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HiT500 Compact Tracked Carrier Mk4 v3

1. seus sevo NUTUS S PAW OORLIH 531114 VLOS 91 0 235 6 ASSY LUVAS 9102 BW 1100 20 Old n 207 SW 100040 1 1708 89 181010 014 2 LNN JOTAN EW 25800710 1 waHsymew 2100 20 84 2 MEWS XZOd X ew 1800 10 2 XOHS VAN SW 8100 20 99 1 LPN IOTAN OW 000 10 Gd t 23826 135 X GW 1 0 10 td 9 000 20 fd 1 LAN 20 SW 4100 50 24 1 4 35 91 9 6200 10 9 2 thio 6000 01 9 1 2 WILT 1974 0620 01 8 09006 1 HOLIANS FULL 9920 07 2204 1 6900404 2 1471 0102 622018 1 AD 40589 94989 00999 HIT500 Workshop Manual TCP 2324 Iss C DCA00259 022260 v4gi d21 4315 4102 9 9334 ALIWIXOMd 7 14 Electrical Schematic OC95 HIT500 4 2006 1574 7 14 Electrical Schematic OC95 HIT500 MK4 2006 Drg 1574 Section 7 Drawings 0 00259 HIT500 Workshop
2. ITEM DESCRIPTION WHERE USED STK No QTY 1 4 1w 380 Cut Length 90 C 90 S 60 Tank Suction To Pump 62 0090 1 2 1 320 Cut Length 90 S 90 C 350 Lefthand Motor Drains From Track Motors 62 0091 1 3 1 320 Cut Length 90 S 90 C 270 Righthand Motor Drains From Track Motors 62 0092 1 4 2w 640 Cut Length FM FM Large Pump To Valve Block 62 0034 1 5 15 8 1w 540 Cut Length 90 C ST Female Oil cooler to Return Filter 62 0093 1 6 1 460 Cut Length 90 S 90 C 180 Valve to Oil cooler 62 0094 1 7 8 8 1450 Cut Length 90 S 90 C 270 Righthand Track Motor 62 0095 1 8 3 8 2w 1425 Cut Length 90 S 90 C 105 Lefthand Track Motor 62 0096 1 9 3 8 2w 1350 Cut Length 90 C 90 C 290 Righthand Track Motor 62 0097 1 10 3 8 2w 1350 Cut Length 90 C 90 C 115 Lefthand Track Motor 62 0098 1 11 3 6 2w 680 Cut Length 90 S Fm Small Pump To valve 62 0035 1 12 Aw 430 Cut Length 45 0 Cross Over Top Cylinders 62 0018 2 13 72 1w 450 Cut Length 457 9075 90 Valve To Cylinder 62 0099 1 14 4 1w 450 Cut Length 457 90 135 Valve To Cylinder 62 0120 1 15 1w 450 Cut Length 45 0 Cross Over Cylinders 62 0018 2 16 72 1w 740 Cut Length 45 90 S 180 Valve To Cylinder 62 0121 1 17 4 1w 740 Cut Length 457 90 180 Valve To Cylinder 62 0122 1 18 1w 550 Cut Length 90 C 90 S Opposite To Lay 270 Sleeved In Pairs
3. 4 CRIMP MALE BULLET SUPPLIED WITH ENGINE 2 13 8 RING CRIMP TERMINAL SUPPLIED WITH ENGINE 1 14 70 0061 RECEPTACLE COVER RS 1505 7 15 70 0063 BLADE COVER 85 1504PVC 1 16 70 0058 RECEPTACLE 0 8 2 1mm TYCO ELECTRONICS 42282 2 10 17 70 0193 BLADE FUSE 15A DURITE 0 375 15 1 SHT 2 OF 2 QUAYSIDE PARK BATES ROAD MALDON ESSE CUS SPA BASIO WWW YCP TITLE WIRING LOOM FORKUBOTAOCOB HIT 500 2006 DWG No TCP 1574 01 WL sce 73 0010 13122005 Loom for Kubota 95 Mk4 2006 1574 01 5120 2 HIT500 Workshop Manual TCP 2324 Iss C 0 00259 ON IMO aia as 9002 006111 RON 43345 Z WOO19NIMMIM FUIL WOT Section 7 Drawings 7 16 Two Speed Mk4 2006 Drg 1574 02 WL 7 16 Two Speed Mk4 2006 Drg 1574 02 WL ANTUHS VIXIA ISN 2345 01239402 335 2 3016 1 Q3AGIASUOL23NNOO 1 FN 20 201 21 93385 WOOT 00 40 HOLIMS 93845 9NDDVILL OQ 5 m on S3FOLIMSOWOIW purum ae i n Nol E BATA 22 5 8 5 ASSY 981
4. 9002 PAW OCGLIH 4415 4102 403 WOOTONTAIM JUL AMA ANTIS 391 373 ISN 2345 uO123NNOO 335 2 BOIS Q3AASIA 5404294402 rawi 004 ew m HOA 3evg NONE x pos ama jos D s z NUS SINISE OAL 8052 8 52140812379 OPAL 7280312443238 8900 02 gt ANOLND 1 AWM VSNISNOH AVL HOW 1 0899 29997 wiogny 9 INISNOH 3129143238 0900 02 2 1 ava 71 HIT500 Workshop Manual 2324 Iss C DCA00259 7 19 Battery Leads Drg 1059 7 19 Battery Leads Drg 1059 Section 7 Drawings f 000 ONIMA sons 9002 O0GLIH ir say Aaya JUIL 3376 LV iJAV13S0 T ALON 43334105 9 2 SANI 990 3AILVO3N 303 BAILISOd 403 933 108 ANIYHS 1 Geo DCA00259 HIT500 Workshop Manual TCP 2324 Iss C 72 Section 7 Drawings 7 20 Jump Lead Link M
5. z 3 2 5844 824863 Bee ke 11334 0138 0 5 5 28544344 z2 8 508848 ind EO 53833383 88 8 8858 586 5 3 E 3 1 aap 5 M 2 HIT500 Workshop Manual TCP 2324 Iss C 79 DCA00259 Section 7 Drawings 7 26 Sound Kit Sequence Ass Chassis Drg 1591 SA 7 26 Sound Kit Sequence Ass Chassis Drg 1591 SA 24012006 DATE 30 0005 CHASSIS HIT 500 2006 TCP 1594 SA QUAYSIDE BATES ROAD ESSEX CH9 BFA 830777 841320 WWW TEP AYLOR CONSTRUCTION PLANT LTD TITLE SOUND KET SEQUENCE assy DW6 Ne NUMBER DENOTE SEQUENCE OF INSTALLATION 2 80 HIT500 Workshop Manual 2324 Iss C 0 00259 Section 7 Drawings 7 27 Sound Kit Sequence Assy Drg 1592 SA 7 27 Sound Kit Sequence Assy Drg 1592 SA 24012006 155 DATE 30 0009 COWL 2006 JCP 1582 SA TAYLOR CONSTRUCTION PLANT LTD 12712 SOUND KIT SEQUENCE ASSY DWS HIT500 Workshop Manual TCP 2324 Iss C DCA00259 81 Section 7 Drawings 7 27 Sound Kit Sequence Assy Drg 1592 SA 82 HIT500 Workshop Manual TCP 2324 Iss C DCA00259 Appendix A Nut
6. Hi 500 Compact T racked Carrier Mk4 v3 Workshop Manual TCP 2324 Iss C Feb 2008 DCA 00259 aoa Construction Plant Ltd d A pede 44 ee eu com Contents 2 HIT500 Workshop Manual TCP 2324 Iss C DCA00259 Contents Contents Preliminary Foreword Warranty Registration Liability Audits and Surveys Service and Warranty Training Warranty Terms General Exclusion Warranty Claim Submission Procedures Certificate of Conformity Kubota Engine Dealers Service Bulletins Machine Identification Theft Deterrence Recovery of a Stolen Machine Safety Flammable Fluid Precaution Electrical Hazard Pre Starting Starting Operating Lubrication and Servicin Specifications 00000 0944 4 40 A Section 1 Description 11 1 1 Introduction 1 2 Electrics 1 2 1 Ignition 5 1 2 2 11 1 2 3 Tracking Speed 12 1 2 4 Sounder Contro 12 1 2 5 Oil Cooler Fan 12 1 2 6 Oil Pressure Light 12 1 2 7 Hours Counter 212 1 3 Hydraulics nne 12 Section 2 Operation 15 2 4 CONTOS 2 1 8 Throttle 2 1 9 Steering 2 2 Daily Pre start Inspectio 2 3 Engine Operation 2 4 Starting the Engine 2 5 Starting the Engine with Jumper Cables 16 2 6 Batte
7. 0 00259 1 280097 oswa 900042 wi gt E 52140412315 0241 620002 9 s 278775 2813 OPAL 12 80 3129 43234 830007 rH 100 1 88809 SPANOWLIIB OAL Boece 29000 1 0 086051 52140412318 DAL SNESNOH 900 0 gt 106 0931 0002 6 SEZOLNSMIS ANNOW TaNVd 8 Fa RR RI Ic E A z S2INDNL233 OAL ZENISNOH 9 9 0 206087 2218 0242 AVMZSNISTOHSTAIdBOSU 090002 z E 912149233 1600070 F 17605 E WLA 09000 1 0170087 2218 OL AVM E 810243231 290070 1 20501 0 3 enaus 8100 84 280 19 421 832208 W001 vu VANNOI 5 oe W3ZZn8 9NINSV A HIT500 Workshop Manual TCP 2324 Iss C 70 Section 7 Drawings 7 18 Loom for Cold Start Mk4 2006 1574 04 WL 7 18 Loom for Cold Start Mk4 2006 1574 04 WL 9100 54 Saas TW 0 2 1 401
8. 63 HIT500 Workshop Manual TCP 2324 Iss C DCA00259 7 12 Cooler Assy Hydraulic Drg 1470 SA 7 12 Cooler Assy Hydraulic Drg 1470 SA Section 7 Drawings J N 9002 FAW 55 321002 UDTAYL enisw 6000 00 9 2000 20 AROS 136 62000 n 39019 5000 04 WW 8 9 Ge WILI VS 2 vas 93008 9 6 WALI VS 6081 9014 SNDINV E 6 WALT VS SET 7735 884402 96 WILI YS 6091 esa BE WILI VE 5091 SALON 286 HLIM 491002 400019 451002 TO 9910 16 ON SQ NOTLV LNETSO ILON SY INTI NI 34010 INOXLVALOS NMOHS SY 6800102 IHL S IEWSSSV 8 INY QnouHS 1084 539718 YOLIZNNO 2 NMOHS SNLILUOd NI 38365 53 387005 WOU TUNYWSIQ T SALON ATEWSSSY DCA00259 HIT500 Workshop Manual TCP 2324 Iss C 64 Section 7 Drawings 7 13 Cold Start Assy Kubota Filter Drg 1925 7 13 Cold Start Assy Kubota Filter Drg 1925 65
9. HIT500 Workshop Manual TCP 2324 Iss C DCA00259 Section 3 Maintenance 3 12 Fuel Filters an 4 Fig 3 8 Fuel tank inlet hose 2 Remove tank neck bayonet fitting and extract filter from top of tank Fig 3 9 Fig 3 9 Top fuel filter 3 Clean the filter or if damaged replace with a new one 4 Goon to check to bottom filter next section 3 12 2 Tank Bottom Filter Parts Fuel bottom filter TCP 10 0006 1 Remove the fuel tank drain plug Fig 3 10 and drain the fuel into a suitable receptacle Fig 3 10 Fuel tank drain plug 25 Section 3 Maintenance 3 12 Fuel Filters 2 Disconnect the fuel line from the tank Fig 3 11 Cold start connections Fig 3 11 Fuel line 3 Unscrew the bottom cap and extract the bottom filter Fig 3 12 Fig 3 14 Fuel valve 2 Unscrew the securing ring Fig 3 15 and remove the filter reservoir Fig 3 12 Tank bottom filter 4 Clean the filter or if damaged replace with a new one Clean out the tank with clean fuel Refit the bottom and top filters and refit the drain plug Tighten the fuel hose clip screws with the torque settings detailed in Appendix A 7 Reconnect the fuel pipe Fig 3 15 Fuel filter removal 3 12 3 Extra Filter 3 Clean the filter with clean fuel or if damaged Parts Extra fuel filter TCP 10 0250 replace with a new one This filter Fig 3 13 can be removed without 4 Clean out the filter reservoir draining the fu
10. 1388 SA 78 7 25 Control Valve Mk4 2006 Drg 1598 79 7 26 Sound Kit Sequence Ass Chassis Drg 1591 TA E AAEE AEA ETA 80 7 27 Sound Kit Sequence Assy Drg 1592 SA 81 Appendix A Nut amp Bolt Torque Specification 83 1 Specific Torque Settings 2 Generic Torque Settings HIT500 Workshop Manual TCP 2324 Iss C DCA00259 Preliminary Preliminary Foreword Thank you very much for purchasing this product We believe that it will serve you without fail Ensure that you read the operating instructions carefully before use With proper handling and maintenance this product will provide reliable long term service This manual is intended to serve as a manual for workshop engineers It assumes an engineering knowledge commensurate with tasks that will be undertaken in a workshop For completeness the manual incorporates operating instructions necessary to familiarise the operator and service engineer with the controls recommended inspections start up operating and shutdown procedures for HiT range of equipment Please read the operating instructions carefully and understand them before operating the equipment Warranty Registration Each machine supplied by Taylor Construction Plant TCP Ltd is accompanied by a registration card This card must be completed in full and returned to Warranty Manager email warranty tcp eu com Taylor Construction Plant Ltd Quayside Indus
11. BEET OL WOINT LI Ere IW EAW OOSLTH Sab STD ASSY ANYA STINVRGAH MTINI HOTAYL 8 OH 000 20 84 8 SNINdS SW 000 20 9925 125 OH 02 GW 2000 70 4 2 MSHSV R 2000 20 24 T 9825 145 X ONY 1000 10 1 TW ZEW WILI 5 T Q3QNOS 100 29 Li T 7000 29 NIMS VA Q3QNO8 2000 29 2 STOW 1000 29 Y usHSvA 929408 2 1 EG WALLIL 6977 Of 1 TVW B S 21 Oy WILI 6 99914159994 BHL vgudd 000 29 8 T 000 9 2 2000 59 5 T 4 2 ASSY ui Td 7000 59 Y NOILOnS 5000 59 P T IWW P E X WALI YS 60 TW X 5100 29 1 33102 2000 08 20 T INKL 1000 06 800 AUS 40114742629 7 24 Hydraulic Tank Assy 1388 7 24 Hydraulic Tank Assy Drg 1388 SA Section 7 Drawings DCA00259 HIT500 Workshop Manual TCP 2324 Iss C 78 Section 7 Drawings 7 25 Control Valve Mk4 2006 Drg 1598 SA 7 25 Control Valve Mk4 2006 Drg 1598 an a jotta T a 58 E E if 8 8 ae AM BIE 3
12. Do not work under or near unblocked or unsupported body Always invert the empty body Do not work under or near any unblocked or unsupported linkage part or machine Always relieve pressure before servicing any pressurised system HIT500 Workshop Manual TCP 2324 Iss C DCA00259 Specifications Preliminary Maximum carrying capacity Skip volume ae Unladen weight i 700 mm Width 28 in 1165 Height 45 8 in Height over skip aa lo Height under skip a 1770 mm Length 69 6 in Max grade ability 45 5 2000 mm Turning circle 78 5 in Track ground pressure Loud Engine with electric start 7 1 kW Kubota OC95 9 5 hp Speed forward 21 Speed reverse i a Power take off optional e Noise level 99 dBa Prelliminary 10 HIT500 Workshop Manual TCP 2324 Iss C DCA00259 Section 1 Description 1 1 Introduction Section 1 Description 1 1 Introduction The HiT500 is a Compact Tracked Carrier designed for general use on building sites Its small size and manoeuvrability make it ideal for operation in confined spaces The rubber tracks give it traction on most kinds of terrain A diesel engine drives a hydraulic pump to provide motive power for track motion and skip movement The pump is coupled directly to the crankshaft at the front of the engine A hydraulic tank fitted in front of the pump under the skip pro
