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probst TM-D-A Operating Instructions Manual

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TM-D-A / TM-150-D-A / TM-200-D-A /
TM-250-D-A
I
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Operating Instructions
52220015 / 52220015 -150 / 52220015-200 / 52220015-250
V2
Translation of original operating instructions

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Summary of Contents for probst TM-D-A

  • Page 1 TM-D-A / TM-150-D-A / TM-200-D-A / TM-250-D-A Operating Instructions 52220015 / 52220015 -150 / 52220015-200 / 52220015-250 Translation of original operating instructions...
  • Page 2 Bitte beachten Sie, dass das Produkt ohne vorliegende Betriebsanleitung in Landessprache nicht eingesetzt / in Betrieb gesetzt werden darf. Sollten Sie mit der Lieferung des Produkts keine Betriebsanleitung in Ihrer Landessprache erhalten haben, kontaktieren Sie uns bitte. In Länder der EU / EFTA senden wir Ihnen diese kostenlos nach. Für Länder außerhalb der EU / EFTA erstellen wir Ihnen gerne ein Angebot für eine Betriebsanleitung in Landessprache, falls die Übersetzung nicht durch den Händler/Importeur organisiert werden kann.

  • Page 3: Table Of Contents

    Safety procedures .......................... 37 Hints to the type plate ........................38 Hints to the renting/leasing of PROBST devices ................38 Disposal / recycling of devices and machines .................. 38 We hereby reserve the right to make changes to the information and illustrations in the operating instructions.

  • Page 4: Ec-Declaration Of Conformity / Ukca-Declaration Of Conformity

    EC-Declaration of Conformity / UKCA-Declaration of Conformity EC-Declaration of Conformity / UKCA-Declaration of Conformity Description: TRANSMOBIL TM-D-A Type: TM-D-A / TM-150-D-A / TM-200-D-A / TM-250-D-A Order number: 52220015 / 52220015 -150 / 52220015-200 / 52220015-250 Manufacturer: Probst GmbH Gottlieb-Daimler-Straße 6 71729 Erdmannhausen, Germany info@probst-handling.de...
  • Page 5 Address: Probst GmbH; Gottlieb-Daimler-Straße 6; 71729 Erdmannhausen, Germany Authorized person for UK-documentation: Name: Nigel Hughes Address: Probst Ltd ; Unit 2 Fletcher House; Stafford Park 17; Telford Shropshire TF3 3DG, United Kingdom Signature, information to the subscriber: Erdmannhausen, 18.01.2024................(Eric Wilhelm, Managing Director)

  • Page 6: Safety

    Safety Safety Safety symbols Danger to life! Identifies imminent hazard. If you do not avoid the hazard, death or severe injury will result. Hazardous situation! Identifies a potentially hazardous situation. If you do not avoid the situation, injury or damage to property can result.

  • Page 7: Safety Marking

    Safety Safety Marking PROHIBITION SIGN Symbol Meaning Order-No. Size 29040210 Ø 30 mm It is not allowed to stand under hanging loads. Danger to life! 29040209 Ø 50 mm 29040204 Ø 80 mm 29040383 102x52 mm Do not lift any components off-centre. 29040594 65x33 mm WARNING SIGN...
  • Page 8 Safety OPERATING INFORMATIONS Symbol Meaning Order-No. Size The specification of the maximum load limit (WLL) on the type 48 x 125 29040730 plate of the suction plate has priority! Function lever for vacuum and travel mode 29040478 185x30 mm Joystick for mast alignment 29040477 50x50 mm Limit the swivel range of the articulated boom when working in the...

  • Page 9: Personal Safety Requirements

    Safety Personal safety requirements Each operator must have read and understood the operating instructions (and all safety instructions). Only qualified, authorized personal is allowed to operate the device and all devices which are connected (lifting device/carrier). The manual guiding is only allowed for devices with handles. Otherwise there is a risk of injury to the hands! Protective equipment Protective clothing...

  • Page 10: General

    Safety 2.8.2 General • Before every usage of the device check the functions and the working condition. Maintenance and lubrication are only permitted when device is shut down! • Do not use the device, until all faults which can cause safety hazards are removed. •...

  • Page 11: General

    General General Authorized use The TRANSMOBIL device is a mobile transport and laying device for transporting a complete range of building materials, as well as for lifting and laying concrete elements, natural stones, bricks, slabs, etc. with the appropriate suction plates on the vacuum tube lifter. In order to be able to use the largest possible working area, the installation should take place to the right of the device.
  • Page 12 General Only suction plates of the manufacturer PROBST shall be used!!! Some suction plates which can be mounted to the device will reduce its working load limit. • The maximum working load limit is indicated on each suction plate. •...

  • Page 13: Survey And Construction

    General Survey and construction 1. crawler chassis 2. drive (diesel engine) 3. control unit 4. vacuum supply 5. mast 6. articulated boom 7. vacuum supply hose 8. lifting unit 9. vacuum operating unit 10. forks (from pallet lifting unit) 11. parking position for vacuum operating unit 52220015 / 52220015 -150 / 52220015-200 / 52220015-250 12 / 38...

  • Page 14: Technical Data

    * at negative pressure - 420 mbar In general, the use of all Probst lifting units is permitted up to a Working Load Limit (WLL) of 250 kg with unrestricted projection. The Working Load Limit (WLL) of the suction plate must always be equal to or...

  • Page 15: Operation

    Operation Operation Starting the drive Before commissioning, all safety instructions/pictograms must be understood and observed in order to protect the operator and the machine from damage. Observe the enclosed operating instructions of the diesel engine (Hatz) and the crawler stacker (HINOWA)! Before each start of work, the oil level on the unit must be checked and, if necessary, topped up with oil (Fig.
  • Page 16 Operation 1. Open the cover. (Fig. 1) 2. Switch on main switch (set to vertical position ( Fig. 2) Before the diesel engine can be started, the selector switch on the control unit l must be set to "Manual (HAND)" (and left in this position) (Fig. 3). Fig.

  • Page 17: Driving With The Chassis

    Operation Driving with the chassis 1. Familiarize yourself with the operating levers on 2. To drive the device, operate the corresponding the trolley. For details, see the enclosed marked function lever, see symbol sticker (Fig. operating instructions (Hinowa) (Fig. 1). Fig.
  • Page 18 Operation Driving with the load sucked in is prohibited. Risk of injury due to the load swinging around, as well as the risk of falling, can lead to serious personal injury and damage to property!!! It is essential to secure the vacuum tube The spring latch (...

  • Page 19: Structure Of The Boom

    Operation Structure of the boom Before the diesel engine can be started, the selector switch on the control unit l must be set to "Manual (HAND)" (and left in this position). 1. To raise the boom arm, start the motor (see chapter "Starting the drive"). (Fig. 1; 1A) Fig.
  • Page 20 Operation 4. First raise the boom arm by ~45 degrees. (Fig. 5. Release the locking mechanism of the extension To stop, set arm. To do this, pull the cable down (Fig. 5). selector switch back to "Manual". Fig. 5 Fig. 4 6.
  • Page 21 Operation 8. The lifting hose is secured to the mobile boom 9. Hook the lifting unit onto the mobile jib hook hook with a rubber strap to prevent it from (Fig. 9). swinging around. Disconnect the lifting hose from this securing device and lay it on the ground (Fig.

  • Page 22: Aligning The Mast

    Operation 12. Raise the boom arm completely to 90°. To do this, set the selector switch back to "Manual (HAND)" and press the joystick backwards (towards the operator) to raise the boom arm. (Fig. 12; 12A). 13. Alternative: Use automatic mode. When the selector switch is set to "Auto", the boom arm moves upwards "automatically".

  • Page 23: Lifting Unit

    Operation 4. Connect the operating unit to the suction plate. 5. Close both quick-release fasteners of the Attach both quick-release fasteners  of the operating unit (fold down ) - the suction plate operating unit to the hooks on the suction plate. is thus firmly connected to the operating unit.
  • Page 24 Operation 2. Open both spring latches on the holder (parking 3. Slowly remove the vacuum tube lifter unit from position) for the vacuum tube lifter unit ( ). the holder (parking position). (Fig. 3). Risk of (Fig. 2) injury! Fig. 2 Fig.
  • Page 25 Operation 6. Open both snap hooks (from the lifting tube 7. Lifting hose is now released for work corset) (Fig. 6) and hook them further up on the lifting tube corset (Fig. 7). Fig. 6 Fig. 7 52220015 / 52220015 -150 / 52220015-200 / 52220015-250 24 / 38...

