TF 220s

MACHINE TYPE / MODEL TF220 S

SERIAL NO. 21020181-01
YEAR OF MANUFACTURE 2012

OPERATION, MAINTENANCE & SPARE PARTS MANUAL

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Important

These operating and maintenance instructions should be read and observed

carefully prior to transport, installation, commissioning, maintenance and
servicing of the machine!

Authorized personnel only, that is familiar with the operating and maintenance
instructions and the appropriate instructions with regard to safety at work and
accident prevention, is allowed to use, maintain and repair this machine.

This instruction manual contains important information on how to operate the

machine safely, properly and most efficiently. Observing these instructions
helps to avoid danger, to reduce repair costs and downtimes and to increase
the reliability and life of the machine.

The operating instructions must always be available wherever the machine is

in use.

DERNASEER ENGINEERING reserve the right to change specification without

prior notice.

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Contents

1 SAFETY

2 TECHNICAL INFORMATION

3 OPERATION

4 MAINTENANCE

5 TROUBLESHOOTING

6 APPENDIX

7 SPARE PARTS

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SAFETY

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SAFETY

SAFETY INTRODUCTION

Operators should be trained in the correct and safe use of all equipment.

Before operation the operator(s) must:-

(i) Have read and understood the Operators manual and Safety signs in this
manual and around the machine.

(ii) Be aware of all the moving parts of the machine.

1.2 SAFETY SIGNS

Particular attention should be paid to the following safety signs.

This is the safety alert symbol. When you see this symbol be alert to the
possibility of personal injury or death.

IMPORTANT

Indicates a statement of company policy as the message relates directly or indirectly

to the safety of personnel and protection of property.

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LOCK OUT EQUIPMENT BEFORE SERVICING.

FALLING HAZARD – DO NOT CLIMB ON TO

WORKING MACHINERY.

BEWARE OF HYDRAULIC OIL LEAKS. HIGH

PRESSURE HYDRAULIC OIL CAN PENETRATE THE
SKIN CAUSING SERIOUS INJURIES. USE A PIECE OF
CARDBOARD TO FIND LEAKS. DO NOT USE BARE
HAND.

OPERATORS MANUAL MUST BE READ AND FULLY

UNDERSTOOD, BEFORE PERFORMING ANY
OPERATION OR MAINTENANCE.
MAINT

EYE PROTECTION MUST BE WORN IN THIS AREA

HEAD PROTECTION MUST BE WORN IN THIS AREA

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EAR PROTECTION MUST BE WORN IN THIS AREA

NIP POINT – KEEP HANDS CLEAR OF MOVING

MACHINERY

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ELECTRICAL AND ENGINE SAFETY

1. Never work on the electrical system of any equipment unless you are thoroughly
familiar with system details.

2. Work on the electrical system must only be carried out by a qualified electrician.

3. The electrical equipment of the machine should be inspected at regular intervals.

Damaged cables or loose connections must be corrected immediately. Use only
original fuses with the specified current rating.

4. It is recommended that an earth leakage safety switch be fitted in the supply line to
the power point on site. Special care should be taken to ensure that earth wires are
correctly connected.

5. Disconnect the battery ground leads whenever performing any electrical

maintenance or servicing to your engine.

6. Battery posts, terminals and related accessories contain lead and lead
compounds, chemicals known to the State of California to cause cancer and
reproductive harm. Wash hands after handling.

7. Never short across the starter terminals of a battery as this can cause a fire and
could also damage the electrical system.

8. Battery electrolyte contains acid and can cause serious injury. Avoid contact with
skin and eyes. Use gloves and protective glasses.

9. Diesel engine exhaust emissions contain products of combustion which may be

harmful to your health. Always operate the machine in a well ventilated area and if
operating in an enclosed area, vent the emissions outside.

10. Do not touch any part of the engine or exhaust system. Allow the engine and
exhaust to cool before performing any repair or maintenance.

11. Never fill the fuel tank with the engine running, while smoking or when near an
open flame.

12. Never overfill the tank or spill fuel. If fuel is spilled, clean it up immediately.

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HYDRAULIC SAFETY

1. Never disconnect any hydraulic circuit without consulting with Dernaseer

Engineering or your local dealer.

2. Only personnel with expert training and experience in hydraulics are

authorized to perform any maintenance or repair work.

3. Return controls to neutral position and relieve all pressure in the hydraulic
system, before attempting to disconnect any hydraulic circuit or component.

4. Do not handle or repair hydraulic equipment with bare hands.

5. Beware of hydraulic oil leaks. Hydraulic fluid under pressure can penetrate the
skin or damage eyes. Fluid leaks under pressure may not be visible. Use a
piece of cardboard to find leaks but do not use bare hand.

