Operations and Service Manual
Contents
1. Crawler Storage Compartmant Turntable Crawler Retainer Lever Crawler GENERAL UNDERSTANDING OF THE TRAKSPORTER AND ITS COMPONENTS The Traksporter is designed to move heavy awkward objects in tight crowded and confined areas There are three 3 general components to the Traksporter Refer to page 7 Power Unit Supplies hydraulic and electrical power to operate the Crawler as well as power to drive and steer the power unit Crawler Provides pushing and pulling as well as steering for the object being moved Radio Control Transmitter Provides forward and reverse motion as well as steering for the Crawler Also houses high low idle switch and emergency stop button GENERAL GUIDELINES FOR USE DO S AND DON TS Always use safe rigging practices The Crawler is designed to operate on a flat horizontal concrete surface or steel plate sufficient to support the Crawler and the load being carried Always try and maintain 100 contact between all of the track pads and the floor surface Always step up or down concrete edge differences using cut pieces of Masonite or shim steel that are greater than 1 4 6mm to prevent damage to concrete or Crawler and to prolong track life Understand that anytime you are traversing a step or void you are losing contact area on some portion of the track pads and the floor surface thus reducing the effective capacity of the Crawler2. HILMAN TRAK SPORTER Operations and Service Manual Model 130 BP Manufactured by HILMAN ROLLERS WWW HILMANROLLERS COM 12 Timber Lane Marlboro NJ 07746 USA tel 732 462 6277 fax 732 462 6355 R 9 1 6 TABLE OF CONTENTS Specifications Components General Understanding of the Traksporter and Its Components General Guidelines for Use Do s and Don ts Riding Surface and Support Starting the Power Unit and Daily Inspection Guidelines for Moving an Object with the Traksporter Maintenance Troubleshooting 10 11 12 13 13 SPECIFICATIONS POWER UNIT Length 65 1651mm Width 30 762 mm Height 47 1194 mm Weight with Crawler 2200 lb 998 kg Weight without Crawler 1660 Ib 753 kg Rear wheel drive hydraulic Front wheel steering hydraulic Engine Kubota Model DF752 BI A 3 cylinder liquid cooled 24 hp 17 9 kW propane fueled 12 volt low oil pressure shut down switch Travel Speeds Approx 150 ft min 46 m min or 1 75 mph Forward and reverse Hydraulics ISO 46W oil for operation between 100 F 38 C and 30 F 1 C for operation other than above specifications consult Manufacturer Circuit reservoir holds approximately 35 gallons of hydraulic oil Hydraulic Filter 3 Micron Hydraulic System Pressure Adjustable from 0 2400 psi 0 165 bar Hydraulic Relief Setting 2700 psi 186 bar SPECIFICATIONS continued CRAWLER UNIT
3. Length 26 660 mm Width 31 787 mm Height 6 5 165 mm Weight 540 lb 245 kg Turning Radius Near zero turn radius Hose 30 9 1 m Two 2 independent tracks driven by four 4 hydraulic motors controlled by two 2 two way hydraulic proportional valves Travel speed is adjustable 0 25 ft min 7 6 m min going forward reverse and turning Capacity directly down on Crawler unit is 60 000 Ib 267 KN maximum RADIO CONTROL Omnex Controls 900 MHz frequency 300 ft 91 m operating range Transmitter powered by 4 C Alkaline Batteries COMPONENTS Hydraulic Hydraulic Temp Level Gauge Pressure Gauge Brake Hydraulic Pump Release Unload Switch Warning 5 Signal Activation z Four way Control Joystick Key Switch High and Low Idle Switch Radiator with aan Pusher Fan PRETANN ARON nN Hane enter NS iin PAAR ARAB TR HN st it WN in cK EE M Haniel un HU M a W i ny hh Ne Ny it Meet N Muffler REAR VIEW COMPONENTS Continued Vent Access Panel Right Control Cabinet Right Engine Compartment Door RIGHT SIDE VIEW Hydraulic Hydraulic Pressure Reservoir Adjustment Knob Hydraulic Filter Left Engine Compartment Door Propane Storage Compartment Fluid Sample Test Port Air Filter LEFT SIDE VIEW COMPONENTS Continued Power Unit Hose Storage Hooks Radio Control Transmitter
4. Always clear a path for the Crawler by removing floor dust dirt and debris This will increase track life by preventing debris from getting lodged into the track drive system Make certain that all anchor bolts and studs are cut flush with the floor surface so there is sufficient clearance for the Crawler and to avoid bottoming out the Crawler Severe track damage or hydraulic motor damage can occur Machine is designed for indoor use and storage Always protect against outdoor conditions such as rain snow extreme cold road salt etc Always tarp during transit Never exceed the following capacities on the Crawler turntable e 60 000 Ib 267kN on an extremely flat surface 100 contact between floor and all track pads e 40 000 Ib 178 kN or less with at least 70 contact between the floor surface and all track pads Never attempt to take an object up or down a 1 8 3mm per linear foot or greater slope Always use the supplied sacrificial rubber pad between the Crawler turntable and the load point unless the load is affixed to the turntable in some other semi permanent or mechanically fastened way consult manufacturer if unsure Never load the Crawler in any location except the turntable The turntable is located such that it will apply the load equally over all of the track pads keeping the load distributed evenly and giving the user maximum Crawler load capacity 10 Always keep hands fingers feet pe
