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Dando TERRIER Mk 1 Operating And Maintenance Manual

Percussive geotechnical drilling rig
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OPERATING AND MAINTENANCE MANUAL
DANDO TERRIER Mk 1
C/W PERCUSSIVE & 2.2m ROTARY MAST
DANDO DRILLING INTERNATIONAL LTD.
UNIT G, FORD AIRFIELD INDUSTRIAL ESTATE,
FORD, Nr ARUNDEL, WEST SUSSEX,
BN18 0HY, ENGLAND
E-MAIL: info@dando.co.uk
WEB SITE: http://www.dando.co.uk
TEL: +44(0)1903 731312 FAX: +44(0)1903 730305

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  • Page 1 OPERATING AND MAINTENANCE MANUAL DANDO TERRIER Mk 1 C/W PERCUSSIVE & 2.2m ROTARY MAST DANDO DRILLING INTERNATIONAL LTD. UNIT G, FORD AIRFIELD INDUSTRIAL ESTATE, FORD, Nr ARUNDEL, WEST SUSSEX, BN18 0HY, ENGLAND E-MAIL: info@dando.co.uk WEB SITE: http://www.dando.co.uk TEL: +44(0)1903 731312 FAX: +44(0)1903 730305...
  • Page 3 SECTION 1 GENERAL...
  • Page 5 Dando Drilling International draw your attention to the Code of Safe Drilling Practice as published by the British Drilling Association, and would recommend that all operators are fully conversant with all aspects covered by this publication and take the necessary steps to become B.D.A.
  • Page 6 SAFETY PRECAUTIONS WARNING. BREATHING DUST IS DANGEROUS TO HEALTH 1) Operate in a well-ventilated place and use appropriate extraction equipment or a damp cloth to remove dust. 2) Dampen all dust. 3) Dispose of waste in heavy gauge plastic sacks in accordance with legislative requirements.
  • Page 7 GUIDANCE NOTES ON SAFETY 1.5.1 PERSONNEL a. Drilling may entail the employment of men inexperienced in this class of work. Care should therefore be taken to explain and enforce safety precautions, and to teach good practice in the handling and use of equipment and plant.
  • Page 8 b. Before travelling, checks should be made to all vehicles for road worthiness, giving special attention to lights, indicators, screen wipers, registration plates, brakes, brake lights, steering, security of loads, particularly overhanging loads, tyre pressure and wear and lack of mud before proceeding onto a public highway.
  • Page 9 o. When loading or un-loading on a public highway, assistants should be used to hold back traffic. These men should be responsible to the vehicle driver only. p. Where the access to and from the site does not have good visibility in all directions, traffic leaving the site should be controlled by a person nominated for that purpose.
  • Page 10 Where working platforms are required to support men, equipment and/or materials, the platform should be properly constructed. It should be of adequate dimensions, and if over 2 metres above ground, should have guard rails and tow boards so placed as to prevent falls of persons or articles from the platform.
  • Page 11 High noise level areas should be identified and hearing protection worn where necessary. g. Where engine noise or other sounds prohibit verbal communication, a clear set of signals which are clearly understood and known by each team member should be used. This will also apply when ear defenders are worn. h.
  • Page 12 o. The jaws of pipe wrenches should be kept in good order and replaced when necessary. p. Pipe or other material should never be used to extend the handle of any type of wrench or tong to obtain greater leverage. q.
  • Page 13 ee. The hoist should not be used to lift with less than three full wraps on the drum. ff. When moving drill rods and casing, gloves should be worn and the working platform clear of grease, mud or ice. gg. Drill rods or corebarrels should never be left balanced across or leaning onto the rig.
  • Page 14 Both the compressor and drilling rig should be equipped with air pressure gauges. Before commencing operations, a check should be made that these are operative, the readings should be noted, and the main air valve checked that it is in proper working order and can be used easily and quickly. This valve should be of the plug cock type.
  • Page 15 1.5.8 PLANT MAINTENANCE a. Plant, machinery and structures should be inspected at regular intervals in accordance with the manufacturer’s recommendations. In the case of plant which is subject to corrosion, steps should be taken to effect repairs before corrosion reaches dangerous limits. b.
  • Page 16 m. When high pressure grease guns are used, protective gloves should always be worn and care taken to avoid injecting grease under the skin. n. Hoses used for steam cleaning should be of the type made for steam service. The metal nozzle should always be securely clamped to the hose and maintained in serviceable condition.
