen:
Following information is displayed on this screen:
• Version of machine control unit
• Battery voltage: 28 V
• Smartlink no
• Mirror heater status (ON/OFF)
• Version of side panel
• Version of monitor panel
ADJUSTMENTS SCREEN

FAILURES & WARNINGS SCREEN

Fig 4.28

Following adjustments can be made on this screen:

Failures and warnings detected and stored by
• Language electronic control units are displayed on this
screen. When a failure occurs, it is displayed under
• Date the heading FAILURES together with the failure
• Time code. Warnings are displayed under the heading
WARNING.
• Brightness
• Pop-up Time
• Date Format
• Time Format

71
4.2.6. SWITCHES/BUTTONS (SIDE CONSOLE)

Fig 4.30

1. Parking Brake Button 4. Mirror Adjustment Switch

Machine is kept still when this button is set in ON When this switch is set in R (right), right rear view
position. Parking brake warning lamp lights on the mirror (outside), when it is set in L ( left), left rear
monitor panel. The catch on the button prevents view mirror (outside) can be adjusted electrically.
the parking brake from being released accidentally. To do this, the switch must be pushed to the
desired direction of adjustment of the mirror.
2. Work Equipment Lock ON/OFF Button
5. Automatic Transmission Cut-off Switch
When this button is set in ON position, the functions
of work equipment control levers are disabled. To If brake pedal is depressed when this switch is
activate work equipment control levers, set this applied, torque from the transmission is reduced
button in OFF position. When the button is in ON and more power is sent to hydraulic system.
position, "work equipment lock is ON" warning
6. N/A
lamp lights.
This button has no function.
3. Mirror Defrosting Button
When this button is activated, rear view mirrors
(outside) are heated for 10 minutes and mist on the
surface of the mirrors is removed. While it is active,
CAUTION lamp turns on.

72
4.2.7. STEERING WHEEL ADJUST LEVER When automatic transmission cut off button is in
OFF position, if the brake pedal is depressed,
service brake is applied.
4.2.9. ACCELERATOR PEDAL
This pedal controls engine speed and engine
output.

Fig 4.31

Forward and backward angle of the steering wheel

can be adjusted by pushing the lever down. To
change the steering wheel angle, push the steering
wheel adjustment lever down with one hand and
with the other hand move the steering wheel to the
desired position.
By pulling the lever up, you can adjust the height of
the steering wheel. To do this, pull the steering
adjustment lever upwards while moving the
steering wheel up and down with the other hand to 1. Accelerator pedal
the desired position. Fig 4.33
4.2.8. BRAKE PEDALS
Engine speed can be freely controlled between low
idle and full speed.

1. Right brake pedal

2. Left brake pedal
Fig 4.32

These pedals operate the service brake.

CAUTION

When accelerator pedal is depressed to move

the attachment, set automatic transmission
cut-off switch always in ON position.

When automatic transmission cut-off switch is

in ON position, if the brake pedal is depressed,
service brake is applied and at the same time
transmission is set to Neutral.

73
4.2.10. STARTING KEY
1. Starting key
Fig 4.34
This key is used for starting and stopping the
engine. The key has 4 different positions and these
positions are explained below:
OFF position
The key can be inserted and removed in this
position. When the key is turned to this position, all
electrical circuits are turned off and the engine
stops
In addition, the parking brake is automatically
applied.
ACC position
When the key is in this position, side panel starts
functioning and the radio and USB work. External
power source (12V) can be used.
ON position
In this position, electric current flows to the
charging circuit, lamp circuit, and accessory circuit.
Keep the starting switch key in ON position while
the engine is running.
START position
This is the engine-start position. Keep the key in
this position during cranking. Immediately after
starting the engine, release the key. It will
automatically return to ON position.
74
4.2.11. ARM REST
1. Arm rest adjustment lever
Fig 4.35
When you pull this lever towards yourself, height of
the arm rest, together with Opera and switch group,
can be adjusted.
4.2.12. LOCKED CAPS
If lockable type fuel tank cap and hydraulic tank cap
are available on the machine, open and close the
cap as explained below. Use the starting switch
when opening or closing the cap.
4.2.12.1. METHOD OF OPENING AND CLOSING
CAP WITH LOCK
TO OPEN THE CAP
1. Insert the starting switch key in the keyhole
securely until the shoulder contacts the keyhole. If
the key is not inserted fully into the keyhole and is
turned, the key may break.
2. Turn the key clockwise and align the groove in
the rotor and the counter mark on the cap. Turn the
cap slowly until "click" sound is heard. Now, cap is
unlocked and can be removed.
TO LOCK THE CAP
1. Screw the cap into place.
2. Insert the starting switch key in the keyhole
securely until the shoulder contacts the keyhole.
If the key is not inserted fully into the keyhole and
is turned, the key may break.
3. Turn the key counterclockwise and pull out the
key.
4.2.13. FRAME LOCK BAR
If the machine is transported or lifted when the
frame lock bar is not applied, the machine may
suddenly articulate.
If the machine articulates, it may harm the people
in the surrounding area.
• Always lock the frame lock bar when
transporting or lifting the machine.
• During maintenance, lock the frame lock bar if
necessary.
The frame lock bar is a device to lock front frame
and rear frame so that machine does not articulate.

1. Frame lock bar

L: Lock position
F: Free position
Fig 4.36

LOCK position (L): Always set the frame lock bar in

this position when transporting or lifting the
machine.
For maintenance, set it in this position if necessary.
FREE position (F): Always set the frame lock bar in
this position when traveling.
Insert the lock pin of the frame lock bar into hinge
securely, then fit the linchpin. If it is not inserted
fully and a load is applied, it may come out and the
frame lock bar may be deformed.
When locking the frame lock bar, lock it as follows.
1. Insert frame lock bar lock pin (1) securely into
hinge at the bottom of the front frame.
2. Always secure it with supplied linchpin (3).

75
4.2.14. TOWING PIN 4.2.15. BATTERY DISCONNECT SWITCH

1. Battery disconnect switch

1. Towing pin Fig 4.37
Towing pin is installed in the counterweight. To
take it out, pull the pin upwards.
When inserting the towing pin, securely fit it into its
place.
Fig 4.38
Battery disconnect switch and engine hood tilt
button are located behind the cover on LH side of
the machine.
When battery disconnect switch (1) is set in OFF
position, running engine will be stopped. Use this
switch in case of an emergency.
Allow 10 minutes after the engine has stopped
before you turn the battery disconnect switch off.
To restart the engine, set battery disconnect switch
in ON position, then turn the starting switch key to
START position.

76
4.2.16. BACK-UP ALARM

Fig 4.39
Fig 4.41
When the machine travels in reverse, the alarm
sounds to warn people in the area that the machine Cabin tilting mechanism is located behind the cover
is traveling in reverse. (1) on RH side of the machine.
The alarm is on when the directional lever is set in
R position.

4.2.17. OPERATION OF OPERATOR'S CAB

TILTING FUNCTION

WARNING

For activating operator's cab tilting function, ask

help from Hidromek Authorized Service or
Dealer. Before operating the tilt pump for tilting
operation, mounting of the cabin bracket pins and
removal of the cabin mounts will be necessary.
After the cabin is tilted, safety lever must be
applied to secure the cabin in the tilted position
to assure safety. Fig 4.42

Operator's cab tilting angle is 35°.

Tighten the catch (B) clockwise and pump the lever
(A) up and down, and the cabin will be tilted. To
lower the cabin, loosen the catch (B) by turning
counterclockwise and pump the lever up and down.

Fig 4.40

Before tilting cabin, work equipment control levers

must be locked.

77
4.2.18. ENGINE HOOD TILT BUTTON

Fig 4.43

Engine hood tilt button is located behind the cover

(1) on LH side of the machine.

Fig 4.44

In emergency cases or while servicing the

machine, set battery disconnect switch (A) in OFF
position.
Battery will be disconnected.

78
4.2.19. FUSES

WARNING

Before replacing a fuse, be sure to turn off the

starting switch.

Fuses protect the electrical equipment and wiring

from burning out.
If fuses become corroded or oxidized, or fuses are
loose in their holders, replace the fuses.
When fuses are replaced, the burnt out and the
replaced fuses must have the same capacity.

Fig 4.45

4.2.19.1. FUSE CAPACITY AND NAME OF CIRCUIT

Fig 4.4

79
FUSE C/FA RELAY C/RA
Nº Name Amper Nº Name
1 Engine Starter 10A 1 Engine Start
2 MCU 30A 2 Turn Signal, Left
MCU 3 Turn Signal, Right
3 30A
4 Lamp, High Beams
4 ECU 10A
5 Lamp, Low Beams
5 Opera-Smartlink (IGN. ON) 10A 6 Lamp, Beacon
6 TCU 7,5A
7 Display (front-side) IGN.ON 10A RELAY C/RB
8 Air Cond. Unit 20A Nº Name
9 Seat 20A 1 Reverse Horn
Side Console 2 Horn
10 10A
3 Mirror Heater
11 Wiper Motor (front) 20A
4 Wiper Motor
12 Wiper Motor (rear) 10A 5 Joystick Safety
13 High beams / Low beams 10A 6 Null
14 Beacon Lamp 15A
15 Horn 7,5A RELAY C/RC
16 Mirror 15A Nº Name
17 Lubrication System (Op.) 10A 1 Wiper Timer Relay
Blower 2 Inside Light Timer
18 20A
19 Null
RELAY C/RD
20 Null
Nº Name
1 Buzzer
FUSE C/FB 2 Null
Nº Name Amper
1 Front Display /Opera (ACC) 5A RELAY C/RE
Power Socket Nº Name
2 10A
1 Blower (1st)
3 Side Display/AMP (ACC) 7,5A 2 Blower (2nd)
4 Null 15A 3 Blower (3rd )
5 ECU (battery) 10A 4 Null
6 TCU (battery) 10A 5 Null
6 Null
7 Display (battery) 7,5A
8 Opera (battery) 10A DATA CONNECTORS
9 Actuator 15A Nº Name
10 Wiper Motor (Park) 10A A Override switch (Optional)
11 Cabinet Light / Turn (Left, Right) 10A B MCU Diagnostic
Null C Data transfer
12
13 Null
14 Null
15 Null
16 Null
17 Null
18 Null
19 Null
20 Smartlink 5A

80
4.2.20. TOOL BOX 4.2.21. FIRE EXTINGUISHER (IF AVAILABLE)

1. Fire extinguisher
1. Tool box Fig 4.47 Fig 4.49

A space is allocated inside the operator's cab on

the left rear corner for fire extinguisher (1).
Mount the bracket of the fire extinguisher on the
stay on the LH rear side and hang the fire
extinguisher there. Show the operator how to use
the fire extinguisher in case of fire.

4.2.22. EMERGENCY EXIT

Fig 4.48

Tool box is located above the step on LH side of

the machine. It is used to keep tools, small parts
and such articles.

1. Emergency hammer
Fig 4.50

Window on the RH side of the operator's cab is the

emergency exit.
In case of an emergency, if the door on the LH side
of the operator's cab fails to open, use the
emergency hammer (1) to break the window glass
on the RH side and use the step on the RH side to
leave the machine.

81
1. AUX inlet
2. USB inlet
3. Power outlet
4. Side panel
Fig 4.51

4.2.23. POWER OUTLET

WARNING

There is a 12V power source on this machine.

The power source with 10A capacity is located
next to the side panel on side strut.

• When using this power source, make sure that

the device to be connected should not exceed the
maximum amperage value.
4.2.24. AUX INLET
When you want to listen to music played on an
external device (mp3 player, cassette player,
mobile phone etc.) through the speakers inside the
cab, connect the earphone/line out outlets of the
device to AUX inlet with a suitable cable. Select
AUX mode by pressing SRC button.
4.2.25. USB INLET
If you want to open mp3 files in a USB connected
memory device, connect the device to USB inlet.
When USB device is connected, tape shifts
automatically to USB mode and starts to play mp3
files available in the device.
If USB device has already been connected, select
media mode by pressing SRC button and mp3 files
start playing.

82
4.3. OPERATION
4.3.1. CHECKS BEFORE STARTING ENGINE,
ADJUSTMENTS
4.3.1.1. WALK-AROUND CHECK AND VISUAL
INSPECTION
Before starting the engine, walk around the
machine and look for anything unusual such as
loose bolts and nuts, leakage of fuel, oil and
coolant. Also check the conditions of work
equipment and hydraulic system.
Also check for loose wiring and connectors and
collection of dust at places that reach high
temperature.
Always hang a warning tag on work equipment
control levers before starting inspection.
Accumulation of flammable materials and leakage
of fuel or oil around the battery or high-temperature
parts of the engine, such as the engine muffler and
turbocharger, may cause fire on the machine.
Check thoroughly and if there is a problem, repair
it, or contact your Hidromek dealer.
Always repair any damage on the handrails and
steps, and tighten any loose bolts. Failure to do so
may cause workers to fall and suffer from serious
personal injuries.
Everyday before starting the engine, do the
following:
1. Check for damage, wear and clearance on work
equipment, cylinders, linkage and hoses. If there
are such problems, correct them by tightening,
repairing or replacing.
2. If there is dirt and dust around the engine,
battery and radiator, remove it.
6. Check for oil leakage from the brake line.
If there is such a problem, correct it by repairing or
replacing at once.
7. Check for damaged or worn tires, wheels, and
wheel hub bolts and nuts, and check for loose
wheel hub bolts and nuts.
Check for cracks or peeling on the tires and for
cracks or wear on the wheels (side rim, rim base,
lock ring). Tighten any loose wheel hub bolts or
nuts. If there are such problems, repair or replace
the part.
If any valve caps are missing, install new caps.
8. Check for damage and loose bolts on the
handrail and steps.
Repair any damage and tighten any loose bolts.
9. Check for damage on the panel, gauges, and
lamps and check for loose bolts
If there are any damaged parts, replace them.
Clean off any dirt on the surface. Tighten any loose
bolts.
WARNING
Before starting operations, clean all dirt on the
surface of the lamps. If lamps are covered with
mud and dirt, they may overheat and be
damaged.
Do not clean the lamps when they are
overheated. The sudden change in temperature
may cause the lens to crack. Turn the lamps off
and wait to cool before cleaning them.
10. Check for loose air cleaner mounting bolts.
Tighten any loose air cleaner mounting bolt.

Check that there is no dirt or dust accumulated 11. Check for loose battery terminals. Tighten any
around the engine or radiator. Check also that no loose terminal.
flammable material (dry leaves, twigs, and such) is
accumulated around the battery, engine muffler,
turbocharger, or other high-temperature parts of
the engine. Remove all dirt, dust, or flammable
material.
3. Check for coolant or oil leakage around the
engine.
Check that there is no oil leakage from the engine
or coolant leakage from the cooling system.
If there are such problems, correct them by
repairing or replacing.
4. Check for leakage from the fuel line.
Check that there is no fuel leakage or damage on
the hoses and tubes. If there are some problems,
correct them by repairing or replacing.
5. Check for oil leakage from the transmission
case, axle, hydraulic tank, hoses and joints. If
there is such a problem, correct it by repairing or
replacing.

83
12. Check for damage on the seat belt and
mounting clamps.
• Even if there appears to be no damage on the
seat belt, replace it as it is mentioned below:
Seat belts must be replaced in the 5th year of being
manufactured, or every 3 years after having been
used (whichever takes place first).
CAUTION
The manufacturing date stamped on the seat belt
is the starting date of the 5 year period. This date
should not be considered as the starting date of
3 year period for the actual use.
Check that there are no loose bolts on the
equipment mounting the seat belt to the machine,
and tighten them if necessary.
Fig 4.52
Tightening torque: 19.6 to 29.4 Nm
If the belt is damaged or fluff is starting to form, or
if there is any damage or deformation on the seat
belt holders, replace the seat belt.
13. Check the tightening torque of bolts on ROPS
structure.
Check for loose and/or damaged bolts. Tighten the
loose bolts to a torque of the specified value.
Replace the damaged bolts (if any) with genuine
Hidromek parts.
14. Clean cab window.
To ensure good visibility through the cab window
during operations, always keep the glass clean.
When cleaning the front glass, use commercial
cleaning detergent and do the work while standing
on the ground.
84
Fig 4.53
15. Check rear view mirror and side view mirrors.
Check that the mirrors are not damaged. Replace
them if they are damaged. Clean the surface of the
mirrors and adjust the angles in such a way that the
operator can see the areas in the rear and on the
sides of the machine from the operator's seat.
When cleaning the mirrors, use a mop with a long
handle.
16. Inspect tires.
Fig 4.54
If worn or damaged tires are used, they may burst
and cause serious injuries or death. To ensure
safety, do not use the following tires.
Wear:
• Tires with a tread grooves of less than 15% of that
of a new tire
• Tires with extreme uneven wear or with stepped-
type wear
Damage:
• Tires with damage that has reached the cords, or
with cracks in the rubber
• Tires with cut or pulled cords
• Tires with peeled (separated) surface
• Tires with damaged bead
• Leaking or improperly repaired tubeless tires
• Deteriorated, deformed or extremely damaged
tires, which do not seem to be usable
17. Inspect rims.
Check the rims (wheels) and rings for deformation,
corrosion and cracks. In particular, check the side
rings, lock rings and rim flanges thoroughly.
4.3.1.2. CHECK BEFORE STARTING
Perform the contents of this section before starting
the work each day. For detailed information refer
to Operation and Maintenance Manual
"Maintenance" section.
1. Check that all the monitors, gauges and warning
systems are functioning properly
2. Check air filter clogging pilot lamp and clean or
change the filter accordingly.
3. Drain water from fuel filters.
4. Check coolant level, and add coolant if
necessary.
5. Check engine oil level, and add if necessary.
6. Check brake oil level, and add if necessary.
7. Check fuel level, and add if necessary.
8. Visually check electric wiring, tighten loose
connections and connectors.
9. Check the function of parking brake.
10. Check the function of brake pedal
11. Check the inflation pressure of the tires, and
adjust if necessary.

85
4.3.1.3. ADJUSTMENTS
4.3.1.3.1 SEAT ADJUSTMENT
Fig 4.55
CAUTION
Always adjust the operator's seat before starting
each operation or when the operators change.
After adjustment, move the seat to confirm that it
is locked. Do not make the seat adjustment while
the machine is travelling.
• Park the machine in a safe place and stop the
engine when adjusting the operator's seat.
• Adjust the operator's seat before starting
each operation or when the operators change.
• Adjust the seat so that the brake pedal can
be depressed all the way down when the
operator's back is against the backrest.
For height and weight adjustments, use the air
compressor built into the seat, so turn the engine
starting switch to ON position when carrying out
these adjustments.
1. Headrest
Pull up or push down the headrest with your two
hands to set it to the desired height.
2. Height and weight adjustment
When the operator is seated, seat suspension is
automatically adjusted to the weight of the
operator. Maximum operator's weight allowed for
this seat is 150 kg.
To increase the height of the seat, pull seat height
adjustment lever (2) upwards. To decrease the
height of the seat, push seat height adjustment
lever (2) downwards.
86
CAUTION
In order to protect the air compressor from being
damaged, do not actuate the adjustment knob
more than 1 minute at a time.
WARNING
To prevent potential injuries, weight adjustment
which is made suitable for the operator's weight
should be rechecked, and if required, it should be
readjusted before starting the machine.
3. Cushion angle adjustment
Set the desired position by keeping button (3) in
Figure 4.55 pressed and by pressing the surface
of the cushion.
4. Cushion depth adjustment
Set the desired position by pressing button (4) in
Figure 4.55 and by moving the cushion forward or
backward.
5. Fore/aft adjustment
Move lever (5) up and move the seat to the desired
position and release the lever.
NOTICE
After adjusting the seat to the desired position,
move the seat forward and backward to confirm
that it is properly fixed and check that the
adjustment lever is located in its
place. Otherwise, the seat may move
unintentionally and may cause injuries.
6. Adjusting backrest angle
To adjust the backrest angle, pull up lock lever (6)
on the left hand side. After adjusting it to the
desired position, release and place the lever in its
place.
NOTICE
After the adjustment, the lock lever must be
placed in its place properly. Otherwise, the
backrest may move unintentionally and may
cause injuries.
7. Lumbar support
To adjust lumbar height and angle, rotate knob (7)
on the left rear side behind the seat.
8. Front-Aft Shock Absorber
During certain travel conditions, this function
increases driving comfort. Thorough this feature,
shocks coming from the front and rear of the
machine are absorbed by the operator's seat. It can
be set into two different positions ON/OFF.
NOTICE
For any problem related to your seat, contact your
Hidromek dealer. Do not disassemble or repair
the seat.
4.3.1.4. ADJUSTMENT OF SEAT BELT
• Before fastening the seat belt, check that there
is no abnormality on the seatbelt or seatbelt
mounting bracket. Replace them if any wear or
damage is found.
• Even if there appears to be no damage on the
seat belt, replace it as it is mentioned below:
• Seat belts must be replaced in the 5th year of
being manufactured, or every 3 years after
having been used (whichever takes place first).
• Fasten the seat belt before starting operations.
• Make sure that the seatbelt is not twisted.
CAUTION
The manufacturing date stamped on the seat
belt is the starting date of the 5 year period. This
date should not be considered as the starting
date of 3 year period for the actual use.
4.3.1.4.1 FASTENING AND REMOVING BELT
Fasten the belt in such a way that it is not too tight.
Fig 4.56
1. Sit on the seat, depress the brake pedal fully,
and adjust the seat so that your back is pressed
against the backrest.
2. In a seated position, pull the belt from the right
hand side and insert the tongue into the buckle until
"click" sound is heard. Then pull the belt to check
that it is securely locked.
3. When removing the belt, press the red button
on the buckle to unbuckle the belt.
Fasten the belt without kinking it.
87
4.3.1.5. ADJUSTING MIRRORS

1. Left mirror
2. Right mirror
Fig 4.57

Be sure to adjust the mirrors before starting work.

If they are not adjusted properly, you cannot secure
the visibility and you may be injured or may injure
someone seriously.
Adjust the mirrors to have a good view from the
operator's seat. In particular, be sure to adjust the
mirrors so that it is possible to see people on the
left and right of the back of the machine.

88
4.3.2. OPERATIONS AND CHECKS BEFORE
STARTING ENGINE
Before starting the engine, check that work
equipment lock button (3) is securely in LOCK
position.

WARNING
Check that there is no obstacle and noone around
the machine. Sound the horn to warn people
nearby before starting the engine.

DANGER

If the work equipment control lever is touched by Fig 4.60

mistake when the engine starts, the work
equipment or machine may move unintentionally
causing serious personal injuries.
3. Lower the bucket onto the ground and check
that work equipment lock button (3) is in LOCK
position. If it is not in LOCK position, move it from
FREE position to LOCK position.

Fig 4.61

Fig 4.58 4. Insert the key in the starting switch, turn the
key to ON position and check that the front monitor
and side panel work.

1.
Check that parking brake button (1) is in ON
position.
Fig 4.59

2. Check that directional (FNR) lever (2) is in N

position.
When starting the engine, if directional lever (2) is
not in N position, the engine will not start.

89
4.3.3. STARTING ENGINE
WARNING
Sit down in the operator's seat before starting the
engine.
Do not attempt to start the engine by short-
circuiting the engine starting circuit. Such an act
may cause serious injuries or fire.
Check that there are no persons or obstacles in the
surrounding area, then sound the horn and start
the engine.
Exhaust gas is toxic. When starting the engine in
confined spaces or in a building, be particularly
careful to ensure good ventilation.
WARNING
Do not keep the starting motor rotating
continuously for more than 20 seconds. If the
engine does not start, wait for at least 2 minutes
before trying to start the engine again.
Avoid sudden acceleration of the engine until it is
warmed up.
Turn the key in starting switch to START position
and then start the engine.
Fig 4.62
90
4.3.4. OPERATIONS AND CHECKS AFTER
STARTING ENGINE
WARNING
Emergency stop of the engine:
If the operation is abnormal or any other trouble
occurs, turn the key in the starting switch to OFF
position to stop the engine.
If the work equipment is operated without warming
up the machine sufficiently, the response of the
work equipment to the movement of the control
lever will be slow. The work equipment may not
move as the operator desires. Follow all warm-up
procedures. Particularly in cold areas, make sure
to warm up the engine and the hydraulic system
properly.
4.3.5. BREAK-IN MACHINE
Your Hidromek machine has been thoroughly
adjusted and tested before shipment. However,
operating the machine under severe conditions at
the beginning can adversely affect the performance
and shorten the machine life.
Be sure to break-in the machine for the initial 100
hours (as indicated by the service meter).
During break-in operations, follow the precautions
described in this manual.
• Do not overload the machine.
• Run the engine at different speed and drive the
machine at different speed.
• Avoid raising engine rpm.
• Do not exceed 3/4 of maximum speed specified
for each gear.
• When travel performance lowers, reduce the gear
instead of depressing the accelerator pedal further.
CAUTION
Idle the engine for 5 minutes after starting it up.
Avoid operation with heavy loads or at high speed.
Immediately after starting the engine, avoid
sudden starts, sudden acceleration, unnecessary
sudden stops, and sudden changes in direction.
After the 100 hour break-in period, you can operate
the machine at full load and you can run the engine
at higher speed.

