User Manual for Crytec models including: D30MB Mini Tracked Dumper, D30MB, Mini Tracked Dumper, Tracked Dumper
Digital User Manuals – Crytec
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DocumentDocumentSave This Manual for Future Reference Original Instruction Mini Tracked Dumper Operator's Manual MODEL NUMBER : D30MB SERIAL NUMBER : Both model number and serial number may be found on the main label. You should record both of them in a safe place for future use. FOR YOUR SAFETY READ AND UNDERSTAND THE ENTIRE MANUAL BEFORE OPERATING MACHINE 300KG Dumper Intended use statement You must read below before operating this machine This machine has been developed and designed for the purpose of transporting hard material such as stone, brick, wood and construction debris. This machine should only be used at the maximum gradients outlined in this manual. You must not exceed the maximum loading weight of 300KG. Material should only be loaded in the bucket area, this machine should not be used to tow or pull any object or vehicle. At no time should this machine be used to carry a human being or animal of any kind!. NO flammable, combustable or chemical products should be transported using this machine Crytec Limited Declaration of Conformity 1. Product Model / Type: a. Product: b. Model: Mini Power Dumper D30MB 2. Manufacturer: a. Name: b. Address: Crytec Limited Unit 1C Upper Mantle Close, Chesterfield S45 9ED, UK 3. This declaration is issued under the sole responsibility of the product manufacturer. 4. The object of the declaration described above is in conformity with the relevant UK Statutory Instruments: 2008 No 1597 The supply of Machinery (Safety) Regulations 2008 (and their amendments) and the Essential Health and Safety and the Essential Health and Safety Requirements 5. We hereby declare that the product described above, to which this declaration of conformity refers to, we have referenced the below designated standards used in relation to which conformity is declared: Reference & Date Title EN ISO 12100 : 2010 EN ISO 3691-6:2015/AC:2016 Safety of Machinery Industrial Trucks - Safety as well as EN ISO 3744:1995 and ISO 6395:1988 6. Additional Information: The technical documentation for the machinery is available from: Name: Address: Signed for & on behalf of: Place of issue: Date of Issue: Name: Function: Signature: Matthew Cryans Unit 1C Upper Mantle Close, Chesterfield S45 9ED Crytec Limited United Kingdom 24/08/2022 Matthew Cryans Director GB TABLE OF CONTENTS The four-speed gearbox, three forward and one reverse, lies at the heart of the unit. It is Introduction 2 Specifications 2 oversized so as to manage safely the huge torques generated by the engine. Thanks to its efficient reduction gearing, it is capable of Symbols 3 moving around in every situation and bearing Safety 4 any load. General Safety Rules 4 Specific Safety Rules 6 Unpacking The Container 7 Contents Supplied 8 Assembly 9 Know your Machine 12 Features & Controls 12 The Engine manufacturer is responsible for all engine-related issues with regards to performance, power rating, specifications, warranty and service. Please refer to the Engine Manufacturer's owner's/operator's manual, packed separately with your unit, for more information. Maintenance Operation 14 16 Specifications Storage Trouble Shooting Parts Schedule 20 21 Item No. 22 Engine D30MB 196cc, 6.5HP Parts Lists 25 Transmission 3F+1R Load Capacity 300 kg Box Length 907-1040 mm Box Width 600-860 mm Box Depth 204 mm Track Width 180 mm Sound power level 101 dB(A) k=2 dB(A) Sound pressure level 81.5 dB(A) k=2 dB(A) INTRODUCTION Vibrating level on Left 10.1 m/s2 k=1.5 m/s2 handlebar grips Right 11.3 m/s2 k=1.5 m/s2 Weight 178 kg Your new mini tracked dumper will more than satisfy your expectations. It has been manufactured under stringent quality standards to meet superior performance criteria. You will find it easy and safe to operate, and with proper care, it will give you many years of dependable service. Carefully read through this entire operator's manual before using this unit. Take special care to heed the cautions and warnings. ENVIRONMENTAL Recycle unwanted materials instead of disposing of them as waste. All tools, hoses and packaging should be resorted, taken to the local recycling center and disposed of in an environment-friendly safe way. 2 MINI TRACKED DUMPER SYMBOLS The rating plate on your machine may show symbols. These represent important information about the product or instructions on its use. Read these instructions carefully. Wear eye protection. Wear hearing protection. Wear protective gloves. Wear safety footwear. Do not remove or tamper with the protection and safety devices. No smoking, sparks, or flames Do not touch parts that are hot from operation. Serious burns may result. Keep your hands clear from all rotating parts. Never start or run the engine inside a closed area. Do not operate on slopes with angle over 20° or tip loading at an inclined position. Be aware, objects may be thrown while in use. The exhaust fumes are dangerous, GB containing carbon monoxide. Staying in the environment can lead to unconsciousness and death. Always turn off the engine before starting maintenance. Keep children and bystanders off and away. MINI TRACKED DUMPER 3 GB SAFETY Protect eyes, face, and head from objects that may be thrown from the unit. Always wear General Safety Rules Understand Your Machine Read this manual and labels affixed to the machine to understand its limