Hinowa HP 1100 Instruction manual

MUHP110020404
MANUAL USE
AND MAINTENANCE
MINIDUMPER MODEL HP1100
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Contents
DECLARATION OF CONFORMITY Page 4
INTRODUCTION Page 5
MINI-DUMPER IDENTIFICATION DATA Page 6
CLASSIFICATION Page 7
TERMINOLOGY Page 7
SAFETY WARNINGS Page 8
PICTOGRAMS Page 9
SAFETY AND ACCIDENT PREVENTION
1. GENERAL WARNING Page 11
1.1 Read carefully safety instructions Page 11
1.2 Follow safety instructions Page 11
1.3 Clothing and protective wear Page 11
1.4 Unauthorised alterations Page 12
1.5 Safety valves Page 12
OPERATING SAFELY
2. MEASURES TO TAKE BEFORE STARTING THE ENGINE Page 13
2.1 Safety in the working area Page 13
2.2 Fire prevention Page 13
2.3 Warning against exhaust fumes Page 14
3. MEASURES TO TAKE WHILE WORKING Page 15
3.1 Precautions when starting engine Page 15
3.2 Precautions when driving Page 15
3.3 Precautions when transporting the crawler Page 15
3.4 Transporting the machine Page 15
3.5 Parking the machine safely Page 16
3.6 Be prepared in case of emergency Page 16
3.7 Wear protective garments Page 16
3.8 Protect yourselves against noise Page 16
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4. OPERATING INSTRUCTIONS Page 17
4.1 Driver’s seat and controls- standard undercarriage Page 17
4.2 Driver’s seat and controls – extensible undercarriage Page 17
4.3 Gasoline engine controls Page 18
4.3.1 Starting the engine Page 18
4.3.2 Using the engine Page 18
4.3.3 Stopping the engine Page 20
4.4 Diesel engine controls Pag. 21
4.4.1 Motor Start Pag. 21
4.4.1.1 Manual start trough self-winding system Pag. 21
4.4.1.2 Electrical start Pag. 22
4.4.2 Motor functioning Pag. 23
4.4.2.1 Motor functioning Pag. 23
4.4.2.2 Checks to be done while the motor is working Pag. 23
4.4.3 Motor stop Pag. 23
4.5 Moving the machine Page 25
4.5.1 Operating the undercarriage – standard versionl Page 25
4.5.1.1 Operating hydraulic tilting Page 26
4.5.1.2 Operating 2nd translation speed Page 26
4.5.1.3 Optional control lever Page 26
4.5.1.4 Operating external tool Page 27
4.5.2 Operating undercarriage – extensible undercarriage Page 28
4.5.2.1 Operating hydraulic tilting Page 29
4.5.2.2 Operating extensible undercarriage Page 29
4.5.2.3 Operating 2nd translation speed Page 30
4.5.2.4 Optional control level Page 30
4.5.3 Manoeuvring on soft soil Page 31
4.5.4 Avoiding manoeuvring on inclined slopes Page 31
4.5.5 Parking and stopping on inclined slopes Page 31
4.5.6 Transporting the machine Page 31
4.5.7 Lifting the machines Page 33
4.5.8 Using rubber tracks Page 33
5 MAINTENANCE Page 34
5.1 Correct machine inspection and maintenance procedures Page 34
5.2 Engine maintenance Page 35
5.2.1 Oil level check Page 35
5.2.2 Engine oil replacement Page 35
5.2.3 Air filter check Page 35
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5.3 Hydraulic system Page 35
5.3.1 Hydraulic oil Page 36
5.3.2 Hydraulic oil filter Page 36
5.3.3 Oil reduction translator Page 37
5.4 Electric system Page 38
5.4.1 Battery Page 38
5.5 Rubber tracks maintenance Page 39
5.5.1 Checking track tension Page 39
5.5.2 Track loosening/tightening procedures Page 39
5.5.3 Checking rubber tracks Page 40
5.5.4 Replacing rubber tracks Page 42
5.6 Checking nuts & bolts tightness Page 44
5.7 Storing the machine Page 45
6. TECHNICAL SPECIFICATIONS Page 46
6.1 Technical data Page 46
6.2 Hydraulic system diagram-standard version-gasoline motor Page 48
6.2.1 Hydraulic system diagram legend Page 48
6.3 Hydraulic system diagram-extensible version-gasoline motor Page 49
6.3.1 Hydraulic system diagram legend Page 49
6.4 Hydraulic system diagram-standard version-diesel motor Page 50
6.4.1 Hydraulic system diagram legend Page 50
6.5 Hydraulic system diagram-extensible version-diesel motor Page 51
6.5.1 Hydraulic system diagram legend Page 51
7. IDENTIFYING MALFUNCTIONS Page 52
Appendix Page 54
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INTRODUCTION
Dear customer,
First of all, thank you for choosing a Hinowa Minidumper HP1100 and we hope
that you will be satisfied by your recent purchase.