4.3.6. NORMAL OPERATION
After the engine starts, do not start operating the
machine immediately. First, carry out the following
operations and checks.
NOTICE
Do not suddenly accelerate the engine before the
warming-up operation is completed.
Do not run the engine at low idle or high idle
continuously for more than 20 minutes. If it is
necessary to run the engine at idle, apply a load
from time to time or run the engine at a mid- range
speed.
1. Immediately after starting the engine, without
depressing the accelerator pedal (1), run the
engine at idle for at least 10 seconds during warm
weather and for at least 15 seconds during cold
weather.
Fig 4.63
2. Depress accelerator pedal (1) lightly and run
the engine without load at medium speed for about
5 min.
Fig 4.64
3. Carry out the following procedure to warm up
the hydraulic oil only in cold weather.
During warm-up operation, confirm that engine is
running smoothly and then set work equipment
control lever lock button (3) in free position. Warm-
up the hydraulic oil by moving the bucket control
lever (4) forward and backward.
4. Keep the bucket in tilt position at relief
pressure for a maximum period of 10 seconds.
With this operation, the hydraulic oil is warmed up
more quickly.
5. Check for abnormal exhaust gas color, noise,
or vibration. If any problem is found, contact your
Hidromek dealer.
4.3.7. STOPPING ENGINE
NOTICE
If the engine is abruptly stopped before it has
cooled down, engine life may be greatly shortened.
Consequently, do not abruptly stop the engine
apart from an emergency.
In particular, if the engine has overheated, do not
abruptly stop it but run it at medium speed to allow
it to cool gradually, then stop it.
1. Run the engine at low idle for about 5 minutes
to cool down gradually.
Fig 4.65
2. Turn the key of starting switch to OFF
position to stop the engine.
3. Remove the key from the starting switch.
4.3.8. CHECK AFTER STOPPING ENGINE
1. Walk around the machine and check the work
equipment, bodywork, and chassis and check also
for oil and water leakage.
2. Fill the fuel tank.
3. Check the engine compartment for paper and
debris. Clean out any paper and debris to avoid a
hazard of fire.
4. Remove any mud stuck under the chassis.
91
4.3.9. MOVING MACHINE (DIRECTION, SPEED),
STOPPING MACHINE
1. Always remove the frame lock bar before
traveling. If it is not removed, the steering wheel
cannot be used for steering, and this may lead to
serious damages or injuries.
2. When moving the machine, check that the
area around the machine is safe, then sound the
horn before starting to warn people in the
surrounding area.
3. Do not allow people to get near the machine.
4. Clear the machine's travel path from any
obstacles.
5. Pay a particular attention to the blind spot in
the rear of the machine when traveling in reverse. Fig 4.67
6. When starting the machine up on a slope,
depress the brake pedal, then depress the 2. Move control lever lock button (3) to FREE
accelerator pedal and gradually release the brake position.
pedal to start the machine off. This makes it
possible to prevent the machine from sliding back.
7. Do not shift transmission to Forward or
Reverse gear to move the machine while the
engine is running at high speed
4.3.10. PREPARATIONS FOR MOVING
MACHINE
Fig 4.68

Move FNR lever to N (Neutral) position.

Fig 4.69
Fig 4.66
3. By moving control lever (2), set the work
1. Check that warning pilot lamp (25) is not equipment to the travel position shown in the
lighted. diagram above.
(A): 75 - 85 cm

92
 NOTE

Unlock FNR lever before selecting the direction

of the machine.

Fig 4.70

4. Depress the brake pedal and move the parking

brake button to OFF position to release the parking
brake.
Keep the brake pedal depressed.

NOTICE

If the parking brake is still on when the parking

brake button is OFF, turn the parking brake
Fig 4.72
button ON, then turn it OFF again.
7. Release the brake pedal and then depress the
accelerator pedal to move the machine.

Fig 4.71

5. Set the desired speed range position.

Set the speed range position as follows: Turn FNR
knob (directional lever) to the desired position.
6. Set travel direction.
Set the directional lever to the desired position:
Position (F): FORWARD Position (N): NEUTRAL Fig 4.73
Position (R): REVERSE
To change directions by using TIPSHIFT switch,
set FNR lever to neutral position and apply FNR
lever lock. Then select travel direction by using CAUTION
TIPSHIFT switch.
When starting the machine up on a slope, turn
Automatic Transmission Cut-off Switch (5) to
OFF position, depress the brake pedal and turn
the gear shift lever to F position, then depress the
accelerator pedal and gradually release the
brake pedal to let the machine move. This makes
it possible to prevent the machine from sliding
back.

93
4.3.11. CHANGING GEAR SPEED 4.3.12. CHANGING DIRECTION
• When changing direction between FORWARD
and REVERSE, check that the new direction of
travel is safe. There is a blind spot behind the
machine, so be particularly careful when
changing direction to travel in reverse.

Fig 4.74

When traveling at high speed, do not shift gear

suddenly. Use the brake to reduce the travel speed
before shifting gear.
Shift gear as follows: Fig 4.76

When shifting gear, turn FNR lever to the desired
position.
When carrying out digging or loading operations,
use the 1st or 2nd gears.
When switching between FORWARD and
REVERSE, stop or slow down the machine.
Turn FNR lever to the desired position:
Position (F): Forward Position (N): Neutral Position
(R): Reverse
To change directions by using TIPSHIFT lever, set
the FNR lever to neutral position and apply FNR
lever lock. Then select the travel direction by using
TIPSHIFT lever.

NOTE

Check that the backup alarm sounds when the

directional lever is operated in REVERSE. If the
backup alarm does not sound, ask your
Hidromek distributor for repair.

Fig 4.75

CAUTION

This machine is equipped with a kickdown switch

(C) which shifts the gear down to 1st if the button
at the tip of the lift arm control lever is pushed
when the machine is traveling in the 2nd gear.
We recommend that the kickdown switch be
used when carrying out digging or loading
operations in the 1st or 2nd gear.

94
4.3.13. STOPPING MACHINE
• Avoid stopping suddenly. As much as possible,
always leave a margin when stopping the
machine.
• Avoid parking the machine on a slope. If it is
unavoidable to park the machine on a slope, stop
the machine facing directly down the slope, fit
blocks under the tires and lower the bucket to the
ground to prevent the machine from moving.
• If the work equipment control lever is touched
unintentionally, there is the danger that the work
equipment or machine may move suddenly and
cause a serious accident. Before leaving the
operator's compartment, always set work
equipment lock button (3) securely in the LOCK
position.
Fig 4.78
• When the parking brake button is turned ON, it is
dangerous to release the brake pedal
immediately. Always keep the brake pedal
depressed until the parking brake pilot lamp lights 1. Release accelerator pedal (1), then depress
up. brake pedal (2) to stop the machine.

Fig 4.79

2. Move FNR lever to N (Neutral) position.

3. Press parking brake button (1) to apply the
parking brake.

CAUTION
Fig 4.77
When the parking brake is applied, transmission
automatically gets to Neutral.

NOTICE

Never use the parking brake switch to brake the

machine when traveling unless it is an
emergency. Apply the parking brake only after
the machine has stopped.

95
4.3.14. AUTOMATIC TRANSMISSION CUT-OFF
FUNCTION

Fig 4.82

In this setting, the fine control of the brake

immediately before dumping the load can be
carried out with the brake only, so this makes it
easy to control and allows the machine to be
brought to a soft and smooth stop.
Fig 4.80

When automatic transmission cut-off button (2) is

activated (ON), automatic transmission cut-off
function works as follows.
When the brake pedal is depressed, brake is
applied according to the amount pressed and also
the transmission is separated (N) depending on the
amount pressed on the pedal.

Fig 4.81

Automatic transmission cut-off function makes the

following operations easier:
If the pedal is pressed when carrying out scooping-
up work, depending on the amount pressed,
transmission driving force is cut at a point where
there is ample braking force, so this prevents the
machine from sliding back.

96
4.3.15. STREERING MACHINE
NOTICE

When the steering wheel is turned fully, if it

reaches the end of its stroke, do not try to turn it
further. Check also that the steering works
properly. If it does not work properly, please
contact your Hidromek dealer for inspection and
repair.

4.3.16. EMERGENCY STEERING

Fig 4.83
WARNING
When traveling at high speed or operating the
machine on steep slopes, never turn the machine
suddenly, which is extremely dangerous.
If the engine stops when the machine is traveling,
the emergency steering is actuated. Note that this
system is only for steering in emergencies, so try
not to stop the engine.
It is particularly dangerous if the engine stops
when traveling on slopes, so never let the engine
stop when traveling on slopes.
If the engine stops, stop the machine immediately
at a safe place.
While the machine is travelling, if the engine stops
unexpectedly or if a failure occurs in the hydraulic
system, emergency steering system activates and
the machine can be moved to a safe place.
If the engine stops unexpectedly or if a failure
occurs in the hydraulic system while the machine is
travelling more than a speed of 3 km/h, emergency
steering system automatically activates and the
steering system is actuated by a pump driven by an
electric motor.
A warning message is displayed on the monitor
panel and side panel and a buzzer sounds.
Emergency steering system automatically
deactivates after functioning for 3 minutes.
In such a case, move the machine immediately to
a safe place and stop it.
Do not leave the operator's seat until the machine
safely comes to a complete stop.

After articulating the machine in a desired angle,

keep the steering wheel in that position. The
machine will keep the same angle. Do not turn the
steering wheel to the opposite direction while
keeping the steering angle, otherwise it will create
a shock impulse and cause a dangerous situation.
When traveling, use steering wheel (1) to turn the
machine.
When the steering wheel is turned to right, the
machine will go to right, and when it is turned to left,
the machine will turn to left. The articulation angle
will be increased or decreased depending on how
much the steering wheel is turned.
On this machine, the front frame is joined to the
rear frame in the center of the machine with a
center pin.
Rear wheels follow the same track as the front
wheels when turning.
Turn the steering wheel lightly to follow the
machine as it turns.

97
4.3.17. OPERATION OF WORK EQUIPMENT 4.3.18. LIFT ARM CONTROL LEVER

Fig 4.84
Fig 4.85
Before leaving the operator's seat, always set work
equipment lock button (3) securely in LOCK Set the work equipment lock button in the FREE
position. If the work equipment lock button is not position before operating the control lever.
locked, and work equipment control lever (A) is
Position (A): Lift arm RAISE
touched unintentionally, this may lead to serious
personal injuries. Position (B): Lift arm STOP/HOLD: The lift arm is
stopped and held in whichever position it is.
If the work equipment lock lever is not set securely
in LOCK position, the work equipment may move Position (C): Lift arm LOWER
and cause serious personal injuries. Make sure
Position (D): Lift arm FLOAT: The lift arm moves
that work equipment lock lever is set securely in
freely under external force.
LOCK position.
When the lever is pulled further than RAISE
Work equipment lock button (3) is used to lock work
position, the lever stops in that position. When the
equipment control levers (A). Press work
lift arm reaches the maximum height, the lever
equipment lock button to set it in LOCK position.
returns to HOLD position.

Fig 4.86

WARNING

Do not use FLOAT function while lowering the

bucket. Use FLOAT function during leveling
works. See section "LEVELING OPERATIONS"
for more information.

98
4.3.19. BUCKET CONTROL LEVER

Fig 4.87

Set the work equipment lock button in FREE

position before operating the control lever.
Position (A): Bucket TILT
Position (B): Bucket STOP/HOLD
The bucket is stopped and held in whichever
position it is.
Position (C): Bucket DUMP
When the bucket control lever is pulled further than
TILT position, the lever is stopped in this position
until the bucket reaches the preset position of the
positioner, and the lever is returned to HOLD
position

Fig 4.88

99
4.3.20. WORKS POSSIBLE BY USING WHEEL
LOADER
In this section, general operations which can be
done by using a wheel loader are explained. Be
sure to operate the machine correctly.
In addition to the following, it is possible to increase
the range of applications by using various
attachments.

4.3.20.1. DIGGING OPERATIONS

Always set the machine facing directly to the front
when carrying out digging or scooping operations. Fig 4.89
Never carry out these operations with the machine
articulated.

NOTICE

If the tires skid, the tire life will be reduced, so avoid

skidding during operations.
Fig 4.90

2. Shift down immediately in front of the material

4.3.20.2. LOADING PILED SOIL OR BLASTED to be loaded. When completing the shift down,
ROCK depress the accelerator pedal and thrust the bucket
into the material.
• When loading piled soil or blasted rock, drive the
machine forward towards the load as follows. To
CAUTION
prevent cuts in the tires or to prevent skidding, be
careful of the following points during an operation.
In order to reduce fuel consumption, depress the
• Always keep the jobsite clean and remove any accelerator pedal as little as possible. If it is
fallen rocks. depressed fully, the fuel consumption will increase,
• When working with stockpiles, operate the but there will be no increase in the amount loaded.
machine in the 1st or 2nd gear and when loading
blasted rock, operate the machine in the 1st gear.
1. When driving the machine forward and
lowering the bucket, stop the bucket about 30 cm
(12 in) off the ground, then lower it slowly.

CAUTION

If the bucket hits the ground, the front tires will be

off the ground causing skid. Fig 4.91

Fig 4.92

100
3. When the material is in a stockpile, keep
cutting edges of the bucket horizontal, and when
loading blasted rock, have the bucket tilted slightly
down.
Be careful not to get blasted rock under the bucket.
This will make the front tires off the ground and
skid.
Try to keep the load in the center of the bucket. If
the load is on one side of the bucket, the load will
cause the machine to become unbalanced.
4. While thrusting the bucket into the material,
raise the lift arm to prevent the bucket from going
into too far. When the lift arm is raised, there will be
increased traction on the front tires.

NOTICE
Fig 4.94
If the bucket is thrust too much and the lift arm
stops rising or the machine stops moving forward, 5. Check that there is enough material loaded
release the accelerator pedal a little. Proper into the bucket, if not, operate the bucket control
operation of the accelerator pedal for each type of lever to tilt the bucket and load the bucket fully.
the soil is necessary to save fuel and to prevent
the tires from being worn.
NOTICE

If the bucket edge is moved up and down while

pushing the load into the bucket and digging, the
front tires will be off the ground and this will cause
the tires to skid.

6. If there is too much material loaded in the

bucket, dump and tilt the bucket quickly to remove
the excessive load. This prevents spillage of the
load during hauling.

Fig 4.93

101
4.3.20.3. DIGGING AND LOADING ON LEVEL
GROUND

Fig 4.95

Fig 4.96

Fig 4.97

• When digging and loading on level ground, set the

bucket edge facing down slightly as shown below
and drive the machine forward. Always be careful
to load the material in the center of the bucket to
keep the balance.
This operation should be carried out in the 1st gear.
Do not set the bucket facing down more than 8
degrees.
1. Set the edge of the bucket facing slightly down.
If the bucket hits a rock in the ground, a large shock
is generated and this may damage the machine.
2. Drive the machine slowly forward, push the lift
arm control lever slightly to the front, and dig in to
scoop up the load a little at a time.
3. Operate the lift arm control lever slightly up
and down to reduce the resistance when driving the
machine forward.
When digging with the bucket, avoid imposing the
digging force on one side of the bucket.

102
4.3.20.4. LEVELING OPERATIONS 4.3.20.6. LOAD AND CARRY OPERATIONS

Fig 4.98

Fig 4.99

While traveling when the bucket is loaded, keep the

NOTICE
Always operate the machine in reverse when
carrying out leveling operations.
If it is necessary to carry out leveling operations
when traveling forward, do not set the bucket
dumping angle to more than 8 degrees.
bucket closer to the ground to lower the center of
gravity.
The load and carry method for wheel loaders
consists of a cycle of scooping -> hauling -> loading
(into a hopper, truck, etc.).
Always keep the travel path properly maintained
and cleaned.

1. Scoop soil into the bucket. Move the machine

backward while spreading soil from the bucket little
by little.
2. Go over the spread soil with the bucket teeth
touching the ground and level the ground by back-
dragging.
3. Scoop some more soil into the bucket, put the
lift arm control lever in FLOAT position, level the
bucket at ground level, and smooth the ground by
moving backward.

4.3.20.5. PUSHING OPERATION

Never set the bucket in DUMP position when
carrying out pushing operations.
When carrying out pushing operations, set the
bottom of the bucket parallel to the ground surface.

103
4.3.20.7. LOADING OPERATIONS
Fig 4.100
For efficient, economical and productive work,
choose such a method that the machine will have
turns and traveling as minimum as possible.
• Always keep the job site level. When the lift arm is
raised with a loaded bucket, it is dangerous to turn
the steering wheel abruptly or apply the brakes
abruptly. Avoid such actions while working.
• It is dangerous to thrust the bucket into the
material to be loaded (borrow pit, crushed rock,
etc.) at high speed. Do not carry out such digging
operations.
WARNING
When the tires skid, the tire life will be reduced, so
do not have the tires skidded during operations.
Avoid excessive bucket vibration.
4.3.20.8. CROSS DRIVE LOADING
Operate the wheel loader towards the stockpile in
the most appropriate direction. After digging in and
scooping up the load, drive the machine straight
back in reverse, then bring the dump truck in
between the stock pile and the wheel loader.
This method provides the least time for loading,
and is extremely effective in reducing the operation
cycle time.
104
4.3.20.9. V-TYPE LOADING
Position the dump truck so that the angle between
direction to the stockpile and the direction to the
dump truck is approx. 60 degrees.
After loading the bucket, drive the wheel loader in
reverse, then travel forward to load the dump truck.
The smaller the turning angle of the wheel loader
is, the more efficient the operation becomes.
When loading a full bucket and raising it to the
maximum height, first shake the bucket to stabilize
the load. This will prevent the load from falling off
on the operator’s cab.
Fig 4.101
Fig 4.102
4.3.20.10. PRECAUTIONS WHEN PILING UP
MATERIALS
When forming materials into a pile, be careful not
to let the rear counterweight come into contact with
the ground.
Do not set the bucket in DUMP position when
piling-up materials.
4.3.20.11. PRECAUTIONS WHEN HANDLING
BLASTED ROCK
If the target load is blasted rock, pay special
attention to the following items when carrying out
the operation to extend the service life of the
machine.
4.3.20.12. OPERATING PROCEDURE TO
PREVENT DAMAGE TO MACHINE
4.3.20.12.1 HANDLING BUCKET
When lowering the bucket to go into the material
pile, do not drop the bucket onto the ground. If the
bucket is dropped suddenly, the bucket, work
equipment, areas around the pins, and the
machine frame will be subjected to excessive
shock, and this will lead to damage or deformation
of various parts of the machine.
4.3.20.12.3 ARTICULATING MACHINE DURING
DIGGING OPERATIONS
Do not carry out operations with the machine
articulated. If the machine is articulated, the
direction of force will be different for the front and
rear wheels. As a result, the power when traveling
will not be transmitted fully to the front wheels, so
this will reduce the digging force and cause
excessive load on the center hinge pin. In addition,
even for the front wheels, the power will not be
transmitted uniformly to the left and right wheels.
The load will be on one wheel, so the tires will be
deformed, and this will reduce the service life of the
tire on that side.

Fig 4.103

In addition, the front wheels will be off the ground,

and this will cause the tires to skid.
When lowering the bucket, reduce the lowering
speed of the bucket when it is close to the ground
and bring it slowly into contact with the ground.
4.3.20.12.2 SHIFTING GEAR WHEN THRUSTING
BUCKET IN
Fig 4.105

When digging work is carried out with the machine

articulated, overall stability of the machine will be
poor and there is the danger that the machine may
tip over.

Fig 4.104

When thrusting bucket into the soil to carry out

excavation, do not shift down the gear while the
accelerator pedal is depressed. If the gear is Fig 4.106
shifted down when the engine speed is high, there
will be an excessive load on the engine, torque When carrying out operations, do not articulate the
converter, transmission, axles, final drive, and the machine. Drive straight forward and thrust the
whole power train. bucket in. If this is done, the load on the bucket will
be uniform, so this makes it possible to avoid load
When shifting down to the 1st gear and thrusting the on one side and makes it easier to load the bucket.
bucket into the soil, release the accelerator pedal
to reduce the engine speed before shifting the gear
down.
Then gradually depress the accelerator pedal. If
the accelerator pedal is depressed abruptly after
shifting down, there will be too much load on the
engine and power train.

105
4.3.20.12.4 BUCKET DUMP ANGLE WHEN
DIGGING OR LOWERING ROADBED
Do not set the cutting edge of the bucket at a large
angle to the ground surface when digging or
lowering the roadbed. Keep angle (a) between the
bucket and the ground surface at a maximum of 8
°. If angle (a) between the cutting edge of the
bucket and the ground surface is more than 8°
when digging or lowering the roadbed, the work
equipment may be damaged.
4.3.20.12.6 LOADING BUCKET
Align the load in the center of the bucket, otherwise
there will be excessive load and it will damage the
bearings of work equipment and frame, also it will
reduce the service life of the machine. Do not load
the bucket or scoop up the load using a part of the
bucket.

Fig 4.107 Fig 4.110

4.3.20.12.5 BUCKET DUMP ANGLE WHEN When carrying out digging or scooping-up
LEVELLING operations, align the load in the center of the
Drive the machine in reverse when carrying out bucket.
leveling operations.

Fig 4.108
Fig 4.111
When leveling operations are carried out with the
machine traveling forward, angle (a) between the
cutting edge of the bucket and the ground surface
should not be more than 8°. If leveling operations
are carried out when angle (a) between the cutting
edge of the bucket and the ground surface is more
than 8°, the bucket cylinder will be forced by the
pushing force of the machine. This will cause the
cylinder to retract and the bucket will have a greater
angle, so there is the risk that the work equipment
may break.

Fig 4.109

106
4.3.20.13. BUCKET DUMP OPERATION WHEN 4.3.20.13.1 FRONT WHEELS GETTING ON
DIGGING BLASTED ROCKS
Do not operate the bucket in DUMP direction when While working, try not to have the front wheels
digging. If the bucket control lever is in DUMP gotten on blasted rock. If the front wheels move on
position during digging, the machine will not be blasted rock, sharp parts of the blasted rock will cut
able to travel forward, the tires will skid, and there the tires.
will be an excessive load on the work equipment.

Fig 4.113

In particular, avoid pushing the bucket in too far,

Fig 4.112
Carry out the scooping-up operations as explained
below.
1. When thrusting the bucket in, raise the lift arm
slightly at the same time. There will be ample
driving force on the front wheels.
2. To fill the bucket, operate the bucket tilt and lift
it 2- 3 times repeatedly when thrusting the bucket
in.
Operate the control lever slowly towards the end of
the bucket tilting.
3. When the bucket reaches the end of the tilt
stroke, depress the brake pedal to stop the
machine
When doing this, do not push the bottom of the
bucket against the material. If the bucket is pushed
against the material, the bucket, cylinders, and
work equipment will be damaged.
4. When the scooping-up operation is
completed, operate the bucket tilt and dump, and
apply the brakes when traveling in reverse to
stabilize the load inside the bucket and prevent the
load from falling off.
and when operating near natural rock after blasting
(roots), and do not let the front wheels get on the
natural rock (roots). For scooping-up operations
near natural rock (roots), do not use a wheel loader.
Use a bulldozer or a hydraulic excavator.
4.3.20.13.2 WORKING WITH LOOSE BOULDERS
Do not use this machine to handle hanging rocks.
Rocks will fall during the operation and hit the
machine or operator's cab causing serious
personal injuries or death. Use a bulldozer or a
hydraulic excavator.
Fig 4.114
Do not use this machine to handle hanging rocks.
There is the danger that the rock will fall during the
operation and hit the machine or operator's cab. If
the fallen boulders hit the work equipment
cylinders, there is the danger that the cylinder will
bend and be unable to move. If the boulders fall on
the operator's cab, there is the danger of serious
personal injuries or death.

CAUTION

• To reduce heat on torque converter, the time

from the start of thrusting in to the completion of
scooping up should not exceed 10 seconds.
• Fuel consumption increases while digging. The
fuel cost can be reduced by shortening the digging
time.

107
4.3.20.13.3 PIT EXCAVATION
Do not try to shave off natural rock (roots)
remaining from blasting. Excessive force will be
applied to the machine, and there is the danger that
this may damage the work equipment or frame. For
pit excavation operations, do not use a wheel
loader. Use a bulldozer or a hydraulic excavator.
Fig 4.115
4.3.20.14. CUTTING FACE OPERATIONS
Fig 4.116
Do not use this machine for cutting faces. If the
cutting face is excavated, excessive force will be
applied to the machine, and there is the danger that
this may damage the bucket, work equipment, or
frame. In particular, do not excavate with the
bucket raised to a height above the travel posture.
For excavation of cutting faces, use a hydraulic
excavator.
108
4.3.20.15. SWITCHING BETWEEN FORWARD
AND REVERSE
Do not switch the direction of travel of the machine
between forward and reverse when traveling at
high speed or when the accelerator pedal is
depressed. When machine is traveling at high
speed or when the accelerator pedal is depressed,
the engine speed is high and if the direction of
travel is switched between forward and reverse,
excessive load will be applied to engine, torque
converter, transmission and other parts of the
power train and this will reduce the service life of
the machine.
Fig 4.117
CAUTION
When switching between forward and reverse,
travel at low speed or stop the machine. Use either
FNR lever or TIPSHIFT to change travel direction.
4.3.20.16. TURNING TIRES WHEN MACHINE IS
STATIONARY
Do not operate the steering wheel when the
machine is stationary. If the steering wheel is
operated when the machine is stationary, it will
cause wear or cuts in the tires. In addition, it will
reduce the durability of the frame and
undercarriage.
Fig 4.118
4.3.20.17. PROCEDURES FOR OPERATIONS Set the shift in F2 position, then gradually depress
FOR V-SHAPE LOADING OF DUMP TRUCKS the accelerator pedal and raise the travel speed.
PREPARATIONS FOR LOADING, GATHERING 2. When lowering the bucket to the ground,
ROCKS reduce the lowering speed of the bucket when it is
close to the ground and bring it slowly into contact
Always keep the job area level and remove any
with the ground.
rocks or boulders.
4. Angle (a) between the bucket and the ground
surface should be maximum 8°, and operate the
tilt and dump so that only the cutting edge comes
in contact with the ground.
5. Drive forward at the right angle to the material
and change the direction that the machine is facing.
6. Operate the accelerator in a way that it is suitable
for the conditions of the road surface so the tires do
not skid.
7. Scoop up the gathered rock. Load rocks or
Fig 4.119
boulders in the center of the bucket.