13. 10 82606 2 17 89715 ASSY SISSVIO 1 AU NOLTLdIDSS ON Tid WILT 57 HIT500 Workshop Manual TCP 2324 Iss C DCA00259 7 6 Chassis Assy Stage 5 1941 05 SA 7 6 Chassis Assy Stage 5 Drg 1941 05 SA Section 7 Drawings wane bowers vesoterwoL NUN 8002 PAW Vp up 939745 ASSY SISSVHO CLT 3915 4406 9 LL YEIHS VAR SW 000 20 9 3805 135 91 X Sw 000 10 zd D 3495 QV3H DIS G2 ZIW 8000 10 4 2 MIVd Q3ASSTIS SISOH v T SIWall VS 2 2215 SASOH F T 0 WALI YS 97 H 6200 09 20710 1 403 8200 09 81 TTN 8000 20 E NT 5000 00 880 2 100 18 2 Weit GAOT 8100 18 0 z WMO 9000 08 820 6 1 2521 9100 09 1010 8 D MSS VA 9000 20 LOATS 1000 02 0 9 1 5591 WONT JOL 5100 09 2 55082 2000 02 1 AAWHS 85080 000 19 880 i QUVNVAS 4908 100048 2 H gt 23715 ASSY SISSVHO 0 1 05 T ALD NOXL
14. Inspect and remove any obstructions from the air cleaner inlet with the engine stopped Check Engine oil level See Section 3 9 Engine Oil Check Note Service air cleaners more often when operating under extremely dusty conditions Do not wash the air cleaner element out with detergent Replace with new 23 Section 3 Maintenance 3 9 Engine Oil Check 3 9 Engine Oil Check Low viscosity oils such as 10W or 10W 30 can be used to aid starting and will provide sufficient oil flow at ambient temperatures below 5 C 23 F Continuous use of low viscosity oils can increase engine wear 1 Run the engine until it is warm and then turn it off Put the machine on a level surface Remove the oil filler dipstick and check the level and condition of the oil The oil should be between the bottom of the dipstick 2 and the top of the thread 3 4 up or replace the oil as necessary Fig 3 3 Engine oil cap and dipstick 3 10 Engine Oil Change Parts Oil filter TCP 10 0007 1 Run the engine until it is warm and then turn it off Put the machine on a level surface Remove the oil filler dipstick Remove the oil drain cap and drain off the oil into a suitable container Remove the engine oil filter Figs 3 4 and 3 5 Wash oil filter in degreaser Replace if damaged or in any case every 1000 hours of operation 7 drain cap and refill to the top of the dipstick thread 3 with f
15. RANE sen wj gt eo EN waisted 4 amaos V 3 54 g oviosmiucd WOO19NINIM JUI 2 dO T LHS 006 062 059 OEE 021 pa 92 amana aaran d 08 3 H 4 gt Phe s 0700 CERI pu 25 IA iet EJ G aware 9 211 e mou e sm Sh 1 of 2 67 HIT500 Workshop Manual TCP 2324 Iss C DCA00259 Section 7 Drawings 7 15 Loom for Kubota OC95 Mk4 2006 1574 01 68 STK DESCRIPTION MANUFACTURER PART No QTY 1 RECEPTACLE HOUSING 4 WAY 5 SUPPLIED WITH ENGINE 2 2 70 0149 IN LINE FUSE HOLDER DURITE 0 376 90 2 3 70 0054 RECEPTACLE HOUSING 4 WAY TYCO ELECTRONICS 180900 0 1 4 70 0050 RECEPTACLE HOUSING 2 WAY TYCO ELECTRONICS 180907 0 3 5 70 0060 6 3 IN LINE RECEPTACLE RS 503LT a 6 70 0062 6 3 BLADE RS DOM6 3 2 5LT 1 7 RECEPTACLE HOUSING 1 WAY S SUPPLIED WITH ENGINE 2 8 5 RING CRIMP TERMINAL DURITE 0 001 02 1 9 M6 RING CRIMP TERMINAL SUPPLIED WITH ENGINE 1 10 FUSE HOLDER S SUPPLIED WITH ENGINE 1 RECEPTACLE HOUSING 6 5 SUPPLIED WITH ENGINE 1 12
16. SST 2ILvW2H2S stem 060021 9 920622 9411 36 1631 HINAS SSiauiniovdnNvW SANWA 823 IBS NI 59411435 aunssand IBY c2 or Robe 331002 1901140 NO21238 ooge 2522 WAS ABA did JAWA oor ay ost ad 0 09 A 301 du 296179 75 HIT500 Workshop Manual 2324 Iss C DCA00259 2040 6000 59 ZH FMS 66614401 9002 PAW OOGLIH LIA ASSV JUL 9 7 23 Hydraulic Hose Assy Drg 1459 SA 7 23 Hydraulic Hose Assy Drg 1459 SA Section 7 Drawings 8 GE WD R a TES 2 700000 7 Tee T E ej LI Wa el a cse SL 10 Le f 0 3931 EE DCA00259 HIT500 Workshop Manual TCP 2324 Iss C 76 Section 7 Drawings 7 23 Hydraulic Hose Assy Drg 1459 SA
17. amp Torque Specification Appendix A Nut amp Bolt Torque Specification 1 Specific Torque Settings Track motor to chassis 70 Nm Sprocket to track motor 70 Nm Rams to chassis body 120 Nm Lifting eye to chassis 85 Nm Fuel filler hose clip 10 Nm Hydraulic tank drain plug 34 Idler and bottom rollers 49 2 Generic Torque Settings Bolts not defined above should be tightened to the torque settings listed in Table A 1 Friction coefficient total 0 14 for screws and nuts without after treatment as well as for phosphate nuts Tighten by hand f nothing special is indicated select correct torque limits from the following tabulations Size 6 9 8 8 10 9 12 9 Some Engine Bolts Standard Hex Bolt Some Engine Bolt Standard Cap head Nm Ibfft Nm Ibfft Nm Ibfft Nm 6 M6 8 5 6 3 10 7 4 14 10 3 17 12 5 M8 21 15 5 25 18 4 35 25 8 41 30 2 M10 41 30 2 49 36 1 69 50 9 83 61 2 12 72 53 1 86 63 4 120 88 5 145 106 9 M14 115 85 135 100 190 140 230 170 M16 180 133 210 155 295 218 355 262 M18 245 181 290 214 400 295 485 358 M20 345 255 410 302 580 428 690 509 M22 465 343 550 406 780 575 930 686 M24 600 443 710 524 1000 738 1200 885 M27 890 656 1050 774 1500 1106 1800 1328 M30 1200 885 1450 1070 2000 1475 2400 1770 Table A 1 Torque settings for Metric 150 Thr
18. BW 1100 20 o 138 Oz X PW 5000 0 2 ANEW 020070 d 2 83825 136 FW 2100 10 8 WIS 2100070 4d 8 5 8000 20 8 135 Se 0100 10 928 LAS X OTW 4800 10 2000 20 fd 2 17108 135 010070 24 LIS Ge X 7000 20 Was 8 5 Ob WALI WS 02 9 9 459 GE WALI 1 9200 08 gr z 1000 22 a 9 woLLca 810079 91 8 drimnoq was _ 600002 g 100060 2 _ 280 2 E0000 2 2 anno INDAS oF TRY soj 6 2 100 70 8 2 NIQ _ 00020 4 2 imDOWS 00008 9 2 wOLOWXTYMA 6100 09 1 240046 t 1 41808 10 1 02 000010 sari 1 500 ASSY 5155942 010100530 UNGMO 7 2 Chassis Assy Stage 1 1941 01 SA 7 2 Chassis Assy Stage 1 Drg 1941 01 SA Section 7 Drawings DCA00259 HIT500 Workshop Manual TCP 2324 Iss C 54 Section 7 Drawi
19. Chassis To Cylinder 62 0123 2 Prs 19 1w 550 Cut Length 90 C 90 S Opposite To Lay 90 Sleeved Pairs Chassis To Cylinder 62 0124 2 Prs 20 1w 550 Cut Length 90 S Male Air Breather Extension 62 0125 1 30 1 2 M22 Male Male 62 0080 1 31 1 2 5 8 Barrel 62 0081 1 32 13 8 Male Female Female Tee 62 0082 1 33 1 4 BSP Male Male 62 0001 10 34 1 4 Extended Bulkhead C W Nuts 62 0005 8 35 3 8 1 4 Male Male 62 0031 4 36 3 8 BSP Male Male Bulkhead Nuts 62 0083 2 37 3 8 BSP Male Male 62 0007 8 38 1 2 BSP Male Male 62 0009 3 39 1 4 BSP Male Female Male Swivel Tee 62 0003 4 40 1 2 5 8 BSP Male Male 62 0010 N R 41 3 4 BSP Male Male 62 0013 1 42 3 8 BSP Test point 62 0015 1 43 118 BSP Test point 62 0084 1 44 1 2 Male Female Block Elbow Drilled and Tapped 1 8 BSP 90 to FM 62 0085 1 45 3 4 5 8 BSP Male Male 62 0086 1 46 3 8 1 2 BSP Male Male 62 0087 1 47 118 BSPP 1 4 BSPP Male Female Extended 62 0088 2 48 3 8 BSP Male Female Block Elbow 62 0113 1 49 3 4 Blanking plug 62 0118 1 50 1 4 Bonded Seal 82 0002 20 51 3 8 Bonded Seal 62 0008 16 52 1 2 Bonded Seal 62 0011 3 53 3 4 Bonded Seal 62 0014 3 54 1 2 Copper Seal 62 0089 1 Hydraulic Hose Assy Parts 1459 Sht 2 Iss C Feb 7 2006 HIT500 Workshop Manual 2324 Iss C DCA00259 77 9027006 4000 89
20. Do not place engine under full load at full speed immediately after starting Always allow the engine to circulate lubricant fully and warm up gradually before operating at full speed and full load A 20 minute warm up is recommended Operate the engine at top rated speed when maximum power is needed for maximum speed or load 2 1 9 Steering WARNING Take due care when driving the machine Steering is achieved by driving one track harder than the other To drive in a straight line apply equal pressures to both Drive levers To steer left press the right hand Drive lever forwards harder than the other and conversely 500 Workshop Manual TCP 2324 Iss C DCA00259 To drive in reverse put the levers in the Reverse positions The same principles of steering left or right apply as driving forwards To turn the machine on the spot drive one track forwards and the other in reverse The machine will stop when both levers are released dead man brake 2 2 Daily Pre start Inspection Full routine maintenance procedures are given in Section 3 Maintenance 1 Ensure that the machine is ready for operation before the starting it 2 The machine should be in a level position to permit accurate checking of fluid quantities in the engine and other components 3 Open the left hand side of the engine enclosure to access to the engine for routine maintenance Note Refer to the engine manufacture s handbo
21. HIT500 Workshop Manual TCP 2324 Iss C DCA00259 Remove all keys any time the machine is left unattended e Immobilise the machine by removing a critical electrical or starting system device Upon receipt of a machine record the machine serial number and the serial numbers of all major components and attachments Keep this list up to date and filed in a safe location for fast retrieval e Place a decal or notice on the machine stating that all serial numbers are recorded Discourage the thief Inspect the gates and fences of the machinery storage yard or construction site Keep machines in well lit areas and ask the local law enforcement authorities to make frequent checks around the storage yard or work site e Liaise with neighbours Ask them to watch equipment left at job sites and to report any suspicious activities to local allow enforcement authorities Make frequent inventories of machines to promptly detect losses or vandalism Recovery of a Stolen Machine In the event of theft immediately notify the law enforcement authorities having jurisdiction Provide the investigating officer with name type of equipment chassis and serial numbers of major attachments and components It would be helpful to show the investigating officer an Operator s Handbook photographs and advertising to familiarise him with the appearance of the machine Report the theft to the insurance company Provide the model an
22. Note Do not crank the engine for more than 40 seconds at a time 3 Crank the engine and check the battery voltage and starter current While cranking the starter current should be 120 140A and the battery voltage should greater then 10V Low current and low voltage suspect battery Low current battery voltage OK check leads Current OK or high tight or seized engine 4 1 2 Engine cranks but will not fire Note Do not crank the engine for more than 40 seconds at a time 1 Connect clamp meter to glow plug supply wire colour black with red stripes as shown in Fig 4 3 to measure glow plug current Fig 4 3 Clamp meter current check 2 Watch the current on the meter and set the ignition switch to PH preheat The measured current should start at around 15A and fall to around 6A after approximately 15 seconds If the glow plug current is correct suspect a fuel problem 29 Section 4 Fault Finding 4 2 Battery Charging Check A low or high current reading indicates a faulty glow plug or wiring To check the wiring disconnect the glow plug at the connector and measure the voltage at the connector socket with the ignition switch set to PH You can check the resistance of the glow plug measured from the connector plug to chassis this should be 1 Ohm approximately Note that a glow plug can be damaged by dirty fuel so check the fuel filters when replacing the glow plug Refer to t
23. Was WALT YS 6G WELT VS CHONDA TS WELT 16 2 451 B E B E LE WALI WRONWL did 28009 000009 BAIR eNrunoo 5100 10 Tur V2 SMI ALS BNA 014 0 NOISNGIXSISDWHX3 480001 E SAVINT ATY 20001 2690 INISINI 000 Am 0 00259 HIT500 Workshop Manual 2324 Iss C 62 Section 7 Drawings 7 11 Engine Service Kit Drg 1469 02 SA 7 11 Engine Service Kit Drg 1469 02 SA f 20 6981 DU 3002 006 1 RN SOND SOTANSS ANTIN SULT g 48579 YALM 7100 07 8 7102 91042108 4015 8000 21 I 000 01 t ASSY ANd 9000 01 2 T SEINVATD 9000 01