6. Wear safety goggles for eye protection. If fluid enters skin or eye, get
immediate medical attention.

7. Ensure that any damaged hoses are replaced with those of the same
specification as the original.

8. Do not exceed safe limits. Never set a pressure relief valve to a pressure
higher than that set at the factory. 185 Bar (2500 PSI).

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SAFETY BEFORE AND DURING OPERATION

Only qualified and trained personnel should attempt to operate this machinery.

1. Read and understand the Operators Manual before you start the machine.
Study the DANGER, WARNING, CAUTION and IMPORTANT safety signs on your
machine.

2. Check your machine and have all systems in good operational condition.
- Check for broken, missing or damaged parts.Replace and make necessary repairs.
- Ensure all safety guards and emergency stops are fitted and in working order.
- See ‘Daily Maintenance’ for more detailed checklist before start-up.

3. Before starting, walk completely around the machine. Make sure no one is under
it, on it or close to it. Let other workmen and bystanders know you are starting up and
do not start
until everyone is clear of the machine.

4. During operation, do not climb onto, over or under moving conveyor belts and
rollers.
Always use ladders, steps and walkways when mounting and dismounting.

5. Hole alignment on mechanical supports must be checked and secured with pins
provided
and in accordance with safety signs.

6. Never check the tension of ‘V’ belts, drive chains and conveyors when machine is
running.

7. Never work or stand beneath machinery or attachments as it is raised or lowered.

8. Never work or stand beneath machinery as they are being loaded with and/or
discharging
material.

9. Follow safe operating practices. Operate the machine controls smoothly. Avoid
sudden
stops, starts or changes in direction.

10. Only use emergency stop buttons or emergency stop lines (if fitted) in
emergency situations or during safety drills.

11. After each day’s operation, always run the machine dry; never leave material in
the beltfeeder on conveyor belts or screenbox. Starting a machine with a full load will
cause strain problems in your machine.

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SAFETY BEFORE AND DURING MAINTENANCE

Maintenance should only be carried out by trained and qualified personnel.

1. Whenever maintenance or service is being carried out a minimum of two (2)

persons should be present at all times. NEVER WORK ALONE.

2. Prepare yourself. Wear a hard hat, safety goggles, hearing protection and other
protective equipment as required by job conditions. Do not wear loose clothing or
jewellery that can catch on controls or moving parts. Long hair must be tied back.

3. Prepare the machine. Move the machine onto a level surface and apply parking
brakes and/or wheel chocks. Shut off the engine and remove the key. Relieve all
hydraulic pressure by returning controls to neutral. Secure all hydraulically operated
attachments with pins provided.

4. Isolate all electrical supplies to the machine before starting any maintenance work.

5. Never attempt repairs or adjustments to the machine while it is running. (Exempt to

this rule: Belt tracking adjustments are only possible during working process - see
Belt Tracking).

6. Remove only guards or covers that provide access. Wipe away excess grease and
oil.

7. Never leave guards off or access doors open when unattended. Keep bystanders
away if access doors are open.

8. When working beneath raised equipment, always use blocks, jack-stands or other
rigid and stable supports. Never work under unsupported equipment.

9. Performing work above 6ft-6” (2m) always use an approved (EN/ANSI) safety
harness. Always use walkways and platforms provided or a safe secure platform
approved by the machine operators management. Do not use any unauthorised or
unsafe platforms.

10. Never operate any type of engine without proper ventilation – EXHAUST FUMES
CANKILL. (See Electrical and Engine Safety for more detailed checklist).

11. Checking for hydraulic leaks. Beware hydraulic fluid under pressure can
penetrate the skin or damage eyes. Fluid leaks under pressure may not be visible.
Use a piece of cardboard to find leaks but do not use bare hand.

12. Wear safety goggles for eye protection. If fluid enters skin or eye, get immediate
medical attention. (See Hydraulic Safety for more detailed checklist).

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

14. Rotating and moving parts must be inspected during maintenance and replaced if
cracked or damaged. Excessively worn or damaged parts can fail and cause injury or
death.

15. After maintenance, tighten all bolts, fittings and connections.

Install all guards, covers and shields. Replace or repair any damaged ones. Refill and
recharge pressure systems with recommended fluids.
Start the engine and check for leaks. Operate all controls and make sure the machine
is
functioning properly. After testing, shut down, check the work you performed (any
missing
cotter pins, washers, locknuts, etc.)?
Recheck all fluid levels before releasing machine for operation.

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TECHNICAL INFORMATION

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TECHNICAL INFORMATION

GENERAL INFORMATION

Familiarisation

Front

Right Side

8
1. Main Conveyor
2. Tracks
3. Beltfeeder/Hopper
4. Jacklegs
5. Fuel Tank
6. Hydraulic Tank Rear
7. Main Lifting Ram
8. Engine Compartment Left Side

1 2 3 4 5 6

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GENERAL INFORMATION

Familiarisation

9 11

10 12

9 Ignition Panel
10 Diesel Fuel Visual Level Gauge
11 Hand Throttle
12 Hydraulic Oil Visual Level Gauge

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KEY COMPONENTS

Engine Compartment

The machine is powered by a

CAT 4.4 water cooled diesel
engine output 75kW (100hp)
coupled to hydraulic pumps.
Fitted in a purpose built
compartment it is situated
at the rear of the machine and
can is hinged from the main
frame.
This allows you to swing the
complete engine compartment
away providing easy access to
all filters and gauges.

Track Undercarriage

The machine is mounted on and

driven by a high specification
tracked undercarriage fitted with
transmittal gearboxes with
integrated brake and overcentre
valve.
The movement of the machine
is controlled by a handheld radio
control transmitter.

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Hopper & Beltfeeder

The Loading Hopper capacity is 8

cu metres.
The variable speed beltfeeder
fitted with a1200mm (47”) wide
belt has a speed of 0-16m/min.
Driven by hydraulic gearbox the
beltfeeder can handle the most
difficult material with maximum
efficiency.

Radio Remote Control

The TF220s is operated using this

remote control. This allows the
operator to perform all of the
machines functions from where he
has a full visual around the
machine and work area.

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TECHNICAL DATA

Conveyor Speeds
METRES/MIN
FEET/MIN

Beltfeeder (Variable Speed) 0-16 0-53

Main Conveyor 92 302

Engine Speed 2200 RPM

Hopper Capacity 8 cu mtrs

Hydraulic Pressures BAR PSI

Maximum Working Pressure on Tracks 245 3550

Maximum Working Pressure on rest of machine 172 2500

Pressure Rating on Hydraulic Hoses 3/8” 330 4800

1/2” 275 4000

3/4” 215 312

TONNES

Machine Weights (Approximate) 22

Tank Capacities Ltrs (UK)

Diesel Tank Capacity 440

Hydraulic Tank Capacity 440

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WORKING DIMENSIONS

3910
1615

27525 2930

10356

25°

25667 2930

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CORRECT USE OF MACHINE

1. This machine should be used, for the loading, conveying, and stockpiling of
Aggregate type materials. e.g. Sand, gravel, Coal, Coke..etc.
This does not include hot materials, which will damage your machine.

2. Machine should be run in well ventilated areas.

3. Appropriate space should be allowed for material stockpiles and loading of

machine.

4. This machine should only be loaded via its Loading hopper and beltfeeder.
.
5. Before operating, ensure the machine has been properly installed.

6. Before operating, the machine should be level across the undercarriage

and along the chassis . Ensuring that the weight of the machine is evenly distributed.

7. Before operation the operator(s) must:

(i) Have received specific and adequate training in the task to be carried out.
(ii) Have read and understood the safety instructions in Section 1
(iii) Knows the location and function of controls and safety features
(iii) Be aware of all moving parts of the machine

8. Before operating the operator(s) must ensure that they are properly equipped with
hard hat, ear and eye defenders.

9. Before operation, all safety guards must be in place

10. Before operation, ensure the machine has been properly lubricated. Always
adhere to the lubrication schedule provided. (See Maintenance)

11. Before transportation on public roads, ensure the machine has been properly
secured with no loose material left in or on the machine.

12. After each day’s operation, always run the machine dry, never leave material in
the beltfeeder or on conveyor belts. Starting a machine with a full load will cause
strain problems in your machine.

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Other Permitted Use

Lifting

On occasions, the machine ma ybe used to lift objects( up to the

weight of 1000kg ) This can be done by slinging the object from the
main conveyor as shown in FIG.1. The load must not exceed 1000 kg.
The machines main conveyor and beltfeeder must be in STOP
mode when perfoming this operation.

FIG. 1

SWL
1000
KG

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OPERATION

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OPERATION

The TF220s Tracked Feeder may only be operated and maintained by

authorised and trained personnel who have fully read and understood this
operators manual.

Attention should be paid to the following points prior to operation.

1. Check your machine and have all systems in good operational condition.

- Check for broken, missing or damaged parts. Replace and make necessary repairs.

- Ensure all safety guards and Remote stops are fitted and in working order.
-
2. Before operation, ensure that personnel are clear from the machine.

3. During operation, do not climb onto, over or under machine. Always use ladders,
steps and walkways when mounting and dismounting.

4. Follow safe operating practices. Operate the machine controls smoothly. Avoid
sudden stops, starts or changes in direction.

5. Only use Remote stop buttons or Remote stop lines (if fitted) in Emergency
situations or during safety drills.

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OPERATING MACHINE

Start Up

Before feeding material into the TF220s , the entire machine must be running.

Starting Engine

The Engine must be started to

provide hydraulic power to all C
functions.