  • Page 26: Control Unit

    Operation Control unit 4.6.1 Setting the floating state without load The floating state without load must be set before commissioning. The hovering state of the lifting device must be adjusted to the respective gripper weight. The position of the flap (2) can be changed for this purpose When you place the suction pad on the load, the flap is fully opened via the plunger.

  • Page 27: Setting The Floating State With Load

    Operation 4.6.2 Setting the floating state with load Adjust the adjusting screw (2) to set the hovering state with load - be careful not to confuse this with the hovering state without load. Twisting clockwise ➔ Floating state is reduced •...

  • Page 28: Valve Tappet Adjustment

    Operation Valve tappet adjustment The valve tappet (1) on the upper side of the suction plate (mounting side of the control unit) is set to 17 mm at the factory and secured with a lock nut. This distance "A" (17 mm from the top edge of the screw to the connection ring) must not be changed under any circumstances, otherwise the valve flap of the control unit will not switch correctly.

  • Page 29: Swivel Range

    Operation • In case of motor failure the load does not drop (non-return valve) Residual vacuum slowly lowers the operating • unit/lifting unit with the suctioned load. • Adjust the motor speed so that there is a minimum vacuum of 0.42 bar (see pressure gauge ...
  • Page 30 Operation To limit the swivel range, position the boom so that the stop is to the left of the center (see Fig. 5). Then insert the socket pin. Remove the socket pin from its parking position (at the bottom of the mast) (Fig. 3) and then insert it at the top of the mast (Fig.

  • Page 31: Locking Of The Boom

    Operation Locking of the boom Risk of injury! The boom can swivel independently and catch persons in the swivel range if it is not guided by the operator! As soon as work with the vacuum lifting unit is interrupted, the boom must be locked! This prevents the boom from swiveling around both axes.

  • Page 32: End Of Work

    Operation 4.12 End of work At the end of each working day, turn the main battery switch to OFF. This prevents the engine from being started by unauthorized persons (anti-theft device) • The device is safely disconnected from the circuit •...

  • Page 33: Transport

    Transport Transport The unit can be transported on a car trailer. The dimensions of the unit and the permissible total weight must be observed! Transporting the device with the boom arm raised is strictly prohibited (see Fig. During transport, the boom arm must be completely folded up and positioned at the bottom in the holder ...
  • Page 34 Transport Fig. 5 Fig. 6 To load the unit onto a car trailer or a flatbed, connect the unit to the carrier (e.g. excavator) via the suspension eye (A) (see Fig. 5). Before transporting the device on a car trailer or a flatbed, it must always be adequately secured against slipping away and tipping over! To secure the device to the car trailer or the flatbed, use the two lifting eyes (A + B, see Fig.

  • Page 35: Maintenance And Care

    Maintenance and care Maintenance and care Maintenance To ensure the correct function, safety and service life of the device the following points must be executed in the maintenance interval. Used only original spare parts, otherwise the warranty expires. All operations may only be made in closed state of the device! For all operations you have to make sure, that the device will not close unintended.

  • Page 36: Device Specific Maintenance

    Maintenance and care 6.1.2 Device specific maintenance Maintenance period Work to be performed Daily controls See enclosed operating instructions of the HATZ diesel engine - 1D81C and the crawler stacker - HINOWA TP2000. Oil level check of the crawler stacker Checking the oil level of the diesel •...

  • Page 37: Trouble Shooting

    Maintenance and care Trouble shooting Malfunction Cause Remedy the hydraulic system is leaking Retighten connections and screw connections the mast can not be the hydraulic cylinders do not hold the Replace the gasket sets in the cylinders aligned pressure the valve has a malfunction Check and clean valve, replace if necessary Cable of the inclination sensor is Replace cable or connect correctly...

  • Page 38: Repairs

    The corresponding legal regulations and the regulations of the declaration of conformity must be observed! • The expert inspection can also be done by the manufacturer Probst GmbH. Contact us at: service@probst-handling.de We recommend affixing the inspection sticker "„Sachkundigenprüfung / Expert inspection" in a •...