  • Page 17 b. Such training should include not only basic safety precautions, but also a thorough understanding of the correct use of all plant, equipment and tools. In addition, knowledge should be given of the forces of both energy and mass which the crew control through the medium of the drill rig. d.
  • Page 18 d. Washing and kitchen waste water should be discharged into a pit or sump dug into the ground remote from ditches and water courses. e. Empty tin cans, bottles, plastic containers, drums and scrap metal, wire rope etc., should be placed in containers for transport to recognised waste disposal sites.
  • Page 19 o. Rig personnel should wear only close-fitting clothing, preferably distinctly coloured overalls. Clothing should be kept clean by frequent washing, and each crew member should have a clean change of work clothes on location at all times. Particular care should be taken to ensure that drawstrings to hoods or other items of clothing are not left dangling so as to become entangled in any moving parts.
  • Page 20 1.5.12 WIRE ROPES - GENERAL SAFETY AND MAINTENANCE a. Regular inspection of ropes in service is essential if high standards of safety are to be ensured, and the relevant test certificate must be obtained and available. b. All running ropes in continuous service should be visually inspected once every working day by an authorised person.
  • Page 21 Rope delivered in reel form should have the reel jacked up to turn freely, so that the rope can be carried straight away from the reel. Provision should be made to stop reel rotation by using a braking device, however simple. g.
  • Page 22 v. When wire rope clips are used, the base of the clip must bear on the “live” end of the rope - the “live” end being the free-running portion of the rope. The “U” section of the clip bears on the dead end of termination fold of the rope. Failure to follow this procedure could cause the “U”...
  • Page 23 1.6 GUIDANCE NOTES ON SAFETY – TERRIER RIGS This manual contains information necessary for working the machine. You are advised to contact the construction company for any necessary spare parts or accessories, or for any other information. When the machine is in use, do not make any abrupt movements, and ensure that there are no unauthorised people in the area of the machine.
  • Page 24 FIGURE 1.1 - SAFETY WEDGE LOCATION...
  • Page 25 RECOMMENDATIONS WHEN OPERATING RIG, WEAR ADEQUATE SAFETY CLOTHING. DO NOT CRANK THE ENGINE FOR MORE THAN 30 SECONDS. ALLOW THE ELECTRIC STARTING MOTOR TO COOL FOR TWO MINUTES BEFORE CRANKING THE ENGINE AGAIN. ALWAYS CLOSE JACK ISOLATING VALVES BEFORE STARTING ALWAYS CHECK ALL CONTROLS ARE IN NEUTRAL WHEN STARTING UP.
  • Page 26 WARNINGS DO NOT ATTEMPT TO OPERATE THE RIG ALONE. ROTARY DRILLING RIGS REQUIRE AT LEAST A TWO MAN CREW FOR SAFE OPERATION. BREATHING DUST IS DANGEROUS TO HEALTH. OPERATE IN A WELL VENTILATED PLACE APPROPRIATE EXTRACTION EQUIPMENT OR A DAMP CLOTH TO REMOVE DUST.
  • Page 27 BEFORE STARTING/SHUTTING DOWN THE ENGINE (EXCEPT IN AN EMERGENCY), ENSURE THAT ALL CONTROLS ARE IN THE NEUTRAL/OFF/MINIMUM POSITION. ENSURE ENDS OF HYDRAULIC HOSES ARE PLUGGED WHEN REMOVED FROM MOTOR. DO NOT ATTEMPT TO MOVE RIG WITH MAST IN RIGGED UP POSITION.
  • Page 29 SECTION 2 TECHNICAL DATA...
  • Page 31 SECTION 2 – TECHNICAL DATA It is imperative that the rig serial number is quoted in any correspondence or spares requisition. RIG SERIAL NUMBER Stamped on a plate which is riveted to rear cross member or chassis near side member, dependant on rig type. GENERAL DATA 2.2.1 RIG DIMENSIONS...
  • Page 32 2.2.5 HYDRAULIC SYSTEM Flow for PTO 19l/min Max. Pressure for Travelling 190Bar 2.2.6 STABILISING OR LEVELLING JACKS Two front legs attached to base of mast. 2.2.7 DRIVE HAMMER Hammer Weight 63.5kg or reduced to 50kg 0 – 50 blows per min. Speed 500 –...
  • Page 33 SECTION 3 OPERATING INSTRUCTIONS...
  • Page 35 SECTION 3 – OPERATING INSTRUCTIONS INTRODUCTORY NOTES The Dando Terrier Mk 1 Drilling Rig is a crawler mounted mobile drilling rig designed for operating in areas of tight space, inclined slopes and difficult access, incorporating a range of proprietary items. Operating and Maintenance procedures for the carrier and these items are supplied with the rig and should be studied before using and setting the rig to work.
  • Page 36 CONTROLS INTRODUCTION The notation of items on the Control Panel has been arranged in a sequence which could reflect the order in which they could be used in a specific drilling application 3.4.1 CONTROL PANEL (SEE FIG. 3.1) FIGURE 3.1 – CONTROLS 3.4.2 VALVE CONTROLS (SEE FIG.
