TCP Hi-T500, Workshop Manual

Page 1: ...8 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 PDF compression OCR web optim...

Page 2: ...Contents 2 TCP 2473 Iss B DCA 00257 PDF compression OCR web optimization using a watermarked evaluation copy of CVISION PDFCompressor...

Page 3: ...ock 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...

Page 4: ...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...

Page 5: ...ave 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 mainte...

Page 6: ...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 K...

Page 7: ...ondition 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 e...

Page 8: ...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 fluid...

Page 9: ...rizontal 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 servic...

Page 10: ...Prelliminary 10 TCP 2473 Iss B DCA 00257 PDF compression OCR web optimization using a watermarked evaluation copy of CVISION PDFCompressor...

Page 11: ...battery T T FS1 30A fuse 1 2 Electrics The diagrams in this section are for explanatory purposes only Refer to drawing TCP 1574 in Section 7 14 Electrical Schematic 0C95 for full information 1 2 1 Ig...

Page 12: ...o the track motors A second valve V4 sets the motors to run at a higher speed When a drive lever is set to forward or reverse one of the microswitches is operated If the tracking speed button is then...

Page 13: ...rol valves Solenoid valve V1 V2 Tracking Tracking speed valve speed supply Fig 1 5 Tracking speed hydraulics Return to tank TCP 2473 Iss B DCA 00257 Section 1 Description 1 3 Hydraulics The Tracking S...

Page 14: ...Section 1 Description 1 3 Hydraulics 14 TCP 2473 Iss B DCA 00257 PDF compression OCR web optimization using a watermarked evaluation copy of CVISION PDFCompressor...

Page 15: ...y 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 A WARNING...

Page 16: ...ure 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...

Page 17: ...ng 2 9 Parking A 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...

Page 18: ...when handling hazardous caustic 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 twi...

Page 19: ...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 A...

Page 20: ...Section 2 Operation 2 12 Average Specific Gravity 20 TCP 2473 Iss B DCA 00257 PDF compression OCR web optimization using a watermarked evaluation copy of CVISION PDFCompressor...

Page 21: ...allow unauthorised personnel to service or maintain this machine Study the manual before starting operating or servicing this machine Always follow the procedures and safety precautions detailed in th...

Page 22: ...ble 3 2 Recommended lubricants Table 3 1 lists the maintenance intervals 3 5 Service Access To access the engine for routine maintenance open the left hand side of the engine enclosure If necessary th...

Page 23: ...essary TCP 2473 Iss B DCA 00257 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 Engine Air Cleaner In...

Page 24: ...r TCP 10 0007 1 Run the engine until it is warm and then turn it off 2 Put the machine on a level surface 3 Remove the oil filler dipstick 4 Remove the oil drain cap and drain off the oil into a suita...

Page 25: ...n the 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 t...

Page 26: ...A 7 Reconnect the fuel pipe 3 12 3 Extra Filter Parts Extra fuel filter TCP 10 0250 This filter Fig 3 13 can be removed without draining the fuel tank 1 Set the fuel valve to Off Fig 3 14 26 Cold sta...

Page 27: ...is 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 Hydraulic filter cap TCP 2473 Iss B DCA 0...

Page 28: ...he oil in the track motors every 1000 hours of operation or at least once per year as follows 1 Run the track motors until they are warm 2 Position the track motor so that one of the drain filler caps...

Page 29: ...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...

Page 30: ...essing 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 ignitio...

Page 31: ...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 enclo...

Page 32: ...oints 32 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 SA 2351 05 1 Switch off the engine and remove the...

Page 33: ...tional 5 7 Valve Block Refer to the drawing in Section 7 24 Control Valve SA 1598 1 Switch off the engine and remove the key 2 Disconnect the hoses from the block labelling each as you go Plug each ho...

Page 34: ...control relays The left hand motor has a banjo connection and the right hand one has a union Fig 5 11 Fig 5 11 Right hand track motor Tighten the sprocket and motor fixing screws with the torque speci...

Page 35: ...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 SA 1...

Page 36: ...from the bolt securing the exhaust Fig 5 1 Positive battery lead Negative battery lead Fig 5 1 Isolate battery 5 Release and remove the throttle cable from the engine Fig 5 2 36 Fig 5 2 Throttle cable...

Page 37: ...environmental hazard TCP 2473 Iss B DCA 00257 Section 5 Parts Replacement 5 12 Engine Removal Fig 5 6 Hydraulic pump location 13 Remove the three bolts securing the base of the engine to the shock abs...

Page 38: ...installed Fitting air filter This is done after the engine has been installed 5 13 1 Drive Shaft Preparation On an engine supplied by TCP the drive shaft will have been cut to length before dispatch F...

Page 39: ...Parts Replacement 5 13 Engine Preparation 3 Fit a Tee piece in the vent tubing of the fuel tank as in Fig 5 15 Fig 5 15 Fuel venting 4 Connect the vent tubing from the banjo to the T piece 5 13 4 Pla...

Page 40: ...ptor fixings 3 Pull off the power take off adaptor Fig 5 20 This will pull off the pump drive coupling 40 leaving only the pump coupling adaptor on the motor shaft Fig 5 20 Pump drive coupling 4 Remov...

Page 41: ...1574 01 WL for details of the engine cable loom Figures 5 24 to 3 20 show the cable loom connections Fig 5 24 Engine cable loom 1 TCP 2473 Iss B DCA 00257 Section 5 Parts Replacement 5 13 Engine Prep...

Page 42: ...Engine Removal 2 Remove the three unions from the pump Fig 5 32 Fig 5 32 Pump unions 3 Remove the two bolts securing the pump to the power takeoff PTO adaptor Fig 5 32 and extract the pump Fitting a n...

Page 43: ...lugs Fig 5 35 Blanking plugs TCP 2473 Iss B DCA 00257 Section 5 Parts Replacement 5 15 Track 3 Lubricate jacking bolts supplied Fig 5 36 Jacking bolts 4 Insert jacking bolts and adjust them equally c1...

Page 44: ...8 Remove idler Fig 5 41 Remove idler 44 9 Place Idler in drive track Fig 5 42 Idler in drive track 10 Slide drive track and Idler on shaft Fig 5 43 Idler on shaft 11 Ensure Idler is fully home Fig 5...

Page 45: ...acking bolts Fig 5 47 Jacking bolts removed TCP 2473 Iss B DCA 00257 Section 5 Parts Replacement 5 15 Track 15 Fit blanking plugs Fig 5 48 Blanking plugs 16 Remove chassis support Fig 5 49 Remove bloc...

Page 46: ...Section 5 Parts Replacement 5 15 Track 46 TCP 2473 Iss B DCA 00257 PDF compression OCR web optimization using a watermarked evaluation copy of CVISION PDFCompressor...

Page 47: ...g 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 T...

Page 48: ...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...

Page 49: ...lar 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 6 Top ram at full bore Forward Ira Fig 6 7 Top ram at annular bore Back Fig 6 8 Bo...

Page 50: ...forwards until the bar locks the drives at the sprockets Warning Take due care to avoid personal injury and equipment damage during this operation Inserting bar M01 Drive locked Fig 6 10 Track locking...

Page 51: ...sure reading of 125 Bar 6 Release the locking bar by briefly driving the machine in reverse 7 Turn off the engine and remove the locking bar from the tracks 6 6 Completion On completion of pressure ad...

Page 52: ...Section 6 Hydraulic Pressure Adjustments 6 6 Completion 52 TCP 2473 Iss B DCA 00257 PDF compression OCR web optimization using a watermarked evaluation copy of CVISION PDFCompressor...

Page 53: ...gs 7 1 Tracked Carrier Assy 2350 GA Section 7 Drawings 7 1 Tracked Carrier Assy 2350 GA J TCP 2473 Iss B DCA 00257 53 PDF compression OCR web optimization using a watermarked evaluation copy of CVISIO...

Page 54: ...is Assy Stage 1 SA 2351 01 a CU Vaa 92 CU 0 z I 7 8 ef ef V En 0 rso 0 8 1191 0 U2 ed ed 04 Cci 40 Val Cda eso ry U p5 LE arC EX4 a g 4 h 54 TCP 2473 Iss B DCA 00257 PDF compression OCR web optimizati...

Page 55: ...351 02 7 3 Chassis Assy Stage 2 SA 2351 02 a 1 4 5 a N 2 A 5 2 A 5 I 0 N 9 n 2 E ro 2 74 E INA E 111 Y 1 2 10 a 9 a 2 9 9 TCP 2473 Iss B DCA 00257 55 PDF compression OCR web optimization using a water...

Page 56: ...OXIMITY SWITCH 1 16 70 0020 monmny swacH Il 17 1574 03C 73 0015 LOOM BUZZER Il 15 1574 04 73 0016 LOOM COLS START 19 235 5 05 73 0040 LOOM TWO SPEED 010 VALVE 20 1925 SA 54 a925 COLD START ASSY Il 21...