Before Starting: B
D
(i) Check the Engine oil level
and the Fuel level and top up if
necessary.
E
(ii) Adjust throttle lever (A) to
approximately halfway.

(iii) Turn the ignition key to the

“ON” position.(B)

The following warning lights on

the control panel will illuminate.

(1) A Red light (C) Oil Pressure

(2) A Red light (D) Alternator

Now turn the key to start A
position (E) the engine will crank
and start after the warning
beeper has sounded for
approximately 7 seconds.
All the lights should extinguish
after start-up). If any of the lights
remain illuminated during
operation, there is a fault
relevant to that indicator.

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OPERATING MACHINE

Before loading material into

the Hopper,
F
• The entire machine
must be running.
• Jack legs must be
lowered to stabilize
machine.
G
Before starting the engine
ensure that all Conveyor H
belts are sufficiently tensioned

The sequence to start the

machine is,

1. Start the Engine and

gradually increase
speed to maximum
(2300 rpm) using
throttle (Item A).
2. Switch on radio remote H
handset, by pulling out
the stop button (F). The
handset power light (G)
will illuminate green.
3. Start the main
conveyor.To do this JACK ENGINE JACK
press and hold button LEGS STOP LEGS

(H) for 10 seconds.

4. Start beltfeeder,To do
this press and hold
button (H) for 10
seconds.

Following the above sequence

ensures no material will
accumulate at transfer points Important
and effect the running of the
machine. Do not press button (F) or “ENGINE
If the belts are not travelling STOP” button when there is material
straight or equally on the idler in the machine. These buttons can
and drive drums, the belts will only be pressed to stop the engine
need “Tracking” (See page when all of the material has been
23). discharged from the machine.
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Raise and Lower Conveyor

Raise and lower of conveyor

can be done by pressing
button (I) to raise conveyor
and button (J) to lower
conveyor.

Slewing

Before slewing, Hopper

must be empty and jack legs
raised to clear ground level.

Slewing can be done by

pressing button (K) to slew left
and button (L) to slew right.

Jack Legs

Jack Legs can be raised and

lowered by pressing button (M)
to raise jack legs and button K L
(N) to lower jack legs.
I

J
JACK ENGINE JACK
LEGS STOP LEGS

M N

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Tracking Machine.

Before Tracking, Hopper

must be empty and jack legs
raised to clear ground level.

In order to track the TF220s,

Press and hold the “track
enable” button (O) for 10
seconds. The “track enabled P
light” (P) will illuminate blue. O
W
Press button (Q) to move both
tracks forward simultaneously. Q
Press button (R) to move both
S
tracks in reverse U
simultaneously.
Press button (S) to move left T V
track forward.
Press button (T) to move left
R
track reverse.
Press button (U) to move right
track forward.
Press button (V) to move right
track reverse.
Once the machine has been
tracked into position, press JACK ENGINE JACK
button (W) to disable the track LEGS STOP LEGS
function.
If “Track Enable” is left on,
after operating tracks, it will
automatically disable within 30
seconds.

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Tracking Conveyor Belts

After initial start up, the belts on the conveyor and feeder can sometimes travel to
the left or right. This can be overcome by following the procedure below.

1. Stop Conveyor

2. Remove guards

3. Slightly loosen bolts on each

bearing (B) using two 24mm
spanners.

4. Start Stockpiler.

5. If the belt is travelling to the

left, incrementally turn bolt
(C) clockwise with a 36mm
spanner. B
If the belt is travelling to the
right, incrementally turn bolt
(D) clockwise with a 36mm
spanner.
As you turn the spanner, the
belt will travel towards the
centre of the drum achieving
uniform belt alignment.

6. Stop Stockpiler.

7. Tighten Bolts (B) on

bearings.

8. Replace Guards

C D

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

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MAINTENANCE

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MAINTENANCE

The TF220S may only be operated and maintained by authorised and

trained personnel who have fully read and understood this operators manual.

LOCK OUT EQUIPMENT BEFORE SERVICING.

Attention should be paid to the following points prior to carrying out

maintenance.

1. NEVER WORK ALONE When maintenance or service is being carried out a

minimum of two (2) persons should be present at all times..

2. Wear the appropriate Personal Protective Equipment as required by job conditions.

Do not wear jewellery or loose clothing that can catch on controls or moving parts.
Long hair must be contained with hairnet.

3. Maintenance or Servicing must never be carried out whilst the machine is running.

4. Remove only guards or covers that provide access. Wipe away excess grease and
oil.

5. Securely support any machine part that must be raised for maintenance.
.
6. When working at heights above (2m) always use an approved (EN/ANSI) safety
harness. Always use walkways and platforms provided or a safe secure platform
approved by the machine operators management. Do not use any unauthorised or
unsafe platforms.

