KIT 120 ASSEMBLY INSTRUCTIONS

Transcription

1 FOUR ASHES MACHINERY LTD. KIT 120 ASSEMBLY INSTRUCTIONS For information regarding the assembly procedures please contact:

2 1- Contents Remove one panel of the crate to facilitate the inventory. The crate can be re used once the machine is assembled for onward shipping of the completed machine if required. Heavy components such as the main chassis will require a minimum of two people or the use of lifting equipment. Please wear appropriate footwear and take care when lifting heavy parts. 2x Rubber Tracks 2x Side Fenders 6x Rollers 2x Cog Wheels and Spacers 2x 160cc Hydraulic Orbital Motors 1x Chassis 1x Front Wheels Axle 2x Track Tensioner Blocks 1x Front Dozer Blade 6x 25mmØ x 35mm Bushes 1x Underside Skid Plate 1x Seat 1x Boom Housing Support Frame 1x Control Valve Units 7 Ports 1x Set of 24 Hoses (details in hydraulic diagram) 1x 6.5hp Gasoline Engine 1x Gear Pump 3.2cc 1x Bell Housing and Coupling 1x Oil Optic Gauge 1x Hydraulic Reservoir Inspection Plate with Gasket and Cap 6x Hydraulic Rams 1x Boom Housing 1x Boom 1x Dipper Arm 2x Pivot Brackets for Bucket 1x Set of Pins: Ø20mm 1x 160mm for slew cylinders 1x 75mm for left hand slew cylinder 2x 100mm for dozer blade 1x 80mm with no head dozer blade 1x 85mm on dipper arm for bucket cylinder 1x 100mm for bucket bracket pear shape head 1x 125mm for bucket bracket pivot round head 2x 195mm for bucket 4x 20mmØ x 25mm Bushes for bucket pins Ø25mm 1x 260mm for boom housing 2x 140mm for boom and boom cylinder

3 2x 110mm for boom 1x 128mm for boom to dipper connection 1x 85mm for dipper cylinder 3x Buckets 1x Ripper Tooth 1x Bag of Mechanical Fittings: M24 14x Washers M20 8x Washers M12 4x 120mm Bolts for tensioning blocks 6x 50mm Bolts for track motors 6x 40mm Bolts for bulkhead to chassis 12x 30mm Bolts for sides and bottom plates 10x Nylon Insert Nuts 4x Nuts to lock bolts on tensioning blocks 24x Washers 8x Large Washers for side plates M10 4x 20mm Bolts for seat base 4x Nuts 8x Washers M8 4x 60mm Bolts for cog wheels and control valves 4x 30mm Bolts for bell housing 4x 20mm Bolts 4x 25mm Bolts 4x Engine rubber mounts 18x 16mm Bolts for pins 10x Washers 4x 40mm Washers for cog wheels M6 4x 12mm Bolts for reservoir plate 4x Allen type Bolts for pump 4x Washers 20x Grease Nipples 3x Lynch Pins 2x Circlips 1x Bag of Hydraulic Fittings: ¾ inch BSP 1x Valve Male / Female 1x Fluted Connector 19mm

4 ½ inch BSP 6x Banjo Screws 12x Self-Centering Washers ⅜ inch BSP 1x Fluted Connector 3x Equal T Male 1x Plug 11x Union M / M 18x Banjo Screws 47x Self-Centering Washers ¼ inch BSP 2x Banjo Screws 4x Self-Centering Washers 2- Introduction These instructions are to help you in the assembly process of the machine(s). They are a guideline only reflecting our own experience in machine assembly. Please take all the necessary steps to ensure your personal safety and of others during the assembly process. Our machines are in constant evolution and our aim is to reduce the assembly time to a minimum. It is possible that the machines you received are slightly different than the one in the pictures and we will update these instructions whenever possible. Your feedback would be appreciated to help improve our services and products. We recommend the use of hydraulic thread lock fluid when fitting non-union hydraulic connectors (i.e not on hoses fittings) or in some cases PTFE tape. Thread lock fluid is also recommended for bolts which are not used in conjunction with a nylon insert nut or spring washer. Check all bolts after a few hours use and again at regular intervals. You will also need a good selection of tools including a set of flat spanners in metric sizes (10, 13, 17, 18, 19, 22,.), adjustable wrench, hex keys, hammer, mallet, hammer, metal file, drill, 6mm and 8mm taps And other consumables like hydraulic oil (20L of ISO HVI46), 4 stoke engine oil (1L of 10W40), grease and grease gun, cable ties, hose wrap, etc.

