Description
Hitachi Shinrai Power BX100 Backhoe Loader Operator Manual
Hitachi Shinrai Power BX100 Backhoe Loader Index:
1. MACHINE INTRODUCTION ………………………………………………………………………………………………………. 1
1.1 RECORD PRODUCT IDENTIFICATION NUMBER(PIN) ……………………………………………………………….1
1.2 ENGINE SERIAL NUMBER …………………………………………………………………………………………………..1
1.3 RECORD REAR AXLE SERIAL NUMBER ………………………………………………………………………………….1
1.4 RECORD FRONT AXLE SERIAL NUMBER ………………………………………………………………………………..1
1.5 RECORD TRANSMISSION SERIALNUMBER …………………………………………………………………………….2
1.6 CHASSIS NUMBER ……………………………………………………………………………………………………………2
1.7 OPERATOR’S MANUAL STORAGE ON THE MACHINE ………………………………………………………………2
1.8 DIRECTION ……………………………………………………………………………………………………………………..3
1.9 COMPONENT IDENTIFICATION …………………………………………………………………………………………..4
2. SAFETY ………………………………………………………………………………………………………………………………. S-1
2.1 SAFETY SIGNS AND OTHER INSTRUCTIONS ……………………………………………………………………….. S-1
2.2 SAFETY-YOURS AND OTHERS ………………………………………………………………………………………….. S-3
2.3 RECOGNISE SAFETY INFORMATION …………………………………………………………………………………. S-3
2.4 UNDERSTAND SIGNAL WORDS ……………………………………………………………………………………….. S-4
2.5 FOLLOW SAFETY INSTRUCTIONS ……………………………………………………………………………………… S-5
2.6 AVOID INJURY FROM ROLLOVER ACCIDENTS …………………………………………………………………….. S-6
2.7 USE SEAT BELT PROPERLY………………………………………………………………………………………………. S-6
2.8 AVOID INJURY FROM REVERSE DIRECTION ACCIDENTS ……………………………………………………….. S-7
2.9 AVOID INJURY FROM ROLL AWAY ACCIDENTS …………………………………………………………………… S-7
2.10 INSPECT THE MACHINE …………………………………………………………………………………………………. S-8
2.11 USE HANDRAILS AND STEPS …………………………………………………………………………………………… S-8
2.12 PREVENT MACHINE RUNAWAY ………………………………………………………………………………………. S-8
2.13 MAINTENANCE OF SEAT BELT …………………………………………………………………………………………. S-9
2.14 SECONDARY EXITS ………………………………………………………………………………………………………… S-9
2.15 DRIVE MACHINE SAFELY ………………………………………………………………………………………………… S-9
2.16 TRAVEL SAFELY …………………………………………………………………………………………………………… S-10
2.17 OPERATE BACKHOE SAFELY ………………………………………………………………………………………….. S-10
2.18 AVOID POWER LINES …………………………………………………………………………………………………… S-10
2.19 BEWARE OF EXHAUST FUMES ………………………………………………………………………………………. S-11
2.20 KEEP RIDERS OFF MACHINE ………………………………………………………………………………………….. S-11
2.21 HANDLE FUEL SAFETY-AVOID FIRES ……………………………………………………………………………….. S-11
2.22 PREPARE FOR EMERGENCIES ………………………………………………………………………………………… S-12
2.23 CLEAN TRASH FROM MACHINE ……………………………………………………………………………………. S-12
2.24 PROTECT AGAINST FLYING DEBRIS ……………………………………………………………………………….. S-12
2.25 WEAR PROTECTIVE CLOTHING……………………………………………………………………………………… S-13
2.26 PROTECT AGAINST NOISE ……………………………………………………………………………………………. S-13
2.27 USE SAFETY LIGHTS AND DEVICES ………………………………………………………………………………… S-13
2.28 WARN OTHERS OF SERVICE WORK ……………………………………………………………………………….. S-14
2.29 PRACTICE SAFE MAINTENANCE ……………………………………………………………………………………. S-14