7. Hydraulics. Return controls to neutral position and relieve all pressure in the
hydraulic system, before attempting to disconnect any hydraulic circuit or component.

8.Checking
Checking for hydraulic leaks. Beware hydraulic fluid under pressure can penetrate
the skin
n or damage eyes. Fluid leaks under pressure may not be visible. Use a piece
of cardboard to find leaks but do not use bare hand.

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9. Wear safety goggles for eye protection. If fluid enters skin or eye, get immediate
medical attention.

10. Keep all parts in good condition and properly installed. Replace any worn or
damaged parts immediately

11. Ensure that all safety signs are clean and clearly visible. Replace any damaged
safety signs.

12. After completion of maintenance work on the machine, all safety devices and
guards must be securely fitted again, and be checked for functioning and reliability
during operation.

13. Operate all controls and make sure the machine is functioning properly before
releasing for operation.

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MAINTENANCE – HYDRAULICS

In order to maintain the hydraulic oil at

its peak performance, two different
types of filter namely:

• Air breather (A)

• Return line filters (B)

Air breather:
This combined unit, which also acts as
a filler cap, filters the displacement of
A
air
.
The filter is rated at 40 microns, and is
of non-replacement type. This must
not be left off the machine at any time.
B
Return Line Filter:
The 2 x 25 micron filters, which are
fitted on the return line before the filter
and remove any tiny particles which
can cause damage to the pumps
and motors etc.

The filter element should be changed

in accordance with the routine
maintenance schedule.

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MAINTENANCE – HYDRAULICS

Changing Hydraulic Oil

It is recommended that the machines

hydraulic oil is warm.This will enable
the oil to flow more easily.

Return all Hydraulic Cylinders to their

closed position to return as much
hydraulic oil back to the tank as
possible. C
• Turn engine off.
• Remove the drain plug (Use a
27mmspanner) at the base of
the tank and drain to an
external container large enough
to hold all the oil. (Hydraulic
Tank Capacity:450 litres.)
• Refill the tank until the oil is
between the Min. and max.
marks on the tank gauge (Item
c).
• Run the machine and operate
hydraulic equipment to circulate
oil.
• Stop the machine and top up
the hydraulic system.

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MAINTENANCE – DIESEL ENGINE

The CAT 4.4 diesel engine should be

maintained in accordance with the
manufacturers instructions as detailed
in the “Operators Handbook”, a copy
of which is included with this manual

CHANGING FUEL FILTER

• Unscrew the fuel filters (C) and

carefully dispose off.
• Fill the new filters with diesel and
fit into position.
• Hand tighten the new filters.
C
WATERTRAP
Draining the Watertrap

• Loosen the draintap (D) on the

base of the watertrap.
• Allow the water to drain off. E
• Tighten the draintap when all the
excess water has been drained
off.

CHANGING WATER-TRAP FILTER

To change the watertrap filter element

(E) follow the procedure outlined.

• Stop the machine.

• Remove the bleed.
• Remove the filter& water-trap
bowl.
• Remove the water-trap bowl
from the filter element. D
• Oil top of the water-trap bowl
• Attach new element to water-
trap-bowl.
• Oil top of filter element.
• Attach the filter element.
• Replace the bleed.

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MAINTENANCE – DIESEL ENGINE

F
CHANGING ENGINE FILTERS & OIL

(See the engine Operators Manual for

more detailed information regarding the
Engine)

CHECKING ENGINE OIL

• Turn off the engine. Open the

Engine Inspection Doors (F).
• Remove dipstick (G) from the
engine and clean. Re-insert the
dipstick fully.
• Remove the dipstick again and
observe that the oil level is H
between the min. and max.
levels. If the level is below the
minimum mark oil must be added
through the filler cap (H).
• It is important the oil level is not
above the maximum level. If this
happens some oil must be
removed.

CHANGING ENGINE OIL I G

• Run the engine to ensure the oil

is warm, this enables the oil to
flow more easily. CHANGING ENGINE OIL FILTER
• Stop the engine and open the
fillercap. It is recommended to change the Oil
• Remove the drain plug located filter when changing the oil.
underneath the engine and drain
the oil to an external container • Loosen the Filter (I) and
large enough to hold all the oil dispose off properly.
(Approx 10 ltrs) • Replace with new filter and
• When all the oil has drained off hand tighten on.
replace the drain plug and refill.
Dip the engine.

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MAINTENANCE – DIESEL ENGINE

(See the engine Operators Manual for more detailed information regarding
the Air Filter)

CHANGING THE AIR FILTER

• Turn off the engine

• Unfasten the Filter Cover (J) by unclipping the holding clamps (K).
• Carefully remove the Filter element.Clean inside the filter and insert a
new filter element.
• Re-attach the filter cover and reclip the holding clamps (K).

