HI T500 - Mini Dumper / Track Carrier
Contents
1. AFB SI EIINTIAI AT AFA M S BISNIS JOL SANIT LO TI SWIV UMAT AFA 553 Waq TAS JIMOT HER LIFHS SSO4 3AAOT Nid B3ANTIAJ 171686 LIS Si X SW 3HSYAL LIVS SW EIJAN Nid YONI MaASS Qiwi LI DO S eS AA dWYT FIN 35389 HISTIA API SSII UJANTIA JOL LdvHS SSOED LSA ASSY AJOS GRIYNY LS NOLLdIH ST ON LHrd 43 10 2005 Issue 9 Operation Safety Maintenance GOD2 80 rO EET dIl GN SAI WO NA IL AMM JAPA my XLS OCECEE EOT 222069 129764134 YJE GWO KISSA Nd Ty J T avou SILVA ang RAISAYNO S SLAVA SISSYHO OW SLT OLI LNW ld NOILIMMHISNOI HOTAVIL I SNISNOH ANA S000 09 Se YLOSNA 2000 27 be BYWNYA BOO9 5 Eg INTAN3 31 LS X23N Ad OZ OIOO TS zz SSOM ANd 8200 69 te dri SSOH EGOD EG 0g 1108 06 X DIW 6000 10 61 ahs w A LY OTW e000 20 BT LIDE D X DIW 2000 10 LI ANNOW ZNIENI 6000 TS GI AINS YA LY ls OPW c000 0 ST JOTAN SW L000 T0 PI JOLIILOAA MOJIH 8000 16 ET O L d HIT 33078 JAVIA 1000 03 sl OUL d SST AJOT JATVA E000 09 TI assy mM LV lil DIW 2000 20 OT AO TAN OTW 9000 10 6 dy Tana 000 TS 8 9000 TG VIH d 2 de X GW 9700 10 9 assy mM LWE BW 1700 20 amp L709 LIS 02 X SW S000 T0 P JAJ INILYITT SOBO T avd yg9 F GO TE ASSY SISSY2. 111 conditions of use have been abnormal or Iv normal maintenance with regard to requirements as set out and detailed by the manufacturer have not been adhered to TAYLOR CONSTRUCTION PLANT Ltd will not pay for normal maintenance or servicing nor any materials used to carry out routine servicing The warranty liability of TAYLOR CONSTRUCTION PLANT 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 TAYLOR CONSTRUCTION PLANT Ltd shall be under no liability whatever to the customer for ant indirect loss and or expense including loss of profit suffered by the customer arising out of a breach by TAYLOR CONSTRUCTION PLANT Ltd of this contract Operation Safety Maintenance 10 2005 Issue 9 Warranty Audits and Surveys TAYLOR CONSTRUCTION PLANT Ltd reserves the right to carry out audits and inspections from time to time in relation 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 TAYLOR CONSTRUCTION PLANT Ltd workshop Once this initial training has been carried out you are responsible to carry further training as reguired by your own Service centre or depot network Serv
3. Remove blanking plugs lubricate jacking bolts supplied Poa Insert jacking bolts adjust equally Adjust until idler is in line with roller 39 Operation Safety Maintenance 10 2005 Issue 9 Slide drive track and Idler on shaft Insure Idler is fully home 40 Operation Safety Maintenance 10 2005 Issue 9 Remove any blocking under chassis run and test 41 10 2005 Issue 9 POT LATUISTY NOILA Operation Safety Maintenance NOT Y ISOSS NOT ALUSSS G g NOTLJIRISSO g G NOT LT SA ML JLP AO9 JUVA ANVI Sid NIVEA OO 29 ass w A AAONCH FT ATW ITN ap ZT gt F Zl UZRISYAM JAAN wre stew ww nF E F GALLI NOILINS WHS y A Live SW KAHSYM INTUJIS SW Ge X SW LIGA LIS TWA ATW 16 6 west SBS WA GAINS 12 7 UAFISY AM Le OTW GE X OTW 17108 Las sHLYISE AISTENSSIUI ASTLSGEJ da 1 Tid LNEWa Y Wale d 3 JTS ASSY SALTA NOLLAR S BET dL OEE B TETEN Yd LAZOGO TZ9rrrr1 S Luna ANY EXW ZUM OLI INYTI AOLSNYLSKQI HO LANI 212 2 1212 42 Operation Safety Maintenance 10 2005 Issue 9 ONE Oo F WO GBET ad ON MA v SSI SLa d AIO EXW JIL WO dou MAA DEEEH FET KWA 22 060 TZITA L VAG GWO KISSA NOGTYW TYCH SILVA SVY ZAISAVNO OUT Lied NOILOMHLISNOI YOTAYI
4. GaliSY M INTYAS 5000 20 9 YIHS YA 35897 000 20 GATTI ISAON SIOD TS ja 2 ALO NO TdIdOS ON tava ON WILI 50 Operation Safety Maintenance 10 2005 Tssne 9 dal ON MQ WOJ n3 gd21 MAM 3 T A GW KISSA NONI UI god SILWA Hard 3QIS Ae LTL OUT LEE Ja Meese BET NEL I LINN ISOH 9200 29 IE I LINN ISOH 5200 29 QE I SUWAHSYM TAINO 9 E 8000 29 67 I JWW JIVW 9 E B G 2100 29 gz I LINN ISOH 200 29 2 I JIWW IIVW 8 G Z T 0100 29 gz I UAHSYM NOS Z AT 1100 29 Gz I avs 001 08 JATYA AATTAU 4100 09 bz I WAHSY M JAANOE b E b OO Z9 cz lz JWW ITW B E B E 100 29 zz I LINN ISOH 200 29 lz z JWW IIVW i c Z I 2E00 29 oz I UAHSVM JAANDE B E IOO 29 l I UAHSYM GAANOT Z AT 1100 29 gr I JIWW IIWW ZAT Z T 6000 29 ZI I LINN 3SOH 2200 29 oT I JMWW IWWZ T Z AT 6000 29 GI I vw 1YW b T B E LEOO g9 bl I TNIOd LS L GI00 29 ET I LINN 3SOH 1200 29 ral z WAHSYM TAINO 9 E 8000 29 II z JWW ITVW P T B E 1600 29 OL z UIANTTAI d AO1 AO SSOWD 6100 29 6 z SASOH YIANTIAZ UJAO SSOUI 8100 29 g 9 JAL bAT EO00 Z9 L g JIHANE H T G000 Z9 9 b aTvd GJAJJ1S SASOH ANIT 0200 29 G lz UAHSY M QNO8 b T 2000 29 t gl AWWA Ww b T 1000 29 E z Sd4QNT1A YAMOT 9100 09 z z 5dHQNI1A2 dOL 5100 09 I LA LD