5 3- Rolling Chassis Once you have identified all the parts, place the main chassis on the floor with a piece of cardboard or similar to avoid damaging the paint work. Fit the front bulkhead frame. And secure with 6x M12 40mm bolts and nylon insert nuts size and washers

6 Move the chassis as per the picture above for easy access, then fit the control valves, Using 2x M8 60mm bolts and nylon insert nuts

7 and the two 160cc hydraulic motors with their hoses. Refer to the hydraulic diagram for the correct hoses. You will need 4x M12 50mm bolts and nylon insert nuts Then assemble the front track tensioners and axle. Excess paint may have to be removed first to facilitate the assembly. 4x M12 120mm bolts are used together with 4x M12 nuts to lock the bolts in position once the rubber tracks are tensioned. Although the front axle is fixed, It is good practice to grease the inside of the tensioning blocks to facilitate future removal.

8 With the machine still on its side as per the pictures, position the rollers and push fully into position onto their axles. Place one rubber track over the rollers and over the cog wheel and then slide the cog wheel onto the orbital motor shaft with the key way in place. Repeat on the other side. Fit all the spacers: 6 x 35mm by 25mm Ø tubes and the cog wheel spacers/fillers and secure the cog wheel(s) with 2x M8 60mm bolts and 4x M8 40mm flat washers and thread lock fluid. Adjust the tension of the rubber tracks to about one inch slack by tightening the 4 long M12 bolts on the tensioning blocks. Then fit the side protection plates with 8x M12 30mm bolts and washers

9 Run the feed and return hydraulic hoses (No. 2 and 3, 10mmØ) inside the chassis ready for later. Make sure that the large banjo (1/2 inch) ends are at the front of the machine towards the control valves. You can now rest the machine on its tracks 4- Boom Housing and Arms For the boom housing, main boom and dipper arm assembly we recommend that you first identify all the relevant pins and if necessary rub the excess paint off. Make sure all the pins fit freely into their bushes or holes and clear any swards of metal if necessary using a metal file. Re-tap and fit all the grease nipples into their location prior assembly. Before installing the boom housing, fit the dozer blade assembly complete with the ram and hoses into position. Feed the hoses through first then install the blade and secure with the pins.

10 Then fit the boom housing and the two digging arms.

11 Place an M24 washer between the boom housing and support before fitting the boom housing.

12 Assemble the bucket pivot bracket again using M20 washers to limit play. Use a selection of large M20 and M24 washers to limit side play of the boom and arm assembly where necessary.

13 5- Hydraulic Components and Hose Diagram T = Hydraulic reservoir M = Engine

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15 Hose listing: No. Diameter / Length (mm) Hydraulic crimped fittings Function 1 19 / 350 None Reservoir to Pump 2 10 / 2050 Banjo ⅜ / Banjo ½ Control Valve to Pump 3 10 / 1900 Banjo ⅜ / Banjo ½ Reservoir Return to Valve 4 8 / 1660 Banjo ⅜ / Banjo ½ Hydraulic Motor Left 5 8 / 1730 BSP ⅜ x90 / Banjo ½ Hydraulic Motor Left 6 8 / 1650 Banjo ⅜ / Banjo ½ Hydraulic Motor Right 7 8 / 1730 BSP ⅜ x90 / Banjo ½ Hydraulic Motor Right 8 8 / 1550 Banjo ⅜ / Banjo ⅜ Main Boom Cylinder 9 8 /1350 BSP ⅜ x90 / Banjo ⅜ Main Boom Cylinder 10 8 / 1650 Banjo ⅜ / Banjo⅜ Dipper Cylinder 11 8 / 1450 BSP ⅜ x90 / Banjo ⅜ Dipper Cylinder 12 8 / 2400 Banjo ⅜ / Banjo⅜ Bucket Cylinder 13 8 / 2700 BSP ⅜ x90 / Banjo ⅜ Bucket Cylinder 14 8 / 1300 Banjo ⅜ / Banjo⅜ Dozer Blade Cylinder