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CHANGING BELTFEEDER
GEARBOX OIL A

(See Maintenance Schedule for

frequency)

• Turn off the engine

• Open the beltfeeder gearbox
cover guard (A) on the left hand
side of the machine to view the
beltfeeder gearbox.

To drain the gearbox.

• Remove the Fill plug (B) this will

allow air into the gearbox to
allow it to drain.
• Remove the Drain plug (C) and
drain the oil to an external
container large enough to hold
all the oil.(Gearbox oil
capacity:0.8 litres)
• Replace the Drain Plug (C).
• Now refill the gearbox until the C
oil fills the sight glass (D). Use
Gearbox oil: ISO VG 150 or SAE
80W/90

DO NOT OVERFILL THE GEARBOX.

B
• Replace the Filler plug (B).
• Close the beltfeeder gearbox
cover guard.

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CHANGING GEARBOX OIL IN

TRACKS
picture (1)
(See Maintenance Schedule for
frequency)

More effective draining will take place if

the oil is hot
A
• Turn off the engine.
• To drain the gearbox. Clean the
area around the gearbox plugs.
Position the Plugs (A&B) as
shown in the picture (1)
ensuring the plug ( B) is at the B
bottom.
• Remove the plug (A) this will
allow air into the gearbox to
allow it to drain.
• Remove the Drain plug ( B) and
drain the oil to an external picture (2)
A
container large enough to hold
all the oil.
• Start the engine and move the
tracks until the Gearbox is in the
Fill Position with the Plugs
(A&B) as shown in the picture
(2).
• Now refill the gearbox through
the Filler plug (A) until the oil
begins to flow from the level B
plug (B).

DO NOT OVERFILL THE GEARBOX.

Approximate oil quantity

2.5 Litres per Gearbox)

• Replace the plugs (A&B).

• After a short period of operation
visually check the oil level.

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picture (1)

TRACK ADJUSTMENT

As the track wears, they become

slack,and should be checked daily. To
establish if the tracks require adjustment
move the machine, a few metres,
backwards and forwards on level ground,
in a straight line. This enables the track to
adopt its natural degree of tension.
Measure the drop as shown in picture 1
This measurement must be between 5-
20mm.
A
To Release Track Tension

• Remove the adjuster cover plate

(A).
• Loosen the Grease fitting (B) on
the end of the track tensioning
cylinder by one half turn only..
Allow grease to leave the tension B
cylinder therefore reducing the
track tension. Retighten the
Grease fitting (B) and replace the
cover plate (A).

To Increase Track Tension

• Remove the adjuster cover plate

(A).
• Using the special grease gun
adaptor(C) attach to a standard
grease gun and place over the C
grease fitting (B).
• Pump the track out to the correct
adjustment.
• When the track drop appears to
be correct, move the machine
backwards and forwards, and
recheck the drop.
• Replace the cover plate (A)

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TF220 MAINTENANCE AND SERVICING SCHEDULE

MAINTENANCE
ACTION
TASK First Start Interval
10 50 100 200 10 50 100 200 500 100
h h h h h h h h h 0h
General
Maintenance
Check and remove
Check/Remove * *
material build up
Ensure all safety
Check/Replace * *
guards are in place
Check for loose
parts,missing Tighten/Replace * *
nuts&bolts
Check hydraulic
Check/Tighten * *
system for leaks
Check hydraulic oil
Check/Top up * *
level
Check Diesel Oil
Check/Top up * *
Level
Change hydraulic oil Change * *
Check hydraulic oil
Change * *
return filter
Grease all Bearings Grease * *
Beltfeeder
Maintenance
Check Conveyor
Belts for Rips and Check/Replace * *
Tears
Check Belt Tension Check/Tension * *
Check Belt
Check/Align * *
Alignment
Check all rollers
Check/Free * *
running freely
Check Tension on
Check/Tension * *
Belt Scrapers
Check Belt skirting
Check/Adjust/Re
rubbers - No * *
place
Spillage
Check for
obstruction to Check/Remove * *
Drums
Change gearbox oil
in feeder Change * *

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TF220 MAINTENANCE AND SERVICING SCHEDULE

MAINTENANCE
ACTION
TASK First Start Interval
10 50 100 200 10 50 100 200 500 100
h h h h h h h h h 0h
Conveyor
Maintenance
Check Conveyor
Belts for Rips and Check/Replace * *
Tears
Check Belt Tension Check/Tension * *
Check Belt
Check/Align * *
Alignment
Check all rollers
Check/free * *
running freely
Check Tension on
Check/Tension * *
Belt Scrapers
Check Belt skirting
Check/Adjust/Re
rubbers - No * *
place
Spillage
Check for
obstruction to Check/Remove * *
Drums

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TF220 MAINTENANCE AND SERVICING SCHEDULE