2.30 REMOVE PAINT BEFORE WELDING OR HEATING ……………………………………………………………… S-15
2.31 AVOID HEATING NEAR PRESSUREIZED FLUID LINE …………………………………………………………… S-16
2.32 AVOID APPLYING HEAT TO LINES CONTAINING FLAMMABLE FLUIDS ………………………………….. S-16
2.33 AVOID HIGH‐PRESSURE FLUIDS ……………………………………………………………………………………. S-16
2.34 CLEAN THE MACHINE REGULARLY ………………………………………………………………………………… S-17
2.35 SERVICE COOLING SYSTEM SAFELY ……………………………………………………………………………….. S-17
2.36 STORE ATTACHMENTS SAFELY ……………………………………………………………………………………… S-17
2.37 DISPOSE OFF WASTE PROPERLY …………………………………………………………………………………… S-18
2.38 GENERAL PRECAUTIONS FOR CAB ………………………………………………………………………………… S-18
2.39 ADJUST THE OPERATOR’S SEAT ……………………………………………………………………………………. S-19
2.40 ENSURE SAFETY BEFORE RISING FROM OR LEAVING OPERATOR’S SEAT ……………………………… S-19
2.41 JUMP STARTING. ……………………………………………………………………………………………………….. S-19
2.42 PRECAUTIONS FOR OPERATIONS ………………………………………………………………………………….. S-20
2.43 INVESTIGATE JOB SITE BEFORE HAND ……………………………………………………………………………. S-20
2.44 PROVIDE SIGNALS FOR JOBS INVOLVING MULTIPLE MACHINES …………………………………………. S-21
2.45 KEEP PERSON CLEAR FROM WORKING AREA ………………………………………………………………….. S-21
2.46 NEVER POSITION BUCKET OVER ANYONE ………………………………………………………………………. S-22
2.47 AVOID UNDERCUTTING ………………………………………………………………………………………………. S-22
2.48 AVOID TIPPING ………………………………………………………………………………………………………….. S-22
2.49 NEVER UNDERCUT A HIGH BANK ………………………………………………………………………………….. S-23
2.50 DIGWITH CAUTION …………………………………………………………………………………………………….. S-23
2.51 OPERATE WITH CAUTION ……………………………………………………………………………………………. S-23
2.52 PRECAUTIONS FOR LIGHTNING…………………………………………………………………………………….. S-23
2.53 OBJECT HANDLING …………………………………………………………………………………………………….. S-24
2.54 PARK MACHINE SAFELY ………………………………………………………………………………………………. S-24
2.55 TRANSPORT SAFELY……………………………………………………………………………………………………. S-24
2.56 SUPPORT MACHINE PROPERLY …………………………………………………………………………………….. S-25
2.57 STAY CLEAR OF MOVING PARTS …………………………………………………………………………………… S-26
2.58 PREVENT BURNS ……………………………………………………………………………………………………….. S-26
2.59 REPLACE RUBBER HOSES PERIODICALLY ………………………………………………………………………… S-26
2.60 PREVENT FIRES …………………………………………………………………………………………………………… S-27
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2.61 EVACUATING IN CASE OF FIRE ………………………………………………………………………………………. S-28
2.63 PRECAUTIONS FOR WELDING AND GRINDING …………………………………………………………………. S-29
2.64 PRECAUTIONS FOR HANDLING ACCUMULATOR AND GAS DAMPER …………………………………….. S-30
2.65 BEWARE OF ASBESTOS AND SILICON DUST AND OTHER CONTAMINATION…………………………… S-30
2.66 PREVENT BATTERY EXPLOSIONS ……………………………………………………………………………………. S-30
2.67 SERVICE AIR CONDITIONING SYSTEM SAFELY ………………………………………………………………….. S-31
2.68 HANDLE CHEMICAL PRODUCTS SAFELY ………………………………………………………………………….. S-31
2.69 NEVER RIDE ATTACHMENT …………………………………………………………………………………………… S-32