5. to switch on the ignition Run position 3 If engine is cold turn to pre heat position 2 and hold for 20 seconds 4 Turn key further clockwise against spring pressure to position 3 to crank engine release key as soon as engine starts firing NOTE Never crank the engine for more than 15 seconds continuously Allow starter at least 30 seconds cooling time between cranking periods to avoid overheating 24 Operation Safety Maintenance 10 2005 Issue 9 Starting the Engine with Jumper cables To access the battery you will be need to tip the body forward in the down position to gain access to the cover plate remove the 3 bolts that secure it to the chassis once this has been done you can remove the plate and locate the battery WARNING CHARGING OF ODYSSEY BATTERIES Check for polarity connections of the discharged battery Do not exceed 15 volts during charge Excessive booster voltage and or incorrect jumper cable connections will destroy working plates inside battery Keep all sources of ignition away from batteries Do not lean over batteries Do not allow the battery to become full discharged you may find that it can not be recover from this state rendering it unserviceable Voltmeter Reading State of charge 12 84 Volts 100 12 50 Volts 12 18 Volts 11 88 Volts Do not jump start a vehicle by using arc welding equipment Currents and voltages are dangerously high and cannot be sufficiently reduc
6. Engine N WARNING l 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 Turn ignition key switch off to shut off fuel and stop engine Make sure body is in the lower position Parking N WARNING When parking the machine overnight or for an extended period the following procedure in addition to that given in Stopping the Engine will help maintain it in good condition for subseguent use Fill the fuel tank completely before parking the machine overnight or for extended periods to prevent condensation If security kit is supplied keep it locked Always park on level ground where possible If it must be parked on a slope position machine at right angles to the slope and block tracks securely Remove key to a place of safety 26 Operation Safety Maintenance 10 2005 Issue 9 WARNING 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 Loading The most common methods of loading this type of machine is with hydraulic excavators or by hand these units can be loaded egually well from the front or the sid
7. Material Loose Density Fill Factor Seer kg m bly Snow Fresh Peat Dry ugar beet Petroleum Coke 1146 Wheat 1231 Coal Bituminous 1290 Fertilizer Mixed 1737 Coal Anthracite 1764 Earth Dry Loose 1150 1939 100 Nitrate Fertilizer 1250 2180 85 Sodium Chloride Dry Salt 1300 2192 85 Limestone Crushed 1530 2580 100 1550 2613 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 3204 5402 Specific Gravity fig 4 29 Operation Safety Maintenance 10 2005 Issue 9 5 Lubrication and Servicing SAFETY PRECAUTIONS Do not allow unauthorised personnel to service or maintain this machine Study the Operator s Handbook and Service Manual before staring operating or servicing this machine Always follow procedures and safety precautions detailed in this manual Do not work under or near an unblocked or unsupported body Always invert the empty body Do not work under or near any unblocked or unsupported linkage or any part of machine Always shut down machine according to the procedure described under Stopping The Engine before cleaning lubricating or servicing the machine Always relieve pressure before servicing any pressurisation system Always attach a DO NOT OPERATE or similar warning sign to ignition switch or a control before c
8. NOILdI40S30 VON 18vd ON WALI 51 Operation Safety Maintenance 10 2005 Issue 9 lt 4002 80 60 86ET d2 L NSM WOJNA JAL MMM Hrg SN ALS OEEEtS TE tk LIOR 129 t 7151 w JS GW XISSI NOUTeW I 2 JO 2 OON SILVA died JOTSAPND ae SJSOHDJITWAJAH JUL WIT LEENI MLSs JAEL 29 St oi Af 3 19 I LINA ASOH I LINA 3SOH rzym aon ue SYOLOW n woose oe JIVA E LINA ASOH z LINA ASOH I LINN ASOH I LINA 3SOH a AL HOILdIHISAC ON LHYd ON WALT YZ Operation Safety Maintenance 10 2005 Issue 9 66ET dl ON SAS STOOL JZI WAS EAW SI WOLNA dou AVAN OSET FB TdT NWA 222069 TO TS Va GWO 3553 NOT TYW TYOU SIL vye avd IIIS AY OLI ANY ld NOILIMYLSNDI HD TAI TOOL SNILYSSNI 1755 51109 INTAIVE STW JARIN dS SIL TIJ TLO NOT LETSISSA ON Lad JJ Operation Safety Maintenance 10 2005 Issue 9 NOTES 54
9. lubricants carefully and clean up spills to avoid fire and slipping hazards e Never rush Walk do not run Operation Safety Maintenance 10 2005 Issue 9 Preventing Fire Hazards x N WARNING General Fire Precautions e 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 e Check the engine for rubbish oily rags or other debris that could cause fires before starting the engine e Safely dispose of greasy oily rags or similar hazards Flammable Fluid Precautions e Don t use diesel fuel or other flammable fluids for cleaning purposes Use approved non flammable solvents e Make sure all fluid systems caps drain valves fittings lines etc are secure and leak free e 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 e 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 e 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 used before servicing fuel system e When preparing machines or components for storage seal and tape all ope