  • Page 37 FIGURE 3.2 – VALVE CONTROLS...
  • Page 38 MOVEMENT CONTROLS How to work the various controls is explained in the following instructions: GEARS: The machine's gears are controlled by levers "1" and "2". We will now look in detail at how to steer the machine forwards and backwards. FORWARD Move both levers REVERSE Move both levers forwards at the same time Equally...
  • Page 39 FAMILIARISATION WITH RIG OPERATION Having completed the initial check over it is recommended that a short period be spent in becoming thoroughly familiar with the actual handling of the controls and running of the rig. At this stage, no drilling equipment would be used and activities would include such events as starting/stopping engine, positioning the levelling jacks, raising and lowering the mast, controlling the movement of the rotary head, controlling the winch etc.
  • Page 40 Withdraw the sample tube from the ground by raising the carriage to the top of its travel. Disconnect the sample tube from the machine by undoing the sample tube connector. The borehole can be advanced by adding 1.00m long drill rods / casing. DYNAMIC PROBING To carry out Dynamic Probing it is necessary to change the weight and drop height.
  • Page 41 Turn Hydraulic PTO Valve to ‘Off’ position (Control 7, Figure 3.1) and disconnect PTO quick connect hoses. Connect remote hydraulic hoses to PTO and to remote control valve – turn PTO back to ‘On’ position. Connect the four main hydraulic hoses from mast assembly to the remote control valve.
  • Page 42 3.14.2 OPERATING INSTRUCTIONS Before attempting to track the machine please ensure that Mast Parking Support (Item 10 Drg PST2250/F/2/01) is in position and all locking pins are in place. Ensure Hydraulic Flow Control Valve is fully open (Item 26 Drg TAV.11- 96614710) and PTO Valve in ‘On’...
  • Page 43 When adding or removing drilling tools from the borehole be sure they are supported at all times by the appropriate holding forks to prevent drilling tools falling down the borehole.
  • Page 45 SECTION 4 GUIDANCE FOR DRILLING APPLICATIONS...
  • Page 47 SECTION 4 – GUIDANCE FOR DRILLING APPLICATIONS DRILL ROD HANDLING To enable rotary drilling work to be carried out efficiently it is essential that all practical steps should be taken to enable the drill rods to be handled as easily and quickly as possible. It is recommended that particular attention should be paid to the following points: The drill rod joints usually have wrench flats cut in to them.
  • Page 48 The load on the hammer is the actual weight of the rotary head and drill rods plus the additional hydraulic pressure which is being applied. For drilling at shallow depths, the requisite load is obtained by applying the necessary hydraulic pressure, which is set by adjusting the Variable Feed Control - No.28.
  • Page 49 When drilling with large diameter bits it may well be necessary to increase bit loading, by the addition of drill collars. When carrying out rotary drilling, it is advisable to turn the top rod through a guide held on the support table fitted at the bottom of the mast. The guide table can be fitted with different sizes of replaceable wearing brushes to suit the diameter of the drill rods being used.
  • Page 50 SERVICE LINE CONNECTIONS Before carrying out any drilling activities you must ensure that the service line ball valve is set so that flow is directed through the valve and into the service line to the drill head and not to bypass. 4.7.1 WATER FLUSH DRILLING Disconnect the water pump discharge hose from the stowage bracket by...
  • Page 51 Connect the foam injection hose to the water pump using the quick connect coupling and thread the other end into the fitting on injection pipe adaptor, ensuring the hose connection is tight. 4.7.3 NOTES Ensure the water pump discharge hose and the air supply hose are not crossed or intertwined.
  • Page 53 SECTION 5 RIG MAINTENANCE AND SERVICE...
  • Page 55 SECTION 5 – RIG MAINTENANCE AND SERVICE It is important that the carrying vehicle, deck engine, compressor and other proprietary items, such as mud and foam pumps are maintained per the supplier’s instructions provided. Operating instructions for such equipment should be carefully studied before attempting to use the units.
  • Page 56 To check the level, follow the instructions on the battery casing. Use only distilled water to top up. Never use acids. The electrolyte could boil over and cause serious burns. Always make certain that the filling cap is perfectly closed. Never drain the battery completely.