16 15 8 / 1300 BSP ⅜ x90 / Banjo ⅜ Dozer Blade Cylinder 16 8 / 400 BSP ⅜ x90 / BSP ⅜ x90 Slew Cylinder Right 17 8 / 650 BSP ⅜ x90 / BSP ⅜ x90 Slew Cylinder Left 18 8 / 960 Banjo ⅜ / BSP ⅜ xstaight T connector 19 8 / 400 BSP ⅜ x90 / BSP ⅜ x90 Slew Cylinder Left 20 8 / 650 BSP ⅜ x90 / BSP ⅜ x90 Slew Cylinder Right 21 8 / 950 BSP ⅜ x90 / BSP ⅜ xstaight T connector 22 8 / 300 Banjo ¼ / BSP ⅜ xstaight Case Drain Right Motor 23 8 / 600 Banjo ¼ / BSP ⅜ xstaight Case Drain Left Motor 24 8 / 400 Banjo ⅜ / BSP ⅜ xstaight T connector to reservoir Notes: banjo fittings on the lower row of the control valves, elbow fittings on the top row. Each banjo screw requires two washers. For the top row of the control valves, you will need to fit one union connector ⅜ male x ⅜ male with a washer on the control valves side before fitting the elbow end of the hoses. Clean the inside of the reservoir we use a hoover extension followed by a magnet to pick up any metal residues. Screw on the metal gauge filter, hand tighten holding the filter at the base so not to distort it. Fit the inspection cover with its rubber gasket and cap using 4x M6 10mm bolts and washers.

17 Install the 5 cylinders with a total of 8 x grease nipples (only needed on the head of the small slew cylinders as per picture below) and 4 union connectors ⅜ male x ⅜ male on the slew cylinders. Don t forget the washers on the cylinder side. Level the slew cylinder into position using M20 washers. Tip: place the heads of the cylinder with the grease nipple facing inwards to avoid the hydraulic hoses getting caught on the nipple when operating (not showing on picture) Kit 360 shown on these pictures. The boom housing, boom and dipper arms are the same as on the Kit 120. Please note that the picture is showing the three large cylinders with union connectors fitted. This has now been changed to banjo fittings so no connectors are needed.

18 6- The Gasoline Engine and Hydraulic Pump Assembly Instructions for the maintenance for the engine are included in the box. Don t forget to fill up with oil. Follow the sequence of pictures below for the pump assembly.

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20 Install the engine into position and fix with the 4 rubber vibration dampers. Very important: Make sure that the pump is facing as per the picture so the feed into the pump (hose no.1, 19mm Ø) is facing upwards. 7. Finishing the Hydraulic System and Test the Machine Connect the hoses for the slew cylinders and connect them to the T connectors inside the chassis frame.

21 Connect return hose no. 3 to the rear of the reservoir and hoses 24 for the case drain of the motors in the other hole. The last remaining hole can be plugged in with the ⅜ plug. Hoses number 22 and 23 shown above, fitted to the case drain of the hydraulic motors. Simply undo the hex bolt and fit the drain hoses with a ¼ banjo screw and two washers. Note: if you experience a leak on these fittings, simply remove the round thin metal plates on the motors so the banjo screw tightens fully.

22 Fit the service valve to the reservoir as per picture. No need for a washer but a thin layer of PTFE tape on the thread. Very important: always keep the valve in the open position when the engine is running to avoid damaging the pump. If necessary remove the red handle to avoid the valve being switch off by accident. Hose no.1 fitted to the pump (pictures taken show the engine and pump mounted sideways)

23 Oil flow out return to reservoir Oil flow in from pump Control valves. Connect all the hoses and secure with cable ties and / or plastic hose wrap to ensure that they don t rub on any part of the machine during operation.

24 Fill up the reservoir with hydraulic fluid to approximately 2 inches from the top to avoid overspill through the breather cap. Fill up the petrol tank of the engine with unleaded and start the machine. Air will be chased gradually through the system until it reaches the reservoir. Let the engine warm up fully and operate the digging at low engine speed to avoid jerky movements. Once you are satisfied that there are no leaks, you can fit the bottom plate underneath the chassis with 4x M12 30mm bolts. Operation manuals can be downloaded from