10. CTURE Data Plate fig 1 14 Operation Safety Maintenance 10 2005 Issue 9 Theft Deterrent Practices 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 Actions to Discourage Theft and vandalism e Removeall keys any time the machine is left unattended e Immobilise the machine by removing a critical electrical or starting system device e 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 e 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 Establish liaison with neighbours and ask them to watch equipment left at job sites and to report any suspicious activities to local allow enforcement authorities e Make frequent inventories of machines to promptly detect losses or vandalism Actions to aid in recovery of stolen machines In the event of theft immediately notify the law enforcement authorities having jurisdiction Provide the investigating officer with name type of equipment chassis and
11. FW ALIJYS NOILVEI3JO 42TLSdYQ ANY BAL TIJ TIO TYNOILJO O L d LRASII LJFT OO L H AIOE OBOT 0100 08 OF ava JAN GIZNYA 6000 08 6 LNIOd SNILSICH 2000 08 8 ANDRIYVW 33 000 08 z amu eee o _ 0 08 9 aa Ts TTG 2T INVAJAH 5000 08 G LENVIKSI LOH SNINSYA r000 08 T INOZ FIS 1812 NIN E000 08 E 77234 TAN FI TOLLNOI 2000 08 000 08 5 SLY id VLYO Wlaas I NOLL dass aq ON Lad ON WALI G 48 Operation Safety Maintenance 10 2005 Issue 9 G02 80 r0 JLA S6ET d2 ON SAS SLAdFd JITAVIS EAW SILI WO NI dOL FAA TYOU SILVA any IOISAKNO TLT LIN Id NOLLI KLSKOJ HOTAVI Ge Hond LAVAS SSO CLYOHS IMOT Nid BJANTTAI HS VM AWPTI AAZRI2S QAFSH LI VOS FISAB LOATd 1104 Las ST X SW POOD TO BT dalriSF M LF SW FD00 C0 6000 08 SNOT BIJIN Nid 8 QNTTA2 al IddiN 35 Ww 32 GB00 20 AL PBO Lares aG ON LAVI ON WILI 49 Operation Safety Maintenance 10 2005 Issue 9 G02 80 rd 47A G6ET d2 ON SAS By ALG WOO N AZ AREMA OEECPB TegTr Nd LLOSA IZ9TFF TL SADWELL SLlavd 33TABIS EXW TILIL YJE GWO KISSA NOU TYW TYOU SILVA any IOISAKNO TLT ANY TA NOLLI KLSKOJ HOTAVI 127 NIG JTUL JALIS FIXKY ATTI ANOA d 2 GNa 17188 LH Se X OTW
12. H3 Tid GO00 06 I ON Ldrd ON WALI 44 Operation Safety Maintenance 10 2005 Issue 9 GOD0 80 FrO FALWA w SSI BH ILS I6ET dou ON M WO NA dok AAA OCECHB TT RWA 27050 Teo TAL dO e YJE GWO KISSA NOT TEW TYOU SILVA vy FIG A dl AYI AVEL ASSUSVS E200 1G AMALL YS TODO T SLU SISSVYHI SAW AUT TLI LN Td NOILIMHLSNOI KOTAYI 1 TINTIVULS Tafta TK LNOBJ E000 21 SAITIOS JOT 1108 GV3H MOT ALV TII AO2 JAS ASI BW sa iya LIBE TE SY ld BIKSYAL Lyd SW 1108 LIS 02 X SW 2000 80 1700 20 5000 10 IQIS ETOO TS tAr NIQ ari SID 0700 20 ZAJE 15 L108 Las DE X SW INIGAIS 6500 TS JOLOW JATIJ LI PO E J LVI MAIS AVIH LIASOS Teas as Tat ANG AIVUL dearna HS w AN 16 14 ISAW OTW AIHE AA BN TNS OTW 62 L109 Ge X OTW Be d 2 ANI 33 LYIS JUNA ITN VASA NOILAIJISII ON 19vd LE EM ON WFLI 45 Operation Safety Maintenance 10 2005 Issue 9 GD02 90 0 EG T dal ON GAD JAPA my ALS OM os 320 18 JA TWA CHW TLL WOO N AZ AAA OEECPB TegTr Nd LLOSA IZ9TFF TL Yd GWO KISSA NOI TH avou SILE ang 3aIsAY Db TLT ANY TA NOLLI KLSKOJ HOTAVI Ge PE EE T De GE ST LI oF m ka NOILISS As3d5 GAL GE azds OMI ASS
13. IN ORDER TO ASSURE CONTINUANCE OF ENGINES WARRANTY e Carefully inspect tracks for cuts or other damage and correct spring preload e Inspect for any leaks whether fuel engine oil or hydraulic oil e Check fuel level Fuel tank should be filled at end of each shift 23 Operation Safety Maintenance 10 2005 Issue 9 Engine Operation N WARNING Do not place engine under FULL LOAD at 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 NEVER IDLE THE ENGINE FOR MORE THAN 5 MINUTES AT A TIME SHUT IT OFF If operated outside its normal operating range shut engine down immediately and report to service or maintenance personnel 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 Starting the Engine 1 Make sure that all levers are in the neutral position 2 Insert switch key and turn clockwise to position 1
14. Operation Safety Maintenance 10 2005 Issue 9 Operating Manual amp Routine Servicing Compact Tracked Carrier Taylor Construction Plant Ltd Quayside EH Bates EZ Mia ashy ssex CMo BIZ Operation Safety Maintenance 10 2005 Issue 9 Operation Safety Maintenance 10 2005 Issue 9 Table Of Contents Warranty policy and procedures Sample certificate of conformity 1 INTRODUCTION Introduction Safety Precautions Machine Identifications Theft Deterrent Practices 2 SAFETY PRECAUTIONS General Preventing Fire Hazards Precaution Electrical Hazard Pre Starting Starting Operating Lubrication and Servicing Decals 3 CONTROLS AND OPERATING Operating Controls Diagram Accelerator Steering the Machine Reversing the Machine 4 OPERATING Pre Starting Inspection Component Checks Engine Operation Starting the Engine With Jumper Cables Moving and Stopping Stopping the Engine Parking Loading Tipping Average Specific Gravity Operation Safety Maintenance 10 2005 Issue 9 LUBRICATION AND SERVICING Safety Precautions Lubrication and Servicing Miscellaneous Servicing Information Recommended Lubricants Lubrication Chart Overall Size Dimensions Various Basic Vehicle Details Miscellaneous Bolt amp Nut Torgue Specification Every 10 Hours of Operation Daily Every 50 Hours of Operation Every 1 000 Hours of Operation Every 2 000 Hours of Opera