MAINTENANCE TASK ACTION First Start Interval
10h 50h 100h 200h 10h 50h 100h 200h 500h 1000h
Track Maintenance
Check Tension of
Check/Tension * *
Tracks
Check Tracks for oil
Check/Repair * *
leakage
Change gearbox oil in
Change * *
tracks

Engine Maintenance
Check Engine Oil level Check/Top up * *
Check water coolant
Check/Top up * *
level
Full engine service Service * *
Air Filter Elements
Air filter pre cleaner Clean * *
Battery Acid Level Check/Top up * *
Change Engine Oil Change * *
Change Oil Filter &
Change * *
Fuel Filter
Slew Ring
Maintenance
Grease Slew Ring Grease * *

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BLANK PAGE

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TROUBLESHOOTING

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BLANK PAGE

55
 TF220s

TROUBLESHOOTING

No Response from any Hydraulic System

Possible Fault Remedy

Low oil Level Top up Hydraulic System with correct fluid

Hydraulic pump shaft broken Replace Pump

Coupling damaged or broken Replace Coupling

Pressure relief valve stuck open position Repair or replace valve cartridge

Motor not turning/Ram not moving Check Hydraulic Pressure and Adjust

Machine operating slowly. No external oil leaks

Possible Fault Remedy

Low oil Level Top up Hydraulic System with correct fluid

Incorrect hydraulic fluid Drain Tank and replace with correct fluid

Leaking relief valve Repair or replace relief valve

Worn control valve spool Replace control valve

Worn hydraulic pump Replace pump

Loose Suction Hose Tighten Suction line

Hydraulic Leaking through motor Check or replace motor

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Tracks will not operate

Possible Fault Remedy

Remote control system not working –

Fuse blown Replace fuse in starter box

Batteries flat in hand held remote Replace batteries
Broken wire in electrical circuit Repair or replace wire

“Track enable” not switched on Switch on track enable

Material lodged in track drive system Isolate machine and clear obstruction

Beltfeeder not working when conveyoris running

Possible Fault Remedy

Remote control system not working –

Fuse blown Replace fuse in starter box

Batteries flat in hand held remote Replace batteries
Broken wire in electrical circuit Repair or replace wire

Key Missing Replace Key

Faulty Control Valve Replace or adjust

Flow Control Valve incorrectly set Reset Flow Control

Belt Loose Tighten Belt

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Beltfeeder not working when conveyoris running

Possible Fault Remedy

Remote control system not working –

Fuse blown Replace fuse in starter box

Batteries flat in hand held remote Replace batteries
Broken wire in electrical circuit Repair or replace wire

Key Missing Replace Key

Faulty Control Valve Replace or adjust

Flow Control Valve incorrectly set Reset Flow Control

Belt Loose Tighten Belt

Excessive Noise when conveyor is running

Possible Fault Remedy

No Grease in bearing Grease Bearings

Conveyor belt rubbing against fixed parts Adjust and Track Conveyor Belt

Drive Drum Scraper to tight Reduce pressure on scraper

Seized Roller Replace Roller

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Conveyor Belt not running

Possible Fault Remedy

Belt Drive Coupling broken or loose Replace or tighten

Bearing Collapsed or seized Replace Bearing

Debris Obstructing End Drum Remove Obstruction

Overloading Clear Material of belt and restart

Belt Loose Tighten belt

Conveyor runs back if stopped with load on belt

Possible Fault Remedy

Non – Return Valve Worn Replace non - return valve

Non – Return Valve Stuck in open Test oil & change filters, change oil if
position due to soiled hydraulic fluid required. Clean / Replace Valve

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APPENDIX

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BLANK PAGE

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APPENDIX
ENGINE PANEL

• Low cost alternative to hard wired traditional panels.

• Compact, attractive design.
• Simplified wiring and installation.
• Superior engine protection and shut down.
• Automatic pre-heat and start-up sequence.
• Battery voltage monitor.
• Tamper proof liquid crystal hour meter display and status indicator.
• Starter motor protection feature.
• Continual fault display after shut down.

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ENGINE PANEL

The control panel is an electronic control panel for engine and machine control. This
panel has many advanced functions that make it a sensible choice for engine control.

FEATURES

TRACK
• 5 engine sensor inputs. ENABLE

• 3 additional specific machine inputs OIL

e.g. e-stop circuit, machine track PRESS
enable.
WATER
• Automatic shutdown on critical fault TEMP
alarm.
ALT
• 6 panel indicators including oil, water
temperature, pre-heat, generic fault, e-
stop pressed, alternator fault.
PRE-HEAT
• 50 amp automotive relays for the
toughest of jobs.

• Individual fused relay outputs with

standard blade automotive fuses.

• LED indicators on all relay outputs.