  • Page 39: Hints To The Type Plate

    Example: Hints to the renting/leasing of PROBST devices With every renting/leasing of PROBST devices the original operating instructions must be included unconditionally (in deviation of the user´s country's language, the respective translations of the original operating instructions must be delivered additionally)!
  • Page 41 Vacuum Hose Lifter Components Lifting hose unit with Operating Valve Unit Keep these Operating Instructions for future use ! Status 08.2012 / Index 05 Page 1/15...
  • Page 42 Vacuum Hose Lifter Components Lifting hose unit with Operating Valve Unit Table of Contents Safety Instructions for the Company Instructions for the Installation, Maintenance and Operating Personnel Hazard Alert Symbols in this Manual Installation Site Requirements Intended Use Emissions Special Hazards Workplace Instructions for the Operator 1.10 Equipment for Personal Protection...
  • Page 43 Vacuum Hose Lifter Components Lifting hose unit with Operating Valve Unit Special Features The unit is equipped with the following special feature(s): (See the Appendix for special operating instructions and spare parts.) If the special features require a separate list of spare parts or parts subject of consumption, the corresponding list in section "Spare parts"...
  • Page 44 Vacuum Hose Lifter Components Lifting hose unit with Operating Valve Unit Safety 1.1 Instructions for the The Vacuum Hose Lifter has been manufactured according to current Company technological standards and is safe. Still, it will present hazards  if the device is not operated by qualified or, at least trained staff, ...
  • Page 45 Transport of persons and animals with the load or the lifting device itself is forbidden! Unauthorized alteration of the lifting device is forbidden for safety reasons! Only suction plates of the manufacturer PROBST shall be used!!! Some suction plates which can be mounted to the device will reduce its carrying capacity.
  • Page 46 Vacuum Hose Lifter Components Lifting hose unit with Operating Valve Unit 1.10Equipment for Wear safety shoes when operating the device. Personal Protection Before transporting dangerous goods the appropriate safety clothes have to be put on. 1.11Behaviour in As an example sudden power failure is an emergency (the device switches off Emergencies invariably!).
  • Page 47 Vacuum Hose Lifter Components Lifting hose unit with Operating Valve Unit Description 3.1 Components of The Vacuum Hose Lifter consists essentially out of: the J UMBO Pos. Description Remarks Coupling customer connection Rotary suction fitting customer connection Lifting tube customer connection Operating unit with regulator handle Securing net...
  • Page 48 Vacuum Hose Lifter Components Lifting hose unit with Operating Valve Unit 3.5 Accessories The installation of a dust filter is urgently recommended to protect the fan from all Dust Filter kinds of dirt (dust from surroundings, dirty loads etc.) Observe the enclosed installation instructions for dust filter. Note: If no dust filter is used, foreign objects must be excluded from the guarantee as a possible cause of failure.
  • Page 49 Vacuum Hose Lifter Components Lifting hose unit with Operating Valve Unit  Mount the rotary suction fitting (7) to the transport trailer (5) of the crane. Fasten it safely! Insert the transport trailer into the crane jib (2).  Mount the end stop (6) at the end of the crane jib. Never work without an end stop on the crane jib, otherwise the lifting device can fall off.
  • Page 50 Vacuum Hose Lifter Components Lifting hose unit with Operating Valve Unit 4.3 Replacing the The lifting tube can be replaced on-site. lifting tube The lifting tube must always be installed with the reinforced section at the bottom! Procedure:  Clamp the rotary inlet in a vice, holding it by the screws of the tube holder (Fig.
  • Page 51 Vacuum Hose Lifter Components Lifting hose unit with Operating Valve Unit Operating 5.1 Safety Local safety requirements are fully applicable. The following safety instructions are Instructions complimentary to the rules in force and do not supersede the latter:  Wear safety shoes. ...
  • Page 52 Vacuum Hose Lifter Components Lifting hose unit with Operating Valve Unit Turn the adjusting screw (2) to adjust the hovering position with the load. Adjusting the hovering Caution: Do not confuse this adjustment with the hovering position without load. position with load ...
  • Page 53 Vacuum Hose Lifter Components Lifting hose unit with Operating Valve Unit Trouble The device must be installed and maintained by qualified personnel, mechanics and electricians. Any work on the electrical equipment may be carried out only by Shooting a qualified electrician. After each repair or maintenance job check the guards as described in the Operating Manual ”Safety”.
  • Page 54 Vacuum Hose Lifter Components Lifting hose unit with Operating Valve Unit Maintenance 7.1 General Notes The Vacuum Hose Lifter may be installed and maintained only by qualified personnel such as mechanics and electricians. After any repair or maintenance work, check the safety devices as described in the section "Safety".
  • Page 55 Vacuum Hose Lifter Components Lifting hose unit with Operating Valve Unit Notes on the On the nameplate the main data for the lifting device is indicated. Name Plate The nameplate is firmly connected to the device. The nameplate contains the following information: Type Device number Order number...
  • Page 56 Hubeinheit mit Bedieneinheit Ersatzteile/ /Spare Parts Hubeinheit / Lifting Hose Assy Dreheinheit / Rotation Unit...
  • Page 57 Hubeinheit mit Bedieneinheit Ersatzteile/ /Spare Parts Hubeinheit / Lifting Hose Assy Menge / Abmessung / Pos. Bezeichnung Description Art. No. Legende Amount Dimension G 2“ - L 56 - D 66,3 G 2“ - L 56 - D 66,3 2700.0007 Flachsauggreifer_PFG Flat suction pad_PFG 4210.0610...
  • Page 58 Hubeinheit mit Bedieneinheit Ersatzteile/ /Spare Parts Ventileinheit, Bedieneinheit / Valve Unit, Operating handle Ventileinheit / Valve Unit...
  • Page 59 Hubeinheit mit Bedieneinheit Ersatzteile/ /Spare Parts Ventileinheit, Bedieneinheit / Valve Unit, Operating handle Menge / Abmessung / Pos. Bezeichnung Description Art. No. Legende Amount Dimension Ventilgehäuse kpl. Valve casing compl. 4210.0612 Federklappe Spring flap 4210.0608 Reibbelag Friction lining 4210.0613 Scheibe Disk 4210.0614 Schieber...
  • Page 61 Produktkonfigurator Händlerübersicht Transmobil TM-D-A / TM-D-A-SILENT 52220015-200 52220015-250 52220015-150 TM-150-D-A TM-150-D-A TM-150-D-A Diesel- Automatik Diesel- Automatik Diesel- Automatik 52220016-200 52220016-150 52220016-250 TM-D-A-SILENT TM-D-A-SILENT TM-D-A-SILENT Diesel- Automatik Diesel- Automatik Diesel- Automatik schallgedämmt schallgedämmt schallgedämmt 52220016 Grundgerät 52220015 Grundgerät TM-D-A-SILENT TM-D-A Diesel- Automatik...
  • Page 62 42100132 42100568 42100539 52220015 © all rights reserved conform to ISO 16016 Datum Name Benennung TRANSMOBIL TM-150-D-A Erst. 31.3.2023 R.Seidel Gepr. Ausf. Diesel Automatik 31.3.2023 R.Seidel mobiles Transport- und Verlegegerät für Bordsteine und mobiles Transport- und Verlegegerät für Bordsteine und Platten Platten Artikelnummer/Zeichnungsnummer...
  • Page 63 42220070 siehe separate Liste see separate list 42101114 42101148 42100568 siehe separate Liste see separate list 42100539 52220015 siehe separate Liste © all rights reserved conform to ISO 16016 see separate list Datum Name Benennung TRANSMOBIL TM-200-D-A Erst. 5.4.2023 R.Seidel Gepr.
  • Page 64 42220070 siehe separate Liste see separate list 42101115 42100568 siehe separate Liste see separate list 42101147 42100539 © all rights reserved conform to ISO 16016 52220015 Datum Name Benennung TRANSMOBIL TM-250-D-A Erst. siehe separate Liste 1.6.2023 R.Seidel Gepr. Ausf. Diesel Automatik 1.6.2023 R.Seidel see separate list...
  • Page 65 42220071 20090022 42220072 16080010 20000010 Länge: 260 mm length: 260 mm 20090022 16080010 20000010 Länge: 260 mm length: 260 mm © all rights reserved conform to ISO 16016 Datum Name Benennung Auflage für Ballast mit max. 250kg am TM150 Erst. 25.5.2010 Dietrich.Pannier Gepr.
  • Page 66 33501437 20000010 20400002 20540033 20000010 20400002 42100567 20400002 20400002 20100015 20100015 20450005 20020006 © all rights reserved conform to ISO 16016 Datum Name Benennung Aufnahme für Bedieneinheit BE Erst. 28.8.2020 R.Seidel Gepr. 23.3.2023 R.Seidel Artikelnummer/Zeichnungsnummer Blatt E42100568 Zust. Urspr. Ers. f. Ers.
  • Page 67 42220142 siehe separate Liste see separate list 42220226 siehe separate Liste see separate list © all rights reserved conform to ISO 16016 Datum Name Benennung Grundeinheit TRANSMOBIL TM-D-A Erst. 28.3.2023 R.Seidel Gepr. 28.3.2023 R.Seidel Artikelnummer/Zeichnungsnummer Blatt E52220015 Zust. Urspr. 42220128 Ers.
  • Page 68 20100014 20400002 20000009 Bei Änderungen Rücksprache TB ! Gewicht: 16,3 kg Schutzvermerk nach DIN 34 beachten! Nachdruck nur mit unserer Genehmigung! Benennung Datum Name Umbauteile auf TM-D-A-XL Erst. 25.4.2013 Ralf.Northe Gepr. Steuersäule, Steuerung Blatt Artikelnummer/Zeichnungsnummer E42220110 Kunde: Urspr. Ers. f.
  • Page 69 26100032 20000126 20400001 33010047 42220148 26200015 22600057 21050157 42220089 24100013 42220146 24100013 20100014 24110009 20000002 21990003 24200021 20000009 20200035 20100023 21070001 20040032 42220078 20440004 20040011 21000376 20000013 33500064 20000126 33700594 24100226 20000018 20100016 20100014 © all rights reserved conform to ISO 16016 siehe separate Liste Datum Name...
  • Page 70 20020006 21600015 20100015 26990003 42220145 20040004 21650001 Bei Änderungen Rücksprache TB ! 21990003 Gewicht: 20100015 6,9 kg Meterware Schutzvermerk nach DIN 34 beachten! meter ware Nachdruck nur mit unserer Genehmigung! Benennung Datum Name Haube TM 150-D-XL komplett Erst. 4.2.2013 Ralf.Northe Gepr.
  • Page 71 Operation, Safety, Maintenance and service Manual Original Instructions - Keep this manual with the machine at all times. TRACKED FORKLIFT PT20GL/TP2000/169835 TP2000/17189300CA TP2000171893021216...
  • Page 72 TP2000 CONTENTS INTRODUCTION ....................Page DECLARATION OF INCORPORATION ............Page NOMENCLATURE ....................Page CONTROL STATION..................Page INFORMATION ON SAFETY ................Page PICTOGRAMS ON THE TP2000 ..............Page 10 SAFETY AND ACCIDENT PREVENTION ............Page 15 1. GENERAL WARNINGS ................Page 15 1.1 Carefully read the instructions ............Page 15 1.2 Follow the safety instructions ..............Page 15 1.3 Clothing and protective equipment ............Page 15 1.4 Unauthorised modifications ..............Page 15...
  • Page 73 TP2000 4.2.2.3 Manoeuvring on soft ground ..........Page 25 4.2.2.4 Avoid operating on a slopes ..........Page 25 4.2.2.5 Parking and stopping on a slopes ........Page 25 4.2.2.6 Towing the machine ..............Page 26 4.2.2.7 Transporting the machine ............Page 26 4.2.2.8 Lifting the machine ..............Page 28 4.2.2.9 Using the rubber tracks ............Page 28 5 MAINTENANCE ....................Page 29 Correct inspection and maintenance procedures ......Page 29...
  • Page 74 TP2000 EC DECLARATION OF CONFORMITY TP2000...
  • Page 75 TP2000 MUTP2000171893021216...

  • Page 76: Introduction

    TP2000 INTRODUCTION • This manual is made to permit customers to properly employ Hinowa hydraulic units on the machines they have designed. • Read this manual with care before making mechanical and hydraulic connec‐ tions between the Hinowa hydraulic unit and your machine. •...

  • Page 77: Declaration Of Incorporation

    TP2000 DECLARATION OF INCORPORATION Preliminary remark: The product hydraulic unit is a partly completed machinery which cannot in itself perform a specific and autonomous application, as it is without any tools, utensils or other parts for a spe‐ cific application. Therefore, in conformity with the provisions of the Machinery Directive, Chapter 1, Article 1, this product does not fall within the scope of this directive and is not subject to the provisions in Chapter 1, Article 5 and Chapter 2, Article 8.

  • Page 78: Nomenclature

    TP2000 NOMENCLATURE To make the safety warnings and the operation and maintenance instructions easier to understand, the names of the various parts of the tracked forklift are listed here below: Idler roller assembly Tracked undercarriage chassis Roller Traction wheel Travel reductin gear oil Track Forks Platform...
  • Page 79 TP2000 Control lever guard Lifting cylinder Hydraulic distributor Lifting points MUTP2000171893021216...