15. PERATION 5 WHEN REVERSING PAY CAREFUL ATTENTION TO CRUSH ZONES PERSONNEL AND OBSTRUCTIONS MAINTENANCE 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 DAILY 5 GREASE DAILY MAXIMUM DESIGN PAYLOAD OF 500kg MAX GRADE 45 DRIVE TIPPING TRACKING FORWARD FORWARD AIE LOWER FORWARD SPEED PRESS SWITCH TO ENGAGE HI SPEED E Lwa HI SPEED CAN ONLY BE 104 NEUTRAL NEUTRAL www tcp eu com STOP STOP nn VIBRATION Tel 44 0 1621 850777 v ahw Fax 44 0 1621 843330 691 BY PASS REVERSE REVERSE sales tcp eu com RAISE BACK TCP 088 N k A view of the handlebar and control 2002 fig 3 21 Operation Safety Maintenance 10 2005 Issue 9 Engine Accelerator This is mounted on the left hand side of handlebar assembly and is operated by the hand Press the lever down as required to increase fuel flow to accelerate the engine Do not place engine under full load at 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 the engine at top rated speed when maximum power is needed for maximum speed and load Steering Via Hydrostatic Drive The steering is performed by N WARNING e To steer the machine apply differing pressure to the contro
16. Y JAWA 2E00 09 PT QaadS OML AIONSIOS LEGB O T 35716 JO ON LD AOU SAL LIA Was ASSY LOAId ASATALAYFI 8aT14N TIIT L VI BIZAKATA MONN 3AJT TOS LINE Gad HATI TOS LINO A Y Ta Al1 TONO NES B ds d TOELNOI MOTTIA Old HLTA ASSY JATVA Old SSTI ASSY JAWA NOTLaISIS39 ON Lava 46 Operation Safety Maintenance 10 2005 Issne 9 p E G J 1 1 a ES 4 RE Z ale sales LU E lg 3 gt A S ar oe 9 b ne Lu S 4 H E L 6 6 6 o 2 a ki E Z E u 5 4 at uj i ma 3 v ald lt lt m Vi po i S 5 a LJ 2 E O a lt U e gl 2 G 6 as z 8 g gig E 5 s 2 ele 8 8 4 E A lt BJ ap LE ia P GE a O Fi me P Pa zr Tal An F lis S aa A wa sd Aj Tal l aN mJ i ME 8 m a E SESE 0858 gin Pr BREE Ait 6 233 53 E fp 47 10 2005 Issue 9 Operation Safety Maintenance GOD2 80 rO FET d2L GN Mo WOD NA dzi AAA JLP my XLS OCECEE EOT 222069 129764134 WG GWO KISSI NOI Ty l TYCH SILVA band IS AY No RE STV93A SW TILIL OLI LNW ld NOILINKISNOI MWTAWL Gz 2 z A 22 tg 02 Gf 5 gt AJNYNALNI
17. a W T ja po Pa a r F k a Recommended Lubricants Note Do not mix Lubricants Code Grade Engine Engine Oil with C CD 10W 30 1 rankcase and 1 85 max Filter Sulphated ash limit Hydraulic oil HV 36 or 6743 4D 46CS Bio Degradable 2 Liquimatic BVG 36 Plantosyn 36 HVI Fuel tank Diesel Fuel Oil A S T M No 2 3 with max Sulphur Diesel Fuel at 0 5 sub zero temp blend No 2 with No 1 Grease Nipples Extreme Pressure Stern Tube No 2 Lithium No Grease C W Consisten 4 Moly Extreme cy Pressure Capabilities Lubrication Chart fig 5 31 Operation Safety Maintenance 10 2005 Issue 9 Operation Safety Maintenance 10 2005 Issue 9 Basic Overall Dimensions fig 7 33 Operation Safety Maintenance 10 2005 Issue 9 General Specification Hi I 500 Maximum Carrying Capacity Kg lbs 500 1100 Skip Volume Lt ft 3 255 9 0 Unladen Weight Kg lbs 448 987 Width mm ins 700 28 ins Height Over Skip mm ins 2500 98 4 ins Length mm ins 1770 69 6 ins Max Gradeability 45 Turning Circle mm ins 2000 78 5 Track Ground Pressure Kg cm psi 0 351 4 99 Speed Forward Kph Mph 4 2 5 Power Take Off 20 1t m 120 bar NNN E General Specification fig 8 34 Operation Safety Maintenance 10 2005 Issue 9 Miscellaneous Bolt amp Nut Torque Specification Friction coefficient total 0 14 for screws and nuts without a
18. ace the assemble install new filter screen and refill tank If contaminated fuel is suspected freguency may need to be increased Every 300 hours of operation e Drain fuel and replace fuel filter e Lubrication greasing Periodic lubrications of moving parts reduces to a minimum the possibility of mechanical failures Every 1 000 hours of operation 6 Months e Lubrication greasing Periodic lubrications of moving parts reduces to a minimum the possibility of mechanical failures e Replace hydraulic oil filter install new element each time do not reuse Every 2 000 hours of operation Annually e Lubrication greasing Periodic lubrications of moving parts reduces to a minimum the possibility of mechanical failures e Hydraulic Oil Tank Drain oil remove and clean filter screen assemblies Reinstall filter screens and refill tank e Hydraulic Oil Filter Clean filter housing and install new element after a year or 2 000 hours of operation whichever comes first All information contained in the Lubrication and Service Chart is extracted from the relevant manufactures Operators Manual and was correct at time of publication User should ensure that information contained in this chart regarding engines and hydraulics reflect the information shown in the relevant manufacturers Operators Manuals supplied with the machine Maintenance procedures should be carried out in conjunction with any additional procedures contained in the r
