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TF220s

15

13.

Clean or replace damaged, missing or painted over safety signs that cannot be

read.

14.

Rotating and moving parts must be inspected during maintenance and replaced if

cracked or damaged. Excessively worn or damaged parts can fail and cause injury or

death.

15.

After maintenance, tighten all bolts, fittings and connections.

Install all guards, covers and shields. Replace or repair any damaged ones. Refill and

recharge pressure systems with recommended fluids.

Start the engine and check for leaks. Operate all controls and make sure the machine

is

functioning properly. After testing, shut down, check the work you performed

(any

missing

cotter pins, washers, locknuts, etc.)

?

Recheck all fluid levels before releasing machine for operation.

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Summary of Contents for TF 220s

Page 1: ...MACHINETYPE MODEL TF220 S SERIAL NO 21020181 01 YEAR OF MANUFACTURE 2012 OPERATION MAINTENANCE SPARE PARTS MANUAL TF 220s ...

Page 2: ...TF220s 1 BLANK PAGE ...

Page 3: ...to safety at work and accident prevention is allowed to use maintain and repair this machine This instruction manual contains important information on how to operate the machine safely properly and most efficiently Observing these instructions helps to avoid danger to reduce repair costs and downtimes and to increase the reliability and life of the machine The operating instructions must always be...

Page 4: ...TF220s 3 BLANK PAGE ...

Page 5: ...TF220s 4 Contents 1 SAFETY 2 TECHNICAL INFORMATION 3 OPERATION 4 MAINTENANCE 5 TROUBLESHOOTING 6 APPENDIX 7 SPARE PARTS ...

Page 6: ...TF220s 5 BLANK PAGE ...

Page 7: ...TF220s 6 SAFETY ...

Page 8: ...TF220s 7 BLANK PAGE ...

Page 9: ...ual and around the machine ii Be aware of all the moving parts of the machine 1 2 SAFETY SIGNS Particular attention should be paid to the following safety signs This is the safety alert symbol When you see this symbol be alert to the possibility of personal injury or death IMPORTANT Indicates a statement of company policy as the message relates directly or indirectly to the safety of personnel and...

Page 10: ...MACHINERY LOCK OUT EQUIPMENT BEFORE SERVICING BEWARE OF HYDRAULIC OIL LEAKS HIGH PRESSURE HYDRAULIC OIL CAN PENETRATE THE SKIN CAUSING SERIOUS INJURIES USE A PIECE OF CARDBOARD TO FIND LEAKS DO NOT USE BARE HAND OPERATORS MANUAL MUST BE READ AND FULLY UNDERSTOOD BEFORE PERFORMING ANY OPERATION OR MAINTENANCE EYE PROTECTION MUST BE WORN IN THIS AREA HEAD PROTECTION MUST BE WORN IN THIS AREA TF220s ...

Page 11: ...ION MUST BE WORN IN THIS AREA NIP POINT TF220s 10 EAR PROTECTION MUST BE WORN IN THIS AREA NIP POINT KEEP HANDS CLEAR OF MOVING MACHINERY TF220s EAR PROTECTION MUST BE WORN IN THIS AREA KEEP HANDS CLEAR OF MOVING ...

Page 12: ...terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling 7 Never short across the starter terminals of a battery as this can cause a fire and could also damage the electrical system 8 Battery electrolyte contains acid and can cause serious injury Avoid contact with skin and eyes Use ...

Page 13: ...ponent 4 Do not handle or repair hydraulic equipment with bare hands 5 Beware of hydraulic oil leaks Hydraulic fluid under pressure can penetrate the skin or damage eyes Fluid leaks under pressure may not be visible Use a piece of cardboard to find leaks but do not use bare hand 6 Wear safety goggles for eye protection If fluid enters skin or eye get immediate medical attention 7 Ensure that any d...

Page 14: ...uring operation do not climb onto over or under moving conveyor belts and rollers Always use ladders steps and walkways when mounting and dismounting 5 Hole alignment on mechanical supports must be checked and secured with pins provided and in accordance with safety signs 6 Never check the tension of V belts drive chains and conveyors when machine is running 7 Never work or stand beneath machinery...