  • Page 80: Control Station

    TP2000 CONTROL STATION The control station is the position at the rear of the machine where the operator stands (on the platform), securely anchored to the control levers. ATTENZIONE WARNING The operator must control the machine from the control station. The maximum possible protection has been provided, taking in consideration that the machine can also be used off‐road;...

  • Page 81: Information On Safety

    TP2000 INFORMATION ON SAFETY To avoid accidents, before starting work and before performing any maintenance operations, all the precautions and warnings contained in this manual must be read, understood and observed. This is the safety warning symbol. When this symbol is identified on the machine or in this manual, care must be taken to avoid the risk of potential personal injuries.

  • Page 82: Pictograms On The Tp2000

    TP2000 PICTOGRAMS ON THE TP2000 1) R . 8 ‐ EAD THE MANUAL TABLE Carefully read the contents of this manual before com‐ missioning, use, maintenance, refuelling or other opera‐ tions on the machine. Label position: in front of the operator on the distributor support.
  • Page 83 TP2000 6) H . 16 ‐ YDRAULIC OIL TABLE Label position: on the hydraulic oil tank. 7) C LOTHING AND PROTECTIVE EQUIPMENT . 4 ‐ TABLE When using the machine or performing maintenance, wear a hard hat, glasses, safety footwear, gloves and acoustic earmuffs.
  • Page 84 TP2000 15) M . 22 ‐ OAD PERMITTED TABLE Indicates the maximum load permitted and the maximum vertical and horizontal distance from the forks. It is forbidden to exceed the capacity limit and the indicated distance of the loadʹs centre of gravity from the forks.
  • Page 85 TP2000 19) H ‐ . 10 ‐ OT SURFACE RISK OF BURNING TABLE Indicates that the operator must pay the utmost atten‐ tion to the hot surfaces of the machine. Label position: near the exhaust silencer. 06056300 20) C . 23 ‐ RUSHING HAZARD FEET TABLE Indicates areas where there is a danger of crushing...
  • Page 86 TP2000 POSITION OF PICTOGRAMS ON THE TP2000 MUTP2000171893021216...

  • Page 87: Safety And Accident Prevention

    TP2000 SAFETY AND ACCIDENT PREVENTION ENERAL PRECAUTIONS PERICOLO DANGER CAREFULLY READ THE INSTRUCTIONS Before performing any operation on the machine, implement all the safety stan‐ dards, precautions and instructions described in the manual. FOLLOW THE SAFETY INSTRUCTIONS Read all the safety messages in this manual and the safety signs on the machine. Check that the safety signs are in good condition, replacing any missing or dama‐...

  • Page 88: Precautions For Use

    TP2000 PRECAUTIONS FOR USE THE PRECAUTIONS TO BE TAKEN BEFORE STARTING WORK SAFETY IN THE WORKPLACE PERICOLO DANGER Before starting the engine, carefully check the conditions of the ground where the machine will be working to look for any irregularities that may make the work dan‐ gerous or the machine unstable.

  • Page 89: Precautions To Be Adopted When Working

    TP2000 PRECAUTIONS TO BE ADOPTED WHEN WORKING PERICOLO DANGER PRECAUTIONS WHEN STARTING THE ENGINE Check your machine carefully by walking around it befo‐ re starting the engine. Warn any people nearby that you are about to start the machine. Do not allow anybody to climb onto the machi‐ PRECAUTIONS WHEN DRIVING To avoid the possibility of accidents or loss of control, do not climb onto the forklift;...

  • Page 90: Transporting The Machine

    TP2000 TRANSPORTING THE MACHINE Strictly heed the local regulations when transporting the machine on public roads. Use a truck or trailer suitable for transporting the machine. Always unload and load the machine on a solid and flat surface. Remember to use a ramp or a loading platform to load/unload the machine. Never select the quick speed control during these operations.

  • Page 91: Operating Instructions

    TP2000 OPERATING INSTRUCTIONS OPERATING POSITION AND CONTROLS AKUU A ‐ Carriage R travel control lever B ‐ Fork swing control lever C ‐ Fork lifting control lever D ‐ Carriage L travel control lever E ‐ 2nd travel speed lever F ‐...

  • Page 92: Moving The Machine Tp2000

    TP2000 MOVING THE MACHINE TP2000 4.2.1 U NDERCARRIAGE OPERATION ‐ Travelling in a straight line Move both levers forwards to travel in a straight line. Pull both levers backwards to travel in reverse. ‐ Steering to the right or left To turn right, move the left lever forwards.

  • Page 93: Nd Travel Speed

    TP2000 4.2.1.1 RAVEL SPEED To engage the 2nd travel speed, shift the lever to the position shown. Use this con‐ trol only when travelling on level and compact ground. 4.2.1.2 S WING FUNCTION ‐ To swing the load forwards, push the lever forwards. ‐...

  • Page 94: Precautions For Use

    TP2000 4.2.2 P RECAUTIONS FOR USE ATTENZIONE WARNING This forklift is not provided with a light unit, therefore it is forbidden to use it when visibility is scarce. ATTENZIONE WARNING Before starting the engine, make sure that all the distributor levers are in neutral position.

  • Page 95: Do Not Work In Dangerous Areas

    TP2000 2000 HE LOAD TO BE LIFTED CANNOT WEIGH MORE THAN KG AND THERE MUST BE A MAXIMUM DISTANCE OF MM BETWEEN THE CENTRE OF GRAVITY OF THE LOAD AND THE HORIZONTAL AND VERTICAL PLANE OF THE FORKS T IS FORBIDDEN TO EXCEED THE CAPACITY LIMIT AND THE INDICATED DISTANCE OF THE ʹ...
  • Page 96 TP2000 4.2.2.2 H ANDLING THE LOAD Only pallets in perfect conditions and not exceeding the indicated dimensions can be loaded; the load must be compact and homogeneous and its weight and the distance of its centre of gravity from the forks must be as indicated. Approach the load to be handled and brake smoothly in such a way as to stop the carriage near the load.

  • Page 97: Avoid Operating On A Slopes

    TP2000 4.2.2.3 O PERATIONS ON SOFT GROUND Avoid driving on very soft ground that is not hard enough to support the machine safely. LWAYS MAKE SURE THERE IS NO RISK OF OVERTURNING The machine is not fitted with a protective structure against overturning. 4.2.2.4 A VOID OPERATING ON SLOPES Warning: manoeuvring on slopes is dangerous.

  • Page 98: Towing The Machine

    TP2000 4.3.2.6 T OWING THE MACHINE IMPORTANTE IMPORTANT The machine must not be towed. Any attempt to tow the forklift may damage the transmission. 4.2.2.7 T RANSPORTING THE MACHINE OADING THE MACHINE ON A TRUCK WITH LOW BED Always load and unload the machine on a firm and level surface. Warning: remember to use a ramp or a loading platform to load/unload the machine.
  • Page 99 TP2000 5. The centre line of the machine must coincide with the centre line of the trailer. IMPORTANTE IMPORTANT Secure the chains or cables to the chassis of the machine. Never place the chains or cables over or against the hydraulic hoses. 6.

  • Page 100: Lifting The Machine

    TP2000 4.2.2.8 L IFTING THE MACHINE To lift the machine correctly, observe the following safety precautions: ‐ The machine must not be carrying any load. ‐ Position the machine on a level surface. ‐ The operator must abandon the driving position when the machine is going to be lifted.

  • Page 101: Maintenance

    TP2000 MAINTENANCE CORRECT INSPECTION AND MAINTENANCE PROCEDURES • Learn how to perform correct maintenance on the trucklift and follow the inspec‐ tion procedures as illustrated in this manual. • Carry out the maintenance operations on solid and level ground. • Never lubricate or grease nor carry out maintenance on the machine while it is •...

  • Page 102: Hydraulic Oil

    TP2000 5.2 HYDRAULIC SYSTEM INTERVAL Qty. MONTH MONTHS YEAR • Check level HYDRAULIC *• • Change l 35 HYDRAULIC *• • Change OIL FILTER TRAVEL AND • Check level ROTATION l.0.5 REDUCTION *• • Change GEAR OIL * FIRST CHANGE 5.2.1 H YDRAULIC OIL Check...