19. an the machine Study the Operator s handbook and Service Manual before starting operating or servicing the machine 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 19 Operation Safety Maintenance 10 2005 Issue 9 Decals Decals fitted to machines may vary from country to country to suit local needs These pages contain a brief description and the location of the decals and control plates that may appear on this machine Ref Part Part Name Oty Number 1 _ 80 0001 Serial Data Plate 11 Control Panel Decal state year Ad 3 80 0003 WamingCrushZone j6 _ 30 0005 Hydraulic Oil Filler o Fuel Filler 7 80 0007 CE Marking 8 1800008 Hoisting Point 80 0009 Danger Keep Clear 2 80 0010 Logo Body HT 500 Left Right Hand l 80 0011 P T O Optional 80 0012 Hydraulic Oil filter and dipstick Decal Layout fig 2 20 Operation Safety Maintenance 10 2005 Issue 9 3 Controls and Operating Operating Control Diagram IMPORTANT READ AND UNDERSTAND THE OPERATOR S MANUAL BEFORE USE 1 ENSURE FUEL TAP IS IN THE ON POSITION 2 DO NOT OVER CRANK ENGINE 15 SECONDS MAX 3 GRADUALLY IDLE A HOT ENGINE BEFORE SWTCHING IT OFF 4 THIS WORK STATION HAS BEEN DESIGNED FOR SINGLE HAND O
20. ation Safety Maintenance 10 2005 Issue 9 1 Introduction Please read carefully and understand before operating the equipment This Handbook is provided as a guide to familiarise the operator and service engineer with the controls recommended inspections start up operating and shutdown procedures for HiT range of equipment Safety Precautions This piece of equipment is designed as a compact tracked carrier with the carrying capacity of 500 Kg only At all times loads should carried with the body in the low position and raised for tipping only 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 grease or other matter that might cause slips hazardous to the operator serviceman 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 Servicemen must be safety
21. body once tipping commences A retained load may result in machine instability Never leave a machine loaded over night or load with a material that could settle with the engine ticking over for a long period Always clean the body of any retained load for efficient sate working Be aware of any precautions and additional safety eguipment that may be needed when handling hazardous caustic or cementious materials If in doubt seek advice Before discharging the load the machine must be on firm level ground If one track is higher than the other a twisting strain is 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 injury could occur Once the load has been tipped move the control levers into the DOWN position If the load does not clear completely the built in stops in the mechanism may used to assist discharge the 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 raise the body only with the machine stationary once raised the machine may be inched forward until the tracks contact the side of the waste skip The body can then be tipped to discharge load 28 Operation Safety Maintenance 10 2005 Issue 9 Average Specific Gravity
22. conscious and alert to recognise potential operating or servicing safety hazards at all times and take necessary precautions to ensure safe operation and servicing of the machine Operation Safety Maintenance 10 2005 Issue 9 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 Service manual containing repair and rebuild procedures are available from the factory Machine Identification Whilst reading this handbook you will notice references to controls and equipment that may not be found on all machines It is important that you know your machine and its equipment and how to operate it properly Information regarding the machine model code and chassis serial number is on the unit serial number plate This plate is on the rear Left hand side the machine model and serial number should always be referenced in any correspondence with your dealer or factory fP Z 4 Tel 44 0 1621 850777 A TA A Fax 44 0 1621 843330 www tcp eu com MODEL NO SERIAL NO ENGINE TYPE ENGINE SERIAL NO YEAR OF MANUFA
23. e Ideally excavators should reguire 90 or less swing 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 return to the machine Avoid over filling the dump body Spillage could damage the tracks and other components Clear up such debris see fig 4 Do not load with machines that are over large and would allow material and fill to fall from the bucket missing the body This can be dangerous to both operator and the unit Pay attention to site conditions to avoid rocks holes or other obstacles Such obstacles present hazards to safe operation but also can needlessly damage tracks Tipping N WARNING The tipping operation usually depends on the type of material being hauled Be aware of other personnel within the operating area A warning buzzer sounds whenever the body is raised above the horizontal position this is as a general warning to the operators and other personnel in the operators zone to take necessary care and precautions If tipping at low level ensure you are clear of all obstacles within the tipping arc of the body It is possible to fully invert the body of the Hi T tracked carrier care must be 27 Operation Safety Maintenance 10 2005 Issue 9 taken that the load to be discharged will readily leave the