5. not shift during transport The Crawler and its hydraulic motors are operating very close to the floor surface Crossing through a trench drain or striking an anchor bolt may bottom out the Crawler and may result in track or motor damage Always use a spotter on the opposite end of the object to watch the rollers and to assure enough clearance The Spotter should be aware of tail swing When placing the Crawler under an object ensure that you will have sufficient umbilical hose slack between the Power unit and the Crawler Whenever possible try and minimize hose dragging and or having the hose slide either in the load path or under the load IMPORTANT Never allow umbilical hoses to tighten between Crawler and power unit Make sure that the object being moved is placed on the center of the turntable keeping the weight distributed evenly between the tracks Use the sacrificial rubber pads supplied with the unit between the top of the turntable and the load point This allows maximum point load contact between the Crawler and the load point and will also allow the Crawler to articulate over any small steps or uneven floor changes Watch the hydraulic oil temperature to ensure it does not exceed 140 F 60 C Do not under any circumstance use the Traksporter if the hydraulic oil is in the overheated condition Shut the unit down and let the oil cool down before using If this is a persistent problem Hilman offers a hydraulic oil c
6. both throttle idle control switches one on the right armrest and one on the radio transmitter are in the low idle position The hydraulic pump unload switch should be in the off position 2 Push the spring loaded power switch toward ON position and release A red flashing indicator light will be illuminated 3 Cycle the E stop button within 5 seconds of turning on To do this push E stop button in while pushing the button in simultaneously twist the button clockwise to set the E stop The red indicator light will go out and a yellow signal light will appear You should hear a mechanical click when this happens 4 Once the red indicator light has turned to yellow the transmitter is set and the Power unit can be started To start the unit turn the key switch clockwise and crank the engine until the engine starts make sure your propane tank valve is open Do not crank the engine for more than 10 seconds continuously or you could damage the starter motor 5 Once running the engine can be switched to high idle from either switch remote or armrest but only one switch will control idle at a time 6 With the hydraulic pump switch turned off the engine will start easier and with less back pressure from the hydraulic pump 7 After starting the engine switch the pump to ON and the gauge on the left armrest will show system pressure The pressure can be adjusted with the black adjustment knob next to the gauge 8 Maximum
7. e free spinning rollers at the other 2 load points Once the object is safely placed on the Crawler and rollers ease the joysticks in the direction you want to travel The control joysticks are proportional in function small movements on the joysticks translate to small slow movements on each respective Crawler track Do not make sudden movements as the Crawler needs to create the momentum to move the object as well as slow the momentum to stop the object Sudden movement can dislodge the Crawler from under the object dropping the load and may cause severe damage Start with the hydraulic pressure at 800 psi 55 bar ref pressure gauge on left armrest If turning the Crawler under the load is difficult or not working increase pressure by 200 psi 13 8 bar and try again Always keep pressure as low as possible in order to achieve just enough turning moving torque The lower the pressure the smoother the Crawler will operate Lower pressure will also give an experienced user a better feel for how the load is moving if the rollers become caught up on cracks anchor bolts floor debris etc Know the path you will be taking the object Mark out the path prior to the move with safety cones so all personnel working nearby understand that heavy equipment is being moved Double check for height width clearance and floor condition floor drains trenches or obstructions protruding from the floor Make sure the object being moved will
8. illed and valve is open Remote Control fault See Omnex Control manual troubleshooting section Crawler does not seem to have power Nh Verify pump unload switch is on load position Check pressure gauge for hydraulic pressure Raise pressure in 200 psi 1 38 bar increments to increase power 3 Verify Power unit is running in high idle position 4 Check hydraulic oil temperature for overheat condition If none of the above checklist resolve the issue contact the manufacturers for assistance 13