Page 15: ...adjustments are only possible during working process see Belt Tracking 6 Remove only guards or covers that provide access Wipe away excess grease and oil 7 Never leave guards off or access doors open when unattended Keep bystanders away if access doors are open 8 When working beneath raised equipment always use blocks jack stands or other rigid and stable supports Never work under unsupported equi...

Page 16: ...15 After maintenance tighten all bolts fittings and connections Install all guards covers and shields Replace or repair any damaged ones Refill and recharge pressure systems with recommended fluids Start the engine and check for leaks Operate all controls and make sure the machine is functioning properly After testing shut down check the work you performed any missing cotter pins washers locknuts ...

Page 17: ...TF220s 16 TECHNICAL INFORMATION ...

Page 18: ...TF220s 17 BLANK PAGE ...

Page 19: ... INFORMATION GENERAL INFORMATION Familiarisation Front Rear Left Side Right Side 1 3 4 5 6 2 7 8 1 Main Conveyor 2 Tracks 3 Beltfeeder Hopper 4 Jacklegs 5 Fuel Tank 6 Hydraulic Tank 7 Main Lifting Ram 8 Engine Compartment ...

Page 20: ...TF220s 19 GENERAL INFORMATION Familiarisation 9 Ignition Panel 10 Diesel Fuel Visual Level Gauge 11 Hand Throttle 12 Hydraulic Oil Visual Level Gauge 9 10 11 12 ...

Page 21: ...the machine and can is hinged from the main frame This allows you to swing the complete engine compartment away providing easy access to all filters and gauges Track Undercarriage The machine is mounted on and driven by a high specification tracked undercarriage fitted with transmittal gearboxes with integrated brake and overcentre valve The movement of the machine is controlled by a handheld radi...

Page 22: ...t has a speed of 0 16m min Driven by hydraulic gearbox the beltfeeder can handle the most difficult material with maximum efficiency Radio Remote Control The TF220s is operated using this remote control This allows the operator to perform all of the machines functions from where he has a full visual around the machine and work area ...

Page 23: ...M Hopper Capacity 8 cu mtrs Hydraulic Pressures BAR PSI Maximum Working Pressure on Tracks 245 3550 Maximum Working Pressure on rest of machine 172 2500 Pressure Rating on Hydraulic Hoses 3 8 330 4800 1 2 275 4000 3 4 215 312 TONNES Machine Weights Approximate 22 Tank Capacities Ltrs UK Diesel Tank Capacity 440 Hydraulic Tank Capacity 440 ...

Page 24: ...TF220s 23 2930 25 25667 10356 2930 1615 3910 27525 WORKING DIMENSIONS ...

Page 25: ...must i Have received specific and adequate training in the task to be carried out ii Have read and understood the safety instructions in Section 1 iii Knows the location and function of controls and safety features iii Be aware of all moving parts of the machine 8 Before operating the operator s must ensure that they are properly equipped with hard hat ear and eye defenders 9 Before operation all ...

Page 26: ...hine ma ybe used to lift objects up to the weight of 1000kg This can be done by slinging the object from the main conveyor as shown in FIG 1 The load must not exceed 1000 kg The machines main conveyor and beltfeeder must be in STOP mode when perfoming this operation FIG 1 ...

Page 27: ...TF220s 26 ...

Page 28: ...TF220s 27 BLANK PAGE ...

Page 29: ...TF220s 28 OPERATION ...

Page 30: ...TF220s 29 BLANK PAGE ...

Page 31: ...maged parts Replace and make necessary repairs Ensure all safety guards and Remote stops are fitted and in working order 2 Before operation ensure that personnel are clear from the machine 3 During operation do not climb onto over or under machine Always use ladders steps and walkways when mounting and dismounting 4 Follow safe operating practices Operate the machine controls smoothly Avoid sudden...