2.70 PRECAUTIONS FOR COMMUNICATION TERMINAL ……………………………………………………………. S-32
3. OPERATOR’S STATION…………………………………………………………………………………………………………….. 1
3.1 INGRESS & EGRESS …………………………………………………………………………………………………………. 1
3.2 SIDE CONSOLE ASSEMBLY‐CLUSTER …………………………………………………………………………………… 2
3.3 FRONT CONSOLE ASSEMBLY …………………………………………………………………………………………….. 4
3.4 PARK BRAKE SWITCH ………………………………………………………………………………………………………. 6
3.5 GEAR LEVER SWITCH (DE‐CLUTCH) ……………………………………………………………………………………. 6
3.6 LOADER LEVER SWITCH (DE‐CLUTCH) ………………………………………………………………………………… 6
3.7 STARTER RELAY ……………………………………………………………………………………………………………… 6
3.8 BRAKE‐STOP LIGHT PRESSURE SWITCHES …………………………………………………………………………… 6
3.9 ENGINE COOLANT TEMPERATURE INDICATOR …………………………………………………………………….. 7
3.10 ENGINE OIL PRESSURE INDICATOR ……………………………………………………………………………………. 7
3.11 BATTERY DISCHARGE INDICATOR ……………………………………………………………………………………… 7
3.12 AIR FILTER RESTRICTION INDICATOR …………………………………………………………………………………. 7
3.13 FUEL LEVEL GAUGE. ……………………………………………………………………………………………………….. 7
3.14 TACHOMETER ……………………………………………………………………………………………………………….. 8
3.15 COOLANT TEMPERATURE GAUGE ……………………………………………………………………………………… 8
3.16 SPEEDOMETER ………………………………………………………………………………………………………………. 8
3.17 TRANSMISSION OIL TEMPERATURE INDICATOR …………………………………………………………………… 9
3.18 IGNITION SWITCH ………………………………………………………………………………………………………… 10
3.19 CABIN LAMP ………………………………………………………………………………………………………………… 10
3.20 MECHANICAL FRONT WHEEL DRIVE (MFWD) INDICATOR ……………………………………………………. 10
3.21 PARKING BRAKE INDICATOR …………………………………………………………………………………………… 11
3.22 AC PANEL ……………………………………………………………………………………………………………………. 11
3.23 STABILIZER CONTROL LEVERS …………………………………………………………………………………………. 11
3.24 BACKHOE CONTROLS ……………………………………………………………………………………………………. 11
3.25 SEAT BELT …………………………………………………………………………………………………………………… 12
3.26 SEAT CONTROLS …………………………………………………………………………………………………………… 12
3.27 LIGHTS ……………………………………………………………………………………………………………………….. 13
3.28 OPERATING WINDSHIELD WIPER …………………………………………………………………………………….. 13
3.29 SIDE WINDOWS‐SECONDARY EXITS …………………………………………………………………………………. 14
3.30 REAR WINDOW DOOR …………………………………………………………………………………………………… 14
3.31 INSPECT MACHINE DAILY BEFORE STARTING …………………………………………………………………….. 15
3.32 CHECK INSTRUMENTS BEFORE STARTING …………………………………………………………………………. 16
3.33 STARTING THE ENGINE ………………………………………………………………………………………………….. 18
3.34 OBSERVE THE ENGINE OPERATION CLOSELY ……………………………………………………………………… 19
3.35 WARM UP THE MACHINE ………………………………………………………………………………………………. 19
3.36 COLD WEATHER WARM‐UP ……………………………………………………………………………………………. 20
3.37 STALLED ENGINE ………………………………………………………………………………………………………….. 20
3.38 STOPPING THE ENGINE‐NORMAL SHUTDOWN ………………………………………………………………….. 21
3.39 DRIVE CONTROLS …………………………………………………………………………………………………………. 22
3.40 GEAR LEVER ………………………………………………………………………………………………………………… 22
4. DRIVING THE MACHINE ………………………………………………………………………………………………………… 23