24. chamber Fig 5 4 shows the fixing points 32 Exhaust chamber fixings Fig 5 4 Exhaust chamber fixing points Fitting the exhaust is the reverse of this procedure 5 5 Ram Refer to Section 7 6 Chassis Assy Stage 5 Drg 1941 05 SA 1 Switch off the engine and remove the key 2 Disconnect the hydraulic hoses at the Ram Fig 5 5 Plug the hoses and take care to avoid oil spillage as this can be an environmental hazard Fig 5 5 Ram connections and fixing 3 At the piston end of the Ram remove the cylinder pin locking screw and knock out the cylinder pin Fig 5 6 HIT500 Workshop Manual TCP 2324 Iss C 0 00259 Fig 5 6 Ram cylinder 4 Atthe cylinder end of the Ram remove the Socket head fixing screw Fig 5 5 5 Remove the Ram Fitting a Ram is the reverse of this procedure Apply retaining compound where the lifting arm fits on the shaft Apply stud lock compound to the bolts and pin retaining screws Tighten the fixing screw to the torque specified in Appendix A The drawing in Section 7 23 Hydraulic Hose Assy Drg 1459 SA shows the hydraulic connections Set the hydraulic pressure as detailed in Section 6 Hydraulic Pressure Adjustments 5 6 Valve Block Refer to the drawing in Section 7 25 Control Valve 4 2006 Drg 1598 SA 1 Switch off the engine and remove the key 2 Disconnect the hoses from the block labelling each as you go Plug each hose and take care to avoi
25. hydraulic pump coupled to its shaft This pump provides two outputs a3cc per rev low flow high pressure output for low speed and general use and an8cc boost output These are combined to provide an 11 cc rev high flow high pressure boost drive for the high speed track drive HIT500 Workshop Manual TCP 2324 Iss C DCA00259 In the idling condition the hydraulic fluid circulates around the system at low pressure When a Tipping control valve is operated it directs the fluid to operate the appropriate rams to move the bucket The valve controls the direction of fluid flow to the rams and hence controls the direction of movement Pressure relief valves mounted on the rams control the fluid pressure applied to each ram When a Drive control valve is operated it directs the fluid in the appropriate direction to hydraulic motors on the track sprocket drive shafts Any leakage within the motor returns to the sump through a return hose HIT500 Workshop Manual TCP 2324 Iss C DCA00259 Section 1 Description 1 3 Hydraulics Normal supply To drive control valves Solenoid Tracking Tracking speed valve speed supply Fig 1 5 Tracking speed hydraulics The Tracking Speed button provides increased drive speed If the button is pressed while either of the Drive levers is pushed fully forwards or backwards solenoid controlled valve V1 Fig 1 5 feeds pressure to operate the tracking speed valve V2 which
26. kubota co uk for the UK http www kubotaengine com kubotaworldwide htm for elsewhere Service Bulletins TCPLtd may from time to time issue service bulletins to keep you up to date as to any improvements or changes that may take place on the complete assembly or component parts Machine Identification This manual may refer to controls and equipment that are not present on your particular machine It is important that you know your machine and its equipment and how to operate it properly nformation regarding the machine model code and chassis serial number is on the unit serial number plate Fig 1 This plate is on the rear left hand side Always quote the machine model and serial number in correspondence with your dealer or the factory CERTIFICATE OF CONFORMITY We declare that this product complies with the following Standards Directives Machinery Directive 89 392 EEC as implemented by The Supply of Machinery Safety Regulations 1992 Amended 1994 500 Mobile road construction machinery Safety Product Tracked Carrier Model HiT 500 Serial No Manufacturer Date 2006 PP Dea Signed Date 2006 Mr Paul Drew Development Manager Fig 1 Data plate Theft Deterrence The owner operator should take the following precautions to discourage theft to aid in recovery in the event that the machine is stolen or to reduce vandalism
27. routes the boosted pressure from the pump to the drive control valves and hence to the motors Pressure relief valve V3 regulates the pressure on the line 13 Section 1 Description 1 3 Hydraulics 14 HIT500 Workshop Manual TCP 2324 Iss C DCA00259 Section 2 Operation Section 2 Operation IMPORTANT READ AND UNDERSTAND THE OPERATOR S MANUAL BEFORE USE 1 THIS MACHINE FITTEDWITH ACOLDSTARTIGNITION SYSTEM TURN KEY TO START POSITION AND HOLD ENGINE WILL STARTAUTOMATICALLY WITHIN 10 SECS DEPENDING ON ENGINE TEMPERATURE 2 GRADUALLY IDLE A HOT ENGINE BEFORE SWITCHING IT OFF THIS WORK STATION HAS BEEN DESIGNED FOR SINGLE HAND OPERATION 4 WHEN REVERSING PAY CAREFUL ATTENTION TO CRUSH ZONES PERSONNEL AND OBSTRUCTIONS MAINTENANCE 1 NEVER PERFORM ANY MAINTENANCE WORK UNDER AN UNPROPPED BODY 2 CLEAN ANY BUILD UP OF MATERIAL FROM MOVING PARTS WASH IF NECESSARY 3 CHECK FUEL DAILY ONLY USE CLEAN FUEL 4 CHECK OIL DALY 5 GREASE DAILY MAXIMUM DESIGN PAYLOAD OF 500kg MAX GRADE 45 DRIVE FORWARD FORWARD 177 3 NEUTRAL NEUTRAL www tcp eu com 5 8 REVERSE REVERSE TIPPING LOWER FORWARD 2 TRACKING SPEED 5 0621 843330 com 2 1 Controls 2 1 8 Throttle This is mounted on the left hand side of handlebar assembly and is operated by hand Press the lever down to increase fuel flow and accelerate the engine
28. used before servicing fuel system When preparing machines or components for storage seal and tape all openings and close containers tightly to seal in all volatile inhibitor fluids and compounds used Follow manufacturer s recommendations when handling and using engine starting fluids and disposing of spent containers Do not puncture or burn empty containers These fluids are explosive and highly flammable Electrical Hazard Never smoke or allow open flames or sparks near batteries Always disconnect batteries before repairing electrical system to avoid danger of fire causing sparks Disconnect battery ground cable first and reconnect last Always disconnect batteries and alternator leads before carrying out any welding on the machine Never check battery charge by placing metal objects across battery posts to avoid sparks at battery posts Use jumper cables only as recommended Improper use can result in battery explosion or unexpected machine motion Never operate engine starter for more than 15 seconds and allow 30 seconds between cranking periods for cooling An overheated starter could cause a fire Pre Starting If engine is to be started and run indoors ensure proper ventilation to remove deadly exhaust gases Always perform Pre Starting Inspection instructions described in this manual to ensure the machine is ready for operation Starting Do not start the engine or operate any control if
29. wrapped around the exhaust pipe and the engine cover ceramic heat barrier are made of toxic material possible low risk carcinogenic Minimise dust release and use appropriate Personal Protection Equipment when handling them 3 4 Maintenance Intervals Service interval Initial Every Every Every Ref Operation Daily 50 hr 100 hr 1000 hr 2000 hr Page 23 Hydraulic filter Change Change 27 Hydraulic oil Check Check Change 27 Engine Oil Check Change Change 24 Oil filter Check Change 24 Lubrication Grease Grease 22 General Inspection Inspect 23 Air filter Check Replace 24 Fuel Filters Check 25 Check clean air filter daily if operating in dusty conditions Table 3 1 Maintenance Intervals 500 Workshop Manual TCP 2324 Iss C 21 DCA00259 Section 3 Maintenance 3 5 Service Access Component Lubricant Specifications Engine Crankcase Engine Oil with 1 85 and Filter max sulphated ash limit ISO HV32 Viscosity Index 170 A S T M No 2 Diesel Fuel at sub zero temp blend No 2 with No 1 Extreme Pressure Stern Tube Grease C W No 2 Lithium No Moly Extreme Pressure Capabilities Consistency Hydraulic System Hydraulic oil Diesel Fuel Oil with Fuel tank max Sulphur 0 5 Grease Nipples Hydraulic Motor Gear Oil Gearbox Viscosity Index 154 EP220 Table 3 2 Recommended lub
30. 1 85 Coal Bituminous 765 1290 100 Fertilizer Mixed 1030 1737 85 Coal Anthracite 1046 1764 100 Earth Dry Loose 1150 1939 100 Nitrate Fertilizer 1250 2180 85 Sodium Chloride Dry Salt 1300 2192 85 Cement Portland 1440 2428 100 Limestone Crushed 1530 2580 100 Sand Dry 1550 2613 100 Asphalt 1600 2698 100 Gravel Dry 1650 2782 85 Clay Wet 1680 2832 110 Sand Wet 1890 3187 110 Fire Clay 2080 3507 100 Ready Mixed Concrete 2194 3698 85 Copper Concentrate 2300 3878 85 Slate 2800 4721 100 Magnetite 3204 5402 100 HIT500 Workshop Manual TCP 2324 Iss C 19 DCA00259 Section 2 Operation 2 12 Average Specific Gravity 20 HIT500 Workshop Manual TCP 2324 Iss C DCA00259 Section 3 Maintenance Section 3 Maintenance 3 1 General Lubrication is an essential part of preventive maintenance It is important that the instructions regarding types of lubricants and the frequency of their application be followed to prolong the useful life of the machine Periodic lubrications of moving parts reduce mechanical failures While servicing thoroughly clean all fittings caps plugs etc to prevent dirt from entering the system Lubricants must be at operating temperatures before draining Do not operate any system unless oil level is within the operating range as indicated on the dipstick or level plug All change and service periods are recommendations based on average operating conditions Lubricants showing evidence of e
31. 114 HOLIMS 43346 H2LIMS 02318 W001 109912 OL z SIINNE 0251 60007 B Tus SIINI OJAL 70312133288 LE vive 00012 OOK 5900 02 E E OITV IAI 190002 Tos E oigo INITNI 65 0900 1 AWA NS on l 0906081 10002 0261 SNISROH 091 6002 v zm BNW 32143238 2014 414142539 8e0 vZ6T d2 1 93945 9NDDVUL HOLIMS 02319 69 HIT500 Workshop Manual 2324 Iss C DCA00259 1574 03 WL laries 7 17 Wiring For Auxiliaries Drg 1574 O3 WL Section 7 Drawings 7 17 Wiring For Auxil soozerer 50 44924 ONIMA QUAIN sus 9002 AW OOG LTH Myre SIRYIUXNY 303 WOOTONTYIM IUIL DINTUHS 9181 74 ISN red 0 VZ8T d2 L 72345 0123 02 335 72 t100 0 2 3015 9NTHIA WOU HOLIMS ALIWIXOUd WOOT Q3MZIA 580123 02 11 1 aus roms 25 12 amp aa
32. 469 01 SA Section 7 Drawings vor hoes TOSI INMA ava wus E yoo casa ROTE 9002 PHW XS EE LO SNISSEU Y ASSY SNISNZ TUU INYU HOWL ZIR 0 E i 2189 16 AGW siet 1 230802 FSN ASAS LnN TNS 68010 18 18 136 81010 7629 41 TST 135 WAH GE 150070 1000710 RRS 136 WICKS USVA OH 5000 20 900010 1704 Gy NTO 8100 20 MNS 106 0 980010 WIS 8200 0 ano NERDS IS 9x 9W 060010 HSM __ 2108 AROS 19 2900710 14505 31852 4091 2000 83 9297 WOOT3NIONG _ 0700 82 WAC 22048 BALAYI LNNOW 1709 SINTSINE WES VS SIHL dO NETO WELT VS
33. 4DRDSaQ CUN Led ON 999 NO 8 SLJYHS LOAId 35549 0 00259 HIT500 Workshop Manual 2324 Iss C 58 Section 7 Drawings 7 7 Engine Enclosure Assy Drg 1471 SA 7 7 Engine Enclosure Assy Drg 1471 SA 3 8001 ON SARI AUAM ava ees 9002 ed ASSY SEAGOTNS ANIONS TILIL VIDT LNG Td 09 a AEROS ASI LIS 97 OW 0500 10 9 WALT INTINYA 5 Idd 122502390 8 ANNSOTUN HW 8100710 WALI NOLLISOd NE NYJ 1204 ZEX W 090070 ed 6 WALT INGE OL NO2TIIS ISN 00020 24 LON 1708 09 9W 68000 JOO T eave 1200 0 425 JANIH 907 9100 0 091 71001 2 9100 2 413455 100 7 SINNOW 99948 6100 06 t 000 08 1981 T AJONYI 6000 08 Opt 9620 INISNI 000 08 ALS ON Lays Wi INWIS NOLLYTIYLSNI GNNOS wos VS 2551471385 DES 588 2 E 59 HIT500 Workshop Manual TCP 2324 Iss C DCA00259 Sec
34. 6 Completion 52 HIT500 Workshop Manual TCP 2324 Iss C DCA00259 Section 7 Drawings 7 1 Tracked Carrier Assy Drg 1600 GA Section 7 Drawings 7 1 Tracked Carrier Assy Drg 1600 GA NER UU 9002 FAW TUM ASSVWSINNYO QIYAL TULI NOUINHLSROT 91 99 0800710 2 2115 74 9TW 9074 2000 20 9 SIW 1708 1000 28 9 324 818 2 08 zoo 0610 04 WAS 4008 1 _ 26100 ASSY 289 29 95 ASSY 6Gbi vS YS 65 ASSY Miva 989915 ASSY 155 2 6009788 90 097 39 46 ASSY SISSVH2 10 1091 5 YO TOST 29715 ASSY SISSYHI ETOYS 50 109 2 89718 ASSY SISSYHO 20 1091 5 20 1091 138 15 ASSY SISSVHO 10 1091 8 9510 1091 Au ON Sud 000 S 53 HIT500 Workshop Manual TCP 2324 Iss C DCA00259 SORTER VS VS 0 1961 021 ON ART 9002 rw 139515 5 SISSVHO WILL 2 BTW 2000 20 07 GH LAS Ge x zw 100 10 ot AFIN 2 BW 4000 10 zu 02 XEHSV
35. A 1 Disconnect the hydraulic hoses from the fan Plug the hoses and take care to avoid oil spillage as this can be an environmental hazard Disconnect the electrical connection Remove the five screws securing the fan assembly to the frame Fig 5 14 and extract the fan assembly from the frame Fig 5 14 Fan fixing screws If fitting a new fan assembly prepare it as follows 4 Separate the fan from the cooler and reassemble with porting as shown in the drawing of Section 7 12 Cooler Assy Hydraulic Drg 1470 SA 5 Remove the blades from the electrical connector and reassemble with the wire colours as shown in drawing TCP 1470 SA this sets reverse fan rotation 6 diode in the line as shown in drawing TCP 1470 SA note the orientation of the diode 7 Fit the fan assembly to the frame and complete the electrical and hydraulic connections 5 10 Engine and Pump Replacement In order to replace the hydraulic pump remove the engine as detailed in Section 5 11 Engine Removal and then remove the pump as detailed in Section 5 13 Hydraulic Fitting a new pump is the reverse of these procedures HIT500 Workshop Manual TCP 2324 Iss C DCA00259 Section 5 Parts Replacement 5 9 Oil Cooler Fan When replacing an engine a new engine must be modified and prepared before fitting as described in Section 5 12 Engine Preparation In addition various parts such as the exhaust and air filter must be fitt
36. Manual 2324 Iss C T FAW OOG LIH 5620 504 2LLVW3H2S Jui UE 1 I mos DENTS Tuy rat LEHA ERT foes ALIX EE GEJAG P 4 A L 7 as i ES 2 numm m 5 2 Tea 5 gt men Missis WILY LS opona 2 A i W Wwe 1 per 2T H TS zu m 01043105 016 an sm mE a iar ap 66 Section 7 Drawings 7 15 Loom for Kubota OC95 Mk4 2006 1574 01 7 15 Loom for Kubota OC95 Mk4 2006 1574 01 6700 54 225 WA 10 5251 421 ON IMO 9002 YAW CCS LIH WO DAMM dVuMINTUHS 9781 74 ISN E 7 4O 2 2945 401294402 335 2 3015 WOU SYOLIANNOD TV 1 Ove Re
37. Pump 5 14 Track Section 6 Hydraulic Pressure Adjustments 6 1 Introduction 6 2 Fitting Test Gauge 6 3 Service Line Relief Valve Adjustment 6 4 Ram Pressure Levels 6 5 Track Drive Pressure 6 6 Completion Contents Section 7 Drawings 53 7 1 Tracked Carrier Assy Drg 1600 53 7 2 Chassis Assy Stage 1 Drg 1941 01 SA 54 7 3 Chassis Assy Stage 1941 02 5 55 7 4 Chassis Assy Stage 3 Drg 1941 03 SA 56 7 5 Chassis Assy Stage 4 Drg 1941 04 SA 57 7 6 Chassis Assy Stage 5 Drg 1941 05 SA 58 7 7 Engine Enclosure Assy Drg 1471 SA 7 8 Labels Decals Drg 1467 SA 7 9 Battery Box Assy Drg 1468 SA 7 10 Engine Assy amp Dressing Kit Drg 1469 01 7 11 Engine Service Kit Drg 1469 02 SA 7 12 Cooler Assy Hydraulic Drg 1470 64 7 13 Cold Start Assy Kubota Filter Drg 1925 65 7 14 Electrical Schematic OC95 500 MK4 2006 Drg 1514 tin 66 7 15 Loom for Kubota OC95 Mk4 2006 1574 67 7 16 Two Speed Mk4 2006 1574 02 69 7 17 Wiring For Auxiliaries 1574 03 70 7 18 Loom for Cold Start Mk4 2006 1574 04 7 19 Battery Leads Drg 1059 7 20 Jump Lead Link Mk4 2006 Drg 1607 73 7 21 Loom For Battery Charger Mk4 2006 Drg 1574 05 74 7 22 Carrier Hydraulics 4 2006 1599 75 7 23 Hydraulic Hose Assy 1459 SA 76 7 24 Hydraulic Tank Assy
38. The solenoid connects to the negative side of the battery through the chassis The Thermal cutout provides a warm start option If the ambient temperature in the engine compartment is greater than 20 C the thermal cutout will be open circuit Hence relay RLA will not then operate As a result the glow plug will not operate and the starter motor will start immediately the ignition switch is set to Start If this warm start option is not required e g for a very cold climate the cutout is linked out so that the start delay is always used If the timer or relay should develop a fault the engine can still be started in the usual manner for a diesel engine Setting the ignition switch to PH Preheat for 5s will power the glow plug Moving the switch on to Start will operate the starter motor This can be done even if the timer is not fitted or if relay RLA will not energize 1 2 2 Charging Circuit Of gt POAC A Accessory 12V Thermal cutout optional Fig 1 1 HIT500 Workshop Manual TCP 2324 Iss C DCA00259 Ignition circuit 11 Section 1 Description 1 3 Hydraulics Accessory 12V Generator FS1 aE 12v battery TL Fig 1 2 Charging circuit The regulator converts the a c output from the generator to d c and regulates the charging current it supplies to the battery to maintain a full charge 1 2 3 Tracking Speed Accessory 12V 15A fuse Micro switches Trac
39. ck leaving the chassis still supported on blocks 3 Disconnect the three hoses from the motor labelling each as you go Fig 5 10 Plug the hoses and take care to avoid oil spillage as this can be an environmental hazard Fig 5 10 Drive motor sprocket amp hoses 4 Remove the sprocket from the motor 8 socket head screws Fig 5 10 5 Remove the five socket head and one set bolt securing the motor to the frame and remove the motor Fitting a motor is the reverse of this procedure Tighten the sprocket and motor fixing screws with the torque specified in Appendix A The drawing Fig 5 12 Isolate battery Section 7 23 Hydraulic Hose Assy Drg 1459 SA shows the hydraulic connections 5 8 Battery The battery is located in a box beneath the engine Item 4 on the drawing in Section 7 5 Chassis Assy Stage 4 Drg 1941 04 SA 4 Remove the two screws securing the box to the frame Fig 5 11 and extract the box pulling the lead through as required Fig 5 11 Battery box Fig 5 13 Battery box removed 1 Isolate the positive battery lead Carefully 5 Remove the lid 2 screws to access the remove the lead from the terminal Fig 5 12 battery and insulate it with tape to prevent a short CAUTION circuit that would damage the battery 34 HIT500 Workshop Manual TCP 2324 Iss C 0 00259 5 9 Oil Cooler Fan The Cooler Assembly is shown on the drawing in Section 7 12 Cooler Assy Hydraulic Drg 1470 S
40. d all serial numbers Report the model and serial numbers of the stolen machine to a dealer handling the respective line of equipment Request that the dealer forward this same information to the equipment manufacturer Safety This piece of equipment is designed as a compact tracked carrier with the carrying capacity of 500 Kg only Always carry loads with the body in the low position and only raise it for tipping when the unit is stationery FAILURE TO COMPLY WITH WARNINGS COULD RESULT IN SERIOUS PROPERTY DAMAGE AND POSSIBLE PERSONAL INJURY The machine should be properly operated and maintained to keep it in safe efficient operating condition Be sure that all controls are free of mud HIT500 Workshop Manual TCP 2324 Iss C DCA00259 Preliminary grease or other matter that might cause slips hazardous to the operator service engineer or other personnel or equipment Report all malfunctions to those responsible for maintenance Do not operate the equipment until corrected Normal service or maintenance performed as required can prevent unexpected and unnecessary down time This handbook describes general inspections servicing and operation with the normal safety precautions required for normal servicing and operating conditions It is not a guide however for other than normal conditions or situations Operators and service engineers must be safety conscious and alert to recognise potential operating or ser
41. d oil spillage as this can be an environmental hazard 3 Disconnect the electrical connections to the microswitches at the rear of the block 4 Remove the four screws securing the block to the frame and extract the block Fitting a valve block is the reverse of this procedure The drawing in Section 7 23 Hydraulic Hose Assy Drg 1459 SA shows the hydraulic connections If installing a new block unions must be fitted to each hydraulic connection prior to connecting each hose Since the input union at the rear is somewhat inaccessible it should be fitted and the hose connected before installing the valve block as follows 5 Remove the coil module to gain access to the input port HIT500 Workshop Manual TCP 2324 Iss C DCA00259 Section 5 Parts Replacement ur 5 6 Valve Block Se Input module port Fig 5 7 Valve block input port 6 input port union Fig 5 8 Input port union 7 Connect the input hose and refit the coil module 2 Fig 5 9 Input hose On completion set the drive pressures as detailed in Section 6 Hydraulic Pressure Adjustments 33 Section 5 Parts Replacement 5 7 Drive Motor 5 7 Drive Motor 2 Remove the test stud lead from the terminal Fig 5 12 1 Switch off th i the key od eee 3 Remove the negative battery lead from the bolt 2 Remove the track from the appropriate side of securing the exhaust Fig 5 12 the machine as described in Section 5 14 Tra
42. draulic Pressure Adjustments 6 5 Track Drive Pressures Fig 6 9 Bottom ram at full bore Raised 6 5 Track Drive Pressures 1 track drive pressure adjustment the track motors must receive drive at full throttle To prevent movement of the machine during the adjustment the track must be immobilized This can be done by placing an iron bar right through BOTH tracks and driving the machine forwards until the bar locks the drives at the sprockets Inserting bar Drive locked Fig 6 10 Track locking bar 2 Push the drive levers forwards and set the throttle on full Fig 6 11 Track drive relief valve Fig 6 12 Drive forwards 3 Adjust the track drive relief valve D for a pressure reading of 175 Bar using the method described Section 6 3 Service Line Relief Valve Adjustment 50 HIT500 Workshop Manual TCP 2324 Iss C DCA00259 Section 6 Hydraulic Pressure Adjustments 6 6 Completion 4 With the motors still attempting to drive forwards press the Tracking Speed button to engage the increased drive speed Check for a pressure reading of 130 Bar Release the locking bar by briefly driving the machine in reverse Turn off the engine and remove the locking bar from the tracks 6 6 Completion On completion of pressure adjustments remove pressure gauge and refit protective cap on test port HIT500 Workshop Manual TCP 2324 Iss C 51 DCA00259 Section 6 Hydraulic Pressure Adjustments 6