Page 32: ...rottle lever A to approximately halfway iii Turn the ignition key to the ON position B The following warning lights on the control panel will illuminate 1 A Red light C Oil Pressure 2 A Red light D Alternator Now turn the key to start position E the engine will crank and start after the warning beeper has sounded for approximately 7 seconds All the lights should extinguish after start up If any of...

Page 33: ...ill illuminate green 3 Start the main conveyor To do this press and hold button H for 10 seconds 4 Start beltfeeder To do this press and hold button H for 10 seconds Following the above sequence ensures no material will accumulate at transfer points and effect the running of the machine If the belts are not travelling straight or equally on the idler and drive drums the belts will need Tracking Se...

Page 34: ...conveyor Slewing Before slewing Hopper must be empty and jack legs raised to clear ground level Slewing can be done by pressing button K to slew left and button L to slew right Jack Legs Jack Legs can be raised and lowered by pressing button M to raise jack legs and button N to lower jack legs ENGINE STOP JACK LEGS JACK LEGS I J L M N K ...

Page 35: ... blue Press button Q to move both tracks forward simultaneously Press button R to move both tracks in reverse simultaneously Press button S to move left track forward Press button T to move left track reverse Press button U to move right track forward Press button V to move right track reverse Once the machine has been tracked into position press button W to disable the track function If Track Ena...

Page 36: ...n bolts on each bearing B using two 24mm spanners 4 Start Stockpiler 5 If the belt is travelling to the left incrementally turn bolt C clockwise with a 36mm spanner If the belt is travelling to the right incrementally turn bolt D clockwise with a 36mm spanner As you turn the spanner the belt will travel towards the centre of the drum achieving uniform belt alignment 6 Stop Stockpiler 7 Tighten Bol...

Page 37: ... into the TF220s ensure that the jack legs are lowered to the ground This stabilises the machine when in operation Before tracking and slewing the machine ensure that the hopper is empty then raise jack legs enough to clear the ground ...

Page 38: ...TF220s 37 BLANK PAGE ...

Page 39: ...TF220s 38 MAINTENANCE ...

Page 40: ...TF220s 39 BLANK PAGE ...

Page 41: ...air must be contained with hairnet Maintenance or Servicing must never be carried out whilst the machine is running Remove only guards or covers that provide access Wipe away excess grease and Securely support any machine part that must be raised for maintenance When working at heights above 2m always use an approved EN ANSI safety harness Always use walkways and platforms provided or a safe secur...

Page 42: ...d parts immediately 11 Ensure that all safety signs are clean and clearly visible Replace any damaged safety signs 12 After completion of maintenance work on the machine all safety devices and guards must be securely fitted again and be checked for functioning and reliability during operation 13 Operate all controls and make sure the machine is functioning properly before releasing for operation ...

Page 43: ...ler cap filters the displacement of air The filter is rated at 40 microns and is of non replacement type This must not be left off the machine at any time Return Line Filter The 2 x 25 micron filters which are fitted on the return line before the filter and remove any tiny particles which can cause damage to the pumps and motors etc The filter element should be changed in accordance with the routi...

Page 44: ...ch hydraulic oil back to the tank as possible Turn engine off Remove the drain plug Use a 27mmspanner at the base of the tank and drain to an external container large enough to hold all the oil Hydraulic Tank Capacity 450 litres Refill the tank until the oil is between the Min and max marks on the tank gauge Item c Run the machine and operate hydraulic equipment to circulate oil Stop the machine a...

Page 45: ... the new filters WATERTRAP Draining the Watertrap Loosen the draintap D on the base of the watertrap Allow the water to drain off Tighten the draintap when all the excess water has been drained off CHANGING WATER TRAP FILTER To change the watertrap filter element E follow the procedure outlined Stop the machine Remove the bleed Remove the filter water trap bowl Remove the water trap bowl from the ...

Page 46: ... cap H It is important the oil level is not above the maximum level If this happens some oil must be removed CHANGING ENGINE OIL Run the engine to ensure the oil is warm this enables the oil to flow more easily Stop the engine and open the fillercap Remove the drain plug located underneath the engine and drain the oil to an external container large enough to hold all the oil Approx 10 ltrs When al...