24. e Monread Road Naas Co Kildare Eire Tel 00 353 458 76225 Fax 00353 459 7476 cmhitd gofree indigo ireland Hurley Engine Services Unit 7 The Maltings Industrial Estate Brassmill Lane Bath Somerset BA1 3JL Tel 01225 336812 Fax 01225 442477 info hurleyengines co uk Operation Safety Maintenance 10 2005 Issue 9 J amp E Motor Engineers 23 Polmont Road Laurieston Falkirk FK2 900 Tel 01324 633266 Fax 01324 633870 jem engines btopenworld com John A Sparks amp Co Ltd Western Industrial Estate Caerphilly CF83 1BQ Tel 02920 807080 Fax 02920 8707081 kevinashworth a sparks com Wwww a sparks com Meetens Industrial Engines Ltd 261 269 Coombe Lane Wimbledon SW20 ORH Tel 0208 9464244 Fax 0208 9472595 sales meetens COMm Northern Lift Trucks Northern Ireland Ltd 1 Flush Park Knockmore Road Lisburn BT28 2DX Tel 02892 673111 Fax 02892 660618 info northern group co uk Phoenix Power Services Unit 12 Thames Trading Centre Woodrow Way Irlam Manchester M44 6BP Tel 0161 775 4053 Fax 0161 776 2047 phoenixpower btclick com Sean Cleary amp Son Eng Ltd I D A Industrial Estate Dublin Road Loughrea Co Galway Eire Tel 00 353 91 841420 Fax 00 353 91 842823 paddycleary eircom net Sleeman amp Hawken Ltd Bridge Road Shaldon Devon TQ14 ODD Tel 01626 872750 Fax 01626 873767 keithmason sleeman hawken demon co uk Trucks Mor
25. ed to make the method safe NOTE Be sure machines are not touching each other Use cables that are equal to cable size on the machine If jumper cables are used to start an engine be sure to follow this procedure Connect one end of a jumper cable usually coloured red to the discharged battery POSITIVE post Connect the other end of the same cable to the POSITIVE post on the booster or charged battery Connect one end of the second cable usually coloured black to the NEGATIVE post of the booster battery Connect the other end of the NEGATIVE cable to machine frame for grounding so that if a spark occurs it is away from battery fumes explosive hydrogen Check for cause of failure on the dead battery 25 Operation Safety Maintenance 10 2005 Issue 9 Moving and Stopping N WARNING l Di 6 Make sure the area around the machine is clear of personne and obstructions before moving off In the first few minutes of travel check carefully for the reguired controls for maximum operating safety 3 Make sure the body is fully down buzzer will sound if in the raised position 4 5 Move levers to the required position apply more accelerators until the required Select the driving direction and the reguired engine speed speed has been reached To stop the machine release the control levers slowly and release the accelerator as the machine slows until it stops Stopping the
26. elevant manufacturers Operation and Maintenance Manual at the intervals specified Lubrication and Miscellaneous Servicing Small circles on the illustration represent points at which lubrication or servicing must take place at the intervals indicated on the left hand side of the lubrication chart 37 Operation Safety Maintenance 10 2005 Issue 9 Note 1 The use of low viscosity oils such as 10W or 10W 30 can be used to aid in starting the engine and providing sufficient oil flow at ambient temperatures below 5 C 23 F Continuous use of low viscosity oils can decrease engine life due to wear Note 2 Operation below the minimum temperatures listed for the oil used without proper preheats or warm up results in greatly reduced life Proper warm up requires 20 minutes minimum with engine at part throttle before operating Note 3 Hydraulic Oil meeting specification is the only oil suitable for use in this hydraulic system 38 Operation Safety Maintenance 10 2005 Issue 9 Replacement of Rubber Drive Track In the event that the drive Track being displaced during operation follow the procedure listed below Typical view of displaced track m a r A Mh TI S WOU RZS may JS 8 K vi adj W TZT ZA iw L A be N lt v a 3s ti S A a jwa a vi N A jay k a m 4 2 gd A ki m i 3 a L iv a m 4 1 i ze z
27. engine HOURS USED Sate hours used on hour clock Please do not guess the hours used DETAILS OF FAILURE Give a full report on the failure ORDER NUMBER An order number will be reguired Note the order number is to cover the diagnostic and call out time as well as to determine the following 1 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 TAYLOR CONSTRUCTION PLANT Ltd and the order number will not be used 11 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 TAYLOR CONSTRUCTION PLANT 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 Kubota UK Engine Dealers Bryce Group Ltd Daimler Close Royal Oak Industrial Estate Daventry Northants NN11 50J Tel 01327 876166 Fax 01327 300244 admin abryco diesel engines co uk www bryco diesel engines co uk C M H LTD Maudlins Industrial Estat