  • Page 103: Travel Reduction Gear Oil

    TP2000 5.2.2 YDRAULIC OIL FILTER Change The hydraulic oil filter D is located at the top of the hydraulic oil tank, behind the distributor guard. Before opening the filter cover, remove the filler cap B (see photo‐ graph Par. 5.3.1) to avoid overpressurizing the tank. To access this, after removing the distributor guard, remove the screws on the filter cover and replace the cartridge.
  • Page 104 TP2000 Choosing the reduction gear oil For the reduction gears, gear oils are recommended with EP additives, and visco‐ sity grade ISO VG150 or SAE 80W/90. In the event of significant variations in temperature, synthetic lubricants are recom‐ mended, with EP properties, minimum viscosity index 165 and viscosity grade VG150 and VG220.

  • Page 105: Maintenance On The Rubber Tracks

    TP2000 5.3 MAINTENANCE ON THE RUBBER TRACKS 5.3.1 HECKING THE TRACK TENSION Stop the machine on firm and level ground. Lift the machine and support it secu‐ rely and safely by placing stable supports under the chassis of the undercarriage. At the centre roller on the undercarriage, measure the distance A of the bottom of the roller from the rigid inner part of the rubber tracks.

  • Page 106: Checking The Rubber Tracks

    TP2000 PERICOLO DANGER It is not normal for the track to remain tight after valve 1 has been turned anti‐ clockwise, or for the track to be still loose after grease has been added through the grease nipple 2.In any case, never attempt to remove the tracks or disassemble the tensioner cylinder, as the pressure of the grease inside the track is very dangerous.
  • Page 107 TP2000 ‐ when the track comes off its guide; ‐ in the event of considerable friction, such as rapid changes in direction. B) Wear and breakage of the metal cores As for the breakage of the steel wires described above, excessive tension may cause the metal cores to bend or break, together with one of the following causes: ‐...

  • Page 108: Replacing The Rubber Tracks

    TP2000 hard surfaces (see photo 7 in the appendix). The damage described in paragraph D points 1, 2, 3 is not considered fatal for the track, and the track can continue to be used, even if with gradual and progressive damage.
  • Page 109 TP2000 Removing the rubber track 1. Stop the machine on firm and level ground, lift it and support it securely and safely. 2. To loosen the track, slowly unscrew valve 1 anticlockwise, giving it no more than one turn. One turn of valve 1 is suf‐ ficient to loosen the track.

  • Page 110: Checking The Tightness Of Nuts And Bolts

    TP2000 4. Turn the sprocket (7) in reverse, pushing the bottom of the track inside the chassis (8). 5. Using a steel tube, position the track and turn the sprocket again. 6. Make sure that the links of the track are correctly meshed on the cogwheel and the idler roller.

  • Page 111: Storing The Machine

    TP2000 STORING THE MACHINE 1. Inspect the machine. Repair any worn or damaged parts. Install new parts where necessary. 2. Clean the filtering elements of the air filter. 3. Lubricate all the greasing points. 4. Place the tracks on stable blocks. Lubricate the pins of the track links with oil (except for rubber tracks).

  • Page 112: Technical Specifications

    TP2000 TECHNICAL SPECIFICATIONS TECHNICAL CHARACTERISTICS NDERCARRIAGE Track width ........................250 mm Support rollers per side ......................5 Travel speed......................1,5 ‐ 2,2 km/h PERATING WEIGHT Operating weight excluding operator (fixed undercarriage) ........845 kg ERFORMANCE Gradeability ......................20° (36,4%) Capacity ........................2000 kg Max distance from the centre of gravity allowed ..........500 mm Max lifting height................
  • Page 113 TP2000 FORKLIFT TP2000 1935 1350 MUTP2000171893021216...

  • Page 114: Key To The Hydraulic System Diagram

    TP2000 HYDRAULIC SYSTEM DIAGRAM 6.2.1 KEY TO THE HYDRAULIC SYSTEM DIAGRAM ‐ ‐ Reduction gear, L track ‐ ‐ Swing cylinders ‐ Drain filter ‐ Reduction gear, R track ‐ Distributor HC‐D9/5 ‐ Lifting cylinder MUTP2000171893021216...

  • Page 115: Appendix

    TP2000 APPENDIX PHOTO NO. 1 CUT STEEL WIRES PHOTO NO. 2 ABRASION AND BREAKAGE OF THE STEEL CORES PHOTO NO. 3 SEPARATION OF THE STEEL CORE MUTP2000171893021216...
  • Page 116 TP2000 PHOTO NO. 4 BREAKAGE OF THE TRACK PATTERN CAU‐ SED BY BENDING STRESS (CURVING) ON THE RUB‐ PHOTO NO. 5 BREAKAGE ON THE OUT‐ SIDE PART OF THE RUB‐ BER UNDER THE EDGE OF THE STEEL CORE PHOTO NO. 6 BREAKAGE ON THE INSI‐...
  • Page 117 TP2000 PHOTO NO. 7 ABRASION OF THE TRACK PATTERN PHOTO NO. 8 ABRASION OF THE RUB‐ BER DUE TO THE GUIDE WHEELS (INITIAL STAGE) PHOTO NO. 9 ABRASION OF THE RUB‐ BER DUE TO THE GUIDE WHEELS (FINAL STAGE) MUTP2000171893021216...
  • Page 118 TP2000 PHOTO NO. 10 CUTS DUE TO SHARP MATERIAL ON THE OUT‐ SIDE PART OF THE RUB‐ PHOTO NO. 11 BREAKAGE AND ABRA‐ SION ON THE OUTSIDE PART OF THE RUBBER CAUSED BY HARD GROUND PHOTO NO. 12 CUT ON THE INSIDE EDGE OF THE RUBBER DUE TO SHARP MATE‐...
  • Page 119 TP2000 PHOTO NO. 13 BREAKAGE OF THE INSI‐ DE PART OF THE RUB‐ BER CAUSED BY CON‐ TACT WITH THE UNDERCARRIAGE CHASSIS MUTP2000171893021216...
  • Page 120 Legal and administrative seat: HINOWA S.p.A. I - 37054 NOGARA (VR) via Fontana Tel. +39 0442 539100 Fax +39 0442 539075 hinowa@hinowa.it marketing: info@hinowa.com www.hinowa.com...
  • Page 122 Kpfkeg Kpfgz Kpfgz Vcx0 "23023022 Carro con cingolo in gomma Carriage with rubber track Train de roulement chenille en caoutchouc Vcx0 "24023022 Torretta Upper structure Tourelle Vcx0 "25023022 Impianto idraulico aspirazione - scarico Intake-draining system Installation aspiration - évacuation Vcx0 "26023022 Impianto idraulico Hydraulic system Installation hydraulique RV42IN1VR4222138;:5722"...
  • Page 123 Kpjcnv ¯pfkeg Kpjqwf Vcx0 "23023022Wagen mit Gummiraupe Carro con oruga de goma Onderstel met rubberen rupsband Vcx0024023022 Oberwagen Torreta Toren Vcx0 "25023022 Hydraulik - Vor- und Rücklauf Instalación de aspiración-descarga Hydraulische installatie afzuiging- de aceite afvoer Vcx0 "26023022Hydraulikanlage Instalación hidráulica Hydraulische installatie RV42IN1VR4222138;:5722"...
  • Page 124 TE M8X16 TCEI M10X25 (12.9) TE M8X35 TCEI M10X18 (12.9) TE M6X12 PT20GL/TP2000/ CARRO CON CINGOLO IN GOMMA WAGEN MIT GUMMIRAUPE 16983500 CARRIAGE WITH RUBBER TRACK CARRO CON ORUGA DE GOMA 01.01.00 Ed.07.2017 TRAIN DE ROULEMENT CHENILLE EN ONDERSTEL MET RUBBEREN RUPSBAND CAOUTCHOUC...
  • Page 125 Y cigp" okv" I wooktcwrg Ecttq"eqp"ekpiqnq" k p" i qooc Tav. 23023022 Ecttkcig"ykvj"twddgt" vtcem Ecttq"eqp"qtwic"fg"iqoc" Vg Vtckp" f g"tqwngogpv" ejgpknng" gp" ecqwvejqwe" xgtdtgQpfgtuvgn" o gv"twddgtgp" twrudcpf Rqu0 """" Eqf0 S0väFguetk|kqpg Fguetkrvkqp Fgukipcvkqp Dgpgppwpi" Fguetkrekôp" Dguejtklxkpi 26667922 Cingolo in gomma Rubber track Chenille en caoutchoueGummiketten Oruga de goma Rubberen rupsband...
  • Page 126 TE M8X30 TE M10X25 TC M6X20 TE M14X60 TE M12X40 TE M8x25 TE M10x65 PT20GL/TP2000/ TORRETTA OBERWAGEN 16983500 UPPER STRUCTURE TORRETA 02.01.00 Ed.07.2017 TOURELLE TOREN...
  • Page 127 Qdgtycigp Vqttgvvc Tav. 24023022 Wrrgt"uvtwevwtg Vqttgvc Vqwtgnng Vqtgp Rqu0 """" Eqf0 S0väFguetk|kqpg Fguetkrvkqp Fgukipcvkqp Dgpgppwpi" Fguetkrekôp" Dguejtklxkpi 28659322 Dente forche pallets Pallet fork tooth Dent de fourches de Palettengabelzahn Diente horquillas Tand vorken palettes paletas 586626J4 Supporto forche pallets Pallet fork support Support fourches de Halterung Soporte horquillas...
  • Page 128 1/5 15L T 12L 3/8" 12L 3/8" 12L 3/8" 12L 3/8" 12L 1/2" 15L PT20GL/TP2000/ IMPIANTO ASPIRAZIONE E SCARICO VOR- UND RÜCKLAUFANLAGE 16983500 SUCTION - DRAINING SYSTEM INSTALACIÓN DE ASPIRACIÓN Y DESCARGA 03.01.00 Ed.07.2017 INSTALLATION ASPIRATION ET DÉCHARGE INSTALLATIE AFZUIGING EN AFVOER...
  • Page 129 J{ftcwnkm" ¤" Xqt/"wpf"T°emncwh orkcpvq"curktc|kqpg" /"uectkeq Tav. 25023022 Kpuvcncekôp" fg"curktcekôp/fguectic" fg"cegkvg Kpvcmg/ftckpkpi" u{uvgo J{ftcwnkuejg"kpuvcnncvkg" ch|wkikpi/chxqgt Kpuvcnncvkqp" curktcvkqp/ê xcewcvkqp Rqu0 """" Eqf0 S0väFguetk|kqpg Fguetkrvkqp Fgukipcvkqp Dgpgppwpi" Fguetkrekôp" Dguejtklxkpi 2936;422 25" Tubo flessibile Flexible pipe Tuyau souple Schlauch Tubo flexible Slang 28675822 Tubo flessibile Flexible pipe Tuyau souple Schlauch...
  • Page 130 3/8" 10L 3/8" 12L 3/8" 10L T 10L 3/8" 12L 1/4" 10L 1/4" 10L 3/8" 12L 1/4" 10L 3/8" 12L PT20GL/TP2000/ IMPIANTO IDRAULICO TRAZIONE HYDRAULIKANLAGE ANTRIEB 16983500 HYDRAULIC SYSTEM FOR TRACTION INSTALACIÓN HIDRÁULICA TRACCIÓN 04.01.00 Ed.07.2017 SYSTÈME HYDRAULIQUE DE TRACTION HYDRAULISCHE AANDRIJFINSTALLATIE...
  • Page 131 Korkcpvq" kftcwnkeq" vtc|kqpg" J{ftcwnkmcpncig" Cpvtkgd Tav. 26023022 J{ftcwnke" u{uvgo"hqt" v tcevkqp Kpuvcncekôp" jkftâwnkec" v tceekôp U{uv ë ""og"j{ftcwnkswg" fg"vtcevkqp J{ftcwnkuejg"ccpftklhkpuvcnncvkg" Rqu0 """" Eqf0 S0väFguetk|kqpg Fguetkrvkqp Fgukipcvkqp Dgpgppwpi" Fguetkrekôp" Dguejtklxkpi 28376522 Leva tipo tondo Lever Levier Hebel Palanca Hendel 28376422 Leva ergonomica Lever Levier Hebel...
  • Page 133 INSTRUCTION BOOK 1D 41. 1D 50. 1D 81. 1D 90. 433 216 08-USA-EPA IV-CARB 10.07-0.1 Printed in Germany...
  • Page 134 A new HATZ diesel engine is ready to work for you This engine is intended only for the purpose determined and tested by the manufacturer of the equipment in which it is installed. Using it in any other manner contravenes the intended purpose. For danger and damage due to this, Motorenfabrik HATZ assumes no liability.
  • Page 135 Contents Page Page Important notes on safe operation 5.3. Maintenance every 250 hours of the engine of operation 5.3.1. Oilbath air cleaner maintenance Description of the engine 5.3.2. Changing engine oil, renewing oil filter General information 5.3.3. Checking and adjusting 3.1.
  • Page 136 Important notes on safe operation of the engine HATZ diesel engines are economical, strongly built and long-lasting. They are therefore frequently chosen for commercially and industrially operated equipment and machinery. Since the engine forms part of the finished equipment or machine, its manufacturer will take all the applicable safety regulations into account.

