TCP Hi-T500 Instruction manual

Compact Tracked

Carrier Mk 5 vl

Workshop Manual

TCP2473 Iss B Feb 2008

DCA 00257

Taylor Construction Plant Ltd.

Quayside Industrial Park, Bates Road,

Maldon, Essex, CM9 5FA

Tel:+44 (0)1621 850777

Fax:+44 (0)1621 843330

mailtcp.eu.com

www.tcp.eu.com

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Contents

2TCP-2473 Iss.B DCA 00257

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Contents

Contents3.4 Maintenance Intervals 21

Preliminary 53.5 Service Access 22

Foreword 53.6 Lubrication 22

Warranty 53.7 General Inspection 23

Registration 53.8 Daily Check 23

Liability 53.9 Engine Oil Check 24

Audits and Surveys 53.10 Engine Oil Change 24

Service and Warranty Training 53.11 Air Filter 24

Warranty Terms 53.12 Fuel Filters 25

General Exclusions: 53.12.1 Tank Inlet Filter 25

Warranty Claim Submission Procedures 63.12.2 Tank Bottom Filter 25

Certificate of Conformity 63.12.3 Extra Filter 26

Kubota Engine Dealers 63.13 Hydraulic Filter/Oil 27

Service Bulletins 63.14 Charging the Battery 28

Machine Identification 63.15 Changing Track Motor Oil 28

Theft Deterrence 6

Recovery of a Stolen Machine 7Section 4 Fault Finding 29

Safety 74.1 Starting 29

General 74.1.1 Engine will not crank properly 29

Fire Precautions 84.1.2 Engine cranks but will not fire 29

Flammable Fluid Precautions 84.2 Battery Charging Check 30

Electrical Hazard 84.3 Tracking Speed 30

Pre-Starting

Starting 88Section 5 Parts Replacement 31

Operating 95.1 Recommended Tools 31

Lubrication and Servicing 95.2 Housing Removal 31

Specifications 95.3 Air Filter 31

5.4 Exhaust System 32

Section 1 Description 11 5.5 Ram 32

1.1 Introduction 11 5.6 Hydraulics Purging 33

1.2 Electrics 11 5.7 Valve Block 33

1.2.1 Ignition 11 5.8 Track Drive Motor 34

1.2.2 Charging Circuit 12 5.9 Battery 34

1.2.3 Tracking Speed 12 5.10 Oil Cooler Fan 35

1.2.4 Sounder Control 12 5.11 Engine and Pump Replacement 35

1.2.5 Oil Cooler Fan 12 5.12 Engine Removal 36

1.2.6 Oil Pressure Light 12 5.13 Engine Preparation 38

1.2.7 Hours Counter 12 5.13.1 Drive Shaft Preparation 38

1.3 Hydraulics 13 5.13.2 Regulator 38

Section 2 Operation 15 5.13.3 Fuel Vent

5.13.4 Plastic Filler Cap Replacement 3939

2.1 Controls 15 5.13.5 Engine Oil 40

2.1.8 Throttle 15 5.13.6 Hydraulic Pump and Power Take-off40

2.1.9 Steering 15 5.13.7 Engine Cable Loom 41

2.2 Daily Pre-start Inspection 15 5.14 Hydraulic Pump 42

2.3 Engine Operation 16 5.15 Track 43

2.4 Starting the Engine 16

2.5 Starting the Engine with Jumper Cables 16 Section 6 Hydraulic Pressure

2.6 Battery Charging 17 Adjustments 47

2.7 Moving and Stopping 17 6.1 Introduction 47

2.8 Stopping the Engine 17 6.2 Fitting Test Gauge 47

2.9 Parking 17 6.3 Service Line Relief Valve Adjustment 48

2.10 Loading 17 6.4 Ram Pressure Levels 49

2.11 Tipping 18 6.5 Track Drive Pressures 50

2.12 Average Specific Gravity 19 6.6 Completion 51

Section 3 Maintenance 21 Section 7 Drawings 53

3.1 General 21 7.1 Tracked Carrier Assy 2350 GA 53

3.2 Engine Maintenance 21 7.2 Chassis Assy Stage 1 SA-2351-01 54

3.3 Safety Precautions 21 7.3 Chassis Assy Stage 2 SA-2351-02 55

TCP-2473 Iss.B DCA 00257 3

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Contents

7.4 Chassis Assy Stage 3 SA-2351-03 56 7.19 Battery Leads.2357 72

7.5 Chassis Assy Stage 4 SA-2351-04 57 7.20 Jump Lead Link 1607 73

7.6 Chassis Assy Stage 5 SA-2351-05 58 7.21 Carrier Hydraulics 2352 74

7.7 Engine Enclosure Assy SA-1471 59 7.22 Hydraulic Hose Assy SA-2353 75

7.8 Labels (Decals) SA-1467 60 7.23 Hydraulic Tank Assy SA-1388 77

7.9 Battery Box Assy SA-2356 61 7.24 Control Valve SA-1598 78

7.10 Engine Assy & Dressing Kit SA-1928-01 62 7.25 Sound Kit Seq. Assy Chassis 1591 SA 79

7.11 Engine Service Kit SA-1928-02 63 7.26 Sound Kit Seq. Assy 1592 SA 80

7.12 Cooler Assy, Hydraulic SA-1470 64

7.13 Cold Start Assy Kubota Filter SA-1925 65 Appendix A Nut & Bolt Torque

7.14 Electrical Schematic 0C95 2355 66 Specification 81

7.15 Loom for Kubota 0C95 1574-01 67 1. Specific Torque Settings 81

7.16 Two Speed Loom WL-1574-02 69 2. Generic Torque Settings 81

7.17 Wiring For Auxiliaries WL-1574-03 70

7.18 Loom for Cold Start WL-1574-04 71

4TCP-2473 Iss.B DCA 00257

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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: [email protected])

Taylor Construction Plant Ltd.

Quayside Industrial 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, or

TCP-2473 Iss.B DCA 00257

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 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 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.

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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 USED: State 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 required

Note that the order number is to cover the

diagnostic and call out time, as well as to determine

the following:

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.

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.kubota.co.uk/ (for the

UK) or http://www.kubotaenqine.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.

Information 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).

-BS/EN500 Mobile road construction

machinery (Safety)

Product :Tracked Carrier

Model :HIT 500

Serial No :HT-Bxxxx

Manufacturer Date :xx/xx/2006

Signed:

Date: xx/xx/2006

Mr Paul Drew

Development Manager

Tel: +44 (0)1621 85[1777

Fax': +44 (0)1E21 843330

vrvyvy.tv.eu.com

MODEL NO:

SERIAL NO:

ENGINE TYPE:

ENGINE SERIAL NO:

CE YEAR OF MANUFACTURE'

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.

TCP-2473 Iss.B DCA 00257

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Remove all keys any time the machine is left

unattended.

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.

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.

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 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.

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,

TCP-2473 Iss.B DCA 00257

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 servicing 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

A WARNING

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.

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Prelliminary

Keep hand controls free from water, grease and

mud to assure 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

A WARNING

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

A 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.

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 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.

A. WARNING

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

A 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 is ready for operation.

Starting

A WARNING

Do not start the engine or operate any control if

there is a '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.

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Operating Specifications

A 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

A WARNING

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.

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.

Preliminary

Maximum carrying capacity 500 kg

(1100 lb)

Skip volume 255 It

(9.0 ft 3)

Unladen weight (9448kg87 lb)

Width 700 mm

(28 in)

Height 1165 mm

(45.8 in)

Height over skip 2500 mm

(98.4 in)

Height under skip 1200 mm

(47 in)

Length 1770 mm

(69.6 in)

Max grade ability 45%

Turning circle 2000 mm

(78.5 in)

Track ground pressure 0.351 g/cm2

(4.99 i)p s

Engine (with electric start)

Kubota 0C95 7.1 kW

(9.5 hp)

Speed forward 4 kph max.

(2.5 mph)

Speed reverse 2 kph

(1.2 mph)

Power take off - optional 20 It/m @

120 bar

Noise level 99 dBa

TCP-2473 Iss.B DCA 00257 9

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Prelliminary

10 TCP-2473 Iss.B DCA 00257

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