DERNASEER TF 220s Manual

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MACHINE TYPE / MODEL

SERIAL NO.

YEAR OF MANUFACTURE

OPERATION, MAINTENANCE & SPARE PARTS MANUAL

TF 220s

TF220 S

21020181-01

2012

Table of Contents

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Summary of Contents for DERNASEER TF 220s

Page 1 TF 220s MACHINE TYPE / MODEL TF220 S SERIAL NO. 21020181-01 YEAR OF MANUFACTURE 2012 OPERATION, MAINTENANCE & SPARE PARTS MANUAL...
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Page 3 The operating instructions must always be available wherever the machine is in use. DERNASEER ENGINEERING reserve the right to change specification without prior notice.
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Page 5: Table Of Contents
TF220s Contents SAFETY TECHNICAL INFORMATION OPERATION MAINTENANCE TROUBLESHOOTING APPENDIX SPARE PARTS...
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Page 7: Safety
TF220s SAFETY...
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Page 9 TF220s SAFETY SAFETY INTRODUCTION Operators should be trained in the correct and safe use of all equipment. Before operation the operator(s) must:- Have read and understood the Operators manual and Safety signs in this manual and around the machine. (ii) Be aware of all the moving parts of the machine.
Page 10 TF220s TF220s LOCK OUT EQUIPMENT BEFORE SERVICING. LOCK OUT EQUIPMENT BEFORE SERVICING. FALLING HAZARD FALLING HAZARD – DO NOT CLIMB ON TO WORKING MACHINERY. WORKING MACHINERY. BEWARE OF HYDRAULIC BEWARE OF HYDRAULIC OIL LEAKS. HIGH PRESSURE HYDRAULIC OIL CAN PENETRATE THE PRESSURE HYDRAULIC OIL CAN PENETRATE THE PRESSURE HYDRAULIC OIL CAN PENETRATE THE SKIN CAUSING SERIOUS INJURIES.
Page 11 TF220s TF220s EAR PROTECTION MUST BE WORN IN THIS AREA EAR PROTECTION MUST BE WORN IN THIS AREA EAR PROTECTION MUST BE WORN IN THIS AREA NIP POINT NIP POINT – KEEP HANDS CLEAR OF MOVING KEEP HANDS CLEAR OF MOVING MACHINERY...
Page 12 TF220s ELECTRICAL AND ENGINE SAFETY 1. Never work on the electrical system of any equipment unless you are thoroughly familiar with system details. 2. Work on the electrical system must only be carried out by a qualified electrician. 3. The electrical equipment of the machine should be inspected at regular intervals. Damaged cables or loose connections must be corrected immediately.
Page 13 TF220s HYDRAULIC SAFETY 1. Never disconnect any hydraulic circuit without consulting with Dernaseer Engineering or your local dealer. 2. Only personnel with expert training and experience in hydraulics are authorized to perform any maintenance or repair work. 3. Return controls to neutral position and relieve all pressure in the hydraulic system, before attempting to disconnect any hydraulic circuit or component.
Page 14 TF220s SAFETY BEFORE AND DURING OPERATION Only qualified and trained personnel should attempt to operate this machinery. 1. Read and understand the Operators Manual before you start the machine. Study the DANGER, WARNING, CAUTION and IMPORTANT safety signs on your machine.
Page 15 TF220s SAFETY BEFORE AND DURING MAINTENANCE Maintenance should only be carried out by trained and qualified personnel. 1. Whenever maintenance or service is being carried out a minimum of two (2) persons should be present at all times. NEVER WORK ALONE. 2.
Page 16 TF220s 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.
Page 17: Technical Information
TF220s TECHNICAL INFORMATION...
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Page 19 TF220s TECHNICAL INFORMATION GENERAL INFORMATION Familiarisation Front Right Side 1. Main Conveyor 2. Tracks 3. Beltfeeder/Hopper 4. Jacklegs 5. Fuel Tank Rear 6. Hydraulic Tank 7. Main Lifting Ram Engine Compartment Left Side...
Page 20 TF220s GENERAL INFORMATION Familiarisation Ignition Panel Diesel Fuel Visual Level Gauge Hand Throttle Hydraulic Oil Visual Level Gauge...
Page 21 TF220s KEY COMPONENTS Engine Compartment The machine is powered by a CAT 4.4 water cooled diesel engine output 75kW (100hp) coupled to hydraulic pumps. Fitted in a purpose built compartment it is situated at the rear of the machine and can is hinged from the main frame.
Page 22 TF220s Hopper & Beltfeeder The Loading Hopper capacity is 8 cu metres. The variable speed beltfeeder fitted with a1200mm (47”) wide belt has a speed of 0-16m/min. Driven by hydraulic gearbox the beltfeeder can handle the most difficult material with maximum efficiency.
Page 23 TF220s TECHNICAL DATA Conveyor Speeds METRES/MIN FEET/MIN Beltfeeder (Variable Speed) 0-16 0-53 Main Conveyor Engine Speed 2200 RPM Hopper Capacity 8 cu mtrs Hydraulic Pressures Maximum Working Pressure on Tracks 3550 Maximum Working Pressure on rest of machine 2500 Pressure Rating on Hydraulic Hoses 3/8”...
Page 24 TF220s WORKING DIMENSIONS 3910 1615 27525 2930 10356 25° 25667 2930...
Page 25 TF220s CORRECT USE OF MACHINE 1. This machine should be used, for the loading, conveying, and stockpiling of Aggregate type materials. e.g. Sand, gravel, Coal, Coke..etc. This does not include hot materials, which will damage your machine. 2. Machine should be run in well ventilated areas. 3.