Page 57: ...Stage 4 SA 2351 04 7 5 Chassis Assy Stage 4 SA 2351 04 te9 6 2 9 8 9 4 11 792 3 714 In P 11 KT 9r NE0 Vag CP 5 TCP 2473 Iss B DCA 00257 57 PDF compression OCR web optimization using a watermarked eval...

Page 58: ...ssis Assy Stage 5 SA 2351 05 7 6 Chassis Assy Stage 5 SA 2351 05 0 0 1 I A 8 8 8 8 v I 4 7 1 Sib to 58 TCP 2473 Iss B DCA 00257 PDF compression OCR web optimization using a watermarked evaluation copy...

Page 59: ...y SA 1471 7 7 Engine Enclosure Assy SA 1471 g 2 0 0 0 8 8 6 6 6 6 6 6 gn On Col 4 Ctl 0 ft A a era nt aet rk 2 9 1 0 TCP 2473 Iss B DCA 00257 59 PDF compression OCR web optimization using a watermarke...

Page 60: ...DECAL WARNING CRUSH ZONE 6 9 057 80 0013 DECAL CAUTION SIGN LGE BODY 1 10 1726 80 0236 DECAL STARTING INSTRUCTIONS 1 11 007 80 0009 DECAL WARNING KEEP CLEAR 2 12 002 80 0007 DECAL CE MARKING 2 13 012...

Page 61: ...ection 7 Drawings 7 9 Battery Box Assy SA 2356 7 9 Battery Box Assy SA 2356 TCP 2473 Iss B DCA 00257 61 PDF compression OCR web optimization using a watermarked evaluation copy of CVISION PDFCompresso...

Page 62: ...Dressing Kit SA 1928 01 1 44 VAACD 0 I 0 0 z t a 5 2 4 2 I a 2 A 3 O 2 ro 8 O 2 9 a 5 5 9 a a m A A 9 7 4 ti A F 1 6 H 5 Po I 17 0 4r 0 9 0 a O 6 8 O 62 TCP 2473 Iss B DCA 00257 PDF compression OCR w...

Page 63: ...FILTIER ASSY a 3 4 20 iii RE USABLE OM FILTER a 4 4 5 i2 5 STOP SOLENOID COIL 5 1522 le oil AIR FILTER SABOT 2 6 20 0249 B F FILTER ELEMENT a iliktfILOR PLANT LW QUAYSIDE POMMIES FIC A0 NALECH ESSEX...

Page 64: ...AS SHOWN NOTE ORIENTATION ORO NB PART ND DESCRIPT7 CITY 1 1436 51 0155 OXL COOLE4 MOUNT PLATE 1 2 61 0007 OIILCOOLE4 MTH 12V FAN 1 SEE ASSY NOTES A VE 3 1459 SA ITE 313 1 2 3SP MARE MALE 1 4 1459 SA I...

Page 65: ...A 1 925 7 13 Cold Start Assy Kubota Filter SA 1925 74 74 N N N 74 D z I n D z gL c 8 di 511 A V 6 6 an r4 9 Va9 Izt1o66 6o ro E r TCP 2473 Iss B DCA 00257 65 PDF compression OCR web optimization using...

Page 66: ...Electrical Schematic 0095 2355 7 14 Electrical Schematic 0C95 2355 66 SISSVH 1 52 I 0321 r L aN 1 I TCP 2473 Iss B DCA 00257 PDF compression OCR web optimization using a watermarked evaluation copy o...

Page 67: ...111 1 sa na 511 dams vnb 1 1 1 1 HINk 2 JO I 1HS 006 nolow c 06 a 066 anDaNaaaagall JO 3 1 0 1 01 aaa a aasn ion 96 069 01 1aVle 021 aDa an aa nn le ANIZIHS 3181X21U 630 S 2 z IRS 72d5 210172NN07 92S...

Page 68: ...USE HOLDER 5 SUPPLIED WITH ENGINE 1 11 RECEPTACLE HOUSING 6 WAY 5 SUPPLIED WITH ENGINE 1 12 214 CRIMP MALE BULLET SUPPLIED WITH ENGINE 2 13 M8 RING CRIMP TERMINAL SUPPLIED WITH ENGINE 1 14 70 0061 REC...

Page 69: ...Ell Z A TZe J FF LIILIILII 5 rocc Y L i z r3 e 2 2 A A V i cb 2 z i LY g F gl rril K Section 7 Drawings 7 16 Two Speed Loom WL 1574 02 00 OTE 05Z Co 0 a C 0 IM MC 0 L 5 TCP 2473 Iss B DCA 00257 69 PD...