43. e machine overnight or for extended periods If a security kit is supplied keep it locked 2 Parkon level ground where possible If it must be parked on a slope position machine at right angles to the slope and block tracks securely 3 Remove key to a place of safety WARNING Make sure the area around the machine is clear of personnel and obstructions before moving off Check tracks hoses wiring tubing and fittings for cuts abrasion fraying or other damage or deterioration Inspect for damage to the body or chassis Attach warning signs to the controls to alert others if lubricant has been drained batteries removed etc 1 the first few minutes of travel try out the controls to ensure you operate with maximum safety 2 Make sure the skip is fully down The siren will sound if in the raised position HIT500 Workshop Manual TCP 2324 Iss C DCA00259 2 10 Loading The most common methods of loading this type of machine are with hydraulic excavators and by hand These units can be loaded equally well from the front or the side Ideally excavators should require 90 or less swing 17 Section 2 Operation 2 11 Tipping Always position the machine on a level firm surface for loading and leave the loading area until indicated by loader driver The following precautions should be observed when approaching the loading area and while being loaded wait until it is safe to ret
44. ead DIN 13 HIT500 Workshop Manual TCP 2324 Iss C 83 DCA00259 Appendix Nut amp Torque Specification 84 HIT500 Workshop Manual TCP 2324 Iss C DCA00259
45. ear face of block and step on crank Fig 5 10 Cutting engine shaft 4 finally fitting the shaft key apply retaining compound 5 12 2 Regulator Remove the Regulator Assembly and bracket from the old engine and fit them on the new one Fig 5 13 Injector banjo 2 Connect a length of vent tubing to the new banjo Fig 5 14 and fit the new vented version in place of the old one Fig 5 13 Fig 5 11 Regulator bracket Fig 5 14 Fuel vent tubing 38 HIT500 Workshop Manual TCP 2324 Iss C 0 00259 Section 5 Parts Replacement 5 12 Engine Preparation 3 Fita Tee piece in the vent tubing of the fuel 5 12 5 Engine Oil tank as in Fig 5 15 1 Remove the dipstick Fig 5 17 Oil filler cap 2 Fill sump with oil of the grade specified in Table 3 2 to the top of the thread Fig 5 18 p mm gt and refit the cap Fig 5 15 Fuel venting 4 Connect the vent tubing from the banjo to the Fig 5 18 Oil level T piece 5 12 4 Plastic Filler Cap Replacement 5 12 6 Hydraulic Pump and E Power Take off Replace the plastic oil filler cap with a metal one as shown Fig 5 16 This cap sits just behind the Special tool Three legged puller Remove the hydraulic pump as described in exhaust pipe and a plastic one could melt 1 Section 5 13 Hydraulic Pump 2 Remove the four bolts securing the Power Take off Adaptor to the engine Fig 5 19 PTO adaptor fixing bo
46. ed to the new engine These can either be new parts or parts removed from the old engine Always fit new gaskets 5 11 Engine Removal 1 Remove the Engine Enclosure Assy Refer to the drawing of Section 7 1 Tracked Carrier Assy Drg 1600 GA 2 Isolate the positive battery lead carefully remove the lead from the terminal Fig 5 1 and insulate it with tape to prevent a short circuit that would damage the battery 3 Remove the test stud lead from the terminal Fig 5 1 4 Remove the negative battery lead from the bolt securing the exhaust Fig 5 1 Fig 5 1 Isolate battery 5 Release and remove the throttle cable from the engine Fig 5 2 35 Section 5 Parts Replacement 5 11 Engine Removal Fig 5 2 Throttle cable WARNING Note Take care not to allow dirt to contaminate fuel or fuel components 6 drain the fuel tank arrange to collect the fuel in a suitable receptacle remove the fuel filler cap remove the fuel drain plug Fig 5 3 and drain the tank Fig 5 3 Fuel drain plug 36 10 Th 12 Refit the drain plug and filler cap Disconnect the fuel line Fig 3 11 Fig 5 4 Fuel line Disconnect the fuel filler tube from the top of the tank Disconnect all electrical connections between the engine and the main frame Keep a note of connections removed Cold start connections z Fig 5 5 Cold start and filter Remove the two C
47. el tank is the reverse of this procedure 1 Set the fuel valve to Off Fig 3 14 26 HIT500 Workshop Manual TCP 2324 Iss C 0 00259 3 13 Hydraulic Filter Oil Parts Hydraulic filter TCP 63 0002 Take care to ensure that no dirt enters the tank or contaminates the cap filter or dipstick Dirt in the hydraulic oil could severely damage the machine Always use hydraulic oil of the correct specification see Table 3 2 No other oil is suitable for use in this hydraulic system The oil level must be checked when oil is cold 1 Remove the hydraulic tank cover Fig 3 16 six screws Hydraulic tank cover Fig 3 16 Hydraulic tank cover 2 Clean around the cap to prevent any dirt from entering when the cap is removed 3 Remove the dipstick to vent the tank This dipstick is not used to check the oil It is to allow the air in the tank to be displaced when filling 4 Unscrew the red cap and extract the filter Fig 3 17 Hyaraulic filter cap HIT500 Workshop Manual TCP 2324 Iss C DCA00259 Section 3 Maintenance 3 13 Hydraulic Filter Oil 5 Put the filter in the cap to keep it clean Fig 3 18 Fig 3 18 Hydraulic filter 6 Check the level and condition of the oil If the oil is contaminated consult TCP Ltd 7 If level is low fill through the filter housing until the level is 6 mm below the tube in the base of the filter housing Fig 3 19 Do not overfill the tan
48. g 5 43 Idler on shaft 11 Ensure Idler is fully home Fig 5 44 Idler fitted 44 12 Fit securing bolt torque 49 Nm Fig 5 45 Securing idler 13 Fit blanking plug b Fig 5 46 Blanking plug fitted 14 Remove jacking bolts Fig 5 47 Jacking bolts removed HIT500 Workshop Manual TCP 2324 Iss C 0 00259 Section 5 Parts Replacement 5 14 Track 15 Fit blanking plugs Fig 5 48 Blanking plugs 16 Remove chassis support Fig 5 49 Remove blocks 17 Run and test 500 Workshop Manual 2324 Iss C 45 DCA00259 Section 5 Parts Replacement 5 14 Track 46 HIT500 Workshop Manual TCP 2324 Iss C DCA00259 Section 6 Hydraulic Pressure Adjustments 6 1 Introduction Section 6 Hydraulic Pressure Adjustments 6 1 Introduction This section describes how to set hydraulic pressures for the rams and for the track drives Pressures are measured at a gauge connected to a port located at A in Fig 6 2 Ensure that the machine is at normal operating temperature before adjusting pressures A Pressure gauge test port B Upper ram Service Line Relief Valves C Lower ram Service Line Relief valves D Track drive Service Line Relief valve 6 2 Fitting Test Gauge Fit the gauge to the test port as shown in Fig 6 1 Fig 6 2 Location of test port and service line relief valves 500 Workshop Manual TCP 2324 Iss C DCA00259 47 Section 6 Hydraulic Pressure Adjustment
49. guess the hours used DETAILS OF FAILURE Give a full report on the failure ORDER NuMBER An order number will be required Note that the order number is to cover the diagnostic and call out time as well as to determine the following e That the failure is to be covered under the terms and conditions of warranty If this is the case then the costs will be covered by TCP Ltd and the order number will not be used e If the failure is determined to be of a non warrantable nature further authorisation to continue will be sought before any rectification work takes place The information above must be provided even if your warranty claim is a parts only claim An invoice will be raised for the exchange parts The reported faulty defective part must immediately be returned to TCP Ltd and full inspection of the parts carried out if the failure is covered under the terms and conditions of warranty a credit note corresponding to the invoice will be despatched to the customer If the failure is deemed to be of a non warrantable nature the invoice should be settled immediately Certificate of Conformity This is a sample Certificate Of Conformity inserted in this manual for reference each machine is issued with a bespoke certificate sent to the head office of the purchaser and copies are available on the request of purchaser Kubota Engine Dealers To locate your nearest Kubota dealer access the Kubota web site at http www
50. h its operating temperature before the engine cranks This delay circuit operates only if the ambient temperature is below 20 degrees 1 Make sure that all levers are in the neutral position 2 Insert switch key and turn fully clockwise to position 3 and hold The engine will crank automatically after approximately 5 seconds 3 Release key when engine starts 16 HIT500 Workshop Manual TCP 2324 Iss C DCA00259 Voltmeter State of Reading charge 12 84 Volts 100 12 50 Volts 75 12 18 Volts 50 11 88 Volts 25 Do not jump start a vehicle by using arc welding equipment Currents and voltages are dangerously high and cannot be sufficiently reduced to make the method safe Be sure machines are not touching each other Use cables that are the same size as those on the machine If jumper cables are used to start an engine be sure to follow this procedure 1 Connect one end of the jumper cable usually coloured red to the discharged battery POSITIVE stud terminal 2 Connect the other end of the same cable to the POSITIVE post on the booster or charged battery 3 Connect one end of the second cable usually coloured black to the NEGATIVE post of the booster battery 4 Connect one end of the jumper cable to a convenient point on the engine frame NEGATIVE 5 Keep grounding point clear of battery so that if a spark occurs it is away from batte
51. he engine workshop manual for more information 4 2 Battery Charging Check The battery is charged from an a c alternator driven by the engine A regulator converts the a c toa d c charging current which it regulates to ensure a full battery charge To check charging start the engine and measure the battery voltage with the throttle advanced The charging voltage should be of the order of 14V If the battery voltage has not increased significantly from its off load value suspect an alternator regulator or wiring problem To check the alternator switch off the engine disconnect the connections to the alternator and connect an a c voltmeter to the alternator Start the engine and measure the off load output from the alternator this should be gt 22V a c If the alternator output is correct check the regulator and wiring as detailed in the engine workshop manual 4 3 Tracking Speed Pressing the Tracking Speed button with a drive lever fully operated should give increased drive to both tracks Check the operation of the tracking speed switches and relay as follows 1 With the ignition switch off and in a quiet environment push one of the Drive levers forwards and listen for the operation of the 30 switch fitted at the rear of the valve block A very faint click should be audible 2 Repeat step 1 for the other lever Also check with the levers in the Reverse positions Note If the bar behind the Drive leve
52. ic or cement materials If in doubt seek advice On discharging the load ensure that the machine is on firm level ground If one track were to be higher than the other a twisting strain would be imposed upon the body hinge pins and chassis This could result in machine instability and damage Use the control levers to position the body Operate from the designed operating position only Keep clear of the tipping mechanism or you could be injured Once the load has been tipped move the Tipping lever into the LOWER position If the load does not clear completely the built in stops in the mechanism may used to assist discharge The ram cylinder does not need to be retracted before extending again To tip into a waste skip choose a position that will allow the body to fully discharge its load Only raise the skip with the machine stationary Once the skip is raised the machine may be inched forward until the tracks contact the side of the waste skip The skip can then be tipped to discharge load HIT500 Workshop Manual TCP 2324 Iss C DCA00259 Section 2 Operation 2 12 Average Specific Gravity 2 12 Average Specific Gravity Loose Density Fill Material kg m Snow Fresh 200 337 100 Peat Dry 400 674 100 Sugar beet 530 894 100 Coke Loose 570 961 85 Barley 600 1012 85 Petroleum Coke 680 1146 85 Wheat 730 123