You have now a working instrument you can rely on as long as you follow the
operating and maintenance instructions.
Carefully read this manual before starting, operating, maintaining, refuelling
or doing any other operations on the machine.
We always have safety in mind when designing and manufacturing our machines.
Unfortunately, our effort is void when the machine is not operated safely.
Preventing accidents is also connected to paying attention, being careful and to
have properly trained people operating, transporting and maintaining the
equipment.
Among the operator’s responsibilities is to read and understand all the safety
instructions given in this manual and to apply them strictly.
Only allow properly trained staff to operate the minidumper. Working with
equipment of which you ignore the technical specifications can cause errors with
subsequent danger to health and safety. In order to acquire all the necessary
preparation, read carefully this manual before starting the machine. In any case the
owner’s responsibility (even if the machine is lent or hired) is to make sure that,
before starting work, all operators read and understand this operator’s manual and
are properly trained to operate this equipment.
This manual is part of the machine and must be always kept with it.
Our machines are constantly been improved and could therefore show
characteristics different from the ones shown in this manual; contact your Hinowa
dealer to have updated information.
Do not hesitate to contact your Hinowa dealer for all useful information or repair; he
is always informed on the best way to operate your machine and will advise you on
suitable equipment. He will also supply you with original spare parts, which is the
only guarantee of quality and perfect replacement. When ordering parts, please
specify the machine serial number if you want to make sure to get the right parts.
Good work with Hinowa!
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MINI-DUMPER IDENTIFICATION DATA
A) “CE” PLATE PLACE AND MARK
B) POSITION OF IDENTIFICATION PLATES OF MACHINE PARTS
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ENGINE SERIAL NUMBER
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CLASSIFICATION
TERMINOLOGY
To help you understand all the safety and instruction warnings as well as the
operating and maintenance instructions of the minidumper HP 1100, you will find
below the names of the machine various parts:
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HP1100 / ***
Minidumper type
Minidumper model
1 Track tensioner sprocket
2 Rubber crawler frame
3 Roller
4 Traction reduction unit
5 Sprocket
6 Rubber track
7 Hydraulic oil tank
8 Engine
9 Fuel tank
10 Oil filter
11 Footboard
12 Hydraulic pump
13 Battery
14 Heat - exchanger
15 Hydraulic distributor
16 Flanges for special equipment
17 Hydraulic auxiliary plugs
1
2
3
4
5
6
7
98
16
17
12
13
14
15
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SAFETY INFORMATIONS
Before starting work and before any maintenance jobs, read, understand and follow
all the precautions and warning given in this manual to avoid any accidents.
This is a safety-warning signal.
Take care when you see this signal on the machine
or in the manual, as there is a potential danger of
bodily injury.
Take the necessary precautions and follow safe
operating procedure.
Words DANGER and WARNING are used along
with this safety signal.
The word danger indicates the most serious risks,
which could cause serious injuries or even death if
danger is not avoided.
It can also cause damage to the machine.
The word ATTENTION indicates possible
dangerous situations, which could cause light
injury or harm to people. This wording can also be
used only in case of possible damage to the
machine
This message is used in case of situations, if not
avoided, could shorten the life of the machine
Hinowa Company cannot foresee all possible dangerous circumstances when
operating or maintaining the machine.
