Manteinance Manual TA 1000

Transcription

1 Manteinance Manua TA 1000 Manuae Manutenzione TA 1000 Juy 2007 Lugio 2007 CIEMMECALABRIA SRL Via Bonfadina, Cazzago San Martino (Bs) Itay Te. (0039) Fax (0039)

2 Attention: Attenzione: How to read this manua Come utiizzare questo Manuae Aim of this Manua is those of providing you a the Codes of the parts that form the Turkey Loader TA The manua has been divided into 08 sections, each section incude a the Codes of the Parts that are part of the machine. To see the codes, pace the your mouse on the red question marks, and you wi see the foowing indication: (CODE *XXXX*) (Q.TY *X*). Between the asterisks of CODE you wi find indicated the code of the part that you are searching, instead between the asterisks of Q.TY you wi find indicated the pieces of this item that you wi find on the machine TA Questo manuae serve per conoscere tutti i particoari sottoforma di codice, che compongono a Caricatacchini TA I manuae è suddiviso in 8 parti ed in ognuna di esse vi sono i codici dei pezzi che compongono i macchinario. Per visuaizzare i codici, posizionatevi con i mouse sui punti di domanda di coore rosso, vi comparirà a seguente scritta: (CODE *XXXX*) (Q.TY *X*). Tra gi asterischi di CODE ci sarà indicato i codice de pezzo che voi state visuaizzando, mentre tra gi asterischi di Q.TY, verrà indicato i numero pezzi di que articoo che sono stati utiizzati per reaizzare a Caricatacchini TA TRY NOW

3 INDEX INDICE C. D. E. B. A. Section F. Sezioni A. Box Raccogitore p. 3 A. Preoader p. 3 B. Canae Principae p. 10 B. Main Tunne p. 10 C. Ingabbiatore p. 19 C. Cager p. 19 D. Cabina p. 29 D. Cabin p. 29 E. Meccanismi di soevamento p. 34 E. Lifting system p. 34 F. Impianto Spostamento p. 44 F. Transfer System p. 44 Impianto Eettrico p. 51 Wiring system p. 51 Motore a scoppio "Perkins" p. 56 Perkins Engine p. 56 TA 1000 Manteinance Manua 2

4 Preoader Components (TA1 M01) Componenti Box (TA1 M01) Tappeto / Motore Idrauico Bet / Hydrauic Motor Pignoni / Catena Sprocket / Chain TA 1000 Manteinance Manua 3

5 Ruo Motorizzato Motor Driver Roer Ruo Foe Ide Roer Supporto Ruo / Ruote scorrimento Pre-Loader Roer Support / Preoader siding whees Supporto Ruo Foe Ide Roer Support TA 1000 Manteinance Manua 4

6 Ruota Cancei Box Preoader doors whees TA 1000 Manteinance Manua 5

7 Regoatore di fusso oio idrauico Box Preoader Hydrauic oi reguator TA 1000 Manteinance Manua 6

8 TA Tunne (TA1M03) Canae TA (TA1M03) Roers and Supports Rui e Supporti Ruo Foe Posteriore con Pignone Back Ide Roer with Sprocket Ruo e supporto posizionati Assembed Roer and Support TA 1000 Manteinance Manua 10

9 Rui foi di Sostegno Ide Roers for the Supporting Rui foi di Sostegno posizionati Assembed Ide Roers for the Supporting TA 1000 Manteinance Manua 11

10 Rui Traino e Foe con Supporti TA Towing and ide Roers with supports Ruo Traino Canae con Supporto TA Tunne towing Roer with Support TA 1000 Manteinance Manua 12

11 Rui Foe Canae con Supporti TA Tunne Ide Roers with Supports TA 1000 Manteinance Manua 13

12 Ruo Foe Anteriore Canae con Supporto TA Tunne front Ide Roer with support TA 1000 Manteinance Manua 14

13 Bet / Hydrauic Motor / Sprocket / Chain Tappeto / Motore Idrauico / Pignoni / Catena TA 1000 Manteinance Manua 15

14 Further Componets Atri Componenti TA 1000 Manteinance Manua 16

15 Cager ( TA1M04 ) Ingabbiatore ( TA1M04 ) Catena / Pignone Nastro Ingabbiatore Chain / Caging Bet Sprocket TA 1000 Manteinance Manua 19