  • Page 57 FIGURE 5.2 - FUSE ALLOCATION TABLE 5.1 - FUSE REFERENCES HYDRAULIC OIL HEADER TANK Plug filled with hydraulic oil, complete change is 20.7LT. For the type of oil see the appropriate lubrication table. Change the oil after the first 200 hours, and afterwards every 1000 hours or once a year.
  • Page 58 TRANSVERSE CONTROL LEVER STROKE ADJUSTMENT FIGURE 5.3 – TRANSVERSE CONTROL LEVER A – FORWARD MOVEMENT STROKE SET SCREW B – REVERSE MOVEMENT STROKE SET SCREW If necessary, machine speed can be adjusted, either forward or reverse, by means of the set screws “A” or “B”; shorter lever stroke corresponds to lower speed.
  • Page 59 Set the machine on a flat surface with compact ground, preferably on an asphalt or stone pavement. Lift the machine and set it on blocks or supports rated for the weight of the machine so that the tracks are approximately 100mm off the ground. Measure the track midline vs.
  • Page 60 CONTROL, FILLING AND OIL REPLACEMENT IN WHEEL REDUCTION GEARS Periodically check for leaks and that, with the machine parked and the gears positioned as illustrated below, the oil reaches the required level: if necessary, top up. FIGURE 5.5 – WHEEL REDUCTION GEARS PLUG POSITION WARNING: When more than 10% of the total quantity needs to be topped up, it may be an indication of a gear leak.
  • Page 61 The oil level control, top-up, filling or emptying must be done with the machine in a level and horizontal position and the engine must be off. Place a container of adequate capacity under the drain plug to collect the oil. DO NOT DISPOSE OF THE USED OIL IN THE ENVIRONMENT.
  • Page 62 HYDROSTATIC TRANSMISSION SYSTEM FIGURE 5.7 – HYDROSTATIC TRANSMISSION SYSTEM WARNING!! Do not insert hands, parts of the body or tools in the fan located on the radiator as it starts automatically. IMPORTANT!! For proper use of the machine it is recommended to bring the hydraulic oil to working temperature by leaving the diesel motor to idle and slightly accelerated for about 5 –...
  • Page 63 5.9.1 HOW TO CHECK AND RESTORE THE PRESSURE IN THE HYDRAULIC TRANSLATION SYSTEM FIGURE 5.8 - DISTRIBUTOR LEFT TRACK To check correct pressure, once the manometer has been positioned in measuring point “P2”, lock the left track by setting a fixed point between the drive wheel and the machine frame.
  • Page 64 5.9.2 HOW TO CHECK AND RESTORE THE PRESSURE IN THE SERVICE SYSTEM (MAST) To check correct pressure, once the manometer has been positioned in measuring point “P3”, bring the mast that uses the machine lift cylinder to the end of its stroke. Rev up the engine to the set number of revolutions (3600 rpm) and read the pressure indicated on the manometer.
  • Page 65 For the use of power take off, please observe the following indications: • Set the throttle lever to the minimum setting • Connect the equipment to be used (breaker, wiper etc) to the power take off rapid couplers • Increase the rpm of the diesel engine moving the throttle accelerator level until the flow rate corresponding to the correct operation of the connected-up equipment is achieved.
  • Page 66 Also grease all those parts that are exposed to the weather and that require protection to prevent oxidation. 5.11 ENGINE MAINTENANCE After each cold start, keep the engine running idle for some minutes. Avoid keeping the engine at the max. Power for an extended period.
  • Page 67 5.12 TERRIER TRACKS OPERATION TO COMPONENT HOURS FOR FIRST BE PERFORMED INVOLVED REPLACEMENT REPLACEMENT OIL FILTER CARTRIDGE HYDRAULIC OIL OIL FOR TRANSMISSION PARTS OPERATION TO COMPONENT DEADLINE FOR SUBSEQUENT BE PERFORMED INVOLVED REPLACEMENT IN HOURS 500 1000 2000 CLEANING TRACK PUMP BODY PROTECTION SPACE...
  • Page 68 5.13 DANDO TERRIER SERVICE MANUAL SPEC SHEET NUMBER DESCRIPTION SERVICE INSTRUCTIONS ST09610X248 Terrier Track Oil Filter Replace Initially at st 50 Hours, then every 500 Hours thereafter PART NUMBER DESCRIPTION SERVICE INSTRUCTIONS ST09611X248 Terrier Track Suction Oil Replace Initially at 1st...
  • Page 69 5.14 TROUBLESHOOTING PROBLEMS: RESEARCH AND SOLUTIONS PROBLEM CAUSE SOLUTION Machine tends to move even - Displacement of the - Follow the instructions on paragraph “Adjustment & when control levers are in position of regulating plate (vibration – loosening of the zero (neutral) position zero settings of the pumps”...
  • Page 71 SECTION 6 SPARE PARTS ILLUSTRATIONS AND LISTINGS...
  • Page 72 -23-...
  • Page 73 TERRIER 2002 SAMPLING RIG ASSEMBLY OF TERRIER 2002 SAMPLING RIG PART NUMBER: PST/2000F200 ITEM PART DESCRIPTION NUMBER PST/2010/F200 Mast General Assembly PST/2114/H000 Wheel Hub Axle PST/2140/F100 Guard Installation PST/2150/F100 Base Fabrication Assembly PST/2153/H000 Staunchion PST/2154/H200 Locking Pin PST/2159/H000 Locking Pin PST/2160/F200 Pivot Frame Assembly PST/2168/H000...