NOTICE

When gathering rocks, if the operation is carried

out over an area longer than the length of the
machine, there is the danger that the machine will
get over boulders and the tires will be cut. When
gathering rocks, always carry out the operation in
an area shorter than the length of the machine.
When carrying out operations with the bucket Fig 4.121
lowered, do not articulate the machine. This will
cause the tires to skid and the tires will be
damaged. WARNING

1. Put the bucket horizontally in contact with the
ground, drive forward, and gather the rocks that
have been scattered after loading or blasting.
2. After collecting the rocks in an area shorter
than the length of the machine, change the
direction of the machine to gather other rocks in
another area and enlarge the working area.
4.3.20.17.1 METHOD OF APPROACHING
MATERIAL
Fig 4.120
1. Set the machine in travel position.
When approaching to material and lowering
the bucket, do not lower the bucket too fast and
bang it to the ground. If the bucket is banged
to the ground, bucket, attachment, bushings,
pins and even chassis is exposed to extreme
shock and vibrations which will result in crack,
damage and deformations in different parts of
the machine.
Besides, levitation of front tires cause spinning
of the tires.
When lowering the bucket to the ground, slow
down the lowering speed just before getting
near to the ground. Gently place the bucket on
the ground.
When levelling road surface or digging, do not
lean the bucket to a position in which bucket
blade has a wide angle with the road surface.
The angle between bucket blade and road
surface should not exceed 8°. If the angle
between the bucket blade and the road surface
exceeds 8˚, attachment could be damaged.
Scoop up the gathered rock. Load rocks or
boulders in the center of the bucket. If the load
is on one side of the bucket, the load will cause
the machine to become unbalanced. This will
shorten the service life of the chassis and the
attachment.

109
110
4.3.20.18. DIGGING OPERATION

NOTICE CAUTION

• Do not shift down with the accelerator pedal When digging up large rocks, in some cases it
depressed (with the engine speed raised). If the may be better not to raise the lift arm too high. If
transmission is shifted down when the engine the lift arm is raised too high, the rear wheels may
speed is high, there will be an excessive load on become off the ground.
the engine, torque converter, transmission, axles,
final drive, and the whole power train. 4. After loading the rock completely into the bucket,
• When thrusting the bucket in, shift down the operate the bucket tilt and lift it 2 - 3 times
gear to the 1st. If the bucket thrusts in at high repeatedly to fill the bucket.
speed, there will be an impact load on the 5. Stop depressing the accelerator pedal, operate
machine and this will reduce the service life of the the control levers slowly, and tilt the bucket back
machine. fully.
• Before shifting down, release the accelerator 6. To prevent the load from falling off the bucket,
pedal to reduce the engine speed. Then gradually after completing the scooping-up operation,
depress the accelerator pedal. If the accelerator operate the bucket in the dump and tilt directions to
is operated abruptly after shifting down, there will stabilize the load
be excessive load on the engine and power train.
• Do not carry out operations with the machine
articulated. If the machine is articulated, the
direction of force will be different on the front
wheels and rear wheels. As a result, the power
when traveling will not be transmitted fully to the
front wheels, so this will reduce the digging force
and bring an excessive load to bear on the center
hinge pin. In addition, even with the front wheels,
the power will not be transmitted uniformly to the
left and right wheels. The load will be on one
wheel, so this will reduce the service life of the tire
on that side.
• Do not push the machine in too far. If it is
pushed in too far, there will be too much load on
the machine and this will reduce the service life of
the work equipment and frame.
Fig 4.122
• Operate the control lever slowly towards the
end of the bucket tilt operation. If the control lever
is operated abruptly, there will be too much load
on the tilt cylinder, and the cylinder may be CAUTION
damaged.
• When working close to pit excavation, do not • If the brakes are operated lightly before
let the front wheels rise up on the cutting face. traveling in reverse, the load in the bucket is
This will cause cuts on the tires. stabilized.
• To prevent overheating of the torque converter,
1. When coming in front of the rock, stop the time from the start of pushing in to the
depressing the accelerator pedal and shift down completion of scooping up should be 10 seconds.
from the 2nd gear to the 1st gear.
2. After shifting down, depress the accelerator
pedal gradually and push the rock.
3. Raise the lift arm slightly and increase the driving
force of the front wheels. When doing this, do not
push in too far.

111
4.3.20.19. TRAVELING IN REVERSE AFTER
EXCAVATING

NOTICE

• Do not turn the steering wheel immediately after

starting to travel in reverse. The bucket is still
thrust into the rocks, so if the steering wheel is
operated, there will be excessive force on the
bucket or frame, which can cause damage on the
frame.
• After shifting the transmission, operate the
accelerator pedal slowly. If the accelerator pedal
is operated abruptly, the tires will skid causing
wear or cuts on the tires.

Fig 4.123

1. After completing the excavation, shift direction to

reverse and travel in reverse without turning the
steering wheel.
2. As a guideline, reverse travel distance (a) should
be as much as 1.5 times of the length of the
machine. The rolling of the tires at such distance
can minimize the wear of the tires.
In addition, keep angle (b) at 60° at the intersection
between the straight line from the material and the
straight line from the dump truck.

CAUTION

Decide on the approaching procedure which is

suitable for the stopping point of the dump truck
and the condition of the material. When doing
this, decide on the stopping point of the dump
truck so that the operating angle for the steering
is 20° the most.

3. When driving in reverse, do not raise the bucket

more than necessary.
Consider the position of the dump truck, the
condition of the road surface, the travel speed, and
the speed of the work equipment when deciding on
the height of the bucket. However, do not raise the
bucket so that the top of the load is higher than the
horizontal line of the sight of the operator.

112

4.3.20.20. APPROACHING DUMP TRUCK
Do not operate the steering abruptly when the
bucket is raised. If the steering is operated abruptly
when the bucket is raised, the machine may tip
over and cause serious personal injuries.
WARNING
• Do not shift down when the accelerator pedal is
depressed (engine speed is high). If the transmission
is shifted down when the engine speed is high, there
will be an excessive load on the engine, torque
converter, transmission, axles, final drive, and the
whole power train. In addition, the tires will skid and
this will cause wear on the tires.
• Do not operate the steering immediately after
switching between forward and reverse (when the
machine is stationary). If the steering is operated
when the machine is stationary, it will cause wear or
cuts on the tires.
• If there is transmission cut-off system on the
machine, turn the transmission cut-off switch to OFF
position and depress the brake, but do not raise the
bucket. In this condition, the brake functions, so heat
is generated in the brake chamber and this will cause
heat fatigue on the parts inside the axle.
1. Release the accelerator pedal to reduce the
engine speed, then depress the parking brake
pedal to stop the machine.
2. Shift gear to FORWARD.
3. Operate the steering to have a 90 degrees
angle with the truck and then drive forward.
Fig 4.124
CAUTION
Operate the steering in the following order:
Release the accelerator pedal.
Shift the gear to FORWARD.
Depress the accelerator pedal to drive forward.
Approach the dump truck.
If this order is followed, engine fuel consumption
will be reduced.
4. Raise the bucket to adjust the bucket height
so that when the bucket is tilted down, the cutting
edge of the bucket does not hit the bottom face of
the dump body or the material.
4.3.20.21. LOADING DUMP TRUCK
NOTICE
• Do not dump the load into the truck from a high
position. If the dump truck is loaded like this, there will
be impact load and this may damage the body.
• Do not operate dump or stop operations when the
engine is running at high speed. There will be impact
pressure being generated in the hydraulic equipment
causing damage to the hydraulic equipment.
• Do not shake the bucket violently to dump the load
left inside the bucket. The machine will sway greatly
and will be damaged. In addition, there will be impact
pressure being generated in the hydraulic equipment
causing damage to the hydraulic equipment.
• When loading the dump truck, do not push the
load forcibly with the bucket to spread it. There will be
impact shock on the machine and the dump truck
causing damage. When pushing the load with the
bucket to prevent rocks from falling, carry out the
operation softly.
• When loading large rocks, first load sand or soil to
act as a cushion. Then load large rocks on top of this.
If large rocks are loaded directly, they will cause
deformation or damage on the dump body.
Fig 4.125
1. When loading the dump truck, load at a point
that it does not hit the dump truck or the pile in the
truck.
Fig 4.126
2. After completing the loading, if there is the
danger that the rocks can fall off, push the load
softly with the bucket
113
4.3.20.22. GETTING AWAY FROM DUMP TRUCK
NOTICE
• Do not shift down when the accelerator pedal is
depressed (when the engine speed is high). If the
transmission is shifted down when the engine
speed is high, there will be an excessive load on
the engine, torque converter, transmission, axles,
final drive, and the whole power train. In addition,
the tires will skid and this will cause wear on the
tires.
• Do not operate the steering abruptly after
switching between forward and reverse (when the
machine is stationary). If the steering is operated
when the machine is stationary, it will cause wear
or cuts on the tires.
Fig 4.127
1. Switch to R2 and drive in reverse.
2. While driving in reverse, lower the lift arm and
operate the steering to face the position for
scooping up.
3. Depress the brake pedal and stop the
machine.
4. Release the accelerator pedal to reduce the
engine speed, then switch from R2 to F2.
5. Then lower the bucket to the ground and drive
forward to clear the surface (remove all boulders).
Do not operate the steering when carrying out
leveling operation. Travel forward with the machine
facing directly to the front.
114
4.3.21. PRECAUTIONS FOR OPERATION
4.3.21.1. PERMISSIBLE WATER DEPTH FOR
OPERATION
When working in water or on swampy ground, do
not let the water come above the bottom of the axle
housing.
Fig 4.128
After finishing the operation, wash and check the
lubricating points.
4.3.21.2. WHEN WHEEL BRAKE DOES NOT
WORK
If the machine is not stopped by depressing the
brake pedal, use the parking brake to stop the
machine.
NOTICE
If parking brake has been used as an emergency
brake, contact your Hidromek dealer to have the
parking brake checked.
4.3.22. PRECAUTIONS WHEN DRIVING UP OR
DOWN SLOPES
4.3.22.1. LOWER THE CENTER OF GRAVITY
WHEN TURNING
When turning on slopes, lower the work equipment
to lower the center of gravity before turning. It is
dangerous to turn the machine abruptly on slopes.
4.3.22.2. BRAKING ON DOWNHILL SLOPE
If the foot brake is used excessively when traveling
downhill, there is the danger that the brake may
overheat and be damaged. To prevent this, use the
shift-down switch to reduce gear.
Normally, the most suitable speed range when
traveling down a slope is the speed range needed
when traveling up that slope.
If the correct speed range is not used, the torque
converter oil may overheat. If this happens, shift
down one speed to reduce the oil temperature.
4.3.22.3. IF ENGINE STOPS UNEXPECTEDLY
If the engine stops unexpectedly on a slope, apply
the parking brake immediately and lower the work
equipment to the ground and stop the machine.
Then put the directional lever in neutral position,
and start the engine again.

4.3.23. PRECAUTIONS WHEN DRIVING
MACHINE
When the machine travels at high speed for a long
distance, the tires become extremely hot. This
causes early wear of the tires and should be
avoided as much as possible. If the machine must
be driven for a long distance, take the following
precautions:
• Follow the local regulations related to this
machine, and drive carefully.
• Before driving the machine, carry out the checks
before starting.
• The most suitable tire pressure, travel speed, or
tire type may differ according to the condition of
the travel surface.
Contact your Hidromek dealer or tire dealer for
more information.
• When the machine is stopped, check tires and
other related parts, check the oil level and coolant
level also.
• Check the tire pressure before starting, when the
tires are cool.
• Check and confirm that there is no abnormality on
the tires and other related parts, and check the oil
level and coolant level also.
• Always travel with an empty bucket.
• Never put "calcium chloride" or "dry ballast" in the
tires when traveling.
4.3.23.1. ATTACHMENT POSITION
ADJUSTMENT
Fig 4.129
• Stop the machine on a level ground and block the
front and back of the tires.
• Apply parking brake (1) (ON).
Fig 4.130
• Apply frame lock bar to fix front and rear frames
• Attach CAUTION tag on work equipment control
levers.
• When the lift arm is raised up, do not go under the
work equipment.
4.3.24. REMOVAL AND INSTALLATION OF
BUCKET
• When pins are hit in with a hammer, pieces of
metal may scatter causing serious injuries.
When carrying out this operation, always wear
goggles, a hard hat, gloves, and other protective
equipment.
• When the bucket is removed, place it in a stable
condition.
• If pins are hit with a strong force, there is a hazard
that the pin may come out and injure people in the
surrounding area. Make sure that there is no one in
the surrounding area and take the necessary
precautions before starting the operation.
• When removing the pins, do not stand behind the
bucket. In addition, be extremelycareful not to put
your foot under the bucket while working on
the machine.
• When removing or inserting the pins, be
extremely careful not to get your fingers caught.
• Never insert your fingers into the pin holes when
aligning the holes.
• Remove or install the bucket in the following
manner, when it is necessary for the convenience
of transportation.
WARNING
Removal and installation method explained here is
for the machines with standard configuration.
Removal and installation procedure may differ
depending on the attachments and optional
equipment installed on the machine.
For bucket removal and installation procedure of the
machines out of standard configuration, please
contact your Hidromek dealer.
For removal-installation of bucket, follow the
instructions given in this section:
115

4.3.24.1. REMOVING BUCKET
1. Park the machine on level and hard ground.
Lower the bucket with its bottom on the ground.
3. Remove mounting bolts (1) and washers (2).
4. Sling bucket linkage part (7), then pull out
connection pin (3). Use a wire rope to fix bucket
linkage part (7) to the lift arm.
5. Remove mounting bolts (4) and washers (5).
6. Pull out bucket hinge pins (6) on both sides of
the bucket.
7. Separate the bucket and the lift arm.

4.3.24.2. INSTALLING BUCKET

1. Before installing the bucket, remove all grease,
mud, or sand and clean the pin, pin hole, and area
Fig 4.131 around the boss.(If there is any rust or dirt inside
the surface of the pin hole, use a sandpaper and
2. Secure the bucket by slinging the linkage parts remove it carefully.) After cleaning, coat the pin and
with a wire rope. inside the surface of the pin hole with grease.
2. Park the machine on level and hard ground, and
position the bucket to be installed in front of the
machine while rear side of the bucket is facing the
machine.
3. Align the joints on bucket (8) with the joints on lift
arm (8) and insert pins (6).
Secure pins (6) by installing washers (5) and bolts
(4).
4. Align bucket linkage parts (7) with joints
(7) behind the bucket and insert pins (6). Secure
pins by installing washers (2) and bolts (1).

Fig 4.132

Fig 4.133

116
4.3.25. PARKING MACHINE
• Avoid sudden stops. Always leave enough
distance for the machine to stop.
• Avoid parking the machine on a slope. If it is
necessary to park the machine on a slope, stop
the machine facing directly down the slope, fit
blocks under the tires and lower the bucket to the
ground to prevent the machine from moving.
• If the work equipment control lever is touched
unintentionally, there is the danger that the work
equipment or machine may move and cause a
serious accident. Before leaving the operator's Fig 4.135
compartment, always set the work equipment lock
button securely in LOCK position.. 2. Place directional lever into N (neutral) position
• When the parking brake switch is turned ON, it is
dangerous to release the brake pedal abruptly.
Always keep the brake pedal depressed until the
parking brake pilot lamp lights up.
• To ensure traffic-flow security while the machine is
parked, provide sufficient lighting and place
warning tags and sign plates to warn the vehicles
and people around the area. Fig 4.136

3. Turn parking brake button (1) ON to apply the

parking brake.

Fig 4.134

NOTICE

Never use the parking brake switch to brake the

machine when traveling except in an emergency.
Apply the parking brake only after the machine Fig 4.137
has stopped.

1. Release accelerator pedal (1), then depress

brake pedal (2) to stop the machine. NOTICE

When the parking brake is applied, transmission

is automatically gets in neutral.

4. Operate lift arm control lever (2) to lower the

bucket to the ground.
5. Apply lock button (3) of lift arm control lever (2)
and bucket control lever (4).

117
4.3.26. CHECKS AFTER COMPLETION OF
OPERATION
Check the engine water temperature, engine oil
pressure, torque converter oil temperature, and
fuel level on the machine monitor.
If the engine is overheated, do not stop it suddenly.
Run the engine at a midrange speed to allow the
engine to cool down before stopping it.
Check that there are no loose bodywork or chassis
mounting bolts.
Check that there are no cracks and/or damage in
the work equipment or bucket.

4.3.27. LOCKING
Make sure to lock the cab door, fuel tank filler cap
and engine hood side panels.

118

4.3.28. TIRE MAINTENANCE
4.3.28.1. PRECAUTIONS WHEN HANDLING
TIRES
If a tire has reached any of the following service
limits, there is the danger that the tire may burst
causing an accident, so to ensure safety, replace it
with a new tire.
Fig 4.138
Service limits for wear
• When the remaining depth of the grooves on the
construction equipment tires (at a point approx. 1/4
of the tread width) is 15% of the groove depth on a
new tire.
• When the tire shows marked uneven wear,
stepped wear or other abnormal wear, or when the
cord layer is exposed.
Service limits for damage
• When there is external damage extending to the
cord or when the cord is broken.
• When the cord is cut or there is dragging.
• When the tire is peeling (there is separation).
• When the bead is damaged.
• For tubeless tires, when there is air leakage or
improper repair.
Please contact your Hidromek dealer when
replacing the tires. It is dangerous to jack up the
machine without taking the necessary precautions.
4.3.28.2. TIRE INFLATION PRESSURE
Measure the tire pressure before starting
operations, and when the tires are cool.
If the tire inflation pressure is too low, there will be
overload on the tires. If it is too high, it will cause
cuts and shock burst on the tires. To prevent these
problems, adjust tire inflation pressure according to
the given table.
Fig 4.139
Deflection ratio = H - h / H x 100
As a guideline that can be checked visibly, the
deflection ratio of the front tire (deflection/free
height) is as follows:
When carrying normal load (lift arm horizontal):
Approx. 10% to 15%
When digging (rear wheels off ground): Approx.
20% to 25%
When checking the tire inflation pressure, check
also for small scratches or peeling on the tire, for
nails or pieces of metal which may cause
punctures, and for any abnormal wear.
Clearing fallen stones and rocks in the operating
area and maintaining the surface will extend the tire
life and reduce costs.
• Hard ground digging on normal road surfaces:
The highest limit shown on the air pressure chart
• Stockpile operations on soft ground: Average
pressure on the air pressure chart
• Operations on sand (which needs less digging
force): The lowest limit shown on the air pressure
chart
If the deflection of the tire is excessive, raise the
inflation pressure within the limits given on the table
(see deflection ratio).
4.3.28.3. PRECAUTIONS FOR USING LOAD
AND CARRY METHOD
When traveling continuously during load and carry
operations, choose the correct tires suitable for the
operating conditions, or choose the operating
conditions suitable for the tires. If this is not done,
the tires will be damaged, so contact your
Hidromek dealer or tire dealer when selecting tires.
119
4.4. TRANSPORTATION While placing the machine on a trailer:
When transporting the machine on highways, 1. Lower the work equipment slowly.
observe all related laws and regulations.
2. Apply work equipment lock button (3).
4.4.1. TRANSPORTATION PROCEDURE
3. Apply parking brake (1).
As a general principle, transport the machine
always on a trailer. 4. Turn the starting switch to OFF position and
stop the engine. Remove the key.
While selecting a trailer, refer to weights and
dimensions given in section "SPECIFICATIONS".
Note that machine specifications (weight and
dimensions) vary depending on the kind of the tire
and bucket.
4.4.2. LOADING AND UNLOADING WORK
When transporting the machine, observe all related
laws and regulations. For transportation
convenience, it may be necessary to disassemble
the machine. Please consult your Hidromek dealer
before transportation.
4.4.2.1. SECURING MACHINE Fig 4.141

5. Set the frame lock bar in LOCK position (L) to

lock the front and rear frames.

Fig 4.142

6. Put blocks in front and behind the wheels, and

secure the machine with chains or wire rope to
prevent the machine from moving during
transportation. Machine fastening points are shown
Fig 4.140 in the figure below:

120
NOTICE

Stow the antenna away or remove it.

(Seal the antenna hole with a suitable plug to avoid
dust or dirt from entering).
İn addition, close the mirrors towards the machine
or remove them if necessary.

121
4.4.3. METHOD OF LIFTING MACHINE
When the machine has to be lifted at a port or
elsewhere, apply following procedure.
• The person using the crane to carry out lifting
operations must be a qualified and experienced
crane operator.
• Never carry out lifting operations if any person is
on the machine being lifted.
• Always use a wire rope that has ample strength
for the weight of the machine being lifted.
• Keep the machine horizontal when lifting it.
• Before lifting the machine always apply the
parking brake, stop the engine and set work
equipment
lock button to LOCK position. To avoid articulation
during transportation, secure front and rear chassis
by engaging safety bar and take other necessary
measures.
• Never enter the area under or around a raised
machine.
Do not attempt to lift the machine in a position other
than shown below procedure and/or do not use
lifting equipment other than the ones explained
below.
4.4.3.1. LIFTING POINTS
Fig 4.143
122
There is a risk of machine’s loosing balance.
NOTICE
This method of lifting is for the machines having
standard configuration.
The method of lifting differs according to the
attachments and options installed. For details of
procedures for machines that do not have
standard configuration, please consult your
Hidromek dealer.
For weight of standard configuration, see
"TECHNICAL SPECIFICATIONS" section.
WARNING
• To avoid wire ropes to be cut by sharp edges of
the machine or to avoid damage of the bodywork
by the wire ropes, insert protective materials
between the wire rope and the machine body.
• If you use a tie bar for lifting, be careful that the
bar should not contact the machine.
Before starting a lifting operation, please consult
your Hidromek dealer.
WEIGHT TABLE

Operating Front axle Rear axle

weight load load

HMK640WL 25.600 kg 13.000 kg 12.600 kg

4.4.3.2. LIFTING PROCEDURE
The machine can be lifted only if it has hook mark
labels. When lifting the machine, stop the machine
on level ground and do as follows.
Fig 4.146
3. Stop the engine, check that the area around
the operator's compartment is safe, then set the
frame lock bar in LOCK position (L) to prevent the
front frame and rear frame from articulating.

Fig 4.144
1. Start the engine, make sure that the machine
is horizontal then set the work equipment in travel
position. Fig 4.147
For details, please refer to “PREPARATIONS FOR
MOVING MACHINE" section. 4. Use wire ropes and slings that are suitable for
the weight of the machine, and fix the wire rope in
(A): 70 - 90 cm the lifting points as shown in the figure.
5. After setting the wire ropes, lift up the
machine and stop at 10 to 20 cm (3.9 to 7.9 in)
above the ground, and check that the wire ropes
are not slack and the machine is level, then
continue lifting up slowly.

Fig 4.145

2. Apply work equipment lock button (3).

123
4.5. COLD WEATHER OPERATION
CAUTION
4.5.1. PRECAUTIONS FOR LOW
TEMPERATURE
If the temperature becomes low, it becomes difficult Measure the specific gravity and calculate the
to start the engine, and the coolant may freeze, so charging rate from the following conversion table.
do as follows.
Electrolyte
4.5.1.1. FUEL AND LUBRICANTS temperatur
Change fuel and oil with low viscosity for all 20°C 0°C -10°C -20°C
components.
Charging
For details of the viscosity, see "RECOMMENDED Rate (%)
FUEL, COOLANT, AND LUBRICANT" section.
4.5.1.2. COOLANT 100 1.28 1.29 1.30 1.31
• Coolant is toxic. Be careful not to get it into your 90 1.26 1.27 1.28 1.29
eyes or on your skin. If it gets into your eyes or on
your skin, wash it off with large amounts of fresh
80 1.24 1.25 1.26 1.27
water and see a physician at once.
• When changing the coolant or when handling 75 1.23 1.24 1.25 1.26
coolant containing antifreeze that has been drained
when repairing the radiator, please contact your As the battery capacity drastically drops in low
HİDROMEK dealer or request help from a temperatures, cover or remove the battery from
company which has expertise in such operations. the machine, store the battery in a warm place,
Coolant is toxic. Do not discharge it into drainage and install it again the next morning.
or onto ground.
If the electrolyte level is low, add distilled water in
the morning before beginning work. Do not add
NOTICE
water after the day's work to prevent electrolyte in
the battery from freezing during the night.
Use the coolant as specified in section
"RECOMMENDED FUEL, COOLANT, AND
LUBRICANT".
4.5.2. PRECAUTIONS AFTER COMPLETION OF
WORK
4.5.1.3. BATTERIES To prevent mud and water from freezing on the
undercarriage and to make it possible for the
• Batteries generate flammable gas. Do not machine to move the following morning without any
approach a battery with fire or sparks. problems, take the following precautions.
• Battery electrolyte is dangerous. If it gets in your • Remove all the mud and water on the machine
eyes or on your skin, wash it off with a large amount body. In particular, wipe off the hydraulic cylinder
of water and consult a physician. rods to prevent damage on the seal caused by
• Battery electrolyte dissolves paint. If it gets on the mud, dirt, or drops of water on the rod from getting
bodywork, wash it off immediately with water. inside the seal.
• If the battery electrolyte is frozen, do not charge • Park the machine on hard, dry ground.
the battery or start the engine with a different power If this is impossible, park the machine on wooden
source. There is the danger that the battery may boards.
explode.
The boards prevent the tracks from freezing, and
• Battery electrolyte is toxic. Do not discharge it allow the machine to be moved the next morning.
into drainage or onto ground.
• Open the drain valve and drain any water
When the ambient temperature drops, the collected in the fuel system to prevent it from
capacity of the battery will also drop. If the battery freezing.
charge ratio is low, the battery electrolyte may
freeze. Maintain the battery charge close to 100% • Fill the fuel tank completely. This minimizes
as much as possible. Insulate it against cold moisture condensation in the tank when the
temperature to ensure the machine can be started temperature drops.
easily the next morning.