  • Page 137: Important Notes On Safe Operation Of The Engine

    Important notes on safe operation of the engine – Stop the engine before performing any maintenance, cleaning- and repair work. – Stop the engine before refuelling. Never add fuel near a naked flame or a source of sparks. Don’t smoke. Don’t spill fuel. –...
  • Page 138 Description of engine 1D41 • 1D50 • 1D81 • 1D90 S / Z engines 2391 / 12 2391 / 7 1 Cooling air inlet 11 Tank filler cap 2 Dry-type air cleaner 12 Oil drain plug, governor housing 3 Decompression lever 13 Oil drain plug, governor side 4 Stop lever 14 Speed control lever...

  • Page 139: Description Of The Engine

    Description of engine Fully-encapsulated version 1D41C • 1D81C engines 2392 / 1 2392 / 4 1 Capsule 10 Silencer (muffler), encapsul. 2 Decompression lever 11 Cooling air outlet 3 Cold-start oil metering device 12 Battery connection and central plug 4 Combustion and cooling air intake for electrical system 5 Oil filter 13 Stop lever...

  • Page 140: General Information

    General information 3.1. Technical data Type 1D41. 1D50. 1D81. 1D90. Engine models S, Z, C S, Z S, Z, C S, Z Mode of operation air-cooled four-stroke diesel engine Combustion method Direct-fuel injection Number of cylinders Bore / stroke 90 / 65 97 / 70 100 / 85 104 / 85...

  • Page 141: Transport

    3.2. Transport 3.5. EPA/CARB-type plates and fuel label A lug is provided on top of the engine as standard equipment, so that the en- There are two EPA/CARB- type plates applied for gine and its auxiliaries can be lifted safely. It the identification of the engine.

  • Page 142: Emission-Related Installation Instructions

    For any offer as well as spare parts orders it is Fuel label necessary to mention the following data (also see spare parts list, page 1): ➁ engine type / spec. (only for special equipment) ➂ engine number ➃ max. engine rated speed LOW SULFUR FUEL OR ULTRA LOW SULFUR FUEL ONLY Attention:...

  • Page 143: Operation

    The engine must be in a horizontal position be- Operation fore adding oil or checking the oil level. 4.1. Before initial start-up Engines are normally delivered without fuel and oil. 4.1.1. Engine oil Qualified are all trademark oils which fulfil at least one of the following specifications: ACEA –...

  • Page 144: Fuel

    4.1.3. Fuel Only refuel when engine is stopped. Never refuel close to open flames or flammable sparks, don’t smoke. Use only pure fuel and clean replenishing cups. Don’t spill the fuel. All diesel fuels sold as fuel and complying with the following minimum specification can be used: EN 590 or...

  • Page 145: Mechanical Oil Pressure Monitor

    At temperatures below 0 °C, winter-grade fuel should be used or parafin added to the fuel well in advance. Paraffin content for: Lowest ambient temperature when Summer Winter starting, in °C fuel fuel 0 up to –10 20 % – –10 up to –15 30 % –...

  • Page 146: Starting The Engine

    050 145 00 L3 / 250 Instructions to activate the mechanical oil pres- sure control are mentioned on the sticker placed Never use any spray starting aids. on the engine. 4.2.1. Preparations for starting IMPORTANT ! Even with mechanical oil pressure monitoring –...

  • Page 147: Starting With The Handle

    050 252 00.874 2283 / 4 After the automatic decompression device has engaged at its limit stop, five turns of the crank handle are needed for the engine to build up compression and fire again. 4.2.2. Starting with the handle For preparations to start the engine, see Chapter 4.2.1.

  • Page 148: Starting With The Handle With Kick-Back Damping

    – Take hold of the starting handle with both hands and turn it at increasing speed. The maximum speed of rotation must have been reached by the time the decompression lever has returned to the „0“ position (compres- sion). As soon as the engine has started, pull the starting handle out of the guide sleeve.