  • Page 74 -25-...
  • Page 75 TERRIER 2002 SAMPLING RIG MAST GENERAL ASSEMBLY PART NUMBER – PST2010F200 ITEM PART DESCRIPTION NUMBER PST/2011/H100 Light Anvil PST/2012/F100 Heavy Anvil PST/2014/H100 Guide Rod PST/2015/H000 Guide Locking Plate PST/2016/H000 Bottom Anvil Stop PST/2017/H000 Drive Block PST/2018/H000 Drive Block Guide PST/2019/H100 Drive Block Cushion PST/2020/H000 Drive Button...
  • Page 76 -27-...
  • Page 77 TERRIER 2002 SAMPLING RIG MAST GENERAL ASSEMBLY PART NUMBER – PST2010F200 ITEM PART DESCRIPTION NUMBER Hex Head Set Screw Hex Head Bolt Socket Countersunk Screw Studding Hex Head Set Screw ST02166X133 Hex Head Bolt ST07891X133 Hex Head Bolt ST03357X127 Ball Bearing ST09882X161 Roller Chain Motor...
  • Page 78 -29-...
  • Page 79 TERRIER 2002 SAMPLING RIG HYDRAULIC PIPEWORK ASSEMBLY PART NUMBER – PST2220F000 ITEM PART DESCRIPTION NUMBER Bonded Seal Bonded Seal M-M Adaptor Air Hose Adaptor M-M Adaptor F-F Swivel Nut Adaptor Bulkhead Fitting Bulkhead Fitting Ball Valve c/w Handle Male Self Sealing Coupling Female Self Sealing Coupling Straight Swivel Nut Hose Fitting Straight Swivel Nut Hose Fitting...
  • Page 80 -31-...
  • Page 81 TERRIER 2002 SAMPLING RIG GUARD INSTALLATION PART NUMBER – PST2140F100 ITEM PART DESCRIPTION NUMBER PST/2026/F100 Guard R.H. PST/2027/F200 Guard Upper L.H. PST/2028/F100 Guard (Sprocket) Lower L.H. PST/2037/H000 Lift Chain Wear Strip PST/2044/F000 Front Mast Guard 5300/001 Rubber Bonnet Fastner Ordinary Nut Spring Washer -32-...
  • Page 82 -33-...
  • Page 83 TERRIER 2002 SAMPLING RIG CORING HEAD ASSEMBLY PART NUMBER – PST2005F100 ITEM PART DESCRIPTION NUMBER PST/2080/H000 Modified Swivel Body PST/2081/H000 Body Guide PST/2082/H100 Connector Cradle PST/2083/H000 Connector Hyd. Motor Soc. Hd Cap Screw Plain Washer Soc Hd. Cap Screw Spring Washer -34-...
  • Page 84 -35-...
  • Page 85 TERRIER 2002 SAMPLING RIG DURBAR SKID PLATE INSTALLATION PART NUMBER – PST2173F000 ITEM PART DESCRIPTION NUMBER PST/2174/H000 Base Plate (Centre) PST/2175/H000 Base Plate (L.H.) PST/2176/H000 Base Plate (R.H.) PST/2177/H000 Base Plate(L.H.) PST/2178/H000 Base Plate (R.H.) PST/2179/H000 Vice Plate PST/2180/H000 Rear Plate PST/2195/H000 Rear Plate (Centre) Soc Head C’Sunk Screw...
  • Page 86 -37-...
  • Page 87 TERRIER 2002 SAMPLING RIG PIVOT RAM ASSEMBLY PART NUMBER – PST2169H000 ITEM PART DESCRIPTION NUMBER RPD07 Barrel RPC005 Piston Rod RP154 Piston RP134 Head Bush RP115 End Plug RP263 Bush RP093 Inlet Port GHK118149 Rod Wiper Seal TSE157118/G Gland TPM216153 Piston Seal ‘O’...
  • Page 88 -39-...
  • Page 89 TERRIER 2002 SAMPLING RIG EXTRACTION RAM ASSEMBLY PART NUMBER – PST2033F100 ITEM PART DESCRIPTION NUMBER RPD10 Barrel RP635 Piston Rod RP157B Piston RP137B Head Bush RP118 End Plug Special Rear Flange RP094 Inlet Port GHK157188 Rod Wiper Seal TSE196157 Gland TPM275196 Piston Seal ‘O’...
  • Page 91 SPARE PARTS ILLUSTRATIONS AND LISTINGS FOR UNDER-CARRIAGE & ENGINE...
  • Page 183 SPARE PARTS ILLUSTRATIONS AND LISTINGS FOR 7:1 HYDRAULIC ROTARY ATTACHMENT (OPTIONAL EXTRA)
  • Page 185 7:1 ROTARY ATTACHMENT, FULL GUARD – (TERRIER OPTIONAL EXTRA) PST2250F201 ITEM PART NUMBER Description PST2065H000 Pin - Mast Foot Plate PST2114H000 Wheel Stub Axle PST2254H101 Housing PST2255M001 Housing Cap PST2258M001 Mast Foot Plate Opening Half Fabrication PST2260F001 Inner Mast Fabrication - Ra PST2261F001 Outer Mast Fabrication –...
  • Page 187 ST09812X549 "O" Ring ST09766X692 Cylinder ST02067X715 Hex Head Set Screw ST03608X722 Lip Seal ST02630X743 Socket Head Cap Screw ST09793X743 Socket Head Cap Screw ST00110X749 Split Cotter Pin ST00660X750 Split Pin ST09873X782 Screw - Hex Soc Shoulder ST00656X881 Ordinary Washer ST04301X850 Ball Valve (Fem/Fem) ST01322X883 Plain Bright Washer...
  • Page 188 - 97 -...
  • Page 189 DANDO TERRIER 2002 ROTARY HYDRAULIC ATTACHMENT 7 : 1 REDUCTION GEARBOX - PART NUMBER: ST09763X476 EX-1023 ITEM PART NUMBER DESCRIPTION Oil Seal Support Screw O-Ring Output Shaft Oil Seal Bearing Output Support Air Escape Plug Oil Level Plug Magnetic Plug...
  • Page 190 - 99 -...
  • Page 191 DANDO TERRIER 2002 HYDRAULIC ROTARY ATTACHMENT 2 SPEED CHANGE UNIT - EX-051 ITEM PART NUMBER DESCRIPTION Flange Screw Pinion Coupling Bearing Bearing Input Shaft Spring Ball Fork Spring Pin Sliding Block Housing Magnetic Plug Oil Level Plug Air Escape Plug...
  • Page 193 APPENDIX A KUBOTA DIESEL ENGINE...
  • Page 233 APPENDIX B MESSERSI MINI TRANSPORTER...
  • Page 235 USE – MAINTENANCE 03672872 MINITRANSPORTER TCH/K722 N° ______________...