124
4.5.3. AFTER COLD WEATHER 4.6.3. AFTER STORAGE
When the season changes and the weather
becomes warmer, do as follows.
NOTICE
• Replace all fuel and oil with fuel and oil of the
specified viscosity. For details, please refer to If machine has been stored without carrying out
"RECOMMENDED FUEL, COOLANT, AND the monthly rust prevention operation, consult your
LUBRICANT" section. Hidromek dealer before using it.
When using the machine after long-term storage,
4.6. LONG-TERM STORAGE do the following before using it.
4.6.1. BEFORE STORAGE • Wipe off the grease on hydraulic cylinder rods.
When storing the machine for a long time (more • Grease all the lubrication points.
than one month), follow the procedure below. • When the machine is stored for a long period,
• Clean and wash all parts and components, then moisture in the air will mix with the oil. Check the
store the machine indoors. If the machine has to be oil before and after starting the engine. If there is
stored outdoors, park the machine on level ground water in the oil, change the oil completely.
and cover it with canvas or any water-proof
material.
• Completely fill the fuel tank. This prevents
moisture from collecting.
• Lubricate and change the oil before the storage of
the machine.
• Coat the exposed portion of the hydraulic cylinder
piston rod with grease.
• Disconnect the negative terminals of the battery
and cover it or remove it from the machine and
store it separately.
• Lock each control lever with lock buttons.
• To prevent rust, add at least 30% antifreeze
inside the coolant.
4.6.2. DURING STORAGE
If it is necessary to perform the rust-prevention
operation while the machine is indoors, open the
doors and windows to improve ventilation and
prevent gas poisoning.
• During storage, operate and move the machine
for a short distance once a month so that a new film
of oil will coat moving parts. At the same time, also
charge the battery.
• When operating the work equipment, wipe off all
the grease from the hydraulic cylinder rods.
• If the machine is equipped with an air conditioner,
operate the air conditioner for 3 to 5 minutes once
a month to lubricate all parts of the air conditioner
compressor. Always run the engine at low idle
when doing this. In addition, check the refrigerant
level twice a year.

125
4.7. INSTRUCTIONS ON WITHDRAWAL FROM
USE AND UTILIZATION
Other disassembled parts, components and
Wheel loader is a machine with a limited operating materials should be treated as follows:
life like any other mechanism. When its operating
life comes to its end, the machine should be Metal parts: can be sent for scrap to be recycled.
dissembled as scrap. Some parts should be Plastic parts: can be gathered and sent for
gathered to be used as secondary raw material, recycling, if this is impossible – can be sent for
others should be discarded as scrap and the ones scrap with other waste materials.
in the third category should be given to special
companies for safe extraction and proper disposal Oil and grease: can be sent to specialized
of environmentally harmful materials. companies for proper disposal of environmentally
harmful materials and stuff (for burning and
Wheel loaders should be dissembled under the recycling).
following procedure to be discarded as scrap:
Flexible tubes are usual wastes. If possible, we
• Remove all hoses and flexible tubes, and drain recommend to remove metal braids and send them
hydraulic oil into previously prepared containers. for scrap. Hoses can be sent to the dump.
• Dismantle all hydraulic cylinders and drain the oil Gaskets and seals: can be sent to the dump.
inside them into previously prepared containers.
Filter fillings: can be sent to specialized
• Remove all gaskets and seals from hydraulic companies for proper disposal of hazardous
cylinders and gather them to be sent to hazardous substances (oil). The same procedure is for oily rag
substance disposal sites. Other parts of the and oily saw dusts.
cylinders are made of ferrous metals and subject to
scrap metal collection.
• Remove fillings of hydraulic cylinders and gather
them to be sent to hazardous substance disposal
sites.
• Remove plastic parts, plain slideways, slide shoe
bearing of rack- bars, pilot ring of fillings and
gaskets, bushings, and gather them to be sent for
recycling.
• Drain hypoid oil from wheel loaders
undercarriage into the previously prepared
containers.
• Remove grease from all parts and gather it into
the same container for used oil.
• Remaining parts of the cylinders are made of
metals. Most of them are made of steel, and only
guide bush is made of bronze. All these metals can
be recycled and used again for manufacture.

CAUTION

Hydraulic oil and grease, even biodegradable, are

very environmentally harmful. Avoid its contacting
soil and its being absorbed by soil!

126
4.8. TROUBLESHOOTING
4.8.1. WHEN MACHINE RUNS OUT OF FUEL
When starting after running out of fuel, fill the fuel
tank, then bleed the air from the fuel system before
starting.
Always watch the fuel level and be careful not to
run out of fuel.
If the engine has stopped because of lack of fuel, it
is necessary to use the priming pump to bleed the
air completely from the fuel circuit.
For detailed information, please refer to
"BLEEDING AIR IN FUEL SYSTEM" section.
4.8.2. METHOD OF TOWING MACHINE
When a disabled machine is towed improperly or
improper rope or method of towing are used,
serious injuries or death can take place.
• Always be sure to check carefully that the
capacity of the wire rope used for towing is ample
enough to carry the weight of the machine to be
towed.
• Never use a wire rope which has cut strands (A),
reduced diameter (B), or kinks (C). There is the
danger that the rope may break during towing
operation. Always wear leather gloves when
handling a wire rope. Never tow a machine on a
slope.
• During a towing operation, never stand between
the towing vehicle and the machine being towed.
• Move the machine slowly and be sure not to apply
any sudden load on the wire rope,other wise the
wire rope may break and cause serious personel
injuries.
• If there is a failure in the brake line, the brakes
cannot be used, so be extremely careful when
towing.
• If the disabled machine has a problem on the
steering or brake systems, do not allow anybody to
ride on the machine during towing operation.
• Towing is carried out to take the machine to a
safe place for an inspection or maintenance.
The machine must not be towed for long distances.
• For details of the procedure for towing a machine
when it is broken down, please contact your
Hidromek dealer.
Fig 4.148
This machine must not be towed unless there is an
emergency. When towing the machine, take the
following precautions.
• Before releasing the brakes, put blocks under the
wheels to prevent the machine from moving. If the
wheels are not blocked, the machine may
unintentionally move.
• When towing a machine, tow it at a low speed of
less than 2 km/h (1.2 MPH), and for a distance of a
few hundred meters to a place where repairs can
be carried out. The machine should be towed only
in emergencies. If the machine must be moved
long distances, use a transporter.
• The towing vehicle should be the same size of
the machine being towed.
• Check that the towing vehicle has enough braking
power, weight and traction to be able to control
itself and the machine to be towed on slopes or on
straight roads.
• Towing pins on the vehicle and on the machine
must have enough capacity.
• To protect the operator against the risk of wire
rope or towing pin breakage, put protector plates in
the connection points.
• Keep the angle of the towing rope as small as
possible.
• Keep the angle between the centerlines of the
vehicle and the machine within 30 degrees.
• When towing a machine downhill, it may be
necessary to connect another towing vehicle to the
rear of the machine being towed in order to provide
ample traction and braking power. This makes it
possible to tow the machine slowly downhill.
• Towing may be carried out under various differing
conditions, so it may be impossible to foresee the
requirements for the particular towing.
• Towing on straight roads will require minimum
traction, while towing on slopes or on rough road
surfaces will require maximum traction.
• Connect a wire rope to the towing pin.
127
4.8.2.1. WHEN ENGINE RUNS
• When the engine is running and the transmission
and steering wheel can be operated, it is possible
to tow the machine out of mud or to move it for a
short distance to the edge of the road.
• The operator should sit on the machine being
towed and operate the steering in the direction that
the machine is towed.
4.8.2.2. WHEN ENGINE DOES NOT RUN
When towing a machine with an engine not
running, use the following procedure.
1. The transmission oil does not lubricate the
system, so remove the front and rear drive shafts.
If necessary, block the tires to prevent the machine
from moving.
2. The steering cannot be operated, so remove the
steering cylinder.
Even if the brakes are in good condition, the brakes
can only be used for a limited number of times.
There is no change in the operating force of the
brake pedal, but the braking force is reduced each
time the pedal is depressed.
3. Connect the towing equipment securely. When
carrying out towing operations, use two vehicles
having the size of the machine being towed.
Connect one machine to the front and the other to
the rear of the machine being towed, then remove
the blocks from the tires and tow the machine.
4. The parking brake cannot be released (OFF). To
release the parking brake, follow the instructions in
"Releasing Parking Brake" section.

128
4.8.2.3. RELEASING PARKING BRAKE
Please ask your Hidromek dealer to release the WARNING
parking brake.
• When releasing the parking brake, stop the When towing a machine, do not tow it more than
machine on level ground and check that the 10 km/h (6.0 MPH).
surrounding area is safe. If it is necessary to
release the brake on a slope in an emergency, Do not move the machine more than 10 km by
block the tires before starting the operation. towing. This rule must be obeyed, otherwise
transmission may be damaged due to lack of
• If the parking brake is released, the brake cannot lubrication.
be used, so check the safety carefully when moving
the machine. If the machine must be moved long distances, use
a transporter.
Parking brake is released by using oil pressure of
brake accumulator.
If for some reason oil pressure of the brake
accumulator is reduced, use the following manual
method to release the parking brake and tow the
machine.
1. Fix and secure the machine.
2. Remove screw cap (4).
3. Loosen lock nut (5) (using open end wrench
24/30 mm) and turn adjustment bolt (3) (using
hexagon wrench 8/10 mm) counterclockwise, until
the brake is released.
Then the parking brake is completely released.

WARNING

When the parking brake is completely released,

the machine will lose its braking ability. Measures
must be taken to avoid unintentional movements
of the machine. Before restarting an operation with
the machine, the brake must be activated.

CAUTION

For an emergency release of the parking brake,

40Nm and 70Nm drives are required respectively.

4. Install lock nut (5) and tighten as tight as

possible. Install screw cap (4) and tighten as much
as possible. By doing so, dust will not enter inside. 1. Pressure bolt
2. Spring pack
3. Adjustment bolt
4. Screw cap
5. Lock nut
6. Piston
P Plain surface
S Hexagon wrench
Fig 4.149

129

4.8.2.4. EMERGENCY TRAVEL OPERATION
The normal gear shifting operation is carried out by
electric signals. If there is a failure in the electrical
system and the machine does not move, please
contact your Hidromek dealer to have the machine
moved.
NOTICE
Always request your Hidromek dealer to carry out
the emergency travel operation.
4.8.2.5. IF BATTERY IS DISCHARGED
• It is dangerous to charge a battery on a machine.
Make sure that it is removed before charging.
• When checking or handling the battery, stop the
engine and turn the starting switch key to OFF
position.
• The battery generates hydrogen gas, so there is
a hazard of explosion. Do not approach the battery
while smoking, or do not do anything that will cause
sparks.
• Battery electrolyte is diluted sulfuric acid, and it
can splash. If it gets on your clothes or on your skin,
immediately wash it off with a large amount of fresh
water. If it gets into your eyes, wash it out with fresh
water and consult a physician as quickly as
possible.
Fig 4.150
• When handling batteries, always wear safety
glasses and rubber gloves.
• When removing the battery, first disconnect the
ground cable (normally the negative (-) terminal).
When installing, install the positive (+) terminal first.
130
When a tool touches the positive terminal and the
chassis, there is the danger that it will cause a
spark, so extremely be careful.
• If the terminals are loose, there is the danger that
the defective contact may generate sparks causing
an explosion.
• When removing or installing the terminals, check
which one is the positive (+) terminal and which one
is the negative (-) terminal.
4.8.2.6. REMOVAL/INSTALLATION OF BATTERY
1. Before removing the battery, remove the
ground cable (normally connected to the negative
(-) terminal). If any tool touches between the
positive terminal and the chassis, there is the
danger of sparks being generated. Loosen the nuts
of the terminal and remove the wires from the
battery.
2. After installing the battery, fix it with the battery
hold down.
3. When installing the battery, connect the
ground cable last. Insert the wire in the hole of the
terminal on the battery and tighten the nut.
4.8.2.7. PRECAUTIONS FOR CHARGING
BATTERY
When charging the battery, if the battery is not
handled correctly, there is the danger of an
explosion. Always follow the instructions in
"BATTERY" section and the instructions in the
manual of the charger, and always do the following.
Fig 4.151
• Do not use or charge the battery if the battery
electrolyte level is below the min. level. This may
cause an explosion. Check the battery electrolyte
level periodically and add distilled water up to the
upper level.
• Set the voltage of the charger to match the
voltage of the battery to be charged. If the correct
voltage is not selected, the charger may overheat
and cause an explosion.
• Connect the positive (+) charger clip of the
charger to the positive (+) terminal of the battery,
then connect the negative (-) charger clip of the
charger to the negative (-) terminal of the battery.
Be sure to attach the clips securely.
• Set the charging current to 1/10 of the value of the
rated battery capacity; when carrying out rapid
charging, set it to less than rated battery capacity.
If the charger current is too high, the electrolyte will
leak or dry up, and this may cause the battery to
catch fire and explode.
• If the battery electrolyte is frozen, do not charge
the battery or start the engine with a different power
source.
• There is the danger that this will ignite the battery
electrolyte and cause the battery to explode.
NOTICE
• Battery capacities for both machines should
be the same.
• Check that the cables and clips are not
damaged or corroded.
• Connect the clips and cables securely.
• Check that the work equipment lock lever
and parking brakes of both machines are in
LOCK position.
• Check that all levers are in neutral position.

4.8.3. STARTING ENGINE WITH BOOSTER

CABLES
When starting the engine with booster cables, 4.8.3.2. CONNECTING BOOSTER CABLES
follow the procedure below.
4.8.3.1. PRECAUTIONS WHEN CONNECTING
AND DISCONNECTING BOOSTER CABLES

Fig 4.153

Keep the starting switches of the machine

Fig 4.152
• When connecting the cables, never have the
positive (+) and negative (-) terminals contact one
another.
• When starting the engine with booster cables,
wear safety glasses and rubber gloves.
• Be careful not to have the machine with a dead
battery and the other machine contact one another.
Otherwise, sparks generated near the battery can
ignite the hydrogen gas given off by the battery.
• Make sure that booster cables are connected
properly. The final connection is to be made on the
engine block of the disabled machine, but sparks
will be generated when this is done, so make the
connection as far as possible from the battery.
• When disconnecting the booster cable, be careful
not to bring the clips in contact with each other or
with the machine body.
functioning properly and the disabled machine in
OFF position.
Connect the booster cables in the numbered
sequence shown in the diagram.
1. Connect one clip of booster cable (A) to the
positive (+) terminal of the disabled.
2. Connect the other clip of booster cable (A) to
the positive (+) terminal of the machine functioning
properly.
3. Connect one clip of booster cable (B) to the
negative (-) terminal of the machine functioning
properly.
4. Connect the other clip of booster cable (B) to
the engine block of the disabled machine.

131
4.8.3.3. STARTING ENGINE
Always check that the work equipment lock button
is set in LOCK position on the machine functioning
properly and the disabled machine. Also check that
all the control levers are in HOLD or NEUTRAL
position.
1. Make sure the clips are firmly connected to the
battery terminals.
2. Start the engine of the machine functioning
properly and run it at high idle speed. Fig 4.155
3. Turn the starting switch of the disabled
machine to START position and start the 1. Turn starting switch key to ON position.
engine. If the engine does not start at first, wait
for at least 2 minutes before trying again.

4.8.3.4. DISCONNECTING BOOSTER CABLES

Fig 4.156

2. Turn control lever lock button (3) to FREE

Fig 4.154
position.
After the disabled engine has started, disconnect 3. Ö Operate thelift arm control lever (2) to lower
the booster cables in the reverse of the order in the bucket to the ground.
which they were connected.
4. Apply control lever lock button (3) again.
1. Remove one clip of booster cable (B) from the
engine block of the disabled machine.
2. Remove the other clip of booster cable (B) from
the negative (-) terminal of the machine
functioning properly.
3. Remove one clip of booster cable (A) from the
positive (+) terminal of the machine functioning
properly.
4. Remove the other clip of booster cable (A) from
the positive (+) terminal of the disabled
machine.
4.8.4. METHOD FOR LOWERING WORK Fig 4.157
EQUIPMENT WHEN ENGINE HAS STOPPED
5. Turn the key of starting switch to OFF position.
After the engine has stopped, work equipment can
be lowered if there is some pressure inside
hydraulic accumulator. Check that surrounding CAUTION
area is safe, then lower the work equipment.
Do this work within the 2 minutes after the engine
has stopped. If you wait more, the pressure
inside hydraulic accumulator will drop and it will
not be possible to lower the work equipment.

132
4.8.5. TROUBLESHOOTING
4.8.5.1. ELECTRICAL SYSTEM
• ( ): Always contact your Hidromek dealer when working on these items.
• In cases of problems or causes which are not listed below, contact your Hidromek dealer for repairs.

Problem Possible causes Solution

Lamp does not glow brightly even Defective wiring Check, repair loose terminals,
when the engine runs at high speed disconnections
Defective adjustment of alternator
belt tension Check belt tensioning
Lamp flickers while engine is running mechanism.

When engine is running, battery Defective alternator Defective wiring Replace, check, repair
charge circuit caution lamp is ON

Abnormal noise is generated from Defective alternator Replace

alternator

Starting motor does not turn when Defective wiring Insufficient battery Check, repair,
starting switch is turned ON charge
Charge

Pinion of starting motor keeps going in Insufficient battery charge Charge

and out

Starting motor turns engine very Insufficient battery charge Defective Charge
slowly starting motor
Replace

Starting motor disengages before Defective wiring Insufficient battery Check, repair
engine starts charge
Charge

Even when engine is stopped, battery Defective wiring Replace

charge caution lamp does not light up
Defective wiring, Defective sensor Check, repair, replace
(starting switch in ON position)

133
4.8.5.2. CHASSIS
( ): Always contact your Hidromek dealer when working on these items.
In cases of problems or causes which are not listed below, contact your Hidromek dealer for repairs.

Problem Possible causes Solution

Transmission
Engine is running but machine does Parking brake applied Release parking brake. Shift lever
not move Directional lever not shifted properly properly.
Transmission oil level is low Add oil to specified level.
Even when engine runs at full throttle, Transmission oil level is low Add oil to specified level.
machine only move slowly and lacks Strainer is clogged Disassemble, clean.
power
Oil is overheating Too much oil or too little oil Machine Add or drain oil to specified level.
speed range is not correct Torque Place in correct speed range.
converter is stalled Check torque converter. Check
Engine is overheating engine.
Noise generated Lack of oil in transmission case Add oil to specified level.
Axle
Noise generated Lack of oil Add or drain oil to specified level.
Disk brake
Brake is not applied when pedal is Disc has reached wear limit Defective Replace disc Check, repair
depressed hydraulic system Lack of oil Add oil to specified level. Bleed air.
Air in brake line
Brake drags or remains applied Vent hole of brake valve is clogged Clean Check, repair Check, repair
Defective brake valve Misoperation of
expander
Poor braking effect Disc is worn Replace
Parking brake
Poor braking effect Loose connection Lining is wet Adjust Clean
Defective hydraulic cylinder spring Replace spring Adjust or replace
Worn out lining
Steering
Steering wheel is heavy Defective hydraulic system Lack of Check, repair
oil Add oil to specified level.
Hydraulic system
Lacks bucket lifting power Takes Lack of oil Add oil to specified level. Replace
time to lift the bucket Clogged hydraulic tank filter filter.
Excessive bubbles in oil Low quality oil being used Oil level Replace with good quality oil Add oil
is low to specified level.
Air in oil line Bleed air.
Hydraulic pressure is low Oil level is low and pump is sucking Add oil to specified level. Then,
in air bleed air.
Movement of cylinder is irregular Oil level is low Add oil to specified level. Check,
Oil leakage inside cylinder repair.

134
4.8.5.3. ENGINE
( ): Always contact your Hidromek dealer when working on these items
In cases of problems or causes which are not listed below, contact your Hidromek dealer for repairs.
4.9. ENGINE PROBLEMS

Problem Possible causes/results and ► solutions

Pinion of starting motor Insufficient battery charge.
does not turn or turns ► Charge battery.
very slowly. Loose wiring of starting motor.
► Tighten the wiring of all terminals.
Loose battery grounding wiring.
► Tighten the wiring of all terminals.
Defective starting motor or starting motor solenoid.
► Let it be checked at a specialized workshop.
Engine does not start or Lack of fuel.
stops immediately after ► Add fuel.
starting. Fuel filter is clogged.
► Change filter element.
Water in fuel pre-filter.
► Drain water in fuel pre-filter.
Fuel pre- filter is clogged.
► Change filter element.
Leakage in low-pressure fuel circuit or insufficient pressure
► Check leakage visually, replace seals if necessary.
► Let the pressure be tested at a specialized workshop. Replace seals.
Engine cannot start at Improper fuel is used.
low temperature Diesel fuel viscosity is impaired due to waxation.
outside. ► Waxation problems can be solved by heating complete fuel system. Machine can
be parked indoors or in a heated place.
► Change to winter fuel.
Improper engine oil is used.
► Change to oil of proper viscosity.
► If still engine cannot start, contact your Hidromek dealer to investigate and solve
the problem.
Engine stops without Disconnection in engine control unit or short circuit in electric wiring.
any specific reason. ► Check fuses.
► Contact Hidromek dealer for inspection of battery.
Leakage in low-pressure fuel circuit or insufficient pressure.
► Check leakage visually.
► Contact Hidromek dealer for testing fuel pressure.
Engine is in emergency Interruption in data exchange among control units.
working mode. ► Check connectors of control units for looseness and corrosion.
► Read failure history of control unit.
► Contact Hidromek dealer for inspection and repair.

135
Problem Possible causes/results and ► solutions
Engine is running There is a problem in fuel system.
unsteadily and ► Check leakage visually.
vibrating. ► Read failure history of control unit.
► Contact Hidromek dealer for inspection and repair.
Engine output is poor Air filter is clogged or dirty.
(there is lack of power). ► Change air filter element.
Charge-air temperature is too high; charge-air cooler or radiator is clogged or dirty.
► Clean charge-air cooler or radiator.
Cooling water temperature is too high.
► Check temperature sensor, replace if required. Check fan speed.
► Check thermostat, replace if required. Contact Hidromek dealer for inspection and
repair.
Defective fuel system (clogging, leakage).
► Check leakage visually
► Contact Hidromek dealer for inspection and repair.
Improper fuel is used.
► Use specified type of fuel.
There is leakage in charge-air system; loosen or damaged charge-air clamp.
► Check for leakage in charge-air system.
► Check pressure sensor of charge-air system, replace if required.
► Contact Hidromek dealer for inspection and repair.
An emission related limitation function is activated
► Check warning lamps and indicator lamps.
There is interruption in Voltage send to control units is dropping (loose connection).
output. ► Check for tightness and corrosion on battery terminals and on connectors of
control units.
Engine braking effect is Contact Hidromek dealer for inspection and repair.
poor.
Fuel consumption is too Contact Hidromek dealer for inspection and repair.
high.
Engine is overheated Insufficient volume of water in cooling system.
(according to cooling ► Add cooling water and bleed air from cooling system.
water temperature Defective cooling water temperature sensor or gauge.
gauge). ► Replace sensor or gauge.
When starting switch is Defective monitor panel or disconnection in wiring.
turned ON, warning ► Contact Hidromek dealer for inspection and repair.
lamps on monitor panel
does not light.

136
Problem Possible causes/results and ► solutions

"Low battery charge" Poly-V-belt is slipping.

warning lamp lights up
► Check function of belt tensioner.
while engine is running.
► Check poly V-belt surface and pulley grooves for wear, damage, shininess.
Replace poly V-belt if required.

Poly V-belt is worn out

► Replace poly V-belt

Defective alternator or sensor.

► Check alternator or sensor.
► Contact Hidromek dealer for inspection and repair.

There is “knocking” Defective ignition.

in engine. ► Contact Hidromek dealer for inspection and repair.

There is “knocking” in Defective bearings.

engine.
► Contact Hidromek dealer for inspection and repair.

Abnormal noise Leakage in air intake or exhaust lines and whistling noise is generated.
generated.
► Investigate the cause. Replace gaskets if required.

Turbine or compressor impellers are touching to housing. Foreign materials in turbine

or compressor impeller housing. Seizure of rotating parts bearings.
► Contact Hidromek dealer for inspection of turbocharger.

Engine valve clearance is too much.

► Contact Hidromek dealer for adjustment of valve clearance.

Power loss due to poly V-belt

► Check poly V-belt surface and pulley grooves for wear, damage, shininess.
Replace poly V-belt if required.