16 Catena / Pignone / Abero Spostamento Chain / Sprocket / Cager Moving Shaft TA 1000 Manteinance Manua 20

17 Motore idrauico Hydrauic Motor TA 1000 Manteinance Manua 21

18 Tappeto Ingabbiatore / Ruo Traino / Ruo di sostegno Caging Bet / Towing Roer / Support Roer Ruo Traino Towing Roer TA 1000 Manteinance Manua 22

19 Ruo Foe anteriore Ingabbiatore Front Ide Roer TA 1000 Manteinance Manua 23

20 Ingabbiatore Superiore Upper Cager Tappeto / Ruo Traino Ingabbiatore Superiore / Supporto Upper Cager Bet / Upper Cager Towing Roer / Support TA 1000 Manteinance Manua 24

21 Roo Foe Ingabbiatore Superiore Upper Cager Ide Roer TA 1000 Manteinance Manua 25

22 Aneo Porta Cuscinetto Bearing Housing TA 1000 Manteinance Manua 26

23 Cabin (TA 1M05) Cabina (TA 1M05) Distributori Vave Body TA 1000 Manteinance Manua 29

24 Regoatori di Fusso Fow Reguators TA 1000 Manteinance Manua 30

25 Cabin Supports (TA1M12) Supporti Cabina (TA1M12) TA 1000 Manteinance Manua 31

26 Hydrauic oi Vave Reguator Vavoa Regoazione Fusso Oio TA 1000 Manteinance Manua 32

27 Hose - Hoder Chain Catena porta tubi TA 1000 Manteinance Manua 33

28 Meccanismi di soevamento e Teaio (TA1M02) Frame and Lifting System TA 1000 Manteinance Manua 34

29 Ciindro Brandeggio Cabina / Cavo D acciaio Cabin Swinging Cyinder / Iron Cabe TA 1000 Manteinance Manua 35

30 Ciindro Teescopico Teescopic Cyinder TA 1000 Manteinance Manua 36

31 Moa a Trazione Traction Spring TA 1000 Manteinance Manua 37

32 Pompa Doppia / Campana Motore Doube Pump / Engine Be TA 1000 Manteinance Manua 38

33 Diese Engine (TA1M08) Motorizzazione Diese (TA1M08) TA 1000 Manteinance Manua 39

34 Engine Further Components Componenti Vari Motore TA 1000 Manteinance Manua 40

35 Engine Further Components Componenti Vari Motore TA 1000 Manteinance Manua 41

36 4 Hand Levers Vave Body Distributore 4 Leve TA 1000 Manteinance Manua 42

37 Oi Gauge Liveo Oio TA 1000 Manteinance Manua 43

38 Transmission (TA 1M10) Trasmissione Caricatacchini (TA 1M10) Differenziae / Baestre / Abero di trasmissione Differentia Gear / Leaf Springs / Transmission Shaft TA 1000 Manteinance Manua 44

39 Riduttore Gear Reducer Ruota Whee TA 1000 Manteinance Manua 45

40 Freno Eettrico Eectric Brake TA 1000 Manteinance Manua 46

41 Towing Eye (TA1M11) Raa Caricatacchini (TA1M11) TA 1000 Manteinance Manua 47

42 Wiring System (TA1M07) Impianto Eettrico (TA1M07) TA 1000 Manteinance Manua 51

43 Push Buttons Pusanti TA 1000 Manteinance Manua 52

44 Pug and Movabe Socket / Soenoid Vave Spina e Presa Mobie / Eettrovavoa TA 1000 Manteinance Manua 53

45 Emergency Push Button Pusante Emergenza TA 1000 Manteinance Manua 54

46 Heater / Oi Cap Resistenza / Tappo Oio TA 1000 Manteinance Manua 55

47 Diese Perkins Engine Motore Diese Perkins TA 1000 Manteinance Manua 56

48 Perkins 400 Series Modes HH, HL, HP and HR USER S HANDBOOK 3 and 4 cyinder naturay aspirated diese engines for industria, construction and agricutura appications 4 cyinder turbo charged diese engines for industria, construction and agricutura appications Pubication TPD 1443E, Issue 3. Proprietary information of Perkins, a rights reserved. The information is correct at the time of print. Pubished in February 2003 by Technica Pubications. Part number

49 400 Series Modes HH, HL, HP and HR Contents Safety precautions Genera data Engine data Fue specification Location of engine parts Engine breather Service schedue Maintenance schedue User s Handbook, TPD 1443E, issue 3