Page 70: ...TE12 71 0003 PANEL MOUNT SIREN 102dB RS 231 2939 9 70 0015 PROXIMITY PROBE LEAD 90 INDUSTRIAL CONTROLS 804001E03 4050 10 70 0053 TAB HOUSING 3 WAY TYCO ELECTRONICS 180940 0 11 70 0057 TAB 0 3 0 8 TYCO...

Page 71: ...7 Drawings 7 18 Loom for Cold Start WL 1574 04 7 18 Loom for Cold Start WL 1574 04 TCP 2473 Iss B DCA 00257 71 PDF compression OCR web optimization using a watermarked evaluation copy of CVISION PDFCo...

Page 72: ...IVE 06 5 190 06 5 ENDS CRIMPED St SOLDERED NOTE 1 USE LAYFLAT SLEEVING T 0 0 I 7051T 0 iT TITLE BATTERY LEADS IDS_ A QmPsIDE HIT500 MK5 v1 2007 FPN 1 STK DATE WWW TCP EU COM DWG No TCP 2357 73 0041 19...

Page 73: ...0 Jump Lead Link 1607 Y Section 7 Drawings 7 20 Jump Lead Link 1607 w 1 0 z J TCP 2473 Iss B DCA 00257 73 PDF compression OCR web optimization using a watermarked evaluation copy of CVISION PDFCompres...

Page 74: ...OTE RELIEF PRESSURE SETTINGS SHOWN ARE IN SERVICE VALUES MANUFACTURERS BENCH TEST SETTINGS ARE 225 275 S 120 130 bar Li r quAysIpEPARK BATeSROn NWENDN ESSEX CA 9 5FA TE1 44162185 TFAX441621843330 WWW...

Page 75: ...ER I I I I I I 1 u L_ _ _ _ _ _ _ L 0G 0 00 0 0 00 00 0 LARGE PUMP 1 SMALL PUMP 2 O 00 q 11 113Fr 00 00 LSEE T P 1388 SA 00 0 0 m r25PEEbli VALVE 3 r 0 00 0 0 0 rg YL I I SIDE PAP I gArf 5 ROM MALDON...

Page 76: ...Pairs Chassis To Cylinder 62 0124 2 Prs 20 1 2 1w 550 Cut Length 90 S Male Air Breather Extension 62 0125 1 2 3 16 R7 420 Cut Length 1 4 BSP 90 C 1 8 Banjo 335 Lefthand Track Motor 62 0192 1 22 3 16 R...

Page 77: ...7 23 Hydraulic Tank Assy SA 1388 0 vl I 100 tau v EL EL vl tqID v v b vl MI E0 fin 0 9 g g g goo go go 4 ozoo ozo 11 q IV IV IV TCP 2473 Iss B DCA 00257 77 PDF compression OCR web optimization using a...

Page 78: ...a COIL MODULE 12V COMPLETE a SWITCH MODULE COMPLETE 2 MICRO SWITCH ONLY PER M DULE I CONTROL LEVER BLACK 2 CINTROL LEVER GREEN 1 CONTROL LEVER YELLOW a SEAL KIT PER MULE 1 TAYLOR COMSTRUCTION PUNT LT...

Page 79: ...Seq Assy Chassis 1591 SA 7 25 Sound Kit Seq Assy Chassis 1591 SA NUMBER DENOTE SEQUENCE OF INSTALLATION TCP 2473 Iss B DCA 00257 2 79 PDF compression OCR web optimization using a watermarked evaluati...

Page 80: ...on 7 Drawings 7 26 Sound Kit Seq Assy 1592 SA 7 26 Sound Kit Seq Assy 1592 SA 1 80 TCP 2473 Iss B DCA 00257 PDF compression OCR web optimization using a watermarked evaluation copy of CVISION PDFCompr...

Page 81: ...orque limits from the following tabulations Size 6 9 Some Engine Bolts 8 8 Standard Hex Bolt 10 9 Some Engine Bolt 12 9 Standard Cap head Nm lbfft Nm lbfft Nm lbfft Nm lbfft M6 8 5 6 3 10 7 4 14 10 3...

Page 82: ...Appendix A Nut Bolt Torque Specification 82 TCP 2473 Iss B DCA 00257 PDF compression OCR web optimization using a watermarked evaluation copy of CVISION PDFCompressor...