  • Page 149: Starting In Cold Weather

    4.2.4. Starting in cold weather – Remove dirt from the cover of the metering device and the surrounding area. Pull off the At temperatures below app. –5 °C, always turn cover; Figs. 21 and 22. the engine over to ensure that it rotates freely. –...
  • Page 150 – Turn start key to position II (fig. 23). Automatic electrical shutdown system (additional equipment) – As soon as the engine runs, release the start key. It must return to position I by itself and This is characterized by a brief flashing of all remain in this position during operation.

  • Page 151: Stopping The Engine

    4.3. Stopping the engine Electrical system Never stop the engine by moving the decompression lever. During breaks in work or at the conclusion of the working pe- riod, keep the starting handle and starting key in a safe place, out of reach of unauthorized persons.

  • Page 152: Maintenance

    Maintenance The engine must be stopped before any maintenance work is attempted. Comply with legal requirements when handling and disposing of old oil, filters and cleaning materials. Keep the engine’s starting key and starting handle out of reach of unauthorized persons. To immobilize engines with an electric starter, disconnect the negative battery terminal.
  • Page 153 The above maintenance chart is supplied with For new or reconditioned engines, the following every engine. This label should be affixed to the must always be carried out after first 25 operat- engine or equipment in an easily visible position. ing hours: The maintenance chart governs the maintenance intervals.

  • Page 154: Maintenance Every 8 - 15 Hours Of Operation

    8 – 15 5.2. Maintenance every hours of operation 5.2.1. Check engine oil level When checking the oil level, the engine should be standing level, and must not be running. – Remove any dirt in the dipstick area. 2393 / 10 –...

  • Page 155: Checking Cooling Air Zone

    5.2.4. Checking cooling air zone – Trap the drops which emerge in a transparent vessel. Since water has a greater specific Severe contamination is a sign that there are gravity than diesel fuel, the water emerges be- large amounts of dust in the atmosphere and fore the diesel fuel.

  • Page 156: Maintenance Every 250 Hours Of Operation

    – If the sealing face is uneven, the air cleaner 5.3. Maintenance every body cracked and/or the filter wool content is hours of operation incomplete, install a new air cleaner. 5.3.1. Oilbath air cleaner maintenance – Attach the upper part of the air cleaner with a new flange gasket.

  • Page 157: Changing Engine Oil, Renewing Oil Filter

    5.3.2. Changing engine oil, renewing oil filter The engine must be stopped, and should stand on a flat, level surface. Drain the engine oil only when it is warm. For oil drain plug, see Chapter 2. Risk of scalding from hot oil. Catch waste oil and dispase acc.

  • Page 158: Checking And Adjusting Valve Clearances

    – Check condition of O-ring „1“ and renew it if necessary (Fig. 36). – Wet the thread and the O-ring of the screw plug with lubricant „K“ (see spare parts list). – Add engine oil up to the „MAX“ mark on the dipstick (see Chapter 4.1.1.) –...

  • Page 159: Clean The Cooling Air System

    5.3.4. Clean the cooling air system Before cleaning, the engine must be stopped and allowed to cool down. Remove parts of air duct. Dry contamination – Clean all air guide elements and the complete cooling air zones on the cylinder head, cylin- der and flywheel blades without making them wet.

  • Page 160: Maintenance Every 500 Hours Of Operation

    5.4. Maintenance every hours of operation 5.4.1. Renewing fuel filter Fuel filter maintenance intervals depend on the purity of the fuel used; reduce them to 250 hours of operation if necessary. Do not smoke or bring a naked flame near the fuel system when working on it.

  • Page 161: Dry-Type Air Cleaner Maintenance

    – Activate mechanical oil pressure monitor (optional extra), chap. 4.1.4. – Run the engine briefly to check the fuel filter and lines for leaks. 5.4.2. Dry-type air cleaner maintenance It is best to clean the filter cartridge only when the maintenance indicator displays the appropri- ate signal.
  • Page 162 Cleaning the filter cartridge Dry contamination 2392 / 16 – Unscrew the hex. nuts and remove them with 2281 / 5 filter cover „1“. – Carefully pull out filter cartridge. – Blow through the filter cartridge from the in- side, moving the jet of dry compressed air up –...

  • Page 163: Malfunctions - Causes - Remedies

    Malfunctions – Causes – Remedies Malfunction Possible causes Remedial action Chap. Engine will not Speed control lever is in stop or start or start is idle position. delayed, although Stop lever in stop position. Set lever to „START“-position 4.2. it can be turned over with the No fuel reaching injection pump.
  • Page 164 Malfunction Possible causes Remedial action Chap. At low Fuel separates has inadequate Check whether clear (not turbid) temperatures. resistance to low temperatures. fuel emerges at the fuel line de- tached from the injection pump. If turbid or separated - either warm up the engine or drain the complete fuel supply system.
  • Page 165 Malfunction Possible causes Remedial action Chap. Engine stops by Fuel supply is interrupted: itself during re- - Tank run dry Add fuel. 4.1.3. gular operation. 4.1.4. - Fuel filter blocked Renew fuel filter. 5.4.1. - Defective feed pump. Check through entire fuel supply system.
  • Page 166 Malfunction Possible causes Remedial action Chap. Low engine power, Air cleaner blocked. Remove dirt from air cleaner. 5.3.1. output and speed, 5.4.2. black exhaust Incorrect valve clearances. Adjust valve clearances. 5.3.3. smoke. Malfunction at injector. See workshop manual. Engine runs very Too much oil in engine.

  • Page 167: Work On The Electrical System

    – Do not splash electrical device with water jet 7. Work on the electrical system or pressure jet during engine cleaning. – When carrying out welding work on the en- Batteries generate explosive gases. gine or attached equipment, attach the earth Keep them away from naked flame (ground) clip as near as possible to the weld- and sparks which could cause them to ignite.
  • Page 168 SUPPLEMENTAL INFORMATION TO THE OWNER'S MANUAL FOR 2008 AND LATER EPA CERTIFIED NONROAD COMPRESSION IGNITION ENGINES. EPA EMISSION CONTROL SUPPLEMENTAL WARRANTY STATEMENT AND EMISSION-RELATED INSTALLATION INSTRUCTIONS.
  • Page 169 MAINTENANCE AND WARRANTY. SUPPLEMENTAL INFORMATION TO THE OWNERS MANUAL FOR 2008 AND LATER EPA CERTIFIED NONROAD COMPRESSION IGNITION ENGINES. The following supplemental information is furnished for EPA Nonroad Compression Ignition Engines which are certified according to 40 CFR Part 89 and Part 1039. This information contains the following specific items: •...
  • Page 170 • Intake manifold • Exhaust manifold • Oil filler cap • Intake and exhaust gaskets at head interfaces • Emission Control Information Labels Only parts manufactured by Hatz and which have passed the Hatz Quality Assurance Program are assured of meeting EPA exhaust emission regulations. UNUSUAL OPERATING CONDITIONS.
  • Page 171 MAINTENANCE SCHEDULE-EPA-RELATED PARTS The following minimum intervals are being adopted for adjustment, cleaning, repair, or replacement of following components: At 1,500 hours, and 1,500-hours intervals thereafter: • Fuel injector tips (cleaning only) At 3,000 hours, and 3,000-hours intervals thereafter: • Fuel injector The exhaust quality of the engines can be influenced by the execution (the quality of execution) of above described maintenance work.
  • Page 172 EPA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS. Motorenfabrik Hatz GmbH & Co. KG warrants the emission control system on your engine for the periods of time listed below provided there has been no abuse, neglect or improper maintenance of your engine. Your emission control system includes: •...
  • Page 173 MANUFACTURERS WARRANTY COVERAGE: The 2008 and later EPA certified nonroad compression ignition engines are warranted for 1500 hours of operation or two years of use, whichever first occurs. If any emission related part on your engine is defective, the part will be repaired or replaced by Motorenfabrik Hatz.
  • Page 174 PARTS WITH SUPPLEMENTAL LIMITED WARRANTY. The following limited warranty is supplemental to the standard HATZ DIESEL LIMITED ENGINE WARRANTY and covers 2008 and later EPA certified engines and applies to the following exhaust emission-related components: • Fuel injection pump • Injection nozzle •...
  • Page 175 SUPPLEMENTAL LIMITED WARRANTY. Hatz Diesel of America, Inc. hereinafter referred to as “HATZ” warrants each of the above-listed parts when installed in a new engine sold by Hatz to be free from defects in material and workmanship under normal use and service, only under the named warranty coverage conditions, after the date of delivery to the original retail purchaser and Hatz will at their option, repair or replace at Hatz's sales headquarters, or at a point designated by Hatz, any part or parts which shall appear to the satisfaction of Hatz upon inspection at...
  • Page 176 EMISSION-RELATED INSTALLATION INSTRUCTIONS “Failing to follow these instructions when installing a certified engine in a piece of nonroad equipment violates federal law (40CFR1068.105(b)), subject to fines or other penalties as described in the Clean Air Act.” “If you install the engine in a way that makes the engine's emission control information labels hard to read during normal engine maintenance, you must place duplicate labels on the equipment.”...
  • Page 177 INSTRUCTIONS ON THE INSTALLATION OF THE EXHAUST SYSTEM Following are the instructions to properly install the exhaust system and related components consistent with the EPA emission regulation requirements. 1D41 · 1D50 · 1D81 · 1D90 S / Z 23 Nm 17 lb ft Exhaust-silencers and protection guard The exhaust silencer is fitted in connection with studs, flat washers and hex.-nuts.
  • Page 178 Preparations: • Remove protection guard in numerical sequence 1...4 (B) if so fitted. It is mounted to the exhaust silencer with three screws. Dismantling: • Remove in numerical sequence 1...3 (C). • For opening screws 1 a special tool is required (HATZ-Ident Nr. 630 815 00). Assembly: •...
  • Page 179 1D41 C · 1D81 C Encapsulated engine Before dismantling the exhaust system the capsule has to be dismounted: • Remove the four screws (2) of the top cover (3). • Remove the side cover (1) by opening the two clips. •...
  • Page 180 Assembly: • Assemble in reverse sequence. • Apply lubricant as specified by HATZ. • Torque to specification! • Before tightening the capsule all screws have to be turned in and the different covers have to be correctly adjusted.
  • Page 181 1D41 C · 1D81 C Sequence of dismantling the exhaust system: • Open screws (1) and (2) and remove with shims. • Remove big silencer with attached sealing gaskets (3). • Open screws (4) and remove with shims. • Remove silencer (5) with attached sealing gaskets (6).
  • Page 182 Assembly: • Assemble in reverse sequence. • Apply lubricant as specified by HATZ. • Torque to specification ! • Ensure gasket-kit is fitted in correct sequence i.e. the creased gaskets (6) face towards exhaust silencer. • Make sure that all parts are correctly placed and tightened. SAMPLING OF EXHAUST EMISSIONS After the engine is installed in the equipment and placed in service, the sampling of exhaust emissions can be performed in a way that prevents diluting the exhaust sample...
  • Page 183 Version 2 Specification 2: Adding a 20-centimeter bended extension to the exhaust pipe Version 1 Version 2 Clamp Engine type Ø d (mm) HATZ-Ident. Nr. HATZ-Ident. Nr. HATZ-Ident. Nr. 039 973 01 830 860 00 503 880 00 1D41 S / Z 830 857 00 830 858 00 037 409 00...