4.1 BOOM LOCK CONTROL ………………………………………………………………………………………………….. 23
4.2 SWING LOCK PIN ………………………………………………………………………………………………………….. 23
4.3 DRIVING ON PUBLIC ROADS …………………………………………………………………………………………… 24
4.4 KEEP RIDERS OFF THE MACHINE ……………………………………………………………………………………… 24
4.5 DRIVING THE MACHINE …………………………………………………………………………………………………. 25
4.6 TRAVEL SPEED ……………………………………………………………………………………………………………… 26
4.7 PARKINGTHE MACHINE …………………………………………………………………………………………………. 26
4.8 BACKHOE TRANSPORT/STORAGE POSITION ……………………………………………………………………… 27
4.9 LOADING MACHINE ON A TRAILER ………………………………………………………………………………….. 27
4.10 TOWING ……………………………………………………………………………………………………………………… 28
4.11 RUNNING ON SLOPE……………………………………………………………………………………………………… 29
5. OPERATING THE MACHINE …………………………………………………………………………………………………… 30
5.1 PREPARING TO OPERATE BACKHOE ………………………………………………………………………………… 30
5.2 OPERATING STABILIZERS ……………………………………………………………………………………………….. 30
5.3 OPERATING BACKHOE‐(TWOLEVERCONTROLS) …………………………………………………………………. 30
5.4 SIDE SHIFT THE BACKHOE ………………………………………………………………………………………………. 32
5.5 OPERATING FRONT LOADER …………………………………………………………………………………………… 32
5.6 OPERATING TIPS ………………………………………………………………………………………………………….. 33
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5.7 WORK AT PROPER ANGLES …………………………………………………………………………………………….. 33
5.8 POSITIONING SPOIL PILES ………………………………………………………………………………………………. 34
5.9 LEVELING THE MACHINE ……………………………………………………………………………………………….. 34
5.10 MOVING WITH BACKHOE ………………………………………………………………………………………………. 35
5.11 USING BACKHOE BUCKET ………………………………………………………………………………………………. 35
5.12 LOADER BUCKET ………………………………………………………………………………………………………….. 37
5.13 DOZING ………………………………………………………………………………………………………………………. 37
5.14 BACK DRAGGING & GRADING …………………………………………………………………………………………. 37
5.15 EXCAVATING BANK OR STOCKPILES …………………………………………………………………………………. 38
5.16 BACKFILLING ……………………………………………………………………………………………………………….. 39
5.17 BACKFILLING LARGE AREAS ……………………………………………………………………………………………. 39
5.18 TRUCK LOADING ………………………………………………………………………………………………………….. 40
6. FUEL & LUBRICANTS ……………………………………………………………………………………………………………. 42
6.1 DO NOT USE GALVANIZED CONTAINERS …………………………………………………………………………… 42
6.2 FUEL TANK ………………………………………………………………………………………………………………….. 42
6.3 ALTERNATIVE AND SYNTHETIC LUBRICANTS ……………………………………………………………………… 42
6.4 LUBRICANTS STORAGE ………………………………………………………………………………………………….. 43
6.5 ATTACH DO NOT OPERATE TAG ………………………………………………………………………………………. 43
6.6 SERVICE YOUR MACHINE AT SPECIFIED INTERVALS…………………………………………………………….. 43
7. PERIODIC MAINTENANCE …………………………………………………………………………………………………….. 55
7.1 PREPARE MACHINE FOR MAINTENANCE ………………………………………………………………………….. 55
7.2 LOADER BOOM SERVICELOCK…………………………………………………………………………………………. 56
7.3 MAINTENANCE AND REPAIR RECORD KEEPING SYSTEM ……………………………………………………… 56
8. MAINTENANCE EVERY 10 HRS OR DAILY ………………………………………………………………………………… 57