If all the instructions and operations allowed for this machine are followed, you can
be sure that the operator and the people nearby can operate safely and without any
risk of damaging the machine.
Please contact us in case of doubt about safety procedures.
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PERICOLO
ATTENZIONE
IMPORTANTE
DANGER
WARNING
IMPORTANT
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PICTOGRAMS
CONSULT THE MANUAL
Carefully read the contents of this manual before starting, operating, doing
maintenance jobs, refuelling or other operations on the machine.
DANGER WORKING AREA
Never stay close or within the working area of the
machine equipment.
HYDRAULIC OIL FILTER
HYDRAULIC OIL LEVEL
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HYDRAULIC OIL
FUEL
LIFTING POINTS
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D
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SAFETY AND ACCIDENT PREVENTION
1GENERAL WARNING
1.1 Read the instructions carefully
Before doing any types of operations on the machine, follow all the safety rules,
warnings and instructions given in this manual.
1.2 Follow safety instructions
Read the meaning of all safety warnings in this manual and the safety signals on
the machine.
Check that all the safety signs are in proper working order, replacing the missing or
damaged ones.
Make sure that new equipment bear correct signs when replacing new parts or
tools.
Learn the proper way of operating the machine and the controls.
Never allow unauthorised and not properly trained people to operate the machine
or/and do maintenance jobs on it.
1.3 Clothing and protective wear
Avoid wearing loose clothes, rings, watches or anything that could get entangled
inside the rotating parts. Do not wear clothes stained with oil or fuel, as they can be
flammable.
When operating the machine or doing maintenance jobs, wear a helmet, safety
glasses and safety shoes, a mask, gloves and noise protection earmuffs.
When working for more than 8 hours with a 90 dBA acoustic level it is absolutely
necessary to wear protective earmuffs.
ATTENZION
E
DANGER
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1.4 Unauthorised alterations
It is absolutely forbidden to do any alterations on the machine, which could damage
its working and its safety. Hinowa declines any responsibility for injury or damage
caused by unauthorised alterations.
1.5 Safety valves
Never alter or/and tamper with the safety valves and the controls in the hydraulic
system.
Hinowa declines any responsibility for injury to people, damage to things and to the
machine if the hydraulic valve standard gauging has been tampered with.
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OPERATING PRECAUTIONS
2P
RECAUTIONS TO TAKE BEFORE STARTING THE ENGINE
2.1 Safety in the working area
Before starting the engine, carefully check the conditions of the working ground to
find out any possible irregularities, which might make working dangerous.
Always take care of people entering within the working range of the machine.
Always warn people before moving the machine.
2.2 Fire prevention
Keep the engine compartment clean; remove any
pieces of wood, paper and other flammable
products; clean properly any fuel, oil or
flammable fluid leaks, as they can be potential
fire risks.
Petrol is extremely flammable and explosive
under certain conditions. Refuel in a well-
ventilated place and when the engine is off.
Never smoke or cause sparks in the refuelling
place or the fuel storage place.
Never fill the tank too much. After refuelling,
make sure that the cap is closed safely and properly.
Make sure there is no fuel leak when refuelling. Petrol fumes or possible leaks
might catch fire.
Make sure the area is dry before starting the engine.
The exhaust pipe gets overheated during work and remains hot even after the
engine has been turned off. Take care not to touch the exhaust pipe when it is hot.
To avoid burns, cool the engine before moving the carriage or starting it.
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ATTENZIO
N
DANGER
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2.3 Warning against exhaust fumes
When working inside a building, make sure there is proper ventilation. If you are not
sure about ventilation, use an extension to evacuate exhaust fumes.
Exhaust fumes can cause death.
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3 M EASURES TO TAKE WHEN WORKING
3.1 Precautions when starting the engine
Before starting the machine, check it properly by walking
around it.
Warn people nearby that you are starting the machine.
Do not allow anyone to climb onto the machine.
3.2 Precautions when driving
In order to avoid possible accidents or loss of control, never climb onto the carriage;
place yourself behind it and hold the handle firmly. To avoid any possible injury from
the machine, keep children and animals away from working area.