53. ion to any reimbursed or outstanding warranty claims in order to determine that all relevant details and information is correct Service and Warranty Training Service and warranty training for service fitters can be requested in writing Initial training is to be carried out at an appropriate TCP Ltd workshop Once this initial training has been carried out you are responsible for any further training required by your own service centre or depot network Warranty Terms One year or 1000 hours whichever occurs first from date of installation All engine warranty issues must be directed to the engine manufacturer or the manufacturer s approved appointed engine dealer General Exclusions THE FOLLOWING ARE WARRANTY EXCLUSIONS AS DETERMINED BY KUBOTA Service items including lubricants coolants filters glow plugs fan belts fuel injection equipment stop solenoid relay charge regulator leaks oil water and air IN ADDITION paintwork wear parts and tracks Prelliminary Warranty Claim Submission Procedures Claims must be reported accurately and all relevant details given as follows OWNERS NAME AND ADDRESS full name and address of customer and site location if different MACHINE TYPE State machine type i e Hi T500 tracked dumper Hi C40 crusher Date of Failure SERIAL NUMBER Serial number of unit ENGINE NUMBER Serial number of engine Hours State hours used on hour clock Please do not
54. k Fig 3 19 Hydraulic tank filler 8 Replace the filter with a new one 9 Refit the cap and dipstick 10 Refit the cover 27 Section 3 Maintenance 3 14 Charging the Battery 3 14 Charging the Battery A battery charging connection lead and socket is built into the Mk4 Fig 3 20 This connection point is designed for use with a Coulombi charger TCP Part No 82 0004 Under no circumstances use this connector to jump start the machine The battery can also be charged by means of a standard 12V car battery charger Connect the charger between chassis negative and the battery test stud Fig 3 20 28 Fig 3 20 Battery test stud HIT500 Workshop Manual TCP 2324 Iss C 0 00259 Section 4 Fault Finding Section 4 Fault Finding 41 Starting 4 1 1 Engine will not crank properly 1 Check the battery voltage with the ignition switch off This can be measured between the battery test stud shown in Fig 4 1 and chassis Fig 4 1 Battery test stud The battery voltage varies with charge as follows Voltmeter reading State of charge 12 84V 100 12 50V 75 12 2V 50 11 9V 25 Fig 4 2 Starter current check HIT500 Workshop Manual TCP 2324 Iss C DCA00259 If a charging problem is suspected check the charging circuit as detailed in Section 4 2 Battery Charging 2 Connect a clamp meter on the battery positive lead as shown in Fig 4 2 to measure the starter current
55. k4 2006 Drg 1607 8100 4097424 ONIMA ava mais 9002 AW 00GLIH ANTIOvaT AALLISOd 404 438 LV3H 31ON 93439705 9 SQN3 292 811 1504 439 006 82 7 20 Jump Lead Link Mk4 2006 Drg 1607 73 HIT500 Workshop Manual TCP 2324 Iss C DCA00259 7 21 Loom For Battery Charger Mk4 2006 Drg 1574 05 WL 7 21 Loom For Battery Charger Mk4 2006 Drg 1574 05 WL Section 7 Drawings 9900 04 60 201 421 ON IMA 9002 00611 ANIYHS 3181 374 ISN V dM INIA Idd 340338 LNIOL ALY INSNI E 830105 934329715 ASN LNANOdWOD Odd AVON QuvQNYIS AQIS ONEYIM SuO123NNOO2 X 504 WOO PUIL 19 2 TWNIWYAL dWI INTI OW 2 1 90982 016 1 ALD wall gc L otv 0 00259 HIT500 Workshop Manual 2324 155 74 Section 7 Drawings 7 22 Carrier Hydraulics Mk4 2006 Drg 1599 7 22 Carrier Hydraulics Mk4 2006 Drg 1599 90028081 66 lt 1 421 ON 9002 IW OOGLIH
56. king speed button Fig 1 3 Tracking speed The Tracking Speed button opens a hydraulic valve that supplies extra power to the track motors When a drive lever is set to forward or reverse one of the microswitches is operated If the tracking speed button is then pressed the circuit is completed to energize relay RLB Contact RLB1 holds the relay on when the button is released Contact RLB2 energizes the high speed valve 12 1 2 4 Sounder Control Accessory 12V 15A fuse FS2 ps Proximity 1 sensor RLC1 Sounder Fig 1 4 Sounder control A sounder operates while the arm has moved to raise the bucket A sensor fitted in the frame senses the presence of the arm When the arm moves away the sensor contacts close and energize relay RLC Contact RLC1 activates the sounder 1 2 5 Oil Cooler Fan The oil cooler fan is powered from the 12V Accessory supply via a diode The diode prevents back emf generated by the fan motor from reaching other circuits when the machine is powered down 1 2 6 Oil Pressure Light An oil pressure switch turns on the oil pressure warning light if the oil pressure is low 1 2 7 Hours Counter The hours counter powered from the 12V Accessory supply via the 15A fuse measures the elapsed time while the machine is operating 1 3 Hydraulics Refer to the Hydraulic Schematic drawing in Section 7 22 Carrier Hydraulics Mk4 2006 Drg 1599 The diesel engine drives a
57. kshop Manual 2324 Iss C DCA00259 Section 7 Drawings 7 4 Chassis Assy Stage 3 Drg 1941 03 SA 7 4 Chassis Assy Stage 3 Drg 1941 03 SA PME i n 5 5 3 4 5 13 833 zd OP ERER FEER ER 5 A HARARE ibi TR 818 1 al cl nl el wl el el ele el ele TNAM B s 8 la 88 8 3 31141 1 14 ii e x masas aes 8 ES is B in M a Wu 2632 X BFE J 56 HIT500 Workshop Manual TCP 2324 Iss C DCA00259 Section 7 Drawings 7 5 Chassis Assy Stage 4 Drg 1941 04 SA 7 5 Chassis Assy Stage 4 Drg 1941 04 SA ENTUM J 9002 IW 0021101 NA PHOVAS ASSY SISSVHO 080 0020 2 OW 7000 20 84 2 3825 135 ZI X 00070 4 9 aHSVA SW 1100 20 Ed 5 SINN 2014887 200010 8 3825 252 LAS 52 x gw 1000 G 63 1 IMDINY TS 9700 50 4 1 Was 100008 8 1 Q31N34 Bind FOCHI 1 XOU Borys T SISSYHO 9007 1 LDISNISSaUay ASSY
58. lts x4 Fig 5 16 New oil filler cap s Fig 5 19 PTO adaptor fixings 3 Pull off the power take off adaptor Fig 5 20 This will pull off the pump drive coupling HIT500 Workshop Manual TCP 2324 Iss C 39 DCA00259 Section 5 Parts Replacement 5 12 Engine Preparation leaving only the pump coupling adaptor on the On fitting the PTO adaptor fill the interior cavity with motor shaft the grease to prevent the ingress of moisture Fig 5 Power take off 23 adaptor Pump drive coupling Fig 5 20 Pump drive coupling 4 Remove the pump coupling adaptor from the motor shaft It is secured by a hex socket screw Fig 5 21 A three legged puller may be required Fig 5 23 PTO grease 5 12 7 Engine Cable Loom Refer to drawing TCP 1574 01 WL for details of the engine cable loom Figures 5 24 to 3 20 show the cable loom connections Fig 5 21 Coupling adaptor On refitting the coupling adaptor note that the adaptor fits with the chamfered end towards the motor Fig 5 24 Engine cable loom 1 Fig 5 22 Coupling adapter chamfer Similarly the pump coupling fits with the chamfered end towards the pump 40 HIT500 Workshop Manual TCP 2324 Iss C 0 00259 Section 5 Parts Replacement 5 12 Engine Preparation B Fig 5 27 Engine cable loom 4 Fig 5 30 Engine cutout solenoid cable HIT500 Workshop Manual TCP 2324 Iss C 41 DCA00259 Section 5 Parts Replacement 5 13 Hydraulic Pump 5 14 Track In
59. ne has been installed 5 12 1 Drive Shaft Preparation On an engine supplied by TCP the drive shaft will have been cut to length before dispatch For an engine obtained from another source the shaft must be cut precisely to the required size Fig 5 10 and all burrs removed 1 Knock out the shaft key Fig 5 8 Fig 5 7 Engine bolts one of three 14 Clear a space on a strong bench to receive the engine WARNING The engine is heavy Get the necessary help 15 With help carefully remove the engine from the machine and transfer it to the bench Refitting the engine once prepared is the reverse of this operation Apply stud lock compound to the bolts securing the PTO adaptor to the block Fig 5 8 Removing shaft key HIT500 Workshop Manual TCP 2324 Iss C 37 DCA00259 Section 5 Parts Replacement 5 12 Engine Preparation 2 Grind off the corner of the key so that it fits snugly right up to the far end of the groove Fig 5 12 Regulator 5 12 3 Fuel Vent Fig 5 9 Shaping the shaft key 1 Remove the old banjo Fig 5 13 3 Mark the shaft and cut it to the dimensions sf shown in Fig 5 10 26 mm cut length of engine shaft Power take off adapter Engine 22 3 3 mm clearance between crank and pump shafts 16 3 mm between r
60. ngs 7 3 Chassis Assy Stage 2 1941 02 7 3 Chassis Assy Stage 2 Drg 1941 02 SA botre ys ava 2 VS 2000 59 YS ABET 188V1S HAW ASSY SISSYHI 0ST 8002 EA PAW PT 239915 ASSY 5155 TILIL TINTA E 1545 MRS 490040 wd 9101951811 2 LANSOUN SW 20000 SN Li BW 1100 20 23 93425 135 52 BW 100 19 14 1 06 HINT LI 096 MT 02 WAIT S 621 97 1 Te WAI 182 062 06 HAINT 10081 MZ i 1 09225 56 0491 BE SWALL YS EY 1 ALE 2405 06 2 OE EWIL YS zy 1 28200 26 HAINT LO GET MZ C 3 246 05 HANTI E LW 01 T 409 9 5 067 06 LNO OBE B E TWHIS S 8 REIT VS 1 2 458 8 8 2 1 Sr WAIT 8 LAN AUD VT 1 QE SEITIE 00 01 1 SISSVHONOILYINSNEGNNOS 000006 1 z H A NOXidRpSHq 55 500 Wor
61. ok for engine maintenance details 4 Engine With engine off check oil level The oil should be just over the top thread at filler Add oil if low See Table 3 2 for correct oil 15 Section 2 Operation 2 3 Engine Operation 5 Inspect the engine air cleaner for any damage If damaged replace it immediately Using an engine with a damaged air cleaner will seriously reduce engine life 6 Check that oil cooler outlet grill between body and chassis is clear of obstructions 7 Carefully inspect tracks for cuts or other damage and for correct spring preload 8 Inspect for any leaks whether fuel engine oil or hydraulic oil 9 Check fuel level Never crank the engine for more than 10 seconds continuously To avoid overheating allow starter at least 30 seconds cooling time between cranking periods To prevent condensation from contaminating the fuel fill the fuel tank at end of each shift 2 3 Engine Operation Do not place engine under full load or full speed immediately after starting ALWAYS allow the engine to fully circulate lubricant and warm up gradually before operating at full speed and full load Operate engine at top rated speed when maximum power is needed for the load 2 5 Starting the Engine with Jumper Cables Access to the battery and starter motor terminals is restricted on the To allow jump starting to take place a Stud Terminal is located on the left rear of
62. old Start Assy fixing screws Fig 5 5 Move this assembly to one side to gain access to the pump Disconnect the three hydraulic hoses from the pump at the front of the engine Fig 5 6 Plug the hoses and take care to avoid oil spillage as this can be an environmental hazard HIT500 Workshop Manual TCP 2324 Iss C DCA00259 Section 5 Parts Replacement 5 12 Engine Preparation 5 12 Engine Preparation Refer to drawing TCP 1928 02 SA A replacement engine obtained from TCP will have been at least partly prepared at the TCP factory for installation An engine obtained from elsewhere will require full preparation prior to installation In addition there are components to be removed from the old engine and fitted to the new one Full preparation involves Cutting the drive shaft to length Fitting a new fuel vent tube between new banjo and a new T piece on the fuel tank overflow pipe Fitting voltage regulator and bracket Fig 5 6 Hydraulic pump location 13 Remove the three bolts securing the base of Installing wiring loom the engine to the shock absorbers Replacing the plastic filler cap with a metal one Fig 5 7 Swap for the one on the old engine Removing the hydraulic pump and power takeoff from the old engine and fitting them to the new one Filling engine with fresh oil Fitting exhaust system This can be done with the engine installed Fitting air filter This is done after the engi