Page 47: ...mation regarding the Air Filter CHANGING THE AIR FILTER Turn off the engine Unfasten the Filter Cover J by unclipping the holding clamps K Carefully remove the Filter element Clean inside the filter and insert a new filter element Re attach the filter cover and reclip the holding clamps K J K ...

Page 48: ...ve the Fill plug B this will allow air into the gearbox to allow it to drain Remove the Drain plug C and drain the oil to an external container large enough to hold all the oil Gearbox oil capacity 0 8 litres Replace the Drain Plug C Now refill the gearbox until the oil fills the sight glass D Use Gearbox oil ISO VG 150 or SAE 80W 90 DO NOT OVERFILL THE GEARBOX Replace the Filler plug B Close the ...

Page 49: ...o the gearbox to allow it to drain Remove the Drain plug B and drain the oil to an external container large enough to hold all the oil Start the engine and move the tracks until the Gearbox is in the Fill Position with the Plugs A B as shown in the picture 2 Now refill the gearbox through the Filler plug A until the oil begins to flow from the level plug B DO NOT OVERFILL THE GEARBOX Approximate o...

Page 50: ...ter cover plate A Loosen the Grease fitting B on the end of the track tensioning cylinder by one half turn only Allow grease to leave the tension cylinder therefore reducing the track tension Retighten the Grease fitting B and replace the cover plate A To Increase Track Tension Remove the adjuster cover plate A Using the special grease gun adaptor C attach to a standard grease gun and place over t...

Page 51: ...ks Check Tighten Check hydraulic oil level Check Top up Check Diesel Oil Level Check Top up Change hydraulic oil Change Check hydraulic oil return filter Change Grease all Bearings Grease Beltfeeder Maintenance Check Conveyor Belts for Rips and Tears Check Replace Check Belt Tension Check Tension Check Belt Alignment Check Align Check all rollers running freely Check Free Check Tension on Belt Scr...

Page 52: ... h 100 0h Conveyor Maintenance Check Conveyor Belts for Rips and Tears Check Replace Check Belt Tension Check Tension Check Belt Alignment Check Align Check all rollers running freely Check free Check Tension on Belt Scrapers Check Tension Check Belt skirting rubbers No Spillage Check Adjust Re place Check for obstruction to Drums Check Remove ...

Page 53: ...nsion Check Tracks for oil leakage Check Repair Change gearbox oil in tracks Change Engine Maintenance Check Engine Oil level Check Top up Check water coolant level Check Top up Full engine service Service Air Filter Elements Air filter pre cleaner Clean Battery Acid Level Check Top up Change Engine Oil Change Change Oil Filter Fuel Filter Change Slew Ring Maintenance Grease Slew Ring Grease ...

Page 54: ...TF220s 53 BLANK PAGE ...

Page 55: ...TF220s 54 TROUBLESHOOTING ...

Page 56: ...TF220s 55 BLANK PAGE ...

Page 57: ...rtridge Motor not turning Ram not moving Check Hydraulic Pressure and Adjust Machine operating slowly No external oil leaks Possible Fault Remedy Low oil Level Top up Hydraulic System with correct fluid Incorrect hydraulic fluid Drain Tank and replace with correct fluid Leaking relief valve Repair or replace relief valve Worn control valve spool Replace control valve Worn hydraulic pump Replace pu...

Page 58: ...rack enable Material lodged in track drive system Isolate machine and clear obstruction Beltfeeder not working when conveyoris running Possible Fault Remedy Remote control system not working Fuse blown Batteries flat in hand held remote Broken wire in electrical circuit Replace fuse in starter box Replace batteries Repair or replace wire Key Missing Replace Key Faulty Control Valve Replace or adju...

Page 59: ...batteries Repair or replace wire Key Missing Replace Key Faulty Control Valve Replace or adjust Flow Control Valve incorrectly set Reset Flow Control Belt Loose Tighten Belt Excessive Noise when conveyor is running Possible Fault Remedy No Grease in bearing Grease Bearings Conveyor belt rubbing against fixed parts Adjust and Track Conveyor Belt Drive Drum Scraper to tight Reduce pressure on scrape...