  • Page 184: Supplemental Information To

    SUPPLEMENTAL INFORMATION TO THE OWNER´S MANUAL FOR 2008 AND LATER CALIFORNIA REGULATIONS FOR HEAVY-DUTY OFF-ROAD ENGINES. CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT AND EMISSION-RELATED INSTALLATION INSTRUCTIONS.

  • Page 185: Engines

    MAINTENANCE AND WARRANTY. SUPPLEMENTAL INFORMATION TO THE OWNER´S MANUAL FOR 2008 AND LATER CALIFORNIA REGULATIONS FOR HEAVY-DUTY OFF-ROAD ENGINES. The following supplemental information is furnished for California Heavy-Duty Off-Road Engines. This information contains the following specific items: • CARB-related engine parts and engine operating conditions •...
  • Page 186 • Oil filler Cap • Intake and exhaust gaskets at head interfaces • Emission Control Information Labels Only parts manufactured by Hatz and which have passed the Hatz Quality Assurance Program are assured of meeting CARB exhaust emission regulations. UNUSUAL OPERATING CONDITIONS. The engine must not be operated at a load factor less than 25 % for an extended period as such operation will cause the fuel injector to foul.
  • Page 187 At 3,000 hours, and 3000 hours intervals thereafter: • Fuel Injectors The exhaust quality of engines can be influenced by the execution (the quality of execution) of above described maintenance work. Therefore, the maintenance work has to be carried out by a qualified workshop. Hatz authorised workshops, for example, are qualified workshops.
  • Page 188 MANUFACTURER’S WARRANTY COVERAGE. The 2008 and later heavy-duty off-road engines are warranted for 1500 hours of operation or two years of use, whichever first occurs. If any emission-related part on your engine is defective, the part will be repaired or replaced by Motorenfabrik Hatz GmbH &...
  • Page 189 HATZ DIESEL SUPPLEMENTAL WARRANTY FOR 2008 AND LATER CALIFORNIA CERTIFIED HEAVY-DUTY OFF-ROAD ENGINES. PARTS WITH SUPPLEMENTAL LIMITED WARRANTY. The following limited warranty is supplemental to the standard HATZ DIESEL LIMITED ENGINE WARRANTY and covers 2008 and later California certified Heavy-Duty off- road engines and applies to the following exhaust emission-related components: •...
  • Page 190 SUPPLEMENTAL LIMITED WARRANTY. Hatz Diesel of America, Inc. hereinafter referred to as "HATZ" warrants each of the above-listed parts when installed in a new engine sold by Hatz to be free from defects in material and workmanship under normal use and service, for a period of twenty-four (24) months after the date of delivery to the original retail purchaser and Hatz will at their option, repair or replace at Hatz's sales headquaters, or at a point designated by Hatz, any part or parts which shall appear to the satisfaction of Hatz upon inspection at such point,...
  • Page 191 EMISSION-RELATED INSTALLATION INSTRUCTIONS “Failing to follow these instructions when installing a certified engine in a piece of nonroad equipment violates federal law (40CFR1068.105(b)), subject to fines or other penalties as described in the Clean Air Act.” “If you install the engine in a way that makes the engine's emission control information labels hard to read during normal engine maintenance, you must place duplicate labels on the equipment.”...
  • Page 192 INSTRUCTIONS ON THE INSTALLATION OF THE EXHAUST SYSTEM Following are the instructions to properly install the exhaust system and related components consistent with the CARB emission regulation requirements. 1D41 · 1D50 · 1D81 · 1D90 S / Z 23 Nm 17 lb ft Exhaust-silencers and protection guard The exhaust silencer is fitted in connection with studs, flat washers and hex.-nuts.
  • Page 193 Preparations: • Remove protection guard in numerical sequence 1...4 (B) if so fitted. It is mounted to the exhaust silencer with three screws. Dismantling: • Remove in numerical sequence 1...3 (C). • For opening screws 1 a special tool is required (HATZ-Ident Nr. 630 815 00). Assembly: •...
  • Page 194 1D41 C · 1D81 C Encapsulated engine Before dismantling the exhaust system the capsule has to be dismounted: • Remove the four screws (2) of the top cover (3). • Remove the side cover (1) by opening the two clips. •...
  • Page 195 Assembly: • Assemble in reverse sequence. • Apply lubricant as specified by HATZ. • Torque to specification! • Before tightening the capsule all screws have to be turned in and the different covers have to be correctly adjusted.
  • Page 196 1D41 C · 1D81 C Sequence of dismantling the exhaust system: • Open screws (1) and (2) and remove with shims. • Remove big silencer with attached sealing gaskets (3). • Open screws (4) and remove with shims. • Remove silencer (5) with attached sealing gaskets (6).
  • Page 197 Assembly: • Assemble in reverse sequence. • Apply lubricant as specified by HATZ. • Torque to specification ! • Ensure gasket-kit is fitted in correct sequence i.e. the creased gaskets (6) face towards exhaust silencer. • Make sure that all parts are correctly placed and tightened. SAMPLING OF EXHAUST EMISSIONS After the engine is installed in the equipment and placed in service, the sampling of exhaust emissions can be performed in a way that prevents diluting the exhaust sample...
  • Page 198 Version 2 Specification 2: Adding a 20-centimeter bended extension to the exhaust pipe Version 1 Version 2 Clamp Engine type Ø d (mm) HATZ-Ident. Nr. HATZ-Ident. Nr. HATZ-Ident. Nr. 039 973 01 830 860 00 503 880 00 1D41 S / Z 830 857 00 830 858 00 037 409 00...
  • Page 199 CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.
  • Page 200 After each completed performance of a maintenance interval the included form must be fill out, stamped, signed and send back to us immediately. via e-mail to service@probst-handling.de / via fax or post Operator: _ _ _ _ _ _ _ _ _ _ _ _ _...

This manual is also suitable for:

Tm-150-d-aTm-200-d-aTm-250-d-a

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