Page 26 TF220s Other Permitted Use Lifting On occasions, the machine 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.
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Page 29: Operation
TF220s OPERATION...
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Page 31 TF220s OPERATION The TF220s Tracked Feeder may only be operated and maintained by authorised and trained personnel who have fully read and understood this operators manual. Attention should be paid to the following points prior to operation. 1. Check your machine and have all systems in good operational condition. - Check for broken, missing or damaged parts.
Page 32 TF220s OPERATING MACHINE Start Up Before feeding material into the TF220s , the entire machine must be running. Starting Engine The Engine must be started to provide hydraulic power to all functions. Before Starting: (i) Check the Engine oil level and the Fuel level and top up if necessary.
Page 33 TF220s OPERATING MACHINE Before loading material into the Hopper, • The entire machine must be running. • Jack legs must be lowered to stabilize machine. Before starting the engine ensure that all Conveyor belts are sufficiently tensioned The sequence to start the machine is, 1.
Page 34 TF220s Raise and Lower Conveyor Raise and lower of conveyor can be done by pressing button (I) to raise conveyor and button (J) to lower 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.
Page 35 TF220s Tracking Machine. Before Tracking, Hopper must be empty and jack legs raised to clear ground level. In order to track the TF220s, Press and hold the “track enable” button (O) for 10 seconds. The “track enabled light” (P) will illuminate blue. Press button (Q) to move both tracks forward simultaneously.
Page 36 TF220s Tracking Conveyor Belts After initial start up, the belts on the conveyor and feeder can sometimes travel to the left or right. This can be overcome by following the procedure below. 1. Stop Conveyor 2. Remove guards 3. Slightly loosen bolts on each bearing (B) using two 24mm spanners.
Page 37 TF220s Before loading material 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.
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Page 39: Maintenance
TF220s MAINTENANCE...
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Page 41 TF220s TF220s MAINTENANCE The TF220S may only be operated and maintained by authorised and may only be operated and maintained by authorised and may only be operated and maintained by authorised and trained personnel who have fully read and understood this operators manual. trained personnel who have fully read and understood this operators manual.
Page 42 TF220s 9. Wear safety goggles for eye protection. If fluid enters skin or eye, get immediate medical attention. 10. Keep all parts in good condition and properly installed. Replace any worn or damaged parts immediately 11. Ensure that all safety signs are clean and clearly visible. Replace any damaged safety signs.
Page 43 TF220s MAINTENANCE – HYDRAULICS In order to maintain the hydraulic oil at its peak performance, two different types of filter namely: • Air breather (A) • Return line filters (B) Air breather: This combined unit, which also acts as a filler cap, filters the displacement of The filter is rated at 40 microns, and is of non-replacement type.
Page 44 TF220s MAINTENANCE – HYDRAULICS Changing Hydraulic Oil It is recommended that the machines hydraulic oil is warm.This will enable the oil to flow more easily. Return all Hydraulic Cylinders to their closed position to return as much hydraulic oil back to the tank as possible.
Page 45 TF220s MAINTENANCE – DIESEL ENGINE The CAT 4.4 diesel engine should be maintained in accordance with the manufacturers instructions as detailed in the “Operators Handbook”, a copy of which is included with this manual CHANGING FUEL FILTER • Unscrew the fuel filters (C) and carefully dispose off.
Page 46 TF220s MAINTENANCE – DIESEL ENGINE CHANGING ENGINE FILTERS & OIL (See the engine Operators Manual for more detailed information regarding the Engine) CHECKING ENGINE OIL • Turn off the engine. Open the Engine Inspection Doors (F). • Remove dipstick (G) from the engine and clean.
Page 47 TF220s MAINTENANCE – DIESEL ENGINE (See the engine Operators Manual for more detailed information 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.
Page 48 TF220s CHANGING BELTFEEDER GEARBOX OIL (See Maintenance Schedule for frequency) • Turn off the engine • Open the beltfeeder gearbox cover guard (A) on the left hand side of the machine to view the beltfeeder gearbox. To drain the gearbox. •...
Page 49 TF220s CHANGING GEARBOX OIL IN TRACKS picture (1) (See Maintenance Schedule for frequency) More effective draining will take place if the oil is hot • Turn off the engine. • To drain the gearbox. Clean the area around the gearbox plugs. Position the Plugs (A&B) as shown in the picture (1) ensuring the plug ( B) is at the...