9. ooler option to keep the hydraulic oil temp under control 12 MAINTENANCE Hydraulic Oil 35 gallons Mobil DTE 25 or equivalent name brand high quality ISO 46 weight hydraulic oil Hydraulic Oil Filter Hydac 0095 MA 003 BN Maintenance Schedule Engine as per enclosed pamphlet Hydraulic System Have hydraulic oil tested once a year or 500 hours whichever occurs sooner right engine compartment door you will see a SenDec engine hour meter A 25 test sample hose is supplied Change oil accordingly to test analysis Change hydraulic filter every 500 hours or when sight gage on the filter head changes from green to red Clean and inspect tracks every 10 hours more often in harsh conditions or if used frequently Lubricate tracks pads rollers and connecting bridge links with WD 40 or light hydraulic oil TROUBLESHOOTING Engine won t start and doesn t turn over 1 2 Check battery and connections Check all fuses fuse panel located in right arm rest control cabinet Engine turns over but does not start 1 DEON Transmitter not on and or e stop switch has not been cycled correctly Transmitter needs to provide signal to receiver This will allow engine to start Blown fuse Check all fuses fuse panel located in right arm rest control cabinet Engine was shut down under high rpm governor arm must reset to low idle manually Transmitter battery low Check that propane tank is adequately f
10. rsonnel away from moving track parts or any moving parts on either the Crawler or the Power Unit 11 Do not ever place personnel or yourself in any type of a pinch point situation with respect to the object being moved Prior to lifting or moving make sure all personnel are kept a safe distance from the object being transported Better yet cone off the entire area around the move area so un knowing personnel do not wander into the vicinity of the object being moved RIDING SURFACE AND SUPPORT Always inspect the concrete or surface to be traveled on for condition hardness and sub support Ensure there are no basements tunnels or voids under slab that may not adequately support the load being moved If there is any doubt contact a structural engineering to analyze the strength of the floor prior to moving At the maximum allowable load 60 000 Ib the crawler will exert a pressure of approximately 760psi on the ground bearing surface If the actual load is below the maximum a load coefficient Le can be used to determine the approximate contact pressure p Actual Load 60 000 lb Contact Pressure p L 760psi Load Coefficient Le An example calculation using an actual load of 30 000 Ib _ 30 000 lb Le gt 0 50 60 000 lb p 0 50 760psi 380psi It is the user s responsibility to ensure the riding surface is adequate to handle the pressure which is generated between the crawler tracks and riding
11. surface Failure to do so may result in damage to the riding surface If necessary steel plate can be laid over a concrete surface to aid in dispersing the load to a greater area 10 STARTING THE POWER UNIT AND DAILY INSPECTION WARNING Do not attempt to operate this machine without first reading and understanding this manual and or receiving training from a qualified manufacturer representative Serious injury death and or extensive damage may result Daily inspection of both the Power Unit and Crawler should be performed to look for obvious problems such as leaks cracks loose or missing bolts etc Periodically check the engine oil engine coolant level and hydraulic oil reservoir to assure all are at proper levels The Crawler should be tilted up and the tracks drive motors hydraulic lines visibly inspected before each move to make sure there are no leaks damage to the Crawler Check the umbilical cord between the Power unit amp Crawler carefully for tears in the scuff cover and or leaks in the flow return hydraulic lines Become familiar with all controls before starting the machine especially how to shut the machine down in an emergency There are two ways to shut the machine down in the event of an emergency one is to use the E stop button located on the side of the remote control transmitter and two is to turn the key switch on the right armrest of the Power unit to the OFF position To start the unit 1 Make sure
12. system pressure is 2400 psi 165 bar You should typically start at 800 psi 55 bar and then increase in small increments if you need more torque Always turn the knob slowly and make small incremental changes to increase torque IMPORTANT Always turn the pump off unload when you are not actively using either the Crawler or the Power unit This will keep the pump from dumping the oil back to reservoir which will tend to overheat the hydraulic oil NOTE The controller has a sleep mode feature After a period of inactivity the unit will turn itself off and will need to be re activated see 2 amp 3 above 11 GUIDELINES FOR MOVING AN OB ECT WITH THE TRAKSPORTER Inspect the object being moved Determine the center of gravity in all directions of the object being moved so you can balance the load properly Become familiar with frame members and how to support a load on three 3 points Always try and choose a load point that is rigid and will not flex while moving Know the total weight of the object how much weight will be placed onto the Crawler and how much will be on the rollers Always try to place the load equally between the Crawler and rollers i e 12 of the load onto the Crawler turntable and 1 of the load onto the other two rollers If more traction is needed for the Crawler then offset the load so that the Crawler has slightly more than 1 2 of the load on it this will also reduce the rolling resistance of th
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