50 400 Series Modes HH, HL, HP and HR Safety precautions These safety precautions are important. You must refer aso to the oca reguations in the country of use. Some items ony appy to specific appications. Do not change the specification of the engine. Do not smoke when you put fue in the tank. Cean away fue, which has been spit. Materia, which has been contaminated by fue, must be moved to a safe pace. Do not cean, add ubricating oi, put fue in the tank or adjust the engine whie it runs. Do not make adjustments that you do not understand. Ensure that the engine does not run in a ocation where it can cause a concentration of toxic emissions. Other persons must be kept at a safe distance whie the engine or auxiiary equipment is in operation. Do not permit oose cothing or ong hair near moving parts. Keep away from moving parts during engine operation. Warning! Some moving parts cannot be seen ceary whie the engine runs. Do not operate the engine if a safety guard has been removed. Do not remove the fier cap or any component of the cooing system whie the engine is hot and whie the cooant is under pressure, because dangerous hot cooant can be discharged. Do not aow sparks or fire near the batteries (especiay when the batteries are on charge) because the gases from the eectroyte are highy fammabe. The battery fuid is dangerous to the skin and especiay to the eyes. Disconnect the battery terminas before a repair is made to the eectrica system. Ony one person must contro the engine. Ensure that the engine is operated ony from the contro pane or from the operators position. If your skin comes into contact with high-pressure fue, obtain medica assistance immediatey. Diese fue and ubricating oi (especiay used ubricating oi) can damage the skin of certain persons. Protect your hands with goves or a specia soution to protect the skin. Do not wear cothing which, is contaminated by ubricating oi. Do not put materia, which is contaminated with oi into the pockets of cothing. Discard used ubricating oi in accordance with oca reguations to prevent contamination. The combustibe materia of some components of the engine (for exampe some seas) can become extremey dangerous if it is burned. Never aow this burnt materia to come into contact with the skin or with the eyes. Ensure that the contro ever of the transmission drive is in the "out-of-drive" position before the engine is started. Use extreme care if emergency repairs must be made in adverse conditions. Do not aow compressed air to contact your skin. If compressed air enters your skin, obtain medica hep immediatey. Caution: Do not cean an engine whie it runs. If cod ceaning fuids are appied to a hot engine, certain components on the engine may be damaged. Fit ony genuine Perkins parts. User s Handbook, TPD 1443E, issue 3 3

51 400 Series Modes HH, HL, HP and HR Genera data Read this section carefuy before the engine is started To start the engine Caution: Ether starting fuids must not be used with these engines. 1 Move the engine speed contro to the maximum speed position. 2 Turn the start key counter cockwise to position 3 and hod it there for 6 seconds unti the red amp is iuminated. 3 When the red amp is iuminated, turn the key cockwise to position 2 to engage the starter motor for 20 seconds maximum. 0 4 When the engine starts, reease the key, which wi return to position 1. 5 Set the engine speed contro to give an even ide speed. Note: If the red amp iuminates rapidy for 2 to 3 seconds, or does not iuminate in 6 seconds, this indicates a faut within the cod start system Turn the start key counter cockwise to position (0) to stop the engine. To eiminate air from the fue system H Loosen the vent screw on the fue fiter. 2 Operate the hand primer unti fue, free of air, fows from the vent screw. Tighten the vent screw. 3 Loosen the vent screw on the fue injection pump. Operate the hand primer unti fue, free of air, fows. Tighten the vent screw. 4 Attempt to Start the engine using the starter motor for a maximum of 15 seconds, wait for 30 seconds before trying again. Caution: When using the starter motor, do not exceed continuous rotation of more than 15 seconds periods. If the engine does not run, on initia rotation, wait for 30 seconds and try again. Antifreeze The cooant must consist of equa quantities of anti freeze and soft water. The corrosion inhibitor in the antifreeze wi be diuted if a concentration of ess than 50% is used. Concentrations of more than 50% of antifreeze may have an adverse effect on the cooing properties of the cooant. If an antifreeze mixture, other than Perkins Powerpart is used to prevent frost damage, it must have an ethanedio base (ethyene gyco) with a corrosion inhibitor. The specification must be at east as good as those specified in "Engine data" on page 5. Caution: Do not use sat water or any other cooant that can cause corrosion in the cosed cooing circuit. Atitude The engine wi run correcty up to an atitude of 600 m (2000 ft). If the engine is to be operated permanenty at an atitude above this, the fue consumption and exhaust emmisions may become excessive. Contact the Perkins Appication Department. Turbo charged engines Because of the power characteristics of the turbo charged engine it is necessary to maintain a high engine speed when cimbing a gradient. To ensure that the engine is not overoaded at ow engine speeds seect a ower gear Adjustment of the engine speed The ide or maximum speed setting must not be changed by the operator because this can damage the engine or transmission. The warranty of the engine can be affected if the seas on the contros of the fue injection equipment are broken during the warranty period by a person who is not approved by Perkins. Adjustment of the engine maximum speed setting can ony be made by a Perkins approved representative to within the imits specified on the emissions compiance abe. In these cases a red cooured tamper evident cap wi be fitted after adjustment. 4 User s Handbook, TPD 1443E, issue 3