137

5. MAINTENANCE
WARNING
Please read and make sure that you fully
understand the SAFETY section before reading
this section.
5.1. MAINTENANCE RULES
Do not perform any inspection and maintenance
operation that is not mentioned in this manual.
5.1.1. SERVICE METER READING
Check the service meter reading every day to see
if it is the time for any necessary maintenance to be
performed.
5.1.2. HİDROMEK GENUINE REPLACEMENT
PARTS
You are recommended to use Hidromek genuine
parts specified in the Parts Book as replacement
parts.
5.1.3. HİDROMEK GENUINE OIL
For lubrication of the machine, use Hidromek
genuine lubricants. Moreover, use oil of the
specified viscosity according to the ambient
temperature.
5.1.4. ALWAYS USE CLEAN WASHER FLUID
Use automobile window washer fluid, and be
careful not to let any dirt get into it.
5.1.5. ALWAYS USE CLEAN OIL AND GREASE
Use clean oil and grease. Also, keep the containers
of the oil and grease clean. Keep foreign materials
away from oil and grease.
5.1.6. CHECKING FOR FOREIGN MATERIALS
IN DRAINED OIL AND ON FILTERS
After oil is changed or filters are replaced, check
the drained oil and filters for metal particles and
foreign materials. If large quantity of metal particles
or foreign materials are found, always report to the
person in charge to carry out the required
procedures.
5.1.7. PRECAUTIONS WHEN ADDING OIL OR
FUEL
If your machine is equipped with a strainer, keep it
in its place while filling oil or fuel.
138
5.1.8. WELDING INSTRUCTIONS
• While doing welding work, turn starting switch to
OFF position and after confirming that electric
circuit is turned off, set the battery switch to OFF
position and remove the battery.
• Do not apply more than 200 V continuously.
• Connect grounding cable within 1 m (3.28 ft) from
the area to be welded. Connecting grounding cable
near electrical system meters and connectors can
damage them.
• If a seal or bearing comes in between the part
being welded and grounding point, change the
grounding point to avoid such parts in between.
Seals and similar parts may catch fire from the
sparks and damage the parts around.
• Do not use the area around the work equipment
pins or the hydraulic cylinders as the grounding
point. Sparks may be generated and damage the
surface layer.
5.1.9. DO NOT DROP ANYTHING INSIDE
MACHINE
• When opening inspection windows or the oil filler
port of the tank to carry out inspection, be careful
not to drop nuts, bolts, parts or tools inside the
machine.
If such things are dropped inside the machine, it
may cause damage and/or malfunction of the
machine and lead to failure. If you drop anything
inside the machine, always remove it immediately.
• Do not put unnecessary things in your pockets.
Carry only the things which are necessary for an
inspection or maintenance.
5.1.10. DUSTY ENVIRONMENT
When working on dusty jobsites, do as follows:
• Clean radiator fins and other heat exchanging
components more frequently. Do not wait until the
fins are clogged before cleaning.
• Clean and replace the fuel filter frequently.
• Clean electrical components, especially the
starting motor and alternator to avoid accumulation
of dust.
• When inspecting or changing oil, move the
machine to a place that is free of dust to prevent
dirt from getting into the oil.
5.1.11. AVOID MIXING DIFFERENT TYPES OR
GRADES OF OIL
If a different brand or grade of oil has to be added,
drain the oil and replace all the oil with the new
brand or grade of oil. Never mix different brands or
grades of oil.
5.1.11.1. LOCKING INSPECTION COVERS
Lock the inspection cover securely into position
with the lock bar. If an inspection or maintenance is
performed with the inspection cover not locked in
position, there is the danger that it may be suddenly
blown shut by the wind and cause injuries to the
workers.
5.1.12. BLEEDING AIR FROM HYDRAULIC
CIRCUIT
After repairing or replacing the parts of hydraulic
circuit, or removing the piping of hydraulic circuit, it
is necessary to bleed the air from the circuit.
For air bleeding procedure, refer to section
"BLEEDING AIR FROM HYDRAULIC TANK".
5.1.13. PRECAUTIONS WHEN INSTALLING
HYDRAULIC HOSES
• When removing parts in locations where there are
O-rings or gasket seals, clean the mounting
surface, and replace with new parts.
When doing this, be careful not to forget to
assemble the O-rings and gaskets.
• When installing the hoses, do not twist or bend
them.
If they are installed in such a way, their service life
will be shortened to a great extend and they may
be damaged.
5.1.14. CHECKS AFTER INSPECTION AND
MAINTENANCE
If you fail to perform the final checks after
inspection and maintenance, unexpected problems
may occur, and this may lead to serious injuries or
property damage. Always do the following:
Checks after stopping the engine
1. Have any inspection and maintenance points
been neglected?
2. Have all inspection and maintenance items been
performed correctly?
3. Have any tools or parts been dropped inside the
machine? It is particularly dangerous if parts are
dropped inside the machine and get caught in the
lever linkage mechanism.
4. Are there any leakage of coolant or oil? Have all
nuts and bolts been tightened?
Checks when the engine is running:
1. For inspections when the engine is running,
employ two workers and observe safety first.
2. Do not operate the engine for long hours with the
engine hood open. High temperature of exhaust
gas may damage the engine hood.
3. Increase the engine speed to check for fuel and
oil leakage.
4. Check if the inspected and maintained parts are
functioning properly.
5.1.15. SELECTING FUEL AND OIL
ACCORDING TO AMBIENT TEMPERATURE
Fuel and oil must be selected according to ambient
temperature. For details, refer to "OIL, FUEL,
COOLANT" section.
5.1.16. SECURELY CLOSE ENGINE PANEL
After completing maintenance and inspection,
make sure that the engine side panel is closed and
securely locked. If not locked, it may unintentionally
open during operation.
139
5.2. OIL, FUEL, COOLANT
You are always recommended to use Hidromek
genuine wear or replacement parts, grease and oil.
When changing oil or adding oil, do not mix
different types of oil. When changing the type of oil
used, drain all the oil and fill the new type of oil.
Always replace the filter at the same time. (There
is no problem if the small amount of oil remaining
in the piping mixes with the new oil).
5.2.1. OIL
Oil for an engine and hydraulic equipment are used
under extremely severe conditions (high
temperature and high pressure), and deteriorates
in a certain period of time.
Always use oil that matches the grade and
maximum and minimum ambient temperatures
recommended in the Operation and Maintenance
Manual. Even if the oil is not dirty, always change
the oil at the specified intervals.
Oil corresponds to blood in the human body, so
always be careful when handling it to prevent any
impurities (water, metal particles, dirt, etc.) from
getting in.
The majority of problems with the machine are
caused by the entry of such impurities. Take
particular care not to let any impurities get in when
storing or adding oil.
Never mix oil of different grades or brands.
Always add the specified amount of oil.
Both having too much oil and too little oil cause
problems.
If the oil in the work equipment is not clear, there is
probably water or air getting into the circuit. In such
cases, please contact your Hidromek dealer.
When changing oil, always replace the filters
belonging to that part at the same time.
We recommend that you have an analysis of oil
periodically to follow the condition of the machine
closely.

WARNING

Always use genuine Hidromek engine oil on your

machine. If you do not use genuine Hidromek
engine oil, service life of emission control system
parts may be reduced. When oil is deteriorated,
poor lubrication ability will cause failure, engine
service life will be shortened, engine performance
drops and fuel consumption increases.

140
Engine oil viscosity
If the outside temperature is under -20 °C, Hidromek strongly recommends
using engine oils of SAE class 5W-30 or 0W-30. Use only all-season oils.

Oil viscosity by temperature (C)

Oil Type
-30 -20 -10 0 10 20 30 40 50

ISO VG 32
Hydraulic Oil ISO VG 46 *
ISO VG 68

Oil viscosity by temperature (C)

Oil Type
-30 -20 -10 0 10 20 30 40 50
Pins and Bushings Grease N.L.G.I NO:2 Lithuim saponified

Oil viscosity by temperature (C)

Fluid Type
-30 -20 -10 0 10 20 30 40 50
Antifreeze and Water Mix ** Long Life Coolant

Oil viscosity by temperature (C)

Fluid Type
-30 -20 -10 0 10 20 30 40 50

Diesel Fuel ASTM D975 NO.1

ASTM D975 NO.2

*: Refers to lubricants that are used in filling at the factory

**: See "Chapter 5.2.3. Coolant” for mixing ratios according to the temperature
SAE: Society of Automotive Engineers
ISO: International Organization for Standardization
NLGI: National Lubrication Grease Institute
ASTM: American Society of Testing and Material
API: American Petroleum Institute

141
5.2.1.1. RECOMMENDED OIL, COOLANT AND GREASE

Engine Engine
(SAE 10W-40) (SAE 5W-30)
OMV Petrol Ofisi PO Maximus 10W-40
Exxon Mobil Mobil Delvac xhp extra 10W-40
Shell Rimula R5 M Shell Rimula R6 ME
Shell Shell Rimula R6
Shell Rimula R6 MS
Castrol Crb Turbomax 10W-40 E4/E7 Castrol Vecton Fuel Saver 5W-30 E7
Castrol Vecton 10W-40 E4/E7
Castrol Castrol Vecton Long Drain 10W-40
Castrol Vecton Long Drain 10W-40 E4/E7
Castrol Vecton Long Drain 10W-40 E7
Elf Performance Experty 10W-40 Elf Performance Experty FE 5W-30
Elf Performance Experty HDX 10W-40 Gulf Gulfleet Supreme 5W-30
Total Gulf Gulfleet Highway 10W-40 Total Rubia TIR 9200 FE 5W-30
Total Rubia TIR 8600 10W-40
Total Rubia TIR 8800 10W-40
International Std No MB 228.5 MB 228.5

Transmission Front axle Rear axle

OMV Petrol Ofisi Maxitrak TMS oil 500 Maxitrak TMS oil 500 Maxitrak TMS oil 500
Mobilfluid 424 Mobilfluid 424 Mobilfluid 424
Exxon Mobil Mobil hydraul 56 Mobil hydraul 56 Mobil hydraul 56
Mobilfluid 428 Mobilfluid 428 Mobilfluid 428
Spirax S4 TXM Spirax S4 TXM Spirax S4 TXM
Shell
Spirax S6 TXME Spirax S6 TXME Spirax S6 TXME
Agri trans plus 80W Agri trans plus 80W
Castrol Agri Trans Plus 10W-30 Agri trans plus 10W-30 Agri trans plus 10W-30
Transmax Agri trans plus 80W Transmax agri trans plus 80W
Dynatrans MPV Dynatrans MPV Dynatrans MPV
Dynatrans MPV Dynatrans Elf Tractelf BF 16 Elf Tractelf BF 16
Total MPWB Total Dynatrans LS 20W-4 Total Dynatrans LS 20W-4
Elf Tractelf BF 16 Dynatrans MPWB Dynatrans MPWB
Dynatrans MPX Dynatrans MPX Dynatrans MPX
International Std No UTTO UTTO UTTO

Concentrated Coolant Premixed Coolant

Hydraulic system Grease
(Antifreeze only) (Antifreeze + water)
Glysantin® G40® Glysantin® Ready Mix
OMV Petrol Ofisi Hydro Oil HD 46 Süper Gres MP-2
(BASF) G40® (BASF)
Mobilgrease XHP 681
Exxon Mobil DTE 10 Excel 46 Mobil Antifreeze Ultra -
Mine
Shell Tellus S2 V 46 - - Gadus S3 V220C 2
Agri Hydraulic Oil Plus Premium Heavy Duty
Castrol Radicool Si OAT -
46 Plus
Total Azolla ZS 46 - - Multis Complex EP 2
N.L.G.I NO:2
International Std No ISO VG 46 MB 325.5 MB 326.5
Lithuim saponified
* These solutions are a mixture of antifreeze and diluted water by volume of %50-50 and guarantees protection
against freezing to -37°C. Before using these products verify protection against freezing temperature on their
packaging. If given temperature is not suitable for the operating conditions of your machine then prepare a
coolant using antifreeze and diluted water according to the mixing ratios given in Chapter “5.2.3 Coolant”.
Using fuel other than extra-low-sulfur diesel fuel (with sulfur content of max. 500 ppm or lower) may have a
harmful effect on the engine and the exhaust gas purification device possibly resulting in a breakdown.

142
5.2.1.2. LUBRICATION CHART

Fig 5.1

143
5.2.2. FUEL
• To prevent the moisture in the air from
condensing and forming water inside the fuel tank,
always fill the fuel tank after completing the day's
work.
• Fuel pump is a sensetive instrument, and if fuel
containing water or dirt is used, it cannot work
properly.
• Be extremely careful not to let impurities get in
when storing or adding fuel.
• Always use the fuel specified for the temperature
in the Operation and Maintenance Manual.
• If fuel is used at temperatures lower than the
specified temperature (particularly at temperatures
below -15 °C (5°F), the fuel will solidify.
• If fuel is used at temperatures higher than the
specified temperature, the viscosity will drop, and
this may result in problems such as a drop in
engine output.
• Before starting the engine, or 10 minutes after
adding fuel, drain the sediment and water from the
fuel tank.
• If the engine runs out of fuel, or if the filters have
been replaced, it is necessary to bleed the air from
the circuit.
• If there is any foreign material in the fuel tank,
wash the tank and fuel system.
NOTICE
Fuel to be used should be diesel oil with ultra low
sulfur content.
To ensure good fuel consumption characteristics
and exhaust gas characteristics, the engine
mounted on this machine uses an electronically
controlled high-pressure fuel injection device and
emission control system. Since high-pressure fuel
injection device requires sensetive parts and
lubrication, if low viscosity fuel with low lubricating
ability is used, the durability may drop greatly.
Additionally, if fuel with high sulfur content is used,
it may cause damage or performance drop on the
engine parts and on the parts of emission control
system.
Consume the fuel in storage tanks and in the
machine fuel tank in the shortest time possible.
144
5.2.3. COOLANT
• The coolant has the important function of
preventing corrosion as well as preventing
freezing. Even in the areas where freezing is not an
issue, the use of antifreeze coolant is essential.
Hidromek machines are delivered from the factory
with coolant which does not contain amine. This
coolant has excellent anticorrosion, antifreeze and
cooling properties. If you use another coolant, it
may cause serious problems, such as corrosion of
the engine and aluminum parts of the cooling
system.
• When using antifreeze, observe the precautions
given in the Operation and Maintenance Manual.
• Coolant is already diluted with distilled water, so
it is not flammable.
• Density of coolant has to be changed according
to ambient temperature.
For details of the coolant density, see "clean inside
of cooling system". Even in areas where it is not
considered necessary to prevent freezing, always
use coolant with a density of over 30% in order to
prevent corrosion of the cooling system. Coolant is
diluted with distilled water that does not contain any
ions or water-hardening substances. Never dilute
the coolant with tap water.
• If the engine overheats, wait for the engine to cool
before adding coolant.
• If the coolant level is low, it will cause overheating,
and will also cause problems related to corrosion
due to air entering the coolant.
5.2.3.1. DENSITY OF COOLANT AND FREEZING
POINT
Freezing temperature (°C)
-18 °C -37 °C -54 °C
(ASTM D 1177)
33 50 60
Antifreeze ratio (%)
77 50 40
Distilled water ratio (%)
Above information is for Glysantin G40 which is
filled at Hidromek plant. Values may differ
depending on the type of antifreeze used. Read the
information written in the documents of the
antifreeze used. Use only the antifreeze
recommended by Hidromek. Use of an antifreeze
that is not recommended by Hidromek can
result in severe engine damage.
5.2.4. GREASE
• Grease is used to prevent seizure and noises at
the joints.
• This construction equipment is used under
heavy-duty conditions. Always use the
Hidromek recommended grease and follow the
change intervals and recommended ambient
temperatures given in this Operation and
Maintenance Manual.
• If a part is hardened due to being used for a long
time, grease the part.
• Always wipe off the previously used grease that
is pushed out when greasing.
• Be particularly careful to wipe off the previously
used grease in places where sand or dirt
sticking the grease causing wear of the rotating
parts.

145

5.2.5. OIL ANALYSIS
Oil analysis is a maintenance service that makes it
possible to prevent machine failures and downtime.
This enables early detection of wear of the machine
drive parts and other problems.
5.2.6. OIL SAMPLING
Sampling intervals
Engine oil: 250 hours
Other components: 500 hours
Precautions when sampling
• Make sure that the oil is well mixed before
sampling.
• Perform sampling at regular fixed intervals.
• Do not perform sampling on rainy or windy days
when water or dust can get into the oil.
For further details of oil analysis, please contact
your Hidromek dealer.
5.2.7. STORING OIL AND FUEL
• Store oil and fuel indoors to prevent any water,
dirt, or other impurities from getting in.
• When keeping drum cans for a long period of
time, put the drum on its side so that the filler port
of the drum is on its side to prevent moisture inside.
When drums have to be stored outside, cover them
with a waterproof material or take other measures
to protect them.
• To prevent any change in quality during long-term
storage, be sure to use the principal of first in - first
out (use the first stored oil or fuel first).
5.2.8. FILTERS
• Filters are vital parts of machines. They prevent
impurities from entering the important parts of fuel,
oil and air circuits causing problems.
Replace all filters periodically. For details, see the
Operation and Maintenance Manual.
However, when working in severe conditions,
replace the filters at shorter intervals according to
the oil and fuel (sulfur content) being used.
• Never try to clean the filters (cartridge type) and
146
use them again. Always replace them with new
filters.
• When replacing oil filters, check if any metal
particles are attached to the old filters. If any metal
particles are found, contact your Hidromek dealer.
• Do not unpack spare filters until they are ready to
be used.
• You are always recommended to use genuine
Hidromek filters.
5.2.9. ELECTRICAL COMPONENTS
• When battery switch is switched to OFF position
for maintenance purposes, close and lock battery
switch box and remove the key. If you do not lock
the box, an unauthorized person may
unintentionally switch it to ON position and may
cause serious injuries due to electric shock.
For more information about functions of battery
switch, refer to section "Battery Switch".
• It is extremely dangerous when the electrical
equipment becomes wet or the covering of the
wiring is damaged. This will cause a short circuit
and may lead to malfunctioning of the machine. Do
not wash inside the operator's cab with water.
When washing the machine, be careful not to let
water get into the electrical components.
• After washing the machine or before
disconnecting the connectors of electrical
components on rainy days, dry the area around the
connectors so that there are no water droplets and
do not allow water to leak into connectors.
• Checks to be done for the electrical system:
Checking fan belt tension, checking damage or
wear on the fan belt and checking battery fluid
level.
• Never install any electric components other than
those specified by Hidromek.
• External electro-magnetic interference may
cause malfunction of the control system controller.
Therefore, before installing a radio receiver or other
wireless equipment, contact your Hidromek dealer.
• When working by the sea, carefully clean the
electrical system to prevent corrosion.
• The optional power source must never be
connected to fuse, starting switch, or battery relay.
It must be connected to the special power
connector.
5.3. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS
5.3.1. TORQUE LIST
If nuts, bolts, or other parts are not tightened to the specified torque, they will loosen or damage the parts they
secure, and this will cause failure of the machine or problems with operation. Always be careful when tightening
these parts.
It is specified otherwise, tighten the metric nuts and bolts to the torque shown on the table below. When it is
necessary to replace any nut or bolt, always use genuine Hidromek spare parts having the same size and
quality.

Bolt size Bolt type Tightening torque Bolt type Tightening torque
(Nm)
(Nm)

M5x0,8 DAC plated 9 Lubricated 8

M6x1 DAC plated 15 Lubricated 14

M8x1,25 DAC plated 37 Lubricated 33

M10x1,5 DAC plated 73 Lubricated 65

M12x1,75 DAC plated 126 Lubricated 112

M14x2 DAC plated 200 Lubricated 180

M16x2 DAC plated 310 Lubricated 275

M18x1,5 DAC plated 468 Lubricated 414

M20x2,5 DAC plated 600 Lubricated 534

M22x1,5 DAC plated 872 Lubricated 770

M27x3 DAC plated 1500 Lubricated 1330

M30x3,5 DAC plated 2050 Lubricated 1820

M33x3,5 DAC plated 2774 Lubricated 2460

M42x4,5 DAC plated 5700 Lubricated 5062

M48x5 DAC plated 8582 Lubricated 7610

Note: Quality of all bolts are 10.9.

For bolts and nuts used on the engine, transmission, axles and torque converters, tightening torques
recommended by the manufacturers will be used.

147
5.4. PERIODICAL INSPECTION AND MAINTENANCE LIST
1000 2000
Item to be serviced 10 hours 50 hours 250 hours 500 hours Remarks
hours hours
Noise and vibration ● 
Low speed running and acceleration control
(Loaded) ● 
Check engine emission (exhaust smoke color) ●  (1)
Check manifold and engine mounting brackets 
Check compression pressure 
Check for loose engine high-pressure piping
clamps, hardening of rubber
Replace every 8000 hours 
Check for cracks and leakage on exhaust
manifold

Check turbocharger bearings

Check hoses for leakage, damage and
deterioration ● ●
Check engine oil level and contamination ●
Check engine valve clearance, adjust 
Change engine oil ● (2)
Change engine oil filter elements ● (2)
Check fuel leakage and damage and deterioration
on fuel hoses ● ●
Change fuel filter elements ● (3)
Engine

Drain water and sediment from fuel filters ●

Check alternator belt tension, adjust if required ● 
Check water pump Every 4000 hours
Check function of monitor lamps and warning
systems ● 
Check general situation and leakage from engine
parts. If there is leakage, investigate the actual
cause and repair. ● 
Check general situation and leakage from air
intake system. If there is leakage, investigate the
actual cause and repair. ● 
Check engine cooling and heating system. Check
general situation of radiator, electric wiring of
heating system and make sure that there is no
damage or leakage. If there is leakage, ● 
investigate the actual cause and repair.
Check exhaust system.
Check general situation of system parts and
confirm that there is no leakage. If there is
leakage, investigate the actual cause and repair.
● 
Check all tanks, units, covers, bellows and
protective covers. If there is leakage or damage,
investigate the actual cause and repair. ● 
Check all pipes, hoses and electrical wiring.
Check for damaged, worn or disconnected parts ● 
and repair or replace.

148
 10 hrs 50 hrs 250 hrs 500 hrs 1000 hrs 2000 hrs
Item to be serviced Remarks
(daily) (weekly) (monthly) (3 monthly) (6 monthly) (annual)
Check hydraulic oil level ●
Clean hydraulic tank breather
●
element
Change hydraulic tank breather
●
element
Change return filter element ■ ●
Hydraulic System

Change pilot filter element ■ ●

Change drain (leakage line) filter
■ ●
element

● Once a
year or
Change hydraulic oil
every 2000
hours

Change hydraulic oil filter element ●

Check hydraulic hoses, replace if
● ● (4)
required
Check function of accumulators ● ●
General check / Visual check ●
Check fuel level ●
Fuel System

Drain water and sediment from fuel

●
tank
Clean fuel tank breather strainer ●
Drain water and sediment from fuel
WHEN REQUIRED
filter on chassis
General check / Visual check ●
Check tire inflation pressures and
●
damage on tires
Check front and rear shafts ●
Clean axle breather element ●
Check axle oil level, fill oil if required ●
Change front and rear axle oil ● (5)
Check transmission oil level ●
Power Train

Change transmission oil and clean

■ ●
intake strainer
Check transmission oil filter ■ ●
Clean transmission breather element ●
Grease articulation pins ●
Grease front and rear shafts ●
Check brake disk wear situation ●
Check parking brake ●
Check and tighten wheel hub nuts ●
Check function of emergency steering
system

General check / Visual check ●
Attachment

Grease attachment pins Check shim

●
clearances and readjust if necessary (6)
Check bucket teeth and replace if
●
necessary
General check / Visual check ●
Check electrical wiring ●
Replace damaged fuses ●
Electrical

Check battery electrolyte level ●

Check alternator ●
Check starting motor Every 4000 hours
Overhaul starting motor and
Every 8000 hours
alternator

149
 10 hrs 50 hrs 250 hrs 500 hrs 1000 hrs 2000 hrs Remarks
Item to be serviced
(daily) (weekly) (monthly) (3 monthly) (6 monthly) (annual)
Check cooling water level ●
Check antifreeze density ●
Cooling System

Check and clean surfaces of radiator

core, oil cooler core, condenser core ●
(machine with A/C)
Clean cooling system
Replace long-life antifreeze once in every 2 years (7)
Change cooling water
Check window washer fluid level, add
●
if required
Clean A/C condenser ●
Check A/C compressor belt tension
● ●
and adjust if required
Check A/C refrigerant ●
Others

Check A/C compressor and adjust Every 4000 hours

Change air cleaner outer element WHEN REQUIRED (8)
Change air cleaner inner element WHEN REQUIRED (8)
Clean A/C inner and outer filters.
WHEN REQUIRED (9)
Replace if required.
Change A/C outer filter WHEN REQUIRED (9)

NOTES
(●) Regular inspection and maintenance
(■) First inspection and maintenance
) This inspection/maintenance
conducted by HİDROMEK dealer.
(1) Please see troubleshooting section.
(2) Depending on used engine oil type and fuel
quality, filter replacement interval can be
shortened. For more information, refer to section
"Oil, Fuel, Cooling Water".
(3) Depending on used fuel quality,
replacement interval can be shortened.
(4) Depending on operation conditions, hoses and
fittings are old, worn out or dried within the time and
they lose their flexibility function.
All the hoses used on this machine must be
checked in periods no longer than 4 years against
becoming old, cracking, fraying, swelling, drying,
flattening, softening and hoses with any of above
defects must be replaced with new ones
immediately.
WARNING
Hoses are subject to very high-pressure. Oil jet
spurting even from a tiny hole may cause serious
injuries. If it happens, immediately see a
physician.
(6) Immediately after an operation under water or
on muddy ground, grease attachment pins and
other parts remaining under water even if the
must be periodic greasing time for the part is sometime later
until the dirty grease is totally pushed out. When it
is necessary to work inside water or mud for a long
period of time, stop operation from time to time and
lubricate such parts more frequently. Use high
performance type grease as specified in section
"Recommended Lubricants".
(7) For specifications of coolant, refer to "Cooling
filter Water" section.
(8) Change at 1000 hours / 1 year or at the time "air
filter clogged" lamp turns on. In case of operation
in extreme dusty conditions, reduce filter element
replacement interval.
(9) In case of operations in extremely dusty
conditions, reduce outer filter element (pollen filter)
replacement interval down to 250 hours.
IMPORTANT
Above maintenance list is prepared for normal
operation conditions. You can adapt this list to suit
the user or severe operating conditions such as
extreme dust, temperature, water and humidity.
For details, please refer to special maintenance
instructions given in this manual and follow your
Hidromek dealer's suggestions.

(5) The interval for changing the axle oil is for

standard operations. If the brake is used frequently
or the brakes make a sound, change the oil after a
shorter interval.