63. resh oil of the grade specified in Table 3 2 24 8 dipstick SM Fig 3 5 Engine oil filter 3 11 AirFilter Parts Air filter 10 0005 1 Remove the cover Fig 3 6 Fig 3 6 Air filter cover 2 Remove the wing nut securing the air filter and remove the air filter Fig 3 7 HIT500 Workshop Manual TCP 2324 Iss C DCA00259 3 remove the whole assembly remove the three screws securing it to the engine body Clean the filter or replace if damaged In any case replace the filter after 100 hours of use Refitting is the reverse of this procedure Do not run the engine with the air filter removed as any ingress of dirt will damage the engine Fig 3 7 Air filter 3 12 Fuel Filters WARNING Take due care when working with fuel Diesel fuel is a health hazard for contact with eyes or sin inhalation and ingestion There is also danger of fire and pollution Dirty or contaminated fuel will damage the engine For this reason three fuel filters are fitted as follows e the top of the fuel tank e the base of fuel tank e On cold start bracket Fig 3 13 Fuel can also be contaminated by condensation in the fuel tank so keep the fuel tank full while the machine is not in use 3 12 1 Tank Inlet Filter This is fitted in the top of the fuel tank 1 Slacken the screws securing the hose on the tank inlet and remove the hose Fig 3 8
64. ricants Table 3 1 lists the maintenance intervals 3 6 Lubrication Do not mix Lubricants 3 5 Service Access To access the engine for routine maintenance open the left hand side of the engine enclosure Parts Grease cartridge TCP 80 0025 Periodic lubrication greasing of moving parts If necessary the right hand panel can also be red ces mechanical failures removed as detailed in Section 5 2 Housing Removal Fig 3 1 shows the lubrication points The circled numbers are the recommended lubricants listed in Table 3 2 Fig 3 1 Lubrication points Note Shown with Engine Enclosure removed 22 HIT500 Workshop Manual TCP 2324 Iss C DCA00259 Section 3 Maintenance 3 7 General Inspection 2500 2690 2825 Fig 3 2 Overall dimensions 3 7 General Inspection Engine air intake Check air intake system for wear or damage to piping loose clamps and leaks Check for loose bolts or fixings Tighten as per bolt chart in Appendix A Check for oil leaks Securely tighten any loose joints and replenish any losses Examine the body particularly the chassis for cracks or broken welds Repair where necessary HIT500 Workshop Manual TCP 2324 Iss C DCA00259 3 8 Daily Check After every 10 hours of operation do a daily walk around inspection Visually check engine for damage listen for any unusual noises e Engine Air Cleaner
65. rs has been damaged the bar may restrict the forward movement of the levers such that the switches do not operate in the forward position If a click is audible check the tracking speed relay as follows 3 Turn the ignition switch to AC 4 Push the drive levers forward fully press the Tracking Speed button and listen for the faint click of the tracking relay This relay is located inside the upper right hand side of the frame In order to repeat this check it is necessary to release the drive levers to the neutral position before trying again If a click is audible at least one of the lever switches and the tracking relay are operating It is possible to check the electrics by removing the solenoid coil module from the rear of the valve block Fig 4 4 energising it and noting the effect on a metal object such as a screwdriver inserted into the coil If the solenoid is operating check the hydraulics Coil module Fig 4 4 Tracking speed solenoid coil HIT500 Workshop Manual TCP 2324 Iss C 0 00259 Section 5 Parts Replacement Section 5 Parts Replacement 5 1 Recommended Tools Pressure gauge 0 200 bar for setting hydraulic pressures AC DC Clamp meter 0 500 amp Spanner snap on Tool LTAM1719 for ram relief valve setting Three leg hydraulic puller for removal of pump drive coupling Spanner for hydraulic in tank rock stopper filter TCP tool 82 0002 5 2 Housing Remo
66. ry 2 7 Moving and Stopping 2 8 Stopping the Engine 2 9 2 10 Loading 2 11 Tipping 2 12 Average Specific Gravity HIT500 Workshop Manual TCP 2324 Iss C DCA00259 Section 3 Maintenance 21 3 1 General 3 2 Engine Maintenance 3 3 Safety Precautions 3 4 Maintenance Interval 3 5 Service Access 3 6 Lubrication 3 7 General Inspection 3 8 Daily 3 9 Engine Oil Check 3 10 Engine Oil Change 3 11 AirFilter 3 12 Fuel Filters 3 12 1 Tank Inlet Filter 3 12 2 Tank Bottom Filte 25 3 12 3 Extra 3 13 Hydraulic Filter Oil 3 14 Charging the Batter Section 4 Fault Finding 4 1 metere 4 1 1 Engine will not crank properly 4 1 2 Engine cranks but will not fire 4 2 Battery Charging Check 4 3 Tracking Section 5 Parts Replacement 31 5 1 Recommended 31 5 2 Housing Removal 5 3 Air Filter 5 4 Exhaust System 5 5 Ram 5 6 Valve Bloc 5 7 Drive Motor 5 8 Battery 5 9 Oil Cooler Fan 5 10 Engine and Pump Replacement 5 11 Engine Removal 5 12 Engine Preparation 5 12 1 Drive Shaft Preparation 5 12 2 Regulator 5 12 3 Fuel Vent 5 12 4 Plastic Filler Cap Replacement 5 12 5 Engine Oil 5 12 6 Hydraulic Pump and Power Take off39 5 12 7 Engine Cable Loom 5 13 Hydraulic
67. ry fumes explosive hydrogen 6 Locate cause of battery failure 2 6 Battery Charging If the battery is not being charged properly refer to Section 4 2 Battery Charging The battery can be charged from the mains as detailed in Section 3 14 Charging the Battery 2 7 Moving and Stopping Section 2 Operation 2 6 Battery Charging 3 Select the driving direction and the required engine speed 4 Move levers to the required position apply more acceleration until the required speed has been reached 5 If running a good distance on a good surface press the Tracking Speed button to increase the speed 6 Tostop the machine release the control levers slowly and release the accelerator as the machine slows until it stops 2 8 Stopping the Engine 1 Cool a hot engine by operating the engine at 1 000 rev min and then slowly decelerating it over a 5 minute period until the engine is idling Let it idle for at least 2 minutes Always cool a hot engine gradually before shutting it off 2 Turn ignition key switch off to shut off fuel and stop engine 3 Make sure body is in the lower position 2 9 Parking WARNING When parking the machine overnight or for an extended period the following procedure in addition to that given in Section 2 8 Stopping the Engine will help maintain it in good condition 1 To prevent condensation from contaminating the fuel fill the fuel tank completely before parking th
68. s 6 3 Service Line Relief Valve Adjustment 6 3 Service Line Relief Valve Adjustment Relief valves are fitted in the service lines for the rams and the track drives to control the hydraulic pressures supplied Details of the pressures are given in Sections 6 4 Ram Pressure Levels and 6 5 Track Drive Pressure Note When removing the valve cap be sure to use a thin wrench to keep the valve from turning and breaking the seal Fig 6 3 1 Cut bond wire 2 Remove cap using a 17mm wrench to undo cap and a thin 17mm wrench to stop the service line relief valve from turning in housing Fig 6 3 3 Push the relevant control lever forward or back as indicated in figure Select full throttle Use a 6 mm socket wrench to set pressure on gauge to pressure indicated Fig 6 5 Fig 6 3 Valve cap removal Release ram control lever and reduce throttle Refit the cap using two spanners as in step 2 8 Fit new bond wire to cap Fig 6 4 Valve with cap removed Fig 6 5 Valve adjustment 48 HIT500 Workshop Manual TCP 2324 Iss C 0 00259 Section 6 Hydraulic Pressure Adjustments 6 4 Ram Pressure Levels 6 4 Ram Pressure Levels There are separate pressure adjustment for the full bore and annular retracted positions of each ram The locations of the valves B upper ram or C lower ram are shown in Fig 6 2 Fig 6 8 Bottom ram annular bore Lowered HIT500 Workshop Manual TCP 2324 Iss C 49 DCA00259 Section 6 Hy
69. the engine mounting frame this Stud Terminal is connected to the positive stud on the battery To access this Stud Terminal open the left hand side of the engine enclosure Do not idle the engine for more than five minutes at a time Shut it off If engine operates outside its normal operating range shut it down immediately and report to Service or maintenance personnel Charging of Odyssey Batteries Check polarity of discharged battery connections Do not allow charging voltage to exceed 15 volts Excessive booster voltage and or incorrect jumper cable connections will destroy plates inside battery Keep all sources of ignition away from batteries Do not lean over batteries Do not allow the battery to become fully discharged The battery may no be able to recover from this state rendering it unserviceable WARNING Never start the engine indoors unless proper exhaust ventilation is provided to remove deadly exhaust gases Once the engine is running move the machine outdoors as soon as possible Exhaust gases are hazardous and can cause unconsciousness and death Operating the engine beyond high idle speed can cause severe engine damage The engine speed must not exceed 3 600 rev min under any circumstances When descending a steep grade use a combination of lever and engine speed 2 4 Starting the Engine The is fitted with delay circuit to allow the glow plug to reac
70. the event that the drive track is displaced during use proceed as follows Fig 5 31 Battery test stud Fig 5 33 Typical displaced track 5 13 Hydraulic Pump 1 Support the chassis on blocks along its length to lift the track 1 Remove the engine from the machine as detailed in Section 5 11 Engine Removal 2 Remove the three unions from the pump Fig 5 32 Fig 5 32 Pump unions Fig 5 34 Track supported Remove the blanking plugs 3 Remove the two bolts securing the pump to the power takeoff PTO adaptor Fig 5 32 and extract the pump Fitting a new pump is the reverse of this procedure Apply stud lock compound to the pump fixing bolts a Fig 5 35 Blanking plugs 42 HIT500 Workshop Manual TCP 2324 Iss C 0 00259 Section 5 Parts Replacement 5 14 Track 3 Lubricate jacking bolts supplied 6 Remove blanking plug CA7 a Pd Fig 5 36 Jacking bolts 4 Insert jacking bolts and adjust them equally 7 Remove securing bolt 5 4 Fig 5 37 Adjusting jacking bolts Fig 5 40 Idler securing bolt 5 Adjust jacking bolts until idler is almost 8 Remove idler touching roller Fig 5 38 Fig 5 38 Idler touching roller Fig 5 41 Remove idler HIT500 Workshop Manual 2324 Iss C 43 DCA00259 Section 5 Parts Replacement 5 14 Track 9 Place Idler in drive track Fig 5 42 Idler in drive track 10 Slide drive track and Idler on shaft SS Fi