8.1 ENGINE OIL LEVEL‐CHECK ………………………………………………………………………………………………. 57
8.2 ENGINE COOLANT LEVEL‐CHECK ……………………………………………………………………………………… 57
8.3 HYDRAULIC OIL LEVEL‐CHECK …………………………………………………………………………………………. 58
8.4 ALL PINS & BUSHES‐CHECK AND GREASE …………………………………………………………………………… 58
8.5 FRONT AXLE MAIN PIVOT‐GREASING ……………………………………………………………………………….. 59
8.6 GEAR SELECTION FORWARD/REVERSE‐CHECK ……………………………………………………………………. 59
8.7 MACHINE CYCLE TIME‐CHECK …………………………………………………………………………………………. 60
8.8 FUEL WATER SEPARATOR DRAIN ……………………………………………………………………………………… 60
8.9 BOOM LOCK ENGAGEMENT‐CHECK ………………………………………………………………………………….. 61
8.10 SWING LOCK ENGAGEMENT‐CHECK …………………………………………………………………………………. 61
8.11 ALL HYDRAULIC CYLINDERS‐CLEAN …………………………………………………………………………………… 62
8.12 TOOTH AND SIDE CUTTERS‐CHECK …………………………………………………………………………………… 62
8.13 WALK‐AROUND INSPECTION …………………………………………………………………………………………… 63
8.14 DOORS/WINDOWS‐CLEAN ……………………………………………………………………………………………… 64
8.15 CYLINDER CHROME CONDITION‐CHECK ……………………………………………………………………………. 65
8.16 AC BELT-CHECK ……………………………………………………………………………………………………………. 65
8.17 TRANSMISSION OIL LEVEL‐CHECK …………………………………………………………………………………….. 66
8.18 BRAKE OIL‐CHECK …………………………………………………………………………………………………………. 67
8.19 FRONT AXLE‐CLEAN……………………………………………………………………………………………………….. 67
8.20 FUNCTION OF ALL GAUGES …………………………………………………………………………………………….. 67
8.21 FAN BELT CONDITION‐CHECK …………………………………………………………………………………………. 68
9. MAINTENANCE EVERY 50 HRS OR WEEKLY …………………………………………………………………………….. 70
9.1 BATTERY/BATTERY TERMINALS ……………………………………………………………………………………….. 70
9.2 DRAIN FUEL TANK WATER AND SEDIMENT ………………………………………………………………………… 70
9.3 ROC OUTSIDE & INTERCOOLER‐CLEANING ………………………………………………………………………… 71
9.4 TYRE PRESSURE/CONDITION‐CHECK …………………………………………………………………………………. 71
9.5 SERVICE BRAKE OPERATION‐CHECK………………………………………………………………………………….. 72
9.6 PARKING BRAKE OPERATION‐CHECK ………………………………………………………………………………… 73
9.7 STABILIZER LEGS LHS & RHS‐CHECK & ADJUST ……………………………………………………………………. 73
9.8 NEUTRAL START SYSTEM‐CHECK ……………………………………………………………………………………… 75
9.9 REFRIGERANT GAS LEVEL-CHECK ……………………………………………………………………………………… 75
9.10 BUCKET (BACKHOE/LOADER) HARD FACING AND RECONDITIONING…………………………………….. 75
9.11 CLEANING THE MACHINE ……………………………………………………………………………………………… 76
9.12 STABILIZER WEAR PADS ADJUSTMENT………………………………………………………………………………78
10. MAINTENANCE EVERY 100 HRS OR TWO WEEKS …………………………………………………………………….. 79
10.1 PROPELLER SHAFT AXLE GREASING ………………………………………………………………………………….. 79
10.2 FRONT HUB BEARING‐GREASING CHECK …………………………………………………………………………… 79
10.3 DOOR FIT AND CATCHES ……………………………………………………………………………………………….. 79
10.4 WIRING AND FUSES‐CHECK …………………………………………………………………………………………… 80
10.5 BATTERY TERMINALS FOR CONDITION TIGHTNESS‐CHECK ………………………………………………….. 80
10.6 ENGINE LOW AND HIGH IDLE RPM‐CHECK & ADJUST …………………………………………………………. 81