150
5.5. PERIODICAL INSPECTION AND
MAINTENANCE PROCEDURES
5.5.1. CHECKS BEFORE STARTING
For details of items below, please refer to the
related sections.
5.5.1.1. WALK AROUND INSPECTION TO BE
CONDUCTED BEFORE STARTING ENGINE
1. Check for damage, wear, and clearance on work
equipment, cylinders, linkage and hoses.
2. Remove dirt and dust around the engine, battery
and radiator.
3. Check for coolant or oil leakage around the
engine.
4. Check for leakage on the fuel line.
5. Check for leakage of oil on the transmission
case, axles, hydraulic tank, hoses and joints.
6. Check for oil leakage on the brake line.
7. Check for damaged or worn tires, wheels, and
wheel hub bolts and nuts, and check for loose
wheel hub bolts and nuts.
8. Check for damage and loose bolts on the
handrail and steps.
9. Check for damage on the gauges, lamps on the
monitor panel and loose bolts.
10. Check and clean rear view mirror.
11. Check for loose air cleaner mounting bolts.
12. Check for loose battery terminals
13. Check for damage on the seat belt and
mounting clamps.
14. Clean cab windows.
15. Check tires.
16. Check rims.
17. Check the monitor of the rear view camera.
5.5.1.2. INSPECTION TO BE CONDUCTED
BEFORE STARTING ENGINE
1. Check the machine monitor.
2. Check coolant level, and add coolant if the level
is low.
3. Check engine oil level in the oil pan, and add oil
if the level is low.
4. Drain water from the fuel filters.
5. Check the air cleaner.
6. Check fuel level, and add.
7. Check the electric wiring.
8. Check tire inflation pressure.
9. Check if window washer fluid functions.
10. Check the function of the wiper.
11. Check the function of the horn.
12. Check the defroster function.
13. Check the locks.
14. Check the emergency exit.
WARNING
Check that there is no obstacle and noone around
the machine. Sound the horn to warn people
nearby before starting the engine.
5.5.1.3. INSPECTIONS AND OPERATIONS
AFTER STARTING ENGINE
1. Check for smooth running of the engine and
check for unusual noise.
2. Check acceleration and deceleration of the
engine.
3. Check the parking brake.
4. Check brake performance.
5. Check for the clearance between the brake
pedal and floor.
6. Check for the abnormalities determined before.
151
5.5.2. EVERY 10 HOUR MAINTENANCE
5.5.2.1. GREASING ATTACHMENT PINS
1. Using a grease pump, pump in grease through
the grease fittings marked by numbers below.
2. After greasing, wipe off any previously used
grease that is pushed out.
3. Check shim clearances and adjust
necessary.
Fig 5.2
Fig 5.3
(1) Bucket connection pin (2 places)
(2) Bucket link pin (2 places)
(3) Z-bar connection pin (2 places)
(4) Z-bar upper connection pin (2 places)
(5) Lift arm connection pin (2 places)
(6) Lift cylinder bottom connection pin (2 places)
(7) Lift cylinder upper connection pin (2 places)
152
CAUTION
If the machine is used under severe conditions or
for 8 hours or more a day, shorten the greasing
intervals.
if Before starting greasing, park the machine in the
position shown below. Lower the bucket to the
ground and set it horizontally.
(8) Z-bar bottom connection pin (2 places)
(9) Bucket cylinder bottom connection pin(2
places)
(10) Shaft bearing (1 place)
(11) Bottom hinge connection pin (1 place)
(12) Upper hinge connection pin (1 place)
(13) Rear axle front pivot pin (1 place)
(14) Rear axle rear pivot pin (1 place)
5.5.2.2. CHECKING ENGINE OIL LEVEL

WARNING WARNING

The parts and oil are extremely hot immediately
after the engine is stopped, and may cause burns.
Wait for the temperature to go down before
starting the work. When removing the oil filler cap,
in order to avoid oil spurting, turn it slowly to
release the internal pressure, then remove it.
Do not fill oil up to MAX marking or above. Proper
oil level is midpoint between MIN and MAX
markings on the dipstick. If you notice an increase
in engine oil level, please contact your Hidromek
dealer.

1. Park the machine on hard and level ground.

Apply the parking brake. Lower the bucket to the
ground.
2. Stop the engine. Wait for about 5 minutes
after stopping the engine to let the oil in the engine
system flow into the oil pan.
3. Pull out the engine oil level dipstick. Wipe the
oil on dipstick surface with a clean cloth and then
fully insert it back to its pipe. Pull out the dipstick
again and check the oil level indicated on the
dipstick.
Minimum oil level and maximum oil level are shown
as MIN and MAX on the dipstick.
Correct oil level should be between MIN and MAX
markings. Do not fill oil in the oil pan above MAX
level. 2. Engine oil level dipstick location
Fig 5.4
4. After filling oil, run the engine at idle speed
and check the engine oil pressure gauge. Do not
increase the engine speed until the oil pressure
builds up. Otherwise the engine may be damaged.
In approximately 10 seconds after starting the
engine, "low oil pressure" warning lamp should go
off.
5. Check for oil leakage on the oil filler cap, oil
filter and, if necessary, on the drain plug at the
bottom of the oil pan.
6. If the oil level is low, remove the oil filler cap
and fill specified type of engine oil up to the proper
level.
7. After adding oil, follow the same procedure
2. Engine oil level dipstick
and check the oil level again.
Fig 5.5
8. Securely tighten the oil filler cap and insert
the oil level dipstick fully in its pipe.

WARNING

Beware of hot fluid and surfaces. When servicing the

machine, always wear protective glasses, gloves, a
hard hat and work clothes.

Fig 5.6. Engine oil level dipstick markings

153
5.5.2.3. CHECK TRANSMISSION OIL LEVEL,
ADD OIL IF NECESSARY

WARNING

The parts and oil are extremely hot right after the
engine is stopped, and may cause serious burns.
Wait for the temperature to go down before
starting an operation.

Transmission oil level is checked while the engine

is at idle speed. Transmission oil level control
Fig 5.7. Transmission oil level gauge
procedure is explained below:
1. Stop the machine on hard and level ground.
Apply the parking brake. Set the gear to neutral.
2. To check the transmission oil level, start the
engine while the transmission is cold.
3. After running the engine for 2 - 3 minutes at
idle speed, the transmission oil level should be
above cold running ("COLD MIN") line on the oil
level gauge.
4. While the engine is running at idle speed and
the transmission is at operating temperature
(between 80°C to 90°C), the transmission oil level Fig 5.8. Transmission oil filler cap
should be between "HOT MIN" and "HOT MAX"
lines.
5. If the transmission oil level is below "HOT
MIN" line, remove the oil filler cap and add
specified oil into transmission. For the specified oil,
please refer to section "OIL, FUECL, COOLING
WATER.

WARNING

Filling oil above maximum allowable level will

cause premature deterioration of the oil due to
overheated parts and foaming.
Early deterioration of oil will speed up wear on
parts and clogging of oil ports due to tiny particles
and metal chips. Overfilling will also cause oil
leakage.

154
5.5.2.4. CHECKING COOLING WATER LEVEL

WARNING

Cooling water is extremely hot immediately after

the engine is stopped and the system is under high
internal pressure. When expansion tank cap is
removed and cooling water is drained under these
conditions, it will cause burns and scalding. For
this reason, first wait for the cooling water
temperature to go down and then gradually turn
the cap and release internal pressure

Fig 5.11. Engine hood raise button

Proceed following steps to check cooling water
level:
1. Stop the machine on level ground and stop the
engine. Lower the attachment on the ground.
4. Confirm that the cooling water and radiator
cap are cold enough to touch by hands.
5. Check the cooling water level in the expansion
tank. Correct cooling water level is between "LOW"
and "FULL" lines on the tank.
6. If the cooling water level is low, wait for about
3 minutes for the engine to cool down, then fill the
specified cooling water through the filler cap of the
expansion tank and securely tighten the cap.

Fig 5.9. Machine maintenance position

2. Open the cover (1) on LH side of the machine.

Fig 5.12

NOTE

Fig 5.10 There are two expansion tanks. Expansion tanks

are located in the back of machine in front of the
3. By using engine hood button (B), raise the
radiator. The tanks do not differ from one another,
engine hood.
so you can fill any of them.

155
5.5.2.5. CHECKING INFLATION PRESSURE OF 5.5.2.5.2 INFLATION OF TIRES
TIRES, INFLATION OF TIRES Adjust inflation pressure properly as specified.
When inflating a tire, check that no one will enter
the working area. Use an air chuck which has a clip
and which can be fixed into the air valve.
While inflating a tire, check the inflation pressure
occasionally so that it will be too high.
If the rim is not fitted properly, it may break and
scatter while the tire is inflated. To ensure safety,
place a guard around the tire and do not work in
front of the rim but work on the tread side of the tire.
If the inflation pressure drops or the rim does not fit
properly, it indicates trouble with the tire or rim. In
this case, be sure to ask a tire repair shop to carry
out repairs.
Be sure to observe the specified inflation pressure.
Do not adjust the inflation pressure of the tires just
after high-speed travel or heavy-duty work.

5.5.2.5.1 CHECKING INFLATION PRESSURE OF Fig 5.13

TIRES
Measure the inflation pressure with a tire pressure When inflating a tire, use an air chuck which can be
gauge when the tires are cool, and before starting fixed into the air valve of the tire as shown in the
work. figure. Do not work in front of the rim but work on
the tread side of the tire.

NOTICE

The optimum tire inflation pressure differs

according to the type of work. For details, see
"TECHNICAL SPECIFICATIONS".

156
5.5.2.6. CHECKING FUEL LEVEL
To prevent the moisture in the air from condensing
and forming water inside the fuel tank, always fill
the fuel tank after completing the day's work.
WARNING
Before supplying the machine with fuel, lower the
work equipment on the ground and stop the
engine. While supplying fuel, do not move
machine control levers.
1) Turn starting switch to ‘I’ (ON) position.
Fig 5.14. Fuel level indicator
2) Check the fuel level on the fuel level indicator.
WARNING
Diesel fuel is flammable and combustible. Do not
approach with flame. Do not smoke near the
engine or while filling fuel. Do not supply fuel while
the engine is running.
1. Fuel tank filler cap
2. Diesel Exhaust Fluid filler cap (It is available on
machines with EU Stage4 engines)
Fig 5.15
3) To fill the fuel tank, open rear cover of the engine
hood to reach fuel tank filler cap (1). Open the fuel
tank filler cap with its key and supply specified
quality of diesel fuel (do not overflow).
4) After filling fuel, securely tighten the fuel tank
filler cap and lock it. Close rear cover of the engine
hood. Raise engine hood and drain water and
sediment from the fuel filters by loosening drain
plugs.
CAUTION
Drain water from fuel filter / water separator every
day. If water gets into the fuel system, the fuel
pump and fuel injectors will be damaged and the
engine performance will lessen.
WARNING
Use clean and rested specified fuel. If you have to
use diesel fuel out of standards, contact your
Hidromek dealer on oil replacement intervals.
Do not use gasoline as fuel. Since it generates
explosive gas inside the fuel tank, do not mix
diesel fuel with gasoline.
DIESEL FUEL
To receive full output and good performance from
your engine, use high quality diesel fuel. High
quality diesel fuel increases service life of your
engine and helps to keep exhaust emission values
within the regulations in force.
Use fuel only with properties given in this manual
in "OIL, FUEL, COOLING WATER" section.
CAUTION
If you use fuel other than the specified fuel in this
manual, following problems may occur: Engine
starting difficulty.
Shorter fuel filter life. Insufficient combustion.
Sediments inside fuel injectors.
Considerably shortened fuel system service life.
Sediments in cylinder combustion chamber.
Engine service life will be shortened.
1. Fuel tank filler cap
2. Diesel Exhaust Fluid filler cap (It is available on
machines with EU Stage4 engines)
Fig 5.16
157
5.5.2.7. CHECKING FOR FLUID LEAKAGE ON
ENGINE
1. Check for any sign of leakage on the whole
engine.
2. Use a cardboard when checking leakage
around high-pressure lines and hoses.
Fig 5.19
WARNING
Do not use your hands when checking fluid
leakage. Use a cardboard above and around the
place where you think there might be leakage to
find the exact location of the fluid leakage.
Highly pressurized fluid leakage from tiny holes
may penetrate under your skin and cause
serious injuries. In such a case, get immediate
medical care.
158
5.5.3. INITIAL 250 HOUR MAINTENANCE
Perform the following maintenance only after the
first 250 hours.
• Change transmission oil filter. For the
maintenance procedure, please refer to every 1000
hour maintenance section.
• Change transmission oil. For maintenance
procedure, please refer to every 1000 hour
maintenance section.
• Change axle oil. For maintenance procedure,
please refer to every 1000 hour maintenance
section.
• Clean axle breathers. For maintenance
procedure, please refer to every 500 hour
maintenance section.
• Change hydraulic oil filter elements. For
maintenance procedure, please refer to every 2000
hour maintenance section.
5.5.4. EVERY 50 HOUR MAINTENANCE
5.5.4.1. DRAIN WATER AND SEDIMENT FROM
FUEL TANK
Fig 5.20
Drain plug (1) is located on the left bottom side of
the fuel tank. Place a container with sufficient
capacity under the drain plug, loosen the drain plug
and drain water and sediment from the tank.

5.5.5. EVERY 100 HOUR MAINTENANCE
Maintenance for every 50 hour service should be
carried out with this maintenance at the same time.
5.5.5.1. CHECK OIL LEVEL IN HYDRAULIC
TANK, AND ADD OIL IF REQUIRED
WARNING
The parts and oil are extremely hot immediately
after the engine is stopped, and may cause
burns. Wait for the temperature to go down before
starting the work.
When removing the filler cap, the oil may spurt,
so turn the cap slowly to release the internal
pressure, then remove it carefully.
1. Hydraulic oil level gauge
2. Hydraulic tank breather
3. Hydraulic oil filler port
Fig 5.21
1. Stop the machine on hard and level ground.
2. Lower the bucket on the ground and stop the
engine
3. Wait for about 5 minutes before checking the
oil level. Proper oil level should be at the midpoint
of hydraulic oil level gauge. The proper oil level is
shown by an arrow on the figure.
NOTICE
If the oil level goes above the midpoint of the
hydraulic oil level gauge, stop the engine and wait
for hydraulic oil to cool down. Then, drain
excessive oil through the drain plug. If the oil level
is higher than the specified level, excess oil may
cause damages and cause hydraulic oil to spurt.
4. Loosen hydraulic tank breather (2) and
release the pressure inside the tank. Then securely
tighten the hydraulic tank breather again.
5. If the oil level is below the midpoint of the
gauge, remove hydraulic oil filler port (3) and
supply oil as required.
5.5.5.2. CLEANING AIR CONDITIONER
FILTERS, AND CHANGING IF REQUIRED
Fig 5.22
If compressed air is used to clean, dust and debris
scatter around, and there is the danger of injuries.
Always wear protective equipment such as
protective glasses and a mask.
When the air conditioner is used, the air filters
should be cleaned. Turn off the air conditioner
before cleaning the filters.
159
 Fig 5.25

5. Remove air conditioner outer filter (3) together

Fig 5.23 with the upper cover.
1. Stop the machine. Lower the work equipment
onto the ground. Apply the parking brake and
remove the starting key.
2. Air conditioner filters are located behind door
(1) on the RH side of the machine.
3. Open door (1) on the RH side.

Fig 5.26

6. Air conditioner inner filter is behind cover (2)

which is fixed by two knobs (5) on each side and
dovetailed at the bottom. Remove knobs (5).
Remove cover (2) of the inner filter.

Fig 5.24

4. Remove A/C outer filter (3) by turning knobs

(4) on both sides to counter clockwise direction.

Fig 5.27

160
7. Open A/C inner filter (6) by moving up retaining
plate (7) while holding it on the lower side. The
plate is hinged on the upper side.
8. After moving the plate up, remove air
conditioner inner filter (6).
9. Apply pressurized air (max. 0.5 bar) to the
removed filter elements from inside through the
pleats, then apply pressurized air from outside and
then again from inside through pleats.
Change the element if it cannot be cleaned with
pressurized air for some reason or change it once
every year.
10. After cleaning the filters, follow the reverse
order of removal and install them.

CAUTION

When the filter is clogged, air flow is reduced and

the A/C unit works noisily.

161
5.5.6. EVERY 250 HOUR MAINTENANCE
5.5.6.1. CHECKING BATTERY ELECTROLYTE
LEVEL
Carry out this procedure before operating the
machine.

WARNING

Do not use the battery if the battery electrolyte

level is below the LOWER LEVEL line. This will 1. Battery box
accelerate deterioration inside the battery and Fig 5.29
reduce the service life of the battery. In addition, it
may cause an explosion.
The battery generates flammable gas and there is
the danger of explosion, so do not approach the
battery with fire or flame.
Battery electrolyte is dangerous. If it gets into your
eyes or on your skin, wash it off with a large
amount of water and consult a physician at once.
When adding distilled water to the battery, do not
allow the battery electrolyte to go above the
UPPER LEVEL line. If the electrolyte level is too
high, it may leak and cause damage to the painted
surface or corrode other parts.
In cold weather, when you add distilled water, to
prevent it from freezing, add the water just before
starting the day's work in the morning.
Try to check the electrolyte level on a daily basis. 2. Battery
Be sure to check it at least once a month. Fig 5.30

2. Use a wet cloth to clean the area around the

5.5.6.1.1 CHECKING ELECTROLYTE LEVEL ON
SIDE OF BATTERY
To check the electrolyte level on the side of the
battery, do the following:
electrolyte level lines and check that the electrolyte
level is between the UPPER LEVEL (U.L.) and
LOWER LEVEL (L.L.) lines. If the battery is wiped
with a dry cloth, static electric may cause fire or
explosion.

1. Open cover (1) of battery box located on the RH

side of the machine.

Fig 5.28
Fig 5.31

3. If the electrolyte level is below the midpoint of

U.L and L.L marks, remove the cap immediately
and add distilled water (commercially available as
"battery water" until it reaches to UPPER LEVEL
(UL) line.
4. When adding distilled water through a cap (3),
also add water through the other caps.

162
5. Clean battery cap breather hole, then securely
tighten the cap.
Keep the battery upper surface clean and wipe it
with a wet cloth.
CAUTION
If distilled water is added above the U.L. line, use
a syringe to lower the level to the U.L. line.
Neutralize the removed fluid with baking soda
(sodium bicarbonate), then flush it with a large
amount of water. If necessary, consult your
Hidromek dealer or battery manufacturer.
5.5.6.2. CHECKING PARKING BRAKE
Fig 5.32
1. Set the machine on a dry downhill slope, apply
the parking brake and check if the parking brake
holds the machine in position.
2. If any problem is detected, please contact your
Hidromek dealer.
5.5.6.3. CHECKING ALTERNATOR AND A/C
COMPRESSOR BELT TENSION
NOTE
Before maintenance and/or repair work, stop the
engine and attach a CAUTION tag on the control
levers.
To bring the engine performance to maximum,
check for cracks and wear on the V-belt. If the belt
is cracked or damaged, replace it.
If the belt is elongated and there is no more
allowance for adjustment, or if the belt is cut or
cracked, replace the belt.
Check the belt whether there is any fluid on its
surface or not.
If below conditions exist, the V-belt must be
replaced.
• If there is crack on more than one layer
• If the belt slips
When required, replace the belt tensioner.
NOTICE
• Check each pulley for damage, wear of the V-
groove, and wear of the V-belt.
Be particularly careful to check that the V-belt is
not in contact with the bottom of the V-groove.
• If the belt is elongated and there is no more
allowance for adjustment, or if the belt is cut or
cracked, replace the belt.
163
5.5.6.4. CHECKING FOR LOOSE WHEEL HUB
BOLTS,AND TIGHTENING IF REQUIRED
If wheel hub bolts (1) are loose, wear on the tires
will increase and cause accidents.
Fig 5.33
1. Check for loose wheel nuts regularly, and
tighten if necessary.
When checking for loose wheel nuts, always turn
the nuts in the direction of tightening with a torque
wrench.
Tightening torque: 780 Nm
2. If it is necessary to replace a wheel nut,
replace all the nuts at the same time.
3. Tighten the wheel nuts in the numbered
sequence shown below. Then, retighten them to
the specified torque.
Fig 5.34
164
5.5.6.5. CLEANING ELEMENTS OF AIR
CONDITIONER FILTERS
For the procedure, please refer to section
"CLEANING AIR CONDITIONER FILTER
ELEMENTS, CHANGING IF REQUIRED".
CAUTION
When the filter is clogged, air flow is reduced and
the Air Conditioner unit works noisily.
5.5.6.6. CHECKING FUNCTION OF BRAKE
ACCUMULATOR
If the engine stops when the machine is traveling,
the oil pressure in the accumulator can be used to
apply the brake and move the machine to a safe
place as an emergency.
1. Stop the machine on level ground and lower
the work equipment completely to the ground.
2. Apply the parking brake.
3. Start the engine, run it at a mid-range speed for
1 minute, then stop the engine.
4. Turn the starting switch key to ON position and
depress the brake pedal repeatedly.
• If the brake oil pressure caution lamp does not
light up even when the brake is depressed 6 times,
the gas pressure in the accumulator is normal.
• If the brake oil pressure caution lamp lights up
when the brake has been depressed 5 or fewer
times, the gas pressure in the accumulator has
probably dropped. Please contact your Hidromek
dealer to have the accumulator inspected.
CAUTION
Carry out the check within the 5 minutes after
stopping the engine. Otherwise, the accumulator
pressure will drop and it will be impossible to check
the cause of the problem.
5.5.6.7. LUBRICATING ATTACHMENT PINS
For the procedure, refer to section "GREASING
ATTACHMENT PINS".
5.5.6.8. CLEANING AND IF NECESSARY
REPLACING FUEL TANK BREATHER ELEMENT
If you clean the breather while the engine is
running, dust and dirt may enter inside the tank and
cause engine failure. Before cleaning and/or
changing the fuel tank breather element, stop the
engine.

1. Fuel tank breather

Fig 5.35

Always stop the engine before doing this operation.

1. Open the cover behind the engine hood.
2. Remove element (1).
3. Apply dry, pressurized air from inside the
element.
4. After cleaning, install the element. When
installing, pay attention to how it should be
mounted.
5. Close the cover behind the engine hood.

WARNING

If the element is dirty or clogged, replace it with a new

one.

165
5.5.7. EVERY 500 HOUR MAINTENANCE 4. Loosen oil filter screw cap with a socket
wrench and wait for the oil to drain from the filter
Every 50, 100 and 250 hour maintenance should
housing.
be carried out at the same time with 500 hour
maintenance.
5.5.7.1. CHANGING OIL IN ENGINE OIL PAN, CAUTION
REPLACING ENGINE OIL FILTER CARTRIDGE
Before removing the screw cap, wait until the oil
inside the filter housing is completely drained.
WARNING
5. Pull out screw cap (4) together with oil filter
The parts and oil are extremely hot immediately element (6) and separate oil filter element (6) from
after the engine is stopped, and may cause burns. the clips by pressing on both sides and remove.
Wait for the temperature to go down before
starting the work.
When removing the oil filler cap, turn it slowly to
release the internal pressure, then remove it.
Have a filter wrench with you.

1. Stop the machine on hard and level ground

and lower the work equipment completely to the
ground.
2. Apply parking brake (1).Set the control lever
lock button in LOCK position.
3. Raise the engine hood.

4. Oil filter screw cap

5. Filter gasket
6. Filter element
Fig 5.38. Oil filter element

NOTE

Fig 5.36 Be sure not to let foreign materials get inside the
filter housing. Do not wipe the filter body at all.
Replacement Of Engine Oil Filter

6. Replace gasket (5). Lightly lubricate the

gasket with engine oil.
7. Attach new oil filter element (6) on screw cap
(4) with clips.
8. Screw then screw cap (4) together with the oil
filter element. Tighten screw cap (4) to a torque of
55 Nm.

CAUTION

Check whether there is old gasket residues on the

cap. If not cleaned, such residues may cause oil
3. Engine oil filter
leakage.
Fig 5.37

166
CAUTION NOTE
Drain the engine oil while the engine is at Check the drained oil, and if there are excessive
operating temperature. metal particles or foreign material, please contact
your Hidromek dealer.
Draining Engine Oil

CAUTION
Dispose drained oil according to the environmental
regulations in force. For disposal and recycling of
oil, you are advised to ask help from professional
specialized companies.

13. After draining the oil completely, tighten the

oil pan drain plug with a hexagon wrench and then
check for leakage.

CAUTION
7. Engine oil filler cap
When outside temperature is low, water or other
Fig 5.39 emulsified substances may stick on dipstick, oil
filler cap and such or drained oil may be in milky
9. Remove engine oil filler cap (7).
consistency due to water vapor in compression
gas. If the cooling water level is normal, this is not
a problem. After changing oil, a little emulsified
CAUTION substance may remain, and this is not a problem
either.
Before removing the filler cap, clean the area
around the cap. Otherwise, dust may enter the
engine and cause damage. Filling Engine Oil

10. Place a suitable container for the oil drained

under the drain plug.
11. Do not drain oil immediately after stopping the
engine. Wait for 5 minutes to let the oil flow to the
oil cartridge.
12. Loosen oil pan drain plug (8) with a hexagon
wrench and drain the oil.

1. Engine oil filler cap

Fig 5.41

14. Remove engine oil filler cap (7).

15. Fill the type and quantity of engine oil which
is specified in this manual.
16. Tighten engine oil filler cap (7).

Fig 5.40

167
Checking Engine Oil Level
17. Run the engine for 1-2 minutes at idle speed
and then stop.

NOTE

Do not increase the engine speed while the engine

oil pressure is still low, otherwise, the engine may
be damaged. Watch "low engine oil pressure"
warning lamp. This lamp must turn off in a few
seconds.

18. Check for leakage on the oil filler cap and if

necessary check for leakage on the oil pan drain
plug.
19. After waiting for about 5 minutes, check the
engine oil level. If required, add oil. For detailed
information, refer to section "Checking engine oil
level, adding oil if necessary".