28. fter treatment as well as for phosphate nuts Tighten by hand If nothing special is indicated select correct torque limits from the following tabulations Metric ISO Thread DIN 13 Size 6 9 8 8 10 9 12 9 Some Engine Bolts Standard Hex Bolt Some Engine Bolt Standard Cap head mmm m mp Nm Fm m Me ps ja o ma k 097 e mo ja jea jes js os 02 mo m jeD s es 0 GD ls ja ma s js foo w jaa 0 m s QD m IOm e es G59 mo js jom ja jam s m lO 6 ma OO jan po jen O00 jon jow 85 M30 1200 885 1450 1070 2000 1475 2400 1770 M30 A 50 C070 W ja770 Torque Settings fig 9 35 Operation Safety Maintenance 10 2005 Issue 9 Every 10 hours of operation Daily Walk Around Inspection e Visually check engine for damage listen for any unusual noises e Engine Air Cleaner Inspect and remove any obstructions from the air cleaner inlet with the engine stopped e Check Engine oil level add oil if low see lubrication chart With the engine off the oil should be just over the last thread at filler Note do not over fill Fabrications e Lubrication greasing Periodic lubrications of moving parts reduce to a minimum the possibility of mechanical failures e Check for any loose bolts or fixings tighten as per bolt chart e Check for any oil leak s securely tighten any loose joints replenish any loses NOTE e Service air cleaners more often when operating under extremely dusty conditions e Do not wash the a
29. ice Bulletins TAYLOR CONSTRUCTION PLANT Ltd 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 Operation Safety Maintenance 10 2005 Issue 9 Warranty Terms for Machines Model Terms TAYLOR CONSTRUCTION PLANT Hi T500 tracked dumper One year or 1200 hours whichever occurs first from date of installation TAYLOR CONSTRUCTION PLANT Hi C40 mobile crusher One year or 1200 hours whichever occurs first from date of installation ALL ENGINE WARRANTY ISSUES MUST BE DIRECIED TO THE ENGINE MANUFACTURER OR THE MANUFACTURERS 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 leaks oil water and air IN ADDITION paintwork wear parts and tracks Operation Safety Maintenance 10 2005 Issue 9 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 1 e Hi T500 tracked dumper Hi C40 crusher DATE OF FAILURE INSTALLATION DATE The actual date of installation not invoice date SERIAL NUMBER Serial number of unit ENGINE NUMBER Serial number of
30. ir cleaner element out with detergent replace with new After first 50 hours of operating new or rebuilt components e With the engine off and body inverted remove red top of filter pull out filter Check level refill hydraulic tank as per lubrication chart Check oil level by remove dipstick if low fill through the filter housing until the level is 6mm below the tube in the base of the filter housing Replace the hydraulic oil filter install new element each time do not reuse e Engine crankcase drain oil replace as per lubrication chart check oil level the oil should be just over the last thread at filler Note do not over fill e Lubrication greasing Periodic lubrications of moving parts reduce to a minimum the possibility of mechanical failures Every 100 hours or operation Monthly e Engine crankcase drain oil replace as per lubrication chart check oil level the oil should be just over the last thread at filler Note do not over fill e Lubrication greasing periodic lubrications of moving parts reduce to a minimum the possibility of mechanical failures e General inspection check entire unit for leaks loose bolts and nuts or damaged parts Examine the body particularly the chassis for cracks or broken welds Repair where necessary 36 Operation Safety Maintenance 10 2005 Issue 9 e Engineairintake Check air intake system for wear or damage to piping loose clamps and leaks e Drain fuel remove filter screen repl
31. l levers e Apply equal pressure on both levers to the forward position will make the machine move forward in the desired direction at speed e The machine will turn only when more or less pressure is applied to either lever proportional to the lever movement To operate in the opposite direction The Reverse procedure is performed by x N WARNING e Apply equal pressure on both levers to the reverse position will make the machine move backward in the desired direction at speed e The machine will stop and hold any position when the both levers are released Dead man Brake 22 Operation Safety Maintenance 10 2005 Issue 9 4 Operating Operating Pre starting Inspection x N WARNING e Before the engine is started ensure the machine is ready for operation e The machine should be in a level position to permit accurate checking of fluid guantities in the engine and other components e Walk around the machine and carry out the Inspections and Components Checks described on the following pages Daily Component Checks e Reference should be made to engine manufactures handbook e Engine With engine off check oil level The level should be just over the last thread at filler Add oil if low See lubricant chart for correct oil e Inspectthe engine air cleaner for any damage replace immediately Using an engine with a damaged air cleaner will seriously reduce engine life THESE INSTRUCTIONS MUST BE ADHERED TO