52 400 Series Modes HH, HL, HP and HR Engine data Engine type 403C C C C-22T Engine code HH HL HP HR Number of cyinders Cyinder arrangement Cyce In-ine Four stroke Induction system Naturay aspirated Turbo charged Combustion system Indirect injection Cubic capacity 1,131 itres (69 in³) 1,496 itres (91 in³) 2,216 itres (135 in³) 2,216 itres (135 in³) Bore 77 mm (3.0 in) 84 mm (3.3 in) 84 mm (3.3 in) 84 mm (3.3 in) Stroke 81 mm (3.1 in) 90 mm (3.5 in) 100 mm (3.9 in) 100 mm (3.9 in) Capacity of the ubricating oi sump and fiter Maximum 4,9 itres (8.6 pints) 6,0 itres (10.5 pints) 10,6 itres (18.6 pints) 10,6 itres (18.6 pints) Minimum 3,4 itres (5.9 pints) 4,5 itres (7.9 pints) 8,9 itres (15.6 pints) 8,9 itres (15.6 pints) Lubricating oi specification Cooant system capacity engine ony Cooant specification Use ony good quaity oi that meets, either of the foowing API CH4 or ACEA E5 1,9 itres 2,6 itres 3,6 itres 3,6 itres Cean soft water with 50% anti freeze concentration ethanedio base / ethyene gyco, corrosion inhibitor to BS 6580 : 1992 or ASTMD or AS Diese fue specification See page 6 Direction of rotation Cockwise from the front Compression ratio 23 : : : : 1 Vave cearances cod intake/exhaust 0,2 mm ( in) Recommended viscosity grades A W 5W20 10W30 15W40 20W o C o F Ambient temperature Aways ensure that the correct viscosity grade of ubricating oi is used for the ambient temperature range in which the engine wi run, as shown in the above chart. User s Handbook, TPD 1443E, issue 3 5

53 Fue specification 400 Series Modes HH, HL, HP and HR To get the correct power and performance from the engine, use good quaity fue. The recommended fue specification for Perkins engines is shown beow: Cetane number: Viscosity: Density: Suphur: Distiation: 45 minimum 2.0 / 4.5 centistokes at 40 C (104 F) 0,835 / 0,855 kg/itre 0.2% of mass, maximum 85% at 350 C (662 F) Cetane number indicates ignition performance. Fue with a ow cetane number can cause cod start probems and affect combustion. Viscosity is the resistance to fow and if this is outside imits, engine performance can be affected. Density: ow density wi reduce engine power, higher density wi increase engine power and exhaust smoke. Suphur: High suphur content (not normay found in Europe, North America or Austraasia) can cause engine wear. Where ony high suphur fues are avaiabe, it wi be necessary to use a highy akaine ubricating oi in the engine or reduce the ubricating oi change interva. Distiation: This is an indication of the mixture of different hydrocarbons in the fue. A high ratio of ight weight hydrocarbons can affect the combustion characteristics. Low temperature fues Specia winter fues may be avaiabe for engine operation at temperatures beow 0 C (32 F). Th ese fues imit the formation of wax in the fue oi at ow temperatures. If wax forms in the fue oi, this coud stop the fow of fue oi through the fiter. Aviation kerosene and R.M.E. type fues These fues may be used, but can effect the engine performance and abiity to start. The ony aviation fues that are permitted for use with these engines are: JP5, JP8 and JET-A if 5% spinde oi is added. Aviation fue JP4 is not recommended. For more information on aviation fues refer to the Perkins Appication Department. Not more than 5% R.M.E. in minera oi diese fue is aowed. Running in Do not operate a new engine at overoad or rapid speed changes. Proonged operation at ight oads at ow speed can cause ubricating oi to enter the exhaust system. Do not operate the engine at overoad or rapid oad change without aowing the engine to warm up, the cooant temperature shoud have reached a minimum of 60 C (140 F). CALIFORNIA Proposition 65 Warning Diese engine exhaust and some of its constituents are known to the state of Caifornia to cause cancer, birth defects and other reproductive harm. 6 User s Handbook, TPD 1443E, issue 3