10.7 HYDRAULIC STALLING RPM‐CHECK & ADJUST …………………………………………………………………… 81
10.8 TRANSMISSION STALLING ……………………………………………………………………………………………… 82
10.9 LUBRICATE SIDE SHIFT FRAME ……………………………………………………………………………………….. 82
10.10 TORQUE DRIVEN SHAFT FLANGE MOUNTING BOLTS …………………………………………………………. 83
10.11 OPERATOR SEAT AND SEAT BELT ……………………………………………………………………………………… 83
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11. MAINTENANCE EVERY 250 HRS OR MONTHLY …………………………………………………………………………. 84
11.1 ENGINE MOUNTING‐CHECK …………………………………………………………………………………………… 84
11.2 TRANSMISSION MOUNTING‐CHECK. ……………………………………………………………………………….. 84
11.3 INTERCOOLER HOSES & CLAMPS- CHECK …………………………………………………………………………. 85
11.4 REAR AXLE DIFFERENTIAL & REDUCTION HUB OIL LEVEL‐CHECK ………………………………………….. 85
11.5 FRONT HUB BEARING‐GREASING ……………………………………………………………………………………. 86
11.6 WHEEL NUT TORQUE‐CHECK …………………………………………………………………………………………. 86
11.7 CHECK AIR INTAKE HOSES AND CLAMPS ………………………………………………………………………….. 86
11.8 CONDITION OF RADIATOR TOP & BOTTOM HOSE‐CHECK……………………………………………………. 86
11.9 ALTERNATOR‐CHECK. …………………………………………………………………………………………………… 87
11.10 BATTERY ELECTROLYTE OIL LEVEL‐CHECK ………………………………………………………………………… 88
11.11 ALL HOSES AND CLAMPS ………………………………………………………………………………………………. 88
11.12 AC FILTER-CLEAN …………………………………………………………………………………………………………. 88
11.13 BODY WORK CABIN‐CHECK ……………………………………………………………………………………………. 89
11.14 OPERATIONAL SPEED‐CHECK …………………………………………………………………………………………. 89
12. MAINTENANCE EVERY 500 HRS OR THREE MONTHS ………………………………………………………………… 90
12.1 CHANGE‐ENGINE OIL & ENGINE OIL FILTER ………………………………………………………………………. 90
12.2 REPLACE‐HYDRAULIC OIL FILTER ……………………………………………………………………………………… 90
12.3 FUEL TANK SUCTION LINES TRAINER‐CLEAN ………………………………………………………………………. 91
12.4 EVAPORATOR-CLEAN …………………………………………………………………………………………………….. 91
12.5 DOOR/WINDOW HINGES‐LUBRICATE ……………………………………………………………………………….. 92
12.6 ENGINE COOLANT CORROSION INHIBITOR LEVEL‐CHECK …………………………………………………….. 92
12.7 CHECK‐PRE CLEANER……………………………………………………………………………………………………… 93
12.8 ROC‐CLEAN ………………………………………………………………………………………………………………….. 94
12.9 HARDWARE TORQUE SPECIFICATIONS ……………………………………………………………………………… 94
12.10 FUEL TANK MOUNTING………………………………………………………………………………………………….. 94
12.11 HYDRAULIC TANK MOUNTING ………………………………………………………………………………………… 95
12.12 AC COMPRESSOR MOUNTING …………………………………………………………………………………………. 95
12.13 FUEL FILTER‐CHANGE …………………………………………………………………………………………………….. 95
12.14 REAR AXLE MOUNTING ………………………………………………………………………………………………….. 96
12.15 CONDENSER-CLEAN ………………………………………………………………………………………………………. 96
12.16 MUFFLER MOUNTING BRACKET …………………………………………………………………………………….. 96
13. MAINTENANCE EVERY 1000 HRS OR SIX MONTHS …………………………………………………………………… 97
13.1 CHANGE‐TRANSMISSION OIL AND TRANSMISSION OIL FILTER………………………………………………. 97
13.2 CLEAN‐TRANSMISSION SUCTION STRAINER ………………………………………………………………………. 97