9. Engine oil level check dipstick

Fig 5.42

168
 2. Stop the engine.
5.5.7.2. REPLACING FUEL PRE-FILTER 3. Apply the parking brake.
ELEMENT
4. Raise the engine hood.
5. Open the engine side cover on the RH side of
WARNING the machine.
When changing the main filter element, change the
After the engine is stopped, all parts and oil are pre-filter elements as well
extremely hot, so it may cause burns. Wait for all
parts and oil to cool down before starting any
replacement.
High pressure is generated inside the engine fuel
piping system when the engine is running.
When replacing the filter, wait for at least 5 minutes
after stopping the engine to let the internal
pressure go down before replacing the filter. Do
not approach with any fire or flame.

4. Primary fuel pre-filter

Fig 5.45

Removing Fuel Filter Element

6. Remove the fuel tank cap and then put it back
1. Main fuel filter again to release the internal pressure in the fuel
2. Fuel pre-filter tank.
Fig 5.43 7. Clean fuel filter modules (1) and (2), and the
areas around.
8. Change main fuel filter (1). Refer to section.
"5.5.7.3. CHANGING MAIN FUEL FILTER
ELEMENT".
9. Put a suitable container under filter (2) to collect
the drained fuel.
10. Loosen fuel pre-filter screw cap (2) with a
socket wrench and let fuel flow from the housing
of fuel filter.

CAUTION

Before removing the screw cap, wait for the fuel in

1. Screw cap of main fuel filter the fuel filter housing to be completely drained.
2. Screw cap of fuel pre-filter
3. Priming pump
Fig 5.44
11. Pull out fuel filter screw cap (2) from its
To change fuel pre-filters, follow the procedure housing together with the filter element, and
explained below: separate the filter element from the screw cap by
pressing on the sides of the element.
1. Park the machine on hard and level ground and
lower the work equipment on the ground.

169
12. To collect the flowing fuel, place a suitable Checking Fuel Filter Element
container under primary fuel pre-filter (4).
24. Start the engine and while the engine is
13. Remove primary fuel pre-filter (4) element. running, check whether there is leakage on the fuel
filter or not. Check only visually and then stop the
14. Turn and remove the water separator cover
engine.
below the element and separate it from the
element.

NOT NOTICE

Do not allow foreign materials to enter inside the
housing. Do not wipe the filter body for any reason.
Otherwise, it may cause failure or damage.
Installing Fuel Filter Element
15. Change the gasket of screw cap (2). Lightly
grease the gasket.
16. Insert the new filter element inside screw cap
(2).
17. Install screw cap (2) fuel pre-filter element in
the filter housing and tighten it to a torque of 55
Nm.
18. Fit a new O-ring on the new primary fuel pre-
filter
(4). Lightly lubricate the O-ring with engine oil.
Genuine Hidromek fuel filter cartridges have a
special filter that has highly efficient filtering ability.
When replacing the filter cartridge, always use a
genuine Hidromek part
The common rail fuel injection system used on this
machine consists of more sensitive parts than the
conventional injection pump and nozzle.
If any part other than a genuine Hidromek filter
cartridge is used, dust or dirt may get in and cause
problems with the injection system. Always avoid
using substitute parts.
When carrying out inspection or maintenance of
the fuel system, pay more attention than normal to
the entry of dirt. If dirt is stuck on any part, use fuel
to wash it off completely.
Have a filter wrench and a container ready to
collect the drained oil.

19. Install element (4) by turning it.

20. When installing, tighten the element until the
packing surface contacts the seal surface of the
filter holder, then tighten it 3/4 of a turn. Tighten
the filter by hand only, do not use a wrench.
21. Turn priming pump (3) handle counter
clockwise and release the handle.
22. Move the priming pump (3) up and down until
pressure is generated on the opposite side.
23. Turn priming pump (3) handle clockwise and
tighten the handle.

170
5.5.7.3. CHANGING MAIN FUEL FILTER
ELEMENT

WARNING
After the engine is stopped, all parts and oil are
extremely hot, so wait for all parts to cool down
before starting any operation.
High pressure is generated inside the engine fuel
piping system when the engine is running.
When replacing the filter, wait for at least 5 minutes
after stopping the engine to let the internal
pressure go down before replacing the filter. Do
not approach with any fire or flame.
NOTICE
Genuine Hidromek fuel filter cartridges have a
special filter that has highly efficient filtering ability.
When replacing the filter cartridge, always use a
genuine Hidromek part.
The common rail fuel injection system used on this
machine consists of more sensitive parts than the
conventional injection pump and nozzle.
If any part other than a genuine Hidromek filter
cartridge is used, dust or dirt may get in and cause
problems with the injection system.
Always avoid using substitute parts.
When carrying out inspection or maintenance of
the fuel system, pay more attention than normal to
the entry of dirt. If dirt is stuck on any part, use fuel
to wash it off completely.
Have a filter wrench and a container ready to
collect the drained oil.

1. Stop the machine on hard and level ground and

lower the work equipment completely to the
ground.
2. Stop the engine.
3. Apply the parking brake.
4. Raise the engine hood.
1. Main fuel filter
5. Open the engine side cover on the RH side of
2. Fuel pre- filter the machine.
Fig 5.46
When changing the main filter element, change the
pre- filter elements as well.

Removing fuel filter element

6. Remove the fuel tank cap and put it back again
to release the internal pressure in the fuel tank.
7. Clean the fuel filter module and the areas
around.
8. Change the fuel pre-filter.
9. Place a container with a sufficient capacity
under the fuel filter to collect the fuel.
10. Loosen main fuel filter screw cap (1) with a
socket wrench and let the fuel flow from the
housing of the fuel filter.

1. Screw cap of main fuel filter

2. Screw cap of fuel pre-filter CAUTION
3. Priming pump
Fig 5.47 Before removing the screw cap, wait until the fuel
in fuel filter housing is completely drained.

171
Pull out fuel filter screw cap (1) from its housing
together with the filter element and separate the NOT
filter element from the screw cap by pressing on the
sides of the element.
Dispose collected water/fuel mixture according to
environmental regulations in force, without
NOTE
harming the environment.

Do not allow foreign materials to enter inside the

housing. Do not wipe the filter body for any reason.
Otherwise, it may cause failure or damage. 16. Tighten drain valve (6) by hand and
disconnect hose (5).
12. Drain water and sediments from the water 17. Tighten the fuel tank cap.
separator.

Installing Fuel Filter Element

Draining water and sediments from the water
separator 18. Replace gasket of screw cap (1). Lightly
lubricate the gasket with grease.
19. Insert a new filter element inside screw cap
(1). Use grease inside the parts kit and lubricate
gaskets (7) and (8).

Fig 5.49
4. Fuel filter module
5. Hose 20. Install screw cap (1) inside the filter housing
together with the fuel pre- filter element and tighten
6. Drain valve it to a torque of 55 Nm.
Fig 5.48
21. Turn priming pump (3) knob
counterclockwise, and release.
NOTE 22. Operate priming pump (3) until counter
pressure is build up.
Drain water from the water separator while the fuel 23. Turn priming pump (3) knob clockwise, and
filter and fuel pre-filter are dismantled. tighten.

Checking Fuel Filter Element

13. Remove the fuel tank cap.
24. Start the engine and check leakage on the
14. Connect a suitable hose (5) to drain valve (6) fuel filter module while the engine is running. Check
of fuel filter module (4). visually only and then stop the engine.
15. Loosen drain valve (6) and collect the drained
water/fuel mixture in a suitable container.

172
5.5.7.4. CHECKING AXLE OIL AND ADDING IF
NECESSARY
WARNING
All parts and oil are extremely hot after the engine
is stopped, and may cause burns. Wait for the
temperature to go down before starting any work.
Fig 5.50. Rear axle
5.5.7.5. CLEANING AXLE BREATHERS
1. Stop the machine on hard and level ground.
Align front and rear frames in line.
2. Apply the parking brake. Set the gear in "N"
(Neutral) position.
3. Lower the work attachment on the ground.
Stop the engine and remove the starting key.
4. Apply the frame lock bar to fix front and rear
frames.
5. Remove both front axle breather (1) and rear
axle breather (2).
6. Use a brush to clean the breather elements
and the area around the breathers.
7. After cleaning the breather element from dirt
and dust, immerse the element in a container filled
with detergent and water.
8. When the breather element is removed, be
careful not to allow dust and dirt to enter through
the mounting hole. Temporarily close the hole by
using a masking band.

Fig 5.51. Front axle

1. Stop the machine on hard and level ground.

Align the front and rear frames in line.
2. Apply the parking brake. Set the gear in "N"
(Neutral) position.
3. Lower the work attachment on the ground.
Stop the engine and remove the starting key.
4. Apply the frame lock bar to fix front and rear
frames.
Fig 5.52. Front axle breather element
Clean the area around filler/drain plug (2) and
remove the plug and gasket washer. Check that the
oil is at the specified level. If required, add oil of the
same type and brand as specified.

CAUTION

Before removing plug (1), carefully clean the

area around it.

5. After cleaning, install the plug and gasket

washer together and tighten it to a torque of 50 Nm.

Fig 5.53. Rear axle breather element

173
5.5.7.6. CLEANING AIR CONDITIONER 5.5.7.7. CHANGING HYDRAULIC TANK
CONDENSER BREATHER ELEMENT
When the condenser gets dirty, clean it by using
water. It is forbidden to use steam cleaner because
it will heat the condenser. WARNING

If cleaning water pressure is high, core fins may be All he parts and oil are extremely hot right after the
damaged. When the cleaning is performed with
engine is stopped, and may cause burns. Wait for
high-pressure water, apply water jet from a safe
the temperature to go down before starting any
distance not to damage the fins.
work.
When highly pressurized water is directed to a When removing the oil filler cap, oil may spurt.
person or if dirt is sprayed with highly pressured When removing the oil filler cap, turn it slowly to
water, it may cause personal injuries. release the internal pressure, then remove it.
Always use protective equipment such as
protective glasses, dust mask and so on.

Fig 5.54. A/C condenser Fig 5.56. Hydraulic tank breather

Cleaning method:
1. Open the rear cover of the engine hood and
apply water to condenser (1) from the top to clean.

1. Hydraulic tank breather

2. Breather element
3. Breather housing
4. Breather cover
Fig 5.57

Fig 5.55. Turning A/C condenser

2. Turn the condenser with the arm on the RH
side, apply water from rear side of condenser, and
from inside to outside and clean.
1. Turn the cover by hand to left.
2. Remove the element.
3. Install the new element.
4. Install the cover and tighten by hand.

174
5.5.7.8. CLEANING RADIATOR FINS 5.5.7.8.2 CLEAN RADIATOR FINS WITH
COMPRESSED AIR
WARNING
Before starting to clean, stop the engine and place
a CAUTION tag on the work equipment control
Do not open engine side covers while the engine
levers.
is running. Before checking the fins, make sure
that engine comes to a complete stop. Cleaning done by opening the engine rear cover
If compressed air, high-pressure water, or steam 1. Open the rear cover of the engine hood.
hits your body directly or if dirt is scattered by
2. Use pressurized air to clean mud, dust and
compressed air, high-pressure water, or steam,
leaves stuck on the fins.
there is the danger of personal injuries. Always
wear protective glasses, dust mask, and other
WARNING
protective equipment.
Steam or water can be used instead of
If radiator is clogged with mud and dirt, apply the
compressed air. However, when using high-
following procedure to clean.
pressure steam jet to clean the fins, keep the
5.5.7.8.1 CLEANING RADIATOR FINS BY nozzle at a safe distance from the fins.
REVERSING COOLING FAN
If the steam jet nozzle is brought too close to the
Fan reversing function can be actuated manually radiator fins, it may damage the fins, so keep the
and automatically. When operating at dusty and nozzle at a suitable distance away from the fins
dirty environment, adjust the fan to automatic when cleaning.
reversing mode. By this way, dirt and dust stuck on
the radiator can be instantly removed and cleaning 3. Check the condition of the rubber hoses. If you
interval can be extended. notice any cracks or hardening, replace with new
ones. Also check hose clamps and tighten the
WARNING loose clamps (if any).
4. After finishing the cleaning work, close the
When operating the fan in reverse direction, pay
engine hood rear cover.
close attention to objects scattered and avoid
your clothes etc to be caught by the fan.
Since dust is going to be pushed out during Cleaning done when the engine side cover is
reversing operation, do not allow anybody to be open
near the machine.
1. Open the engine side covers on both sides
behind the engine hood.
Manual Reversing of Fan
2. Use pressurized air to clean mud, dust and
When Fan Manual Reversing Mode is selected, fan
leaves stuck on the fins.
reversing function is activated and in 3 minutes it is
automatically deactivated. 3. Check the condition of rubber hoses. If you
notice any cracks or hardening, replace with new
WARNING ones. Also check hose clamps and tighten the
loose clamps (if any).
When working, never rotate the fan reverse with 4. To remove the scattered dust and dirt from the
your hands. machine, use an air gun.
Automatic Reversing of Fan 5. After finishing the cleaning work, close the
engine hood side covers and fix them.
Automatic Reversing Function has 3 different
modes. Active mode can be changed by selecting
another mode.
1.Mod: Acts 2/3 minutes in every 2 hours and
periodically becomes active as long as the machine
is in operation.
2.Mod: Acts 2/3 minutes in every 1 hour and
periodically becomes active as long as the machine
is in operation.
3.Mod: Acts 3 minutes in every 30 minutes and
periodically becomes active as long as the machine
is in operation.

175
5.5.7.9. GREASING SHAFTS

WARNING

Before starting to grease, stop the machine on

hard and level ground. Apply the parking brake
and set FNR lever in N (Neutral) position. To
avoid the engine’s running unintentionally, place
"DO NOT OPERATE" warning tags on the work
equipment control levers. Failure to obey the
regulations may cause serious injuries and death.

1. Using a grease pump, pump in grease through

the grease fittings marked with arrows (1).
2. After greasing, wipe off any previously used
grease that was pushed out.

Fig 5.68

176
5.5.8. EVERY 1000 HOUR MAINTENANCE
Maintenance for every 50, 100, 250 and 500 hours
should be carried out at the same time with this
maintenance.
5.5.8.1. CHANGING OIL IN TRANSMISSION
CASE, CLEANING STRAINER

WARNING
All the parts and oil are extremely hot right after the
engine is stopped, and this may cause burns. Wait
for the temperature to go down before starting any
work.
When removing the oil filler cap, oil may spurt.
When removing the oil filler cap, turn it slowly to
release the internal pressure, and then remove it.

WARNING
After changing transmission oil, transmission should
be calibrated using a special device. Therefore, have
the transmission oil change and calibration of the
transmission in Hidromek Authorized Service.

Draining transmission oil 1. Oil drain plug

1. While the transmission is at operating 2. Oil strainer cover
temperature, stop the machine on hard and level
Fig 5.58. Front view of transmission
ground. Apply the parking brake.
2. Lower the front attachment on the ground. Stop
the engine and remove the starting key.
3. Find oil drain plug (1) which is located on the
transmission under the machine, towards the rear
side of the operator's cabin.
4. To collect the drained oil, place a suitable
container under oil drain plug (1).
5. Remove drain plug (1) and O-ring of the plug.
Clean O-ring grooves on the plug and remove
residues on the magnetic portion. Wait for the oil to
drain completely. Re-install the drain plug to its
hole with a new O-ring and tighten it to a torque of 3. Oil strainer and gasket
80 Nm.
Fig 5.59
Cleaning transmission oil strainer
1. When changing transmission oil, always check
the transmission suction strainer. If strainer is
damaged, it must be replaced with a new part.
2. To pull out transmission oil strainer (3), remove
the bolts of strainer cover (2). Remove cover (2),
strainer (3), and the O-ring.
3. Remove the dirt stuck on the strainer, then wash
in clean diesel oil or flushing oil. If the strainer is
damaged, replace it with a new part.
4. Before re-installing strainer (3), lubricate the
sealing element shown with an arrow on the figure.
5. After cleaning the parts, re-install in reverse 4. Oil strainer cover and O-ring
order. Change O-ring (O-ring size: 90x4). Lubricate 5. Bolt and nut
sealing element shown by arrow in the figure.
Fig 5.60
6. Install M8/8.8x16 bolts and washers and tighten
the strainer cover bolts to a torque of 23 Nm.

177
Filling transmission oil
1. Remove the transmission oil filler cap and fill
specified amount of oil.
2. Run the engine at idle speed.
3. Set FNR lever in N (neutral) position.
4. Fill transmission oil until it reaches to "COLD
MIN" level line on the transmission oil level gauge.
5. Stop the machine and heat up transmission
oil.
6. Select all the gears in order on FNR lever.
7. Check the transmission oil level again and if 6. Transmission oil filler cap
necessary, add oil. Fig 5.61
8. Check whether there is leakage of oil on the
transmission or not.
Check that the transmission oil level is correct. For
details please refer to section "CHECKING
TRANSMISSION OIL LEVEL, ADDING IF
REQUIRED".

7. Transmission oil level gauge

Fig 5.62

178
5.5.8.2. CHANGING TRANSMISSION OIL
FILTERS
Whenever oil is changed, transmission oil filter has
to be changed as well.

WARNING

All the parts and oil are extremely hot right after
the engine is stopped, and may cause burns. Wait
for the temperature to go down before starting any
work.

1. While the transmission is at operating

temperature, stop the machine on hard and level
ground. Apply the parking brake.
2. Lower the front attachment on the ground. Stop
the engine and remove the starting key.
3. Raise the engine hood. Fig 5.63. Transmission oil filters
4. Remove the side panel located at the rear right
side of the machine and front side of the engine
room. Transmission filter holder is fixed on chassis.
5. Set a container directly under transmission filter
case (1) to collect the drained oil.
6. Clean the filters and filter holders.
7. Using a filter wrench, remove the filters.

WARNING
Fig 5.64. Transmission oil filler cap
When changing the filters, it is very important to
keep the system clean, therefore make sure not to
let dirt and dust enter in transmission lines or
parts.

8. Lightly lubricate the O-rings of the new filters.

9. Tighten the filter until O-ring contacts the filter
holder. Then tighten further (1/3 to 1/2 of a turn).
Tighten the filter with your hands only, and do not
use a filter wrench or any other tool.

WARNING Fig 5.65. Transmission oil level gauge

When installing new filters do not apply extreme

force.

10. Check that the transmission oil level is correct.

For details please refer to section "CHECKING
TRANSMISSION OIL LEVEL, ADDING IF
REQUIRED".
11. Check that there is no oil leakage on the
transmission oil filters.

179
5.5.8.3. CLEANING TRANSMISSION BREATHER
ELEMENT

CAUTION

When the breather element is removed, be careful

not to allow dust and dirt to enter the mounting
hole. Temporarily close the hole by using a
masking band.

1. Stop the machine on hard and level ground.

Apply the parking brake.
2. Lower the front attachment on the ground.
Stop the engine and remove the starting key. Fig 5.66
3. Tilt the operator's cabin. For detailed
information, refer to section "OPERATION OF
OPERATOR'S CABIN TILTING MECHANISM".
4. Find transmission breather (1) located on the
transmission housing.
After cleaning dirt and dust on breather element
(1), immerse the element (1) in a container filled
with detergent and water

1. Transmission breather
Fig 5.67. Transmission view from top

5.5.8.4. CHECK OF ENGINE AIR INTAKE PIPING

CLAMPS FOR LOOSENESS
Check the clamps between the air cleaner,
turbocharger, aftercooler, and engine for
looseness. If any clamp is loose, retighten it.

5.5.8.5. CHANGING AIR CONDITIONER

FILTERS
For details, refer to section "CLEANING AIR
CONDITIONER FILTERS, CHANGING IF
REQUIRED".

5.5.8.6. CHANGING HYDRAULIC TANK RETURN

FILTER ELEMENT

180
WARNING
All the parts and oil are extremely hot right after
the engine is stopped, and may cause burns. Wait
for the temperature to go down before starting any
work.
When removing the oil filler cap, oil may spurt.
When removing the oil filler cap, turn it slowly to
release the internal pressure, and then remove it.
1. Hydraulic return filter element
2. Hydraulic return filter cover lock
3. Hydraulic return filter cover key
Fig 5.69
1. Lower bucket horizontally on the ground,
apply the parking brake and then stop the engine.
2. Remove the hydraulic tank breather and
release the tank internal pressure. Then re-install
the hydraulic tank breather.
3. Open return filter cover (1) using its own key
(if available).
4. Remove return filter cover (1) with a wrench
of
55 mm by loosening it counterclockwise.
NOTICE
After opening the cover, be careful not to allow
dust and dirt to go inside.
5. Pull out return filter element (7).
6. Install a new return filter element.
7. Clean the disassembled parts and metal
chips stuck on the magnetic rod under the cover.
1. Cover
4. O-ring
5. Magnetic rod
6. O-ring
7. Return filter element
Fig 5.70
8. Replace the O-ring of the cover if there is any
damage or deterioration.
9. Install return filter cover (1) and tighten it to a
torque of 30 Nm with a torque wrench.
10. Check hydraulic oil level. For details, refer to
section "CHECKING OIL LEVEL IN HYDRAULIC
TANK, ADDING OIL IF REQUIRED".
11. Check for oil leakage on the filter cover.
12. Run the engine at low idle, then operate the
steering, bucket, and lift arm cylinders before the
end of their stroke 4 to 5 times (stop 100 mm before
their stroke end).
WARNING
If the engine runs at high speed immediately after
startup or a cylinder is pushed up to its stroke end,
air taken inside the cylinder may cause damage to
the piston packing.
13. Next, operate the steering, bucket, and lift arm
cylinders to the end of their stroke 3 to 4 times, then
stop the engine. Bleed air while engine is running
at low idle.
14. Check hydraulic oil level. For details refer to
section "CHECKING OIL LEVEL IN HYDRAULIC
TANK, ADDING OIL IF REQUIRED".
181
5.5.8.7. CHANGING HYYDRAULIC TANK DRAIN
LINE (LEAKAGE) FILTER ELEMENT
WARNING
All the parts and oil are extremely hot right after
the engine is stopped, and may cause burns. Wait
for the temperature to go down before starting any
work.
When removing the oil filler cap, oil may spurt.
When removing the oil filler cap, turn it slowly to
release the internal pressure, and then remove it.
1. Hydraulic drain (leakage) filter
2. Hydraulic drain (leakage) cover socket
Fig 5.71
1. Lower the bucket horizontally on the ground,
apply the parking brake and then stop the engine.
2. Remove the hydraulic tank breather and release
the tank internal pressure. Then re-install the
hydraulic tank breather.
3. Remove drain filter cover (1) with a 36 mm
wrench by turning it counterclockwise.
NOTICE
After opening the cover, be careful not to allow
dust and dirt to go inside.
4. Remove pressure parts (4) and by-pass valve
(5).
5. Pull out drain filter element (6).
6. Install new drain filter element (6).
7. Clean the disassembled parts and metal chips
stuck on the magnetic rod under the cover.
182
8. Replace O-ring (3) of the cover if there is any
damage or deterioration.
9. Install drain filter cover (1) and tighten to a torque
of 25 Nm with a torque wrench.
1. Cover
3. O-ring
4. Pressure parts
5. By-pass valve
6. Drain filter element
Fig 5.72
10. Check hydraulic oil level. For details refer to
section "CHECKING OIL LEVEL IN HYDRAULIC
TANK, ADDING OIL IF REQUIRED".
11. Check oil leakage on the filter cover.
12. Run the engine at low idle, then operate the
steering, bucket, and lift arm cylinders before the
end of their stroke 4 to 5 times (stop 100 mm before
their stroke end).
WARNING
If the engine runs at high speed immediately after
startup or a cylinder is pushed up to its stroke end,
air taken inside the cylinder may cause damage to
the piston packing.
13. Next, operate the steering, bucket, and lift
arm cylinders to the end of their stroke 3 to 4 times,
then stop the engine. Bleed air while the engine is
running at low idle.
14. Check hydraulic oil level. For details refer to
section "CHECKING OIL LEVEL IN HYDRAULIC
TANK, ADDING OIL IF REQUIRED".
5.5.8.8. CHANGING HYDRAULIC PILOT FILTER
ELEMENT
WARNING
All the parts and oil are extremely hot right after
the engine is stopped, and may cause burns. Wait
for the temperature to go down before starting any
work.
When removing the oil filler cap, oil may spurt.
When removing the oil filler cap, turn it slowly to
release the internal pressure, and then remove it.
6. Pull the pilot filter element to separate it from
the filter holder.
7. Replace the O-ring and gaskets with new
parts.
8. Install a new pilot filter element by pressing
on it.
9. Install the filter case to its location and tighten
it to a torque of 35-40 Nm.
10. Check hydraulic oil level. For details refer to
section "CHECKING OIL LEVEL IN HYDRAULIC
TANK, ADDING OIL IF REQUIRED".
11. Check the oil filter for oil leakage.
12. Run the engine at low idle, then operate the
steering, bucket, and lift arm cylinders before the
end of their stroke 4 to 5 times (stop 100 mm before
their stroke end).

WARNING

If the engine is run at high speed immediately after

startup or a cylinder is pushed up to its stroke end,
air taken inside the cylinder may cause damage to
the piston packing.

13. Next, operate the steering, bucket, and lift

arm cylinders to the end of their stroke 3 to 4 times,
then stop the engine. Bleed air while the engine is
running at low idle.
14. Check hydraulic oil level. For details refer to
section "CHECKING OIL LEVEL IN HYDRAULIC
1. Drain plug TANK, ADDING OIL IF REQUIRED".
2. Socket
3. Filter case
NOTICE
4. Filter holder
Fig 5.73 After opening the cover, be careful not to allow
dust and dirt to go inside.

1. Lower the bucket horizontally on the ground,

apply the parking brake and then stop the engine.
2. Remove the hydraulic tank breather and
release the tank internal pressure. Then re-install
the hydraulic tank breather.
3. Place a suitable container under the pilot filter
to collect hydraulic oil to be drained.
4. Remove the drain plug under the pilot filter
and drain the oil inside the filter.
5. Loosen the pilot filter case with a 24 mm
wrench and remove it. When the case is removed,
pilot filter element stays attached on the filter
holder.