Page 60: ... Obstructing End Drum Remove Obstruction Overloading Clear Material of belt and restart Belt Loose Tighten belt Conveyor runs back if stopped with load on belt Possible Fault Remedy Non Return Valve Worn Replace non return valve Non Return Valve Stuck in open position due to soiled hydraulic fluid Test oil change filters change oil if required Clean Replace Valve ...

Page 61: ...TF220s 60 APPENDIX ...

Page 62: ...TF220s 61 BLANK PAGE ...

Page 63: ...tractive design Simplified wiring and installation Superior engine protection and shut down Automatic pre heat and start up sequence Battery voltage monitor Tamper proof liquid crystal hour meter display and status indicator Starter motor protection feature Continual fault display after shut down ...

Page 64: ...c machine inputs e g e stop circuit machine track enable Automatic shutdown on critical fault alarm 6 panel indicators including oil water temperature pre heat generic fault e stop pressed alternator fault 50 amp automotive relays for the toughest of jobs Individual fused relay outputs with standard blade automotive fuses LED indicators on all relay outputs TRACK ENABLE OIL PRESS WATER TEMP ALT PR...

Page 65: ... 6 AIR FAULT Air filter fault LCD message 7 TEMP Over temperature sensor LCD message 8 AUX1 Spare input LCD message 9 AUX2 Spare input LCD message 10 AUX2 Low hydraulic oil LCD message Outputs Output No Name Description Indication Rating 1 FUEL SOL1 Fuel solenoid LED 50A 2 FUEL SOL2 Fuel solenoid LED 50A 3 PRE HEAT Pre heat relay LED 50A 4 START Starter solenoid relay LED 50A 5 OIL FAN Oil cooler ...

Page 66: ...e has started and the key is released the controller will wait for 5 seconds before reading from sensor inputs This allows the engine adequate time to build oil pressure before reading from the sensor On activation of an engine fault the controller will de activate the fuel solenoid relays These are wired in series for added protection in the event of a relay malfunction The display will hold on t...

Page 67: ...hen relay outputs are active If the fuse is blown the LED will not light Note It is recommended that an external isolator switch and fuse are fitted to supply power to the panel This would provide protection in the unlikely event of a relay malfunction or some other short circuit SPADE CONNETIONS ...

Page 68: ...TF220s 67 BLANK PAGE ...

Page 69: ...E Supply Voltage 1 X V Alkaline battery type 6AM6 6F22 PP3 Range Dependant on conditions Typical 80m Transmission Type 433 92MHz Momentary Latching operation Operating Temperature 20c to 60c Housing IP65 Sealed Switch Type Membrane Sealed ENGINE STOP JACK LEGS JACK LEGS ...

Page 70: ... CH 12 Track Dump Valve C O CH 13 CH 14 Beacon C O CH 15 Jack Legs Up C O CH 16 Jack Legs Down C O CH 17 Track Enable C O CH 18 CH 19 Engine Stop C O CH 20 Engine Stop C O Working Frequency 433 92 MHz Range Typical 80m Supply Voltage 12 24V DC Fuse T100mA Relay Type K4BC12 Relay Contacts rated at 12A 240V AC 30V DC Supply Current Standby 12 24V 40mA Supply Current Active 12 24V 100mA Max Code Sele...

Page 71: ... Forward Valve Right Forward Valve Left Reverse Valve Right Reverse Valve Fuel Pump Solenoid RL2 RL6 E Stops on RL3 RL4 RL5 Fuse ENGINE STOP RELAY DISABLES FOR 15 SECS 7 SECS DELAY BEFORE MOVEMENT RELAYS CAN BE OPERATED Done in software TRACK ENABLE SIREN AND BEACON Movement Sounder Beacon EXAMPLE WIRING ...

Page 72: ...TF220s 71 BLANK PAGE ...

Page 73: ...TF220s 72 SPARE PARTS ...

Page 74: ...TF220s 73 BLANK PAGE ...

Page 75: ...TF220s 74 ...

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