Page 50 TF220s picture (1) TRACK ADJUSTMENT As the track wears, they become slack,and should be checked daily. To establish if the tracks require adjustment move the machine, a few metres, backwards and forwards on level ground, in a straight line. This enables the track to adopt its natural degree of tension.
Page 51 TF220s TF220 MAINTENANCE AND SERVICING SCHEDULE MAINTENANCE ACTION TASK First Start Interval General Maintenance Check and remove Check/Remove material build up Ensure all safety Check/Replace guards are in place Check for loose parts,missing Tighten/Replace nuts&bolts Check hydraulic Check/Tighten system for leaks Check hydraulic oil Check/Top up level...
Page 52 TF220s TF220 MAINTENANCE AND SERVICING SCHEDULE MAINTENANCE ACTION TASK First Start Interval Conveyor Maintenance Check Conveyor Belts for Rips and Check/Replace Tears Check Belt Tension Check/Tension Check Belt Check/Align Alignment Check all rollers Check/free running freely Check Tension on Check/Tension Belt Scrapers Check Belt skirting Check/Adjust/Re...
Page 53 TF220s TF220 MAINTENANCE AND SERVICING SCHEDULE ACTION MAINTENANCE TASK First Start Interval 10h 50h 100h 200h 10h 50h 100h 200h 500h 1000h Track Maintenance Check Tension of Check/Tension Tracks Check Tracks for oil Check/Repair leakage Change gearbox oil in Change tracks Engine Maintenance Check Engine Oil level...
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Page 55: Troubleshooting
TF220s TROUBLESHOOTING...
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Page 57 TF220s TROUBLESHOOTING No Response from any Hydraulic System Possible Fault Remedy Low oil Level Top up Hydraulic System with correct fluid Hydraulic pump shaft broken Replace Pump Coupling damaged or broken Replace Coupling Pressure relief valve stuck open position Repair or replace valve cartridge Motor not turning/Ram not moving Check Hydraulic Pressure and Adjust Machine operating slowly.
Page 58 TF220s Tracks will not operate Possible Fault Remedy Remote control system not working – Fuse blown Replace fuse in starter box Batteries flat in hand held remote Replace batteries Broken wire in electrical circuit Repair or replace wire “Track enable” not switched on Switch on track enable Material lodged in track drive system Isolate machine and clear obstruction...
Page 59 TF220s Beltfeeder not working when conveyoris running Possible Fault Remedy Remote control system not working – Fuse blown Replace fuse in starter box Batteries flat in hand held remote Replace batteries Broken wire in electrical circuit Repair or replace wire Key Missing Replace Key Faulty Control Valve...
Page 60 TF220s Conveyor Belt not running Possible Fault Remedy Belt Drive Coupling broken or loose Replace or tighten Bearing Collapsed or seized Replace Bearing Debris 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...
Page 61: Appendix
TF220s APPENDIX...
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Page 63 TF220s APPENDIX ENGINE PANEL • Low cost alternative to hard wired traditional panels. • Compact, attractive 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.
Page 64 TF220s ENGINE PANEL The control panel is an electronic control panel for engine and machine control. This panel has many advanced functions that make it a sensible choice for engine control. FEATURES TRACK • 5 engine sensor inputs. ENABLE • 3 additional specific machine inputs e.g.
Page 65 TF220s ENGINE PANEL SPECIFICATIONS Inputs Input No Name Description Indication OIL FAULT Low oil pressure sensor LED + LCD message WATER TEMP Water temperature sensor LED + LCD message Alternator fault LED + LCD message TRACK EN Track machine enabled LED + LCD message FUEL LOW Fuel level low sensor fault...
Page 66 TF220s ENGINE PANEL CONTROL PHILOSOPHY Start sequence The unit is only powered on by switching the key switch to ON position. The following time sequence is activated automatically on pressing AND HOLDING the key to the start position: Diagnostic functions When the engine has started and the key is released, the controller will wait for 5 seconds before reading from sensor inputs.
Page 67 TF220s ENGINE PANEL RELAY BOARD & CONNECTIONS SPADE CONNETIONS Note: LED indicators are lit when 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.
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Page 69 TF220s REMOTE CONTROL SYSTEM TRANSMITTER TECHNICAL DATA METAL RANGE 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 JACK ENGINE...
Page 70 TF220s ULTRABEAM RADIO RECEIVER TECHNICAL DATA 433.92 MHz Working Frequency 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- <40mA 24V) Supply Current Active (12-24V) 100mA (Max) Code Selection...
Page 71 TF220s EXAMPLE WIRING Fuse E-Stops on ENGINE STOP RELAY DISABLES FOR 15 SECS Fuel Pump Solenoid TRACK ENABLE / SIREN AND BEACON Movement Sounder & Beacon 7 SECS DELAY BEFORE MOVEMENT RELAYS CAN BE OPERATED (Done in software) Right Reverse Valve Left Reverse Valve...
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Page 73: Spare Parts
TF220s SPARE PARTS...
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