ENGINE HRS 000000

12.4V E-STOP
PRESSED

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ENGINE PANEL

SPECIFICATIONS

Inputs
Input No Name Description Indication

1 OIL FAULT Low oil pressure sensor LED + LCD message

2 WATER TEMP Water temperature sensor LED + LCD message
3 ALT Alternator fault LED + LCD message
4 TRACK EN Track machine enabled LED + LCD message
5 FUEL LOW Fuel level low sensor fault LCD message
6 AIR FAULT Air filter fault LCD message
7 TEMP Over temperature sensor LCD message
8 AUX1 Spare input LCD message
9 AUX2 Spare input LCD message
10 AUX2 Low hydraulic oil LCD message

Outputs

Output No Name Description Indication Rating

1 FUEL SOL1 Fuel solenoid LED 50A
2 FUEL SOL2 Fuel solenoid LED 50A
3 PRE-HEAT Pre-heat relay LED 50A
4 START Starter solenoid relay LED 50A
5 OIL FAN Oil cooler fan relay LED 50A
6 AUX 1 Spare LED 50A
7 SIREN Siren output relay LED 16A
8 TRACK EN Remote enable relay (track control) LED 16A

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ENGINE PANEL

CONTROL PHILOSOPHY

Start sequence

The unit is only powered on by switching the key switch to ON position.

The following time sequence is activated automatically on pressing AND HOLDING

the key to the start position:

Diagnostic functions

When the engine has started and the key is released, the controller will wait for 5
seconds before reading from sensor inputs. This allows the engine adequate time to
build oil pressure before reading from the sensor.

On activation of an engine fault, the controller will de-activate the fuel solenoid relays.
These are wired in series for added protection in the event of a relay malfunction.
The display will hold on the appropriate indicator for that fault until the key switch is
turned off.

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ENGINE PANEL

RELAY BOARD & CONNECTIONS

ENABLE
TRACK

SIREN

SPADE CONNETIONS

Note:
LED indicators are lit when relay outputs are active.
If the fuse is blown the LED will not light.

Note:
It is recommended that an external isolator switch and fuse are fitted, to
supply power to the panel. This would provide protection in the unlikely event of a
relay malfunction or some other short circuit.

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REMOTE
CONTROL SYSTEM

TRANSMITTER TECHNICAL DATA

METAL RANGE

Supply Voltage

1 X V Alkaline battery, type

6AM6, 6F22, PP3

Range

Dependant on conditions
Typical 80m

Transmission Type

433.92MHz
Momentary/ Latching operation

Operating Temperature

-20c to 60c

Housing

IP65 Sealed

Switch Type
JACK ENGINE JACK
LEGS STOP LEGS
Membrane Sealed

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ULTRABEAM RADIO RECEIVER

TECHNICAL DATA

433.92 MHz
Working Frequency
Range Typical 80m

Supply Voltage 12 – 24V DC

Fuse T100mA
Relay Type K4BC12
Relay Contacts rated at 12A 240V AC / 30V DC
Supply Current Standby (12- <40mA
24V)
Supply Current Active (12-24V) 100mA (Max)
Code Selection Factory Pre Programmed
Operating temperature -10 to 60 degrees Celsius
Storage temperature -20 to 60 degrees Celsius
Coax Length 3m Aerial supplied with mounting
bracket
RELAY FUNCTION CONFIGURATION
CH 1 Left Track Forward C/O
CH 2 Right Track Forward C/O
CH 3 Left Track Reverse C/O
CH 4 Right Track Reverse C/O
CH 5 Conveyor Right C/O
CH 6 Conveyor Left C/O
CH 7 Conveyor Down C/O
CH 8 Conveyor Up C/O
CH 9 Feeder Enable C/O
CH 10 Conveyor Enable C/O
CH 11 Conveyor Jack Legs Dump Valve C/O
CH 12 Track Dump Valve C/O
CH 13
CH 14 Beacon C/O
CH 15 Jack Legs Up C/O
CH 16 Jack Legs Down C/O
CH 17 Track Enable C/O
CH 18
CH 19 Engine Stop C/O
CH 20 Engine Stop C/O

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EXAMPLE WIRING

Fuse +V
E-Stops on e

0V

ENGINE STOP RELAY

RL6 DISABLES FOR 15 SECS

Fuel Pump
Solenoid

TRACK ENABLE /
RL5 SIREN AND BEACON

Movement
Sounder &
Beacon
7 SECS DELAY BEFORE
MOVEMENT RELAYS CAN
BE OPERATED
(Done in software) RL4
Right Reverse
Valve
RL3
Left Reverse
Valve
RL2
Right Forward
Valve
RL1
Left Forward
Valve

Please ensure there is diodes fitted to the solenoid valves.

0V +V of
supply of

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SPARE PARTS

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74