71. there is NOT OPERATE similar warning sign attached to any control Use jumper cables only as recommended Improper use can result in battery explosion or unexpected machine motion Always obey Starting the Engine instructions Start and operate the machine only from the operator s station HIT500 Workshop Manual TCP 2324 Iss C DCA00259 Operating Always perform Pre Operating Checks described in this manual to ensure the machine is ready for operating Do not operate the machine if exposed personnel enter the immediate work area Be sure the body is fully down before moving the machine warning buzzer will sound if body is not fully down Always try to face or look in the direction the machine is travelling Always operate straight up or down slopes whenever possible Side hill operation can cause sideslip and possible rollover Slow down when moving in congested areas Do not race with other machines Stop in authorised areas only except in an emergency Always watch for holes soft edges or other hazards when dumping over a spoil bank Operate body raising mechanism on firm level surface only a buzzer will sound to warn the operator and others in the area once the body raises above horizontal Lubrication and Servicing Do not allow unauthorised personnel to service or maintain the machine Study the Operator s handbook and Service Manual before starting operating or servicing the machine
72. tion 7 Drawings 7 8 Labels Decals Drg 1467 SA 7 8 Labels Decals Drg 1467 SA Decals fitted to machines may vary from country to country to suit local needs Part No Part Name 80 0076 Control Panel Mk4 80 0001 Data Plate Serial No 80 0077 Muffler lt 80 0004 Warning Hot Exhaust 80 0012 Oil Filter amp Dipstick 80 0005 Oil Filler 80 0010 H T 500 Body Logo 80 0003 Warning Crush Zone 80 0013 Caution Sign 80 0020 Starting Instructions 80 0009 Warning Crush Zone 80 0007 Marking 80 0011 PTO Optional OO 00 0114 1 60 HIT500 Workshop Manual 2324 Iss C DCA00259 Section 7 Drawings 7 9 Battery Box Assy Drg 1468 SA 7 9 Battery Box Assy Drg 1468 SA wore 3002 CS ASSY XOSAMXLLYS TULL ALAIN JOTAN GW 2 LIS GW OVS UISUVHI 9 gt 1 2000 08 OF XOT 8 t 3598 RALLYE Fen ALB NM WALI 61 HIT500 Workshop Manual 2324 Iss C DCA00259 7 10 Engine Assy amp Dressing Kit 1469 01 SA 7 10 Engine Assy amp Dressing Kit Drg 1
73. trial Park Bates Road Maldon Essex CM9 5FA UK Failure to register your machine may invalidate the manufacturer s warranty Liability The warranty period begins when the product is delivered to and installed at the first purchaser Only genuine parts may be used to carry out repairs Failure to use only genuine parts may invalidate the manufacturers warranty TCP Ltd will not be held responsible if the machine has been used to perform tasks that demand more than it s design and strength limitations or the machine has undergone modifications not approved by TCP Ltd or conditions of use have been abnormal HIT500 Workshop Manual TCP 2324 Iss C DCA00259 normal maintenance with regard to requirements as set out and detailed by the manufacturer have not been adhered to TCP Ltd will not pay for normal maintenance or servicing nor any materials used to carry out routine servicing The warranty liability of TCP Ltd is limited to diagnosis repair or replacement of the defective part and actuating the repair depending on the product terms and conditions this will be free of charge TCP Ltd shall be under no liability whatever to the customer for any indirect loss and or expense including loss of profit suffered by the customer arising out of a breach by TCP Ltd of this contract Audits and Surveys TCP Ltd reserves the right to carry out audits and inspections from time to time in relat
74. ure non slip control Handle fuels and lubricants carefully and clean up spills to avoid fire and slipping hazards Never rush Walk do not run Fire Precautions Clean all dirt oil grease and other fluids from systems and components to minimise fire hazards and aid in spotting loose or leaking lines fittings etc Check the engine for rubbish oily rags or other debris that could cause fires before starting the engine Safely dispose of greasy oily rags or similar hazards Flammable Fluid Precautions Take due care when working with fuel Diesel fuel is a health hazard for contact with eyes or sin inhalation and ingestion There is also danger of fire and pollution Don t use diesel fuel or other flammable fluids for cleaning purposes Use approved non flammable solvents Make sure all fluid systems caps drain valves fittings lines etc are secure and leak free Never use an open flame match lighter etc when checking fuel lubricant coolant and battery fluid levels or when checking for fluid leaks Use a flashlight or other safe lighting only Shut off engine and use extra caution if engine is hot when refuelling Never smoke while checking or adding fuel or other fluid or handling fluid containers and lines Use care and do not stand downwind when adding fuel or other flammable fluids to tanks and reservoirs to avoid fluids being blown or splashed onto clothing Close fuel tank shut off valves if
75. urn to the machine Avoid over filling the skip Spillage could damage the tracks and other components Clear up any such debris Do not load with machines that are too large and would allow material and fill to fall from the skip missing the body This can be dangerous to both operator and the unit Pay attention to site conditions avoid rocks holes or other obstacles Such obstacles present hazards to safe operation but also can needlessly damage tracks 2 11 Tipping The tipping operation usually depends on the type of material being hauled WARNING Be aware of other personnel within the operating area A warning buzzer sounds whenever the skip is raised above the horizontal position This is a general warning to the operators and other personnel in the area to take necessary care and precautions If tipping at low level ensure you are clear of all obstacles within the tipping arc of the skip It is possible to fully invert the body of the Hi T tracked 18 carrier care must be taken that the load to be discharged will readily leave the body once tipping commences A retained load may result in machine instability Never leave a machine loaded overnight or for a long period with a material that could settle Always clean any retained load from the skip for efficient safe working Be aware of any precautions and additional safety equipment that may be needed when handling hazardous caust
76. val Full access to the engine can be achieved by opening the right and left hand engine enclosures as follows 1 Remove air cleaner cover and filter See Section 5 3 Air Filter 2 Release and remove the three M8 bolts securing the air cleaner body and intake extension to the engine 3 Release the enclosure clips The right hand enclosure will now swing outwards Note Should the need arise both enclosures can be removed 4 Release and remove the 8no M6 countersunk head screws that attach the enclosures hinges to the chassis Do not release the screws that attach the hinges to the enclosures Refitting is the reverse of this procedure Do not run the engine with the air filter removed Ingress of dirt can damage the engine HIT500 Workshop Manual TCP 2324 Iss C DCA00259 5 3 Air Filter Parts Air filter TCP 10 0005 To remove the Air Filter Assembly 1 Remove the cover secured by a wing nut Fig 5 1 Air filter cover 2 Remove the air filter secured by a wing nut Fig 5 2 Air filter 3 Remove the filter assembly from the engine three screws Refitting is the reverse of this procedure 31 Section 5 Parts Replacement 5 4 Exhaust System 5 4 Exhaust System WARNING Parts Exhaust down pipe complete with wrap TCP 99 1944 1 Remove the exhaust pipe Exhaust pipe fixings Fig 5 3 Exhaust pipe fixings 2 Remove the exhaust
77. vicing safety hazards at all times and take necessary precautions to ensure safe operation and servicing of the machine All information illustrations and specifications contained in this publication are based on the latest product information available at the time of publication The right is reserved to make changes at any time without notice Continuing improvement and advancement of the design may cause changes to your machine that may not be included in this publication This Handbook contains lubrication and routine servicing instructions most of which can be performed in the field General Read this operator s Handbook and learn the operating characteristics and limitations of the machine Know what operating clearances the machine requires Know clearances of all side and overhead obstructions such as wires etc for operating safety Be aware of operating hazards that weather changes can create on the job Know proper procedures to follow when a severe rain or electrical storm strikes Never attempt to operate or work on a machine when not feeling physically fit Know what safety equipment is required and use it Such equipment may be hardhat safety glasses reflector type vests respirators and earplugs Never wear loose clothing rings and watches etc that might catch levers and controls and cause loss of control Prelliminary Keep hand controls free from water grease and mud to ass
78. vides a reservoir of oil for the pump Drive to the tracks is by two hydraulic motors at the rear of the track The motors are individually powered to provide steering Skip movement is effected by hydraulic rams one set for tipping and one for raising the skip A warning siren sounds while the skip is raised Levers on the control panel route hydraulic oil at pressure to the rams and drive motors to control operations A Tracking Speed button opens a valve to provide additional hydraulic flow to the motors to increase tracking speed A hand throttle provides control of engine power to tailor engine output to the task in hand 1 2 Electrics The diagrams in this section are for explanatory purposes only Refer to drawing TCP 1574 in Section 7 14 Electrical Schematic OC95 HIT500 4 2006 Drg 1574 for full information 1 2 1 Ignition The ignition circuit features automatic starting using Solenoid Ignition switch 5s timer and relay to power the glow plug When the ignition switch is set to Start the contacts of the 5s timer are initially closed so that relay RLA is energized and contact RLA1 connects 12V to the glow plug After a 5s delay the timer contacts open and de energize relay RLA Contact RLA1 changes over to disconnect the glow plug and connect the starter motor solenoid instead Once the engine has started releasing the ignition switch disconnects the starter motor solenoid
79. xcessive heat oxidation or dirt should be changed more frequently to prevent these conditions Lubricants change and service periods must be established on the basis of individual job conditions 3 2 Engine Maintenance Since the workshop manual provided by the engine manufacturer contains comprehensive information on servicing the engine this Routine Maintenance section only provides information on the engine for daily servicing and where it differs from the standard application covered by the engine workshop manual Refer to the manufacturer s manual for all other information and instructions relating to the engine 3 3 Safety Precautions Do not allow unauthorised personnel to service or maintain this machine e Study the manual before starting operating or servicing this machine Always follow the procedures and safety precautions detailed in this manual e Do not work under or near an unblocked or unsupported skip Always invert the empty skip Do not work under or near any unblocked or unsupported linkage or any part of machine e Always shut down machine according to the procedure described in Section 2 8 Stopping the Engine before cleaning lubricating or servicing the machine e Always relieve pressure before servicing any pressurised system Always attach a DO NOT OPERATE similar warning sign to ignition switch or a control before cleaning or servicing the machine e The ceramic insulation

HiT500 Compact Tracked Carrier Mk4 v3

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