32. leaning or servicing the machine LUBRICATION AND SERVICING 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 to a minimum the possibility of mechanical failures Thoroughly clean all fittings caps plugs etc to prevent dirt from entering the system while servicing Lubricants must be at operating temperatures when 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 excessive 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 30 Operation Safety Maintenance 10 2005 Issue 9 Miscellaneous Servicing Information When required e Hydraulic Tank Cold Oil Level e Hydraulic oil dipstick is not used to checked oil it is there to allow the air in the tank to be displaced when filling e To ad oil remove red top of filter pull out filter and remove dipstick if low fill through the filter housing until the level is 6mm below the tube in the base of the filter housing oz rg tas m
33. ley Ltd Bruntcliffe Road Morley Leeds LS27 OJZ Tel 0113 2526777 Fax 0113 2380310 trucksmorley tiscali co uk Universal Engine Power Ltd Unit 9 Flitch Industrial Estate Chelmsford Road Great Dunmow Essex CM6 1XJ Tel 01371 875331 Fax 01371 874777 info unipower uk com www unipower uk com Wood Leigh Power Equipment Ltd Unit 20 Highcroft Industrial Estate Enterprise Road Horndean Waterlooville Hants PO8 OBT Tel 02392 571360 Fax 02392 592056 enquiries woodleighpower free online co uk www woodleighpower co uk Yardbury Kinetics Ltd Altens Trade Centre Hareness Circle Aberdeen AB12 3LY Tel 01224 897947 Fax 01224 872374 a huntley yardburykinetics com 11 Operation Safety Maintenance 10 2005 Issue 9 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 BS EN500 Mobile road construction machinery Safety Product Tracked Carrier Model HiT 500 Serial No HT BXxxx Manufacturer Date xx xx 2002 Signed Pp Date xx xx 2002 Mr Paul Drew Development Manager 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 reguest of purchaser Oper
34. nings and close containers tightly to seal in all volatile inhibitor fluids and compounds used e 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 Operation Safety Maintenance 10 2005 Issue 9 Precautions Electrical Hazard x N WARNING Never smoke or allow open flames or sparks near batteries Leave battery box open when charging batteries in machine for adeguate ventilation of explosive gas Hydrogen produced 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 charger 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 x N WARNING 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 i
35. s ready for operation Starting x N WARNING Do not start the engine or operate any control if there isa DO NOT OPERATE or 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 18 Operation Safety Maintenance 10 2005 Issue 9 Operating N WARNING 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 x N WARNING Do not allow unauthortsed personnel to service or mant
36. 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 and 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 15 Operation Safety Maintenance 10 2005 Issue 9 2 Safety Precautions General N WARNING e Read this operator s Handbook and learn the operating characteristics and limitations of the machine Know what operating clearances the machine requires e 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 Keep hand controls free from water grease and mud to assure non slip control e Handle fuels and
37. tion Replacement of Rubber Track Operation Safety Maintenance 10 2005 Issue 9 Operation Safety Maintenance 10 2005 Issue 9 Operation Safety Maintenance 10 2005 Issue 9 Warranty Policy and Procedures Foreword Thank you very much for purchasing this Taylor Construction Plant Ltd product We believe that it will serve you without fail Ensure that you read the Operator s Manual carefully before use With proper handling and maintenance this TAYLOR CONSTRUCTION PLANT Ltd product will provide excellent service over an extended period of time Registration Each machine supplied by TAYLOR CONSTRUCTION PLANT 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 Industrial Park Bates Road Maldon Essex CM9 5FA 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 TAYLOR CONSTRUCTION PLANT Ltd will not be held responsible if 1 the machine has been used to perform tasks that demand more than it s design and strength limitations or 11 the machine has undergone modifications not approved by TAYLOR CONSTRUCTION PLANT Ltd or
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