54 400 Series Modes HH, HL, HP and HR Location of engine parts Introduction Perkins engines are buit for specific appications and the views that foow do not necessariy match your engines specification. Left side 1 Lubricating oi pressure switch option L0101 or L0103 2Fan 3 Cooant temperature switch 4 Crankshaft puey 5 Induction manifod 6 Cooant outet 7 Exhaust manifod 8 Starter motor 9 Aternator 10 Drive bet User s Handbook, TPD 1443E, issue 3 7

55 400 Series Modes HH, HL, HP and HR Right side 11 Engine breather 12 Cooant drain pug 13 Lubricating oi fiter 14 Lubricating oi drain pug 15 Lubricating oi fier cap 16 Atomiser 17 Engine identification abe 18 Mechanica stop contro (eectrica stop contro at rear of pump) 19 Fue injection pump 20 Speed contro ever 21 Fue ift pump 22 Lubricating oi dipstick User s Handbook, TPD 1443E, issue 3

56 AM Series Modes HH, HL, HP and HR Engine breather To renew the engine breather assemby (cosed system) The breather assemby (A1, A3 and A4) shoud be renewed every 2000 hours by a person who has had the correct training. Caution: Ensure that the components of the breather assemby are fitted in their correct position (A). If they are incorrecty fitted, the engine may be damaged. 1 Reease the four setscrews (A2) and remove the breather cover (A1), the spring (A4) and the diaphragm assemby (A3). Caution: It is important that the area around the vent hoe (A6) is cean. 2 Cean the breather cavity (A5) in the rocker cover. 3 Fit a new breather assemby into the cavity in the rocker cover, ensuring that the breather cover, diaphragm and spring are assembed correcty. 4 Tighten the four setscrews A H1010 Service schedue Preventive maintenance periods The preventive maintenance periods in the "Maintenance schedue" on page 10 appy to average conditions of operation. Check the periods given by the manufacturer of the equipment in which the engine is instaed. Use the periods that are shortest. When the operation of the engine must conform to the oca reguations these periods and procedures may need to be adapted to ensure correct operation of the engine. It is good preventive maintenance to check for eakage and oose fasteners at each service. These maintenance periods ony appy to engines that are operated with fues and ubricating ois that conform to the specifications given in this handbook. User s Handbook, TPD 1443E, issue 3 9

57 400 Series Modes HH, HL, HP and HR Maintenance schedue The schedues, that foow, must be appied at the interva (hours or months) that occur first. A Every day or every 8 hours B Every 250 hours or 6 months C Every 500 hours or 12 months D Every 1000 hours E Every 2000 hours F Every 3000 hours A B C D E F Operation Check the cooant eve Check concentration of the cooant (1) Check the tension and condition of the drive bet Renew the aternator drive bet Drain water from the pre-fiter (If fitted) Renew fue fiter canister Check atomisers for performance (2) Check the eve of the engine ubricating oi Renew the engine ubricating oi (fi sowy, ensure correct quantity is used) (3) Renew the engine oi fiter Cean the air fiter and empty the dust bow of the air fiter in extremey dusty conditions Renew the air fiter and empty the dust bow of the air fiter in norma conditions Cean the turbocharger impeer casing and turbocharger compressor casing (2) Check the vave cearances of the engine, if necessary, adjust (2) Check a hoses and hose connections Renew the engine breather Check the aternator and the starter motor (2) Inspect the eectrica system for security of cabes and wear Check and correct any eaks or engine damage (1) Renew the antifreeze every 2 years. If a corrosion inhibitor is used instead of antifreeze, it shoud be renewed every 6 months. Ensure the correct quantity is used. (2) By a person who has had the correct training. (3) The oi change interva wi be affected if the oad factor is greater than 40% or the incorrect specification oi is used. If you are unsure of how to cacuate the oad factor for the appication contact your nearest Perkins distributor. Refer to "Engine data" on page 5 for the correct oi specification. 10 User s Handbook, TPD 1443E, issue 3