183
5.5.9. EVERY 2000 HOUR MAINTENANCE
Maintenance for every 50, 100, 250, 500 and 1000
hours should be carried out with this maintenance
at the same time.
5.5.9.1. CHANGING OIL IN HYDRAULIC TANK,
REPLACING HYDRAULIC FILTER ELEMENT
WARNING
All the parts and oil are extremely hot right after
the engine is stopped, and may cause burns.
Wait for the temperature to go down before
starting any work.
When removing the oil filler cap, oil may spurt.
When removing the oil filler cap, turn it slowly to
release the internal pressure, and then remove it.
CAUTION
When the valve is opened, pressurized oil may
come out from the valve at first. Be careful not to
get it on you.
5. After draining the oil, set the drain valve in
close position.
6. Remove 3 bolts (2) and then remove the drain
plug cover. While doing this, check the O- ring of
the cover and replace it if damaged.
7. Remove filler filter element (3) and install a
new filler filter element (3).
8. Place the cover and fix it with 3 bolts (2).
Tightening torque of the bolts (2): 35 Nm.
9. Remove oil filler plug (3).
10. Fill specified amount of hydraulic oil through
oil filler plug (3) and install the cover.
11. Tightening torque of the oil filler plug: 30 Nm.
12. Check hydraulic oil level. For details refer to
section "CHECKING OIL LEVEL IN HYDRAULIC
TANK, ADDING OIL IF REQUIRED".

1. Hydraulic tank breather

2. Hydraulic oil filler plug bolts
3. Hydraulic oil filler plug
Fig 5.74

1. Lower the bucket horizontally on the ground,

apply the parking brake and then stop the engine.
2. Remove the hydraulic tank breather and
release the tank internal pressure. Then re-install
the hydraulic tank breather.
3. Hydraulic oil tank drain valve is located on the
right rear side of the machine. Connect one end of 2. Spring
the connection hose to the tip of the hydraulic oil
3. Filler filter element
tank valve and place the other end of the hose
inside a drum with a sufficient capacity. 4. Filter holder
4. Set the drain valve to open position and drain Fig 5.75. Parts of hydraulic oil filler filter
the oil.

184
5.5.9.2. CHANGING AXLE OIL
WARNING
All the parts and oil are extremely hot right after
the engine is stopped, and may cause burns.
Wait for the temperature to go down before
starting any work.
When removing the plug, oil may spurt, so turn
the plug slowly to release the internal pressure,
and then remove it carefully.
10. Fill the specified oil through the hole of the
filler / level plug. For the specified oil, refer to
section ‘Oil, Fuel, Cooling water".
11. Oil level should be just at the edge of the
filler/level hole.
CAUTION
Before removing plugs (1) and (2) clean the area
around them.
12. Install the plug and gasket washer together
after cleaning and tighten it to a torque of 50 Nm to.

CAUTION

When the brakes are used more frequently due to

the types of operations, change the axle oil at
shorter intervals.
Fig 5.76. Front axle

Fig 5.77. Rear axle

1. Stop the machine on hard and level ground.

Align the front and rear frames in line.
2. Apply the parking brake. Set the gear in "N"
(Neutral) position.
3. Lower the work attachment on the ground.
Stop the engine and remove the starting key.
4. Apply the frame lock bar and fix the front and
rear frames.
5. Place a sufficient container under drain plug
(1) to collect the oil to be drained.
6. Clean the area around oil drain plug (1) and
filler/level plug (2).
7. Remove oil drain plug (1) and its gasket
washer. Wait for the oil to be drained. Drain plug is
magnetic. Wipe the plug to clean. Carefully inspect
the metal particles stuck on the magnetic part.
8. Install oil drain plug (1) with its gasket washer
and tighten it to a torque of 50 Nm.
9. Remove filler/level plug (2) and its gasket
washer.

185
5.5.9.3. CHECKING BRAKE DISC WEAR
Wear amount of the brake disk should be checked
at least once a year. When disk wear amount
reaches its service limits, you must check more
frequently without waiting for the specified interval.
Particularly, disks must be checked if any of the
situations mentioned below exist:
• Noise during braking
• Low braking power
• Low deceleration speed
• After changing brake oil
• When braking pressure changes
Fig 5.79
Wear amount of a brake disk must be measured on
four different points, on both sides of the front axle
and rear axle. Apply the same control procedure for
all. WARNING

On axles with sinter disk:

When X ≤ 3,5 mm, disks on both sides have to be
replaced.

8. Install the inspection plug with a new O-ring

and tighten it to a torque of 50 Nm.

NOTICE
Fig 5.78. Inspection plug
This work requires two workers. While the one
1. Do this inspection, when the brake oil presses the pedal, the other checks the clearance.
temperature is below 60°C.
2. Before starting this inspection, apply the
parking brake.
3. Apply the frame lock bar and lock the front
and rear frames.
4. Remove the inspection plug.
5. Press the brake pedal.
6. Using a feeler gauge, check clearance "X"
shown on the figure.
7. "X" dimension is equal to the thickness of the
inner clutch disk on the piston side.

186
5.5.9.4. CHECKING FUNCTIONS OF
HYDRAULIC ACCUMULATOR
If the engine stops when the work equipment is
raised, and it is impossible to start the engine
again, it is possible as an emergency measure to
actuate the valve with the oil pressure stored in the
accumulator and lower the work equipment on the
ground.
1. Apply the parking brake.
2. Raise the work equipment to the max height,
then operate lift arm control lever to HOLD position
3. Stop the engine.
4. Turn the starting switch to ON position.
5. Leave the work equipment lock button in
FREE position.
6. After checking that the area around the
machine is safe, set the lift arm control lever to
FLOAT position and lower the work equipment to a
point which is 1 m above the ground.
7. When the work equipment is 1m above the
ground, return the lift arm control lever to LOWER
position and lower the work equipment slowly to the
ground.

CAUTION

Carry out the check within the 2 minutes after

stopping the engine. Otherwise, the accumulator
pressure will drop and it will be impossible to check
the cause of the problem.
If the work equipment stops while it is moving, the
gas pressure in the accumulator has probably
dropped. Please contact your
Hidromek dealer to have the accumulator
inspected.

5.5.9.5. CHECKING ALTERNATOR

Contact your Hidromek dealer for an inspection or
repair. If the engine works frequently, carry out this
inspection more frequently.

5.5.9.6. CHECKING AND IF NECESSARY

ADJUSTING ENGINE VALVE CLEARANCE
As special tools are required, contact your
Hidromek dealer for removing and adjusting the
engine valve clearance.

187
5.5.10. EVERY 2 YEAR MAINTENANCE
5.5.10.1. CHANGING COOLANT AND CLEANING
INSIDE OF COOLING SYSTEM
WARNING
Immediately after the engine is stopped, the
engine coolant is hot and the pressure inside the
radiator is high. Removing the cap of expansion
tank and draining the water under this condition
could cause burns and scalding. For this reason,
allow the engine to cool down, then turn the cap of
expansion tank slowly to release the pressure and
remove the cap .
WARNING
Before standing up or leaving the operator's seat,
set the work equipment lock lever to LOCK
position.
The coolant density varies according to the
ambient temperature, but it must always be a
minimum of 30%.
Antifreeze is toxic. When opening the drain valve,
be careful not to get water containing antifreeze on
you. If it gets in your eyes, wash your eyes with
large amount of fresh water and see a physician at
once.
When changing coolant or draining coolant from
the radiator before carrying out repairs, contact
your Hidromek dealer or ask companies to handle
any coolant containing antifreeze. Antifreeze is
toxic, so never pour it into drainage water ditches
or drain it into the ground.
For detailed information about coolant, please refer
to section "OIL, FUEL, COOLING WATER". Check
the density with a coolant tester. Prepare a
container whose capacity is larger than the
specified coolant volume to collect the drained
coolant.
Prepare a hose to use it when filling coolant.
To drain cooling water, do the following steps:

For details of starting the engine, see "CHECK

BEFORE STARTING ENGINE, ADJUST" and
"STARTING ENGINE" in the OPERATION section
of the Operation and Maintenance Manual.

WARNING
Fig 5.80. Machine maintenance position
Never enter the area behind the machine when
the engine is running. 1. Park the machine on level ground and stop the
engine. Lower the attachment on the ground.
Clean the inside of the cooling system, change the
coolant according to "Coolant Density Table" in
section "Oil, Fuel and Coolant".
The coolant has the important function of
preventing corrosion as well as preventing
freezing. Even in the regions where freezing is not
an issue, the use of antifreeze coolant is essential.
If you use another coolant other than the one
recommended by Hidromek, it may cause serious
problems, such as corrosion on the engine and on
the aluminum parts of the cooling system.
To maintain the anticorrosion properties of coolant,
always keep the density of coolant between 30%
and 64%. 1. Parking brake button
When preparing the coolant, antifreeze and 2. Work equipment control lever lock button
distilled water mixture specified by Hidromek must
Fig 5.81
be used. When using coolant, investigate the
lowest temperatures in the past and decide on the
density of the coolant as it is shown on the coolant
density table below. When actually deciding on the
density of the coolant, set it for a temperature 10°C
(18°F) below the actual temperature.

188
2. Apply parking brake (1). 6. Check that the expansion tank cap is cool
enough to touch by hand. Gradually turn the cap to
release the internal pressure and then remove it.

Fig 5.82

3. Set the frame safety bar in LOCK (L) position.

5. Cooling water drain valve and hose

Fig 5.86

7. Remove the panel on the RH side of the

Fig 5.83
4. Open cover (3) on the LH side of the machine.
engine.
8. Place a container under the coolant drain hose
to collect the coolant. Open radiator drain valve (5)
and drain the water. After draining the water, close
radiator drain valve (5).
9. Fill water into the cooling system through the
expansion tank. After filling the system with water,
close the expansion tank cap.
10. Start the engine after filling water.

4. Engine hood raise button

Fig 5.84

5. Raise the engine hood up by using engine

hood raise button (4).
Fig 5.87

11. Slightly depress accelerator pedal to run the

engine with no load for about 5 minutes to warm-
up the engine.
12. Upon completion of warm-up operation,
confirm that engine speed is stable and then press
control lever lock button (2) to release the lock.

Fig 5.85

189

Fig 5.88
13. Set the bucket control lever in tilt position (A)
first, then set it back in dump position (C), repeat
this operation several times to raise the hydraulic
oil temperature.
With above operation, hydraulic system works in
relief pressure and cause hydraulic oil temperature
to increase in a short time.
Fig 5.89
14. To increase the oil temperature of the
steering valve, operate the steering wheel
approximately 10 times to left and right.
While doing this, make sure not to relieve the oil
pressure in the system longer than 5 seconds.
Fig 5.90
15. By repeating the above steps from 12 to 14,
the temperature indicated on the engine cooling
water temperature gauge, located on the monitor
panel, will increase.
190
16. Stop the engine. Remove the expansion tank
cover and open the drain valve to drain the water.
After cooling water is completely drained, close the
drain valve.
17. Fill cooling water through the cap of the
expansion tank up to the top.
For the density of cooling water refer to section
"COOLING WATER DENSITY TABLE".
18. To bleed the air inside cooling water, first run
the engine at low idle for 5 minutes and then run at
higher speed for another 5 minutes. Leave the
expansion tank cap open while doing this.
19. Stop the engine and wait for about 3 minutes
to cool down. Check the cooling water level
through the expansion tank. Cooling water level
should be between FULL - LOW lines at midpoint.
If required, add cooling water.
Fig 5.91
NOTE
There are two expansion tanks in the cooling
system. Expansion tanks are located behind the
machine in front of the radiator. Both tanks are the
same and any of them can be filled with cooling
water.
5.5.11. EVERY 4000 HOUR SERVICE
Maintenance for every 50, 100, 250, 500, 1000 and
2000 hours should be carried out with this
maintenance at the same time.

5.5.11.1. CHECKING WATER PUMP

Check that there is no leakage of water on the
water pump. If there is any water leakage, please
ask your Hidromek dealer to repair it or replace it.

5.5.11.2. CHECKING STARTING MOTOR

Contact your Hidromek dealer to have the starting
motor inspected. If the engine works frequently,
carry out the inspection more frequently.

5.5.11.3. CHECKING AIR CONDITIONER

COMPRESSOR, ADJUSTING IF REQUIRED
Please ask your Hidromek dealer to carry out this
service.

5.5.11.4. CHECKING FOR LOOSE ENGINE HIGH

- PRESSURE PIPING CLAMPS, AND CHECKING
FOR HARDENING OF RUBBER
Check visually and feel with your hands to check
that there are no loose mounting bolts on the high-
pressure piping clamps and that there is no
hardening of any rubber parts. If there are such
problems, ask your Hidromek dealer to replace the
parts.

5.5.12. EVERY 8000 HOUR SERVICE

Maintenance for every 50, 100, 250, 500,
1000, 2000 and 4000 hours should be carried out
with this maintenance at the same time.

5.5.12.1. REPLACEMENT OF ENGINE HIGH-

PRESSURE PIPING CLAMPS
Contact your Hidromek dealer to have the engine
high-pressure clamps replaced.

5.5.12.2. OVERHAULING OF STARTING MOTOR

AND ALTERNATOR
Contact your Hidromek dealer to overhaul the
starting motor and the alternator.

191
5.5.13. MAINTENANCE TO BE CONDUCTED
WHEN REQUIRED NOTICE

5.5.13.1. REPLACING AIR CLEANER ELEMENT

Do not remove the inner element unless it is
necessary to be replaced.
Make sure that elements are fitted properly.
Otherwise, foreign particles and dust may enter the
engine and cause serious engine problems.
If inspection or maintenance is carried out when the
engine is running, dirt will get into the engine and
damage it. Always stop the engine before carrying
out these operations.
When using compressed air, there is the danger
that dirt may be blown around and cause serious
Fig 5.93 injuries. Always use protective glasses, a dust
mask, and other protective equipment.

Replace the outer element when "air filter clogged"

WARNING
Do not replace the air filter when the engine is
running.
Do not run the engine without an air filter or with a
damaged air filter.
If the engine has worked in dusty environments,
reduce filter replacement intervals.
warning lamp on the machine monitor turns ON.
HİDROMEK does not recommend cleaning the
outer element.
Air intake port of air filter is on the RH side of the
machine. Follow below procedure to remove the
filter elements.

Fig 5.95

1. Cover
2. Outer filter
3. Inner filter
4. Filter housing
5. Dust evacuator
Fig 5.94

192
Fig 5.96 Fig 5.99

1. Remove the air filter cover by unlocking the 4. Remove the dust evacuator.
clips on four sides of the housing.
5. Carefully clean the dust evacuator, inside of
the air filter housing and the cover.

Fig 5.97

2. Pull the outer air filter element backwards. Fig 5.100

6. Hold the handle of the inner filter element and

remove the element by pulling backwards.

WARNING

Never remove the inner element. Dust will enter

the engine and cause serious problems.

WARNING

The inner element must not be used again after

cleaning. When replacing the outer element,
replace the inner element at the same time.

Fig 5.98
WARNING
3. Pull the outer air filter element upwards and
remove. Do not reuse any element with damaged pleats,
gaskets or seals.

193
5.5.13.2. CHECKING WINDOW WASHER FLUID
LEVEL, ADDING IF REQUIRED
Window washer tank is located on the LH side of
the machine under the step. Filler cap of window
washer tank is on the right upper corner of the step.
Check the level of water in window washer tank and
if the level is low, fill with fluid used in automobiles.
While supplying water, be careful not to let dust and
dirt enter.
Fig 5.101
194
5.5.13.3. REPLACING BUCKET TEETH
Replace the bucket teeth and the segment edges
before they wear down to the end face of the
bucket.
1. Raise the bucket to put blocks underneath to
prevent it from lowering. The bottom of the bucket
should be horizontal.
2. To remove the bucket tooth, use a
screwdriver to take out the adapter notch and
release the tooth. When the tooth is released,
remove it.
3. Clean the installation surface of the bucket
tooth.
4. Install the new tooth on the bucket.
If the mounting surface is worn out, repair the
mounting surface before installing the new tooth.
Fig 5.102
5.5.13.4. CHECKING AIR CONDITIONER
5.5.13.4.1 CHECKING FUNCTION OF AIR
CONDITIONER
If the refrigerant used in the air conditioner gets into
your eyes or on your hands, it may cause loss of
sight or frostbite. Do not touch the refrigerant.
Never loosen any part of the refrigerant circuit.
Do not approach any point where the refrigerant
gas is leaking with open flame.
1. Start the engine and run it at approx. 1,500
rpm.

Fig 5.104

5. By pressing air conditioner button (7), turn the

air conditioner to ON position.
6. If the cooling effect of the air conditioner is
poor, contact your Hidromek dealer to have the
refrigerant (gas) level checked.

2. A/C key
9. Temperature down key
10. Temperature up key
11. Fan speed lower key
12. Fan speed increase key
13. Aircon ON/OFF key
14. Outside air intake key
Fig 5.103 9. A/C condenser
Fig 5.105

2. Press fan key (12) and set the fan to its 5.5.13.4.2 MAINTENANCE SCHEDULE OF AIR
maximum speed. CONDITIONER

3. Pres temperature adjustment key (9) and set

the temperature to 18°C. Maintenance schedule
Check Check Checks
4. Open the doors and windows fully. point items before 6 months Changing
operation interval
Filter clogged,dust Check － 2 year
Condenser clogged,dust Check － －
loosening,
Belt damage Check － 2 year
A/C gas quantity － Check －
loosening,
Piping damage,leak － Check －
Receiver
drier － － － 2 year

195
5.5.13.5. REPLACING FUSES
Refer to FUSES section for details.
5.5.13.6. CHECKING FUNCTION OF CDC
ACCUMULATOR
When CDC button is set in ON position, CDC
function is activated and the vertical movements of
the machine during traveling are absorbed. With
this function, comfortable driving of the machine is
provided and as a result of this smooth running,
spillage of load on the bucket while traveling is
minimized.
Check CDC accumulator as follows:
*CDC: Comfortable Drive Control
1. Set CDC button in ON position and watch
vertical movements of the machine.
2. Set CDC button in OFF position and watch
vertical movements of the machine.
3. If there is no remarkable difference in vertical
movements of the machine while CDC button is set
in ON and OFF positions, the gas pressure of CDC
accumulator may have dropped.
Contact Hidromek dealer to check CDC
accumulator gas pressure.
CAUTION
To check the gas pressure of CDC accumulator,
• Set CDC button in ON position.
• Set FNR lever in Forward position.
• Drive machine above 6 km/h.
CDC activates in above conditions.
After CDC is activated, if machine speed drops
below 4 km/h, CDC is de-activated.
196
5.5.13.7. SELECTION/INSPECTION OF TIRES
If a tire or a rim is handled improperly, the tire may
burst or may be damaged and the rim may be
broken and scattered, and these can cause serious
injuries or even death.
1. Since maintenance, disassembly, repair and
assembly of the tires and rims require special
equipment and skill, be sure to ask a tire repair
shop to do the work.
2. It is prohibited to do welding and to have a fire
near the tires.
5.5.13.7.1 SELECTION OF TIRES
Select the tires according to the conditions of the
use and the weight of the attachments on the
machine. Use only specified tires and inflate them
to the specified pressure.
WARNING
Consult your Hidromek dealer about what tires are
appropriate to be used.
• If you install tires increasing the machine weight
(such as urethane), the machine may be damaged
due to this unforeseen weight. Do not use this type
of tires.
• If a tire not recommended by Hidromek is used,
the tire may not fit on the rim properly. Operator's
comfort will also be impaired.
NOTICE
The optimum tire inflation pressure differs
according to the type of work. For details, see
"TECHNICAL SPECIFICATIONS".
5.5.13.8. BLEEDING AIR FROM FUEL SYSTEM
After supplying fuel to an empty fuel tank, the air
inside the system must be bled from the system
with a hand operated pump.
First, the air from the primary fuel pre-filter must be
bled and then the air in the engine fuel circuit must
be bled by using the priming pump on the engine.
When you see some water accumulated inside the
primary fuel pre-filter, remove the drain plug and
drain the water. Drain the water accumulated
inside the fuel pre-filter regularly.

Draining Water Collected Inside the Primary

Fuel Pre- filter
1. Place a container under the filter to collect water-
fuel mixture to be drained.
2. Loosen drain valve (5) by turning it
counterclockwise.
3. Operate hand pump (4) and drain water-fuel
mixture.
4. Tighten drain valve (5) by turning it clockwise

Bleeding air the from system by using the hand

pump on the primary fuel pre-filter
1. Remove the fuel tank cap.
1. Filter holder
2. Place a container under the pre-filter. 2. Filter body
3. Air bleeder
3. Remove air bleeder plug (3). 4. Hand pump
5. Drain valve
4. Operate hand pump (4) on the pre-filter until fuel
without bubbles starts to flow through the air
bleeder plug.
Fig 5.106. Primary Fuel pre- filter
5. Tighten air bleeder plug (3).
NOTE

NOTE
If the fuel tank is completely empty, operate hand
pump (4) until pressure is generated on the
opposite side and bleed the air.
Then use the hand pump on the main filter and
bleed the air from the total circuit. Follow the
instructions in "Bleeding the air from system by
using the hand pump on the main filter" section.

CAUTION

The fuel injection pump and fuel injectors used on

this engine are more sensitive than the ones used
in conventional systems. Entry of foreign materials
may cause serious engine failures. For this
reason, when dust enters the system, wash it with
clean fluid.
Be careful when removing the air bleeder on top
of the fuel filter since fuel may spurt due to internal
pressure.

197
Draining water from the main filter
1. Place a container under the filter to collect
water-fuel mixture to be drained.
2. Loosen drain valve (6) by turning it
counterclockwise.
3. Keep the valve open until water-fuel mixture
is drained and clean fuel starts to flow.
4. Tighten drain valve (6) by turning it clockwise

Bleeding air from the system by using the hand

pump on the main filter
Fig 5.107. Main fuel filter Drain Plug
Bleed the air inside the fuel system by operating
the hand pump.
Do not use different procedures while bleeding air
from the fuel system. Otherwise, starting motor
may be damaged.
1. Turn starting switch to ON position.
2. Set FNR lever in "N" (neutral) position.
3. Remove the fuel tank cap.
4. Operate hand pump (7) about 250 times in 3
minutes or operate it until opposite pressure is
generated.
Fig 5.108. Hand Pump
5. Press "Engine Start / Engine Stop" button
for about 5 seconds and start the engine.
6. If the engine starts, set the engine to higher
speed.
7. If the engine does not start, repeat the above
procedure.
8. Install the fuel tank cap.
9. Turn the starting switch to START position
and keep it in this position. Do not depress the
accelerator pedal.

NOTE

Starting procedure will be automatically cancelled

in 40 seconds.

10. After waiting for about 1 minute, repeat the

starting procedure.
11. If the engine starts, depress the accelerator
pedal several times.
12. Air is completely bled from the fuel system.

198
5.5.13.9. DRAINING WATER AND SEDIMENT
FROM CHASSIS FILTER, CHANGING
STRAINER IF NECESSARY

1. Filter holder
2. Filter case

Fig 5.109

Follow the procedures below to drain water and

sediment from the chassis fuel filter:
1. Stop the machine on hard and level ground.
Align the front and rear frames in line.
2. Apply the parking brake. Set the gear in "N"
(Neutral) position.
3. Lower the work attachment on the ground. Stop
the engine and remove the starting key.
4. Place a container under the filter to collect water-
fuel mixture to be drained.
5. Separate the case and strainer inside from filter
holder (1) by turning filter case (2) clockwise.
6. Drain water-fuel mixture.
7. Clean inside the filter case and strainer. Replace
the strainer if it cannot be cleaned.
8. Replace the O-ring.
9. Insert the strainer into filter case (2) and fix it on
filter holder (1) by turning clockwise.

199
6. COMMUNICATION INFORMATION
Manufacturer: Hidromek A.Ş.
Title: Hidromek-Hidrolik ve Mekanik Makine İmalat Sanayi ve Ticaret Anonim Şirketi

6.1. PLANTS AND AFTER SALES SERVICES

MAIN PLANT / HEAD OFFICE
Address Ahi Evran OSB Mahallesi Osmanlı Caddesi No: 1 Sincan/ANKARA TURKEY
Phone 90 312 267 12 60
Fax 90 312 267 12 39
İnternet www.hidromek.com.tr
E-mail info@hidromek.com.tr
Customer line musteriiletisimhatti@hidromek.com.tr
444 6 465 (HMK)

AFTER SALES SERVICES DEPARTMENT

Address Şehit Osman Avcı Mahallesi No: 479 (İstanbul Yolu 17.Km) Etimesgut/Ankara
Phone +90 312 280 87 40
Fax +90 312 280 87 48
Spare Parts Fax +90 312 280 87 49
E-mail ssh@hidromek.com.tr

İZMİR PLANT
Address Ege Serbest Bölgesi, Akçay Caddesi, 144/1, Ayhan Sokak, No: 24, Gaziemir/İZMİR
Phone +90 (232) 251 69 00 - 251 60 57
Faks +90 (232) 251 01 20
E-mail esb@hidromek.com.tr

TAYLAND PLANT
Address Amata Nakorn Industrial Estate Phase 7, 700/669 Moo 1, T.Phanthong A.Phanthong,
Chonburi 20160, TAYLAND
Phone +66 38 447 349
Faks +66 38 447 355

SPAIN (OFFICE)
Address C/De la Maquina 14, Poligono Industrial El Regás, 08850 - GAVA(BARCELONA)
Phone +34 93 638 8465
Faks +34 93 638 0714
E-mail contact@hidromek.es

RUSSIA (OFFICE)
Address 72, Zhivopisnaya str., village Oktyabrskiy, Krasnodar, Russia, 350032
Phone +7 861 290 3007
E-mail HidromekRus@hidromek.ru

200