NEVER OPERATE THE MINIDUMPER AT NIGHT.
3.3 Precautions when transporting loads
To avoid accidents or tipping over, follow the loads restrictions indicated on p.40
Make sure the load is properly secured and does not exceed the dimensions of the
carriage or obstruct the operator’s view.
To avoid overturning, never change directions with the transporting carriage when
operating on slopes. Never operate the carriage on upwards slopes with an over
25° slant and on downwards slopes with an over 25° slant.
Take care when reversing with the carriage, as there is an increased risk of falling
and skidding.
On steep downward slopes, always operate at minimum speed. Never reverse on
downward slopes.
3.4 Transporting the machine
Observe local regulations when transporting the machine on public roads.
Use a lorry or a trailer suitable for transporting the machine.
Always load or unload the machine on a flat or solid surface.
ATTENZIO
N
DANGER
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Always use a ramp or a loading platform when loading or unloading the machine.
Never use high-speed gears.
Avoid steering when driving up or down a ramp as it could be very dangerous. If
steering is absolutely necessary, first go back to the ground or the flatbed, change
direction and then start driving again.
Never operate any levers except the drive lever when driving up or down a ramp,
this is to avoid unbalancing the machine. There is a bump at the top of the ramp.
Take care when crossing it.
Fix chains and cables to the machine frame.
3.5 Parking the machine safely
Park the machine on a flat and solid surface with enough space for controlling. If
you have to park on a slope, put safety blocks under rubber tracks.
3.6 Be prepared in case of emergency
Be prepared in case of fire.
Keep handy a first aid kit and a fire extinguisher.
Keep emergency numbers for doctors, ambulance, hospital and fire brigade near
the telephone.
3.7 Wear protective garments
Wear tight fitting garments and safety equipment appropriate to the job you are
doing.
3.8 Protect yourselves against noise
Prolonged exposure to loud noise can cause ear damage or loss of hearing.
Wear a suitable noise protection device such as earplugs or earmuffs to protect you
against deafening or loud noises.
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4OPERATING INSTRUCTIONS
4.1 Driver’s seat and controls – standard version
4.2 Driver’s seat and controls – extensible version
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ABD
CE
BCE
F
A- Control joystick– carriage left shift D-Clutch joystick – 2nd shift speed
B- Control joystick – dumper tipping E- Control joystick – accessory
C- Control joystick – carriage right shift F-Accelerator joystick
A- Control joystick– carriage left shift E-Clutch joystick – 2nd speed
B- Control joystick – dumper tipping F-Control joystick – accessory
C- Control joystick – carriage right shift G-Accelerator joystick
D- Control joystick - extension
FDCF
AB
D
C
G
E
F
G
GASOLINE ENGINE VERSION DIESEL ENGINE VERSION
GASOLINE ENGINE VERSION DIESEL ENGINE VERSION
EAB
AD
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4.3 GASOLINE ENGINE CONTROLS
(Consult also the engine operator’s manual)
4.3.1 Starting the engine
1. Position the fuel valve to ON.
2. Position the air lever to CLOSE.
NB: Never use the air lever when the engine is hot and the air temperature is rather
high.
4.3.2 Using the engine
1. As the engine gets warmer,
gradually position the air lever to
OPEN.
FUEL VALVE
AIR LEVEL
AIR LEVEL
CLOSE
CLOSE
OPEN
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2. Position the acceleration control lever
to obtain the desired rpm.
Oil alarm system (optional)
The oil alarm system is designed to prevent damages to the engine, as a result of
lack of oil in the sump. Before the oil level drops below the minimum level, the
alarm system stops the engine automatically. The engine switch remains in ON
position.
NB:
If the engine stops and does not start again, check the oil level in the engine
before checking any other parts.
Circuit switch
The circuit switch protects the battery recharging circuit. A short circuit or a wrongly
connected battery will make it suddenly trip.
In this case, before disconnecting the circuit switch, find the origin of the trouble
and put it right.
To disconnect the circuit switch, press CIRCUIT BREAKER button.
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BUTTON CIRCUIT BREAKER
ACCELERATION CONTROL LEVER
HIGH LOW
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