  • Page 237: Table Of Contents

    CONTENTS 1. GENERAL ACCIDENT PREVENTION 2. . MAIN CHARACTERISTICS 2.1. MACHINE ID 2.2. MAIN PARTS OF THE MACHINE 2.3. CHARACTERISTICS - TECHNICAL DATA 3. SAFETY - OPERATING STANDARDS 3.1. SAFETY LABELS AND STICKERS 3.2. GENERAL STANDARDS FOR SAFETY AND USE 4.

  • Page 238: General Accident Prevention

    1. 1. GENERAL ACCIDENT PREVENTION For the machine to function properly, it must be set-up correctly (installation and use) and the oil level for the various mechanisms must be checked. Inadequate controls or errors in installation and use can compromise machine efficiency and jeopardize operator safety. All information and illustrations contained in this manual refer to the model in production at the time of publication.
  • Page 239 Never remove the installed safety devices. Never park the machine in a place with unstable ground which could give way, particularly when it is full. Never operate the machine with inappropriate clothing (garments stained with oil, torn, etc.). The manual and some parts of the machine bear the following symbols to indicate safety messages.

  • Page 240: Main Characteristics

    2. 2. MAIN CHARACTERISTICS 2.1. MACHINE ID The machine is equipped with a special label bearing the information that identifies the unit. This label is riveted to the control casing on the handlebar (front side). For any requests, always indicate the type and machine number reported on this label.

  • Page 241: Main Parts Of The Machine

    2.2. MAIN PARTS OF THE MACHINE 1 - CONTROL PANEL 2 - ENGINE 3 - TRACK 4 - SCREW TRACK TIGHTENER 5 - H.P.T.O. 6 - MACHINE LIFT HOOKS 7 - MOBILE FOOTBOARD...

  • Page 242: Characteristics - Technical Data

    2.3. CHARACTERISTICS - TECHNICAL DATA CHARACTERISTICS The machine has been designed and built for loading, transport and dumping of soil, sand, excavation debris and other loose materials suitable in terms of the characteristics and performance indicated in this manual. When necessary, the front of the machine can be equipped with a self-loading bucket (OPTIONAL) to facilitate loading operations.
  • Page 243 TECHNICAL DATA TCH/K722 Operational weight Diesel engine type KUBOTA D 722-E Rpm max 3600 Max. power at max r.p.m.) HP/Kw 19,9/14,9 Displacement cm³ Cylinders n° Max. torque at 2600 rpm daNm Cooling type water Transmission type hydraulic Gear pumps for driving n°...
  • Page 244 Implementation of EEC Directive 14/2000 regarding limiting noise produced by operating machinery. = 101 dB Guaranteed noise level: = 85 dB Acoustic pressure at operator's ear: Implementation of EEC Directive 44/2002 regarding minimum safety and health prescriptions for on-the-job exposure to the risks derived from mechanical vibrations. Daily action values ...

  • Page 245: Safety - Operating Standards

    3. 3. SAFETY - OPERATING STANDARDS 3.1. SAFETY LABELS AND STICKERS Besides indicating the various operations to control and use the machine, the labels also highlight the risks related to operating the machine. Operators who normally wear eyeglasses must wear them to read the labels. Keep the labels clean and legible paying particular attention to the safety indications.

  • Page 246: General Standards For Safety And Use

    3.2. GENERAL STANDARDS FOR SAFETY AND USE The present manual contains the information required to run the machine. Contact the Manufacturer for any spare parts, accessories or information you might require. The tracked dumper fit with bucket or open dump body serves to carry and dump materials.
  • Page 247 Lifting of the loading bucket for unloading, must be carried out very slowly to prevent swinging, which could cause the machine to tip over. Before lifting the load, check that the material contained in the loading bucket has been positioned in a way to prevent its accidental escape during movement. If the loading bucket is also equipped with a shovel, it must be positioned as high as possible, to prevent it from interfering with the remaining structure when tipping over.
  • Page 248 USE OF THE OPERATOR FOOTBOARD:  The FOOTBOARD must be LIFTED (max height) while the OPERATOR is on the GROUND.  The FOOTBOARD must be LOWERED with the OPERATOR ON IT. Never walk behind the unit while the footboard is lowered. It is strictly FORBIDDEN to leave the machine unattended with the engine on.

  • Page 249: Driving - Control Position

    4. 4. DRIVING - CONTROL POSITION 4.1. MACHINE CONTROLS – RIGHT TRACK LEVER – LEFT TRACK LEVER – SPEED SELECTOR LEVER – HYDRAULIC CYLINDER CONTROL LEVER – HYDRAULIC OPTIONAL TOOL CONTROL LEVER – ACCELERATOR LEVER – P.T.O. SWITCH – DRIVING HANDLEBAR To operate the various commands, follow the indications reported below:...

  • Page 250: Driving

    4.2. DRIVING: We will now take a close look at the operations required to drive forward, back and to steer. “1” “2” To drive the machine, operate levers “1” “2” FORWARD: push levers forward simultaneously by the same amount. “1” “2”...
  • Page 251 TURNING LEFT WHEN DRIVING FORWARD: “1” “2” WITH THE MACHINE AT A STANDSTILL : - push lever forward of lever “2” “1” WITH THE MACHINE MOVING: pull lever back vs. lever TURNING LEFT WHEN BACKING UP: “1” “2” WITH THE MACHINE AT A STANDSTILL: - pull lever back vs.

  • Page 252: Services

    4.3. SERVICES “4” Lever : dumping cylinder control This lever controls the dumping cylinder opening / closing. To open the cylinder, push the lever forward; to close it, just pull the lever back. “5” ” Lever : hydraulic optional tool control This lever controls another section of the main valve to operate another tool.

  • Page 253: Starting Up And Stopping The Engine

    4.4. STARTING UP AND STOPPING THE ENGINE The diesel engine powers the dumper. Below an extract from the user’s manual provides an outline of its use. For more details, see the user’s manual for the engine installed in the machine. Before starting up the engine, check that the machine is in perfect condition and, in particular, check the following: ...
  • Page 254 HOW TO ENSURE EXCELLENT START-UP EVERY TIME OPERATION N° 1 – move the throttle lever at the centre of its stroke. “F” OPERATION N° 2 – turn the key (Ref. A) clockwise to position “ON” (Ref. B) and then to position “GL” (Ref. C) for the plug pre-heating. Keep the key in this position until the light has gone out (Ref.

  • Page 255: General Maintenance

    5. 5. GENERAL MAINTENANCE 5.1. GREASE POINTS 50 h Refill the grease points at the times indicated. (for the type of grease, follow the indications in the lubricant table) Always keep the lubricators clean and efficient, and replace them when they are worn or damaged.

  • Page 256: Checks And Controls

    5.2. CHECKS AND CONTROLS Pay particular attention to the items indicated below: 1 – HYDRAULIC OIL TANK FILLER CAP 2 – FUEL FILLER CAP 3 – HYDRAULIC OIL RETURN FILTER 4 – AIR FILTER 5 – REDUCTION GEAR 6 – COOLER 7 –...
  • Page 257 1 – HYDRAULIC OIL TANK FILLING CAP. Complete change lt. 20,7. For the type of fluid, follow the indications in the lubricant table. Replace the oil after the first 200 HOURS of operation and every 1000 HOURS thereafter or once a year. Before refilling the oil, check that the dipstick screwed in the plug stays immersed by about 10 mm.
  • Page 258 3 – HYDRAULIC OIL RETURN FILTER The return filter “C” is located under the engine bonnet. Capacity: 50 l/min Filtering level: 10 micron Replace the filter after the first 50 HOURS of operation every HOURS thereafter. substitution, unscrew the filter “C” from the support and change with a new one with the same features.
  • Page 259 5 – WHEEL REDUCTION GEARS Each track is driven by a reduction gear coupled to a hydrostatic motor, fitted with an internal “negative” type multiple-disk brake. With the engine off, the brake is always on (parking). For inspection, filling and oil change in the wheel reduction gears, follow the instructions indicated and specified below: Periodically check (see maintenance table) for leaks, and that with the machine off and the reduction gears positioned as previously...
  • Page 260 The filling out of the gear has to be done immediately after operation when the oil is still hot to avoid deposits of impurities. Pay attention when emptying, as the hot oil may cause serious burns. Clean the plug with detergent, taking extreme care to keep it clean during the refilling phase.
  • Page 261 6 – DIESEL ENGINE COLLING SYSTEM The cooler is located in the rear side of the machine, under the engine cover. A special indicator on the dashboard signals inefficiency of the diesel engine cooling circuit. The level is checked and topped up with the engine cold; should the refilling cap “E”...

  • Page 262: Tightening The Tracks

    5.3. TIGHTENING THE TRACKS With use, the tracks tend to loosen. When operating with loose tracks, they tend to slip over the driving wheel teeth causing it to jump its housing or to work in precarious fashion, damaging and causing wear to the housing.
  • Page 263 - Avoid extended use of the machine in marine or salty environments since this can cause the metal core to detach from the rubber. - The basic characteristics of the rubber used to produce the tracks require that they be used at temperatures ranging from –...

  • Page 264: Pumps Maintenance

    5.4. PUMPS MAINTENANCE In order to do the maintenance on the pumps it is necessary, after lifting the skip, to loose the screws V and remove the protection panel of the pumps. After finished the necessary maintenance, locate again the panel and tie the screws placing the pieces as shown in below left picture.

  • Page 265: Maintenance Summary Table

    5.7. MAINTENANCE SUMMARY TABLE OPERATION HOURS FOR FIRST TO BE COMPONENT INVOLVED REPLACEMENT PERFORMED Oil filter cartridge REPLACEMENT Hydraulic oil FREQUENCY OF SUBSEQUENT OPERATION TO BE COMPONENT INVOLVED REPLACEMENTS (in hours) PERFORMED 1000 Tracks CLEANING Pump body guard space Hydraulic oil tank Battery fluid level CONTROLS AND POSSIBLE...

  • Page 266: Hydrostatic Transmission System

    6. 6. HYDROSTATIC TRANSMISSION SYSTEM WARNING!!! DO NOT INSERT HANDS, PARTS OF THE BODY OR TOOLS IN THE FAN LOCATED ON THE RADIATOR AS IT STARTS AUTOMATICALLY. IMPORTANT!!! For proper use of the machine it is recommended to bring the hydraulic oil to work temperature by leaving the diesel motor to idle and slightly accelerated for about 5 –...
  • Page 267 HOW TO CHECK AND RESTORE THE PRESSURE IN THE HYDRAULIC TRANSLATION SYSTEM DISTRIBUTOR LEFT TRACK To check correct pressure, once the manometer has been positioned in measuring point “P2”, lock the left track by setting a fixed point between the drive wheel and the machine frame.

  • Page 268: Hydraulic Power Take-Off H

    7. 7. HYDRAULIC POWER TAKE-OFF H.P.T.O. FEATURES: The machine is equipped with a hydraulic power take-off “ ” with simple effect to be used with particular accessories or hydraulic equipment. The main characteristics of the power take-off are: MAX FLOW RATE 45 lt/min PRESSURE The hydraulic power take-off H.P.T.O.

  • Page 269: Electrical System

    8.ELECTRICAL SYSTEM The battery “ ” is located under the engine cover, on the left side, seen from the front. BATTERY CHARACTERISTICS VOTAGE: 12 V ABSORBED POWER: 55 Ah CHARGE: 450 A A – INGNITION KEY B - BATTERY The key, set on switch “ ”...
  • Page 270 Keep cable terminals secured well and protect with grease or, better still, with pure Vaseline. When disconnecting the battery, the ground cable (-) must be disconnected first. When connecting the battery, the positive cable (+) must be connected first. Keep equipment and metal objects away from the battery terminals because they could cause short-circuiting of the terminals themselves and the danger of burns.

  • Page 271: Troubleshooting: Causes And Remedies

    9. 9. TROUBLESHOOTING: CAUSES AND REMEDIES RIMEDI PROBLEM CAUSE SOLUTION There is no oil in the tank Check the level and top up if necessary Air in the hydraulic Check that the piping and transmission system connections are intact The machine moves jerkily Hydraulic.
  • Page 272 PROBLEM CAUSE SOLUTION Mechanical impediment Remove the obstacle Check and replace if Cylinder or gasket damaged necessary Joint and or hydraulic pump Check and replace if failure necessary The cylinder does not move Check and replace if Hydraulic piping failure necessary Check and restore if Distributor pressure too low...

  • Page 273: Notes On Maintenance

    10. 10. NOTES ON MAINTENANCE HOURS PARTS DATE WORK PERFORMED WORK INVOLVED...
  • Page 275 APPENDIX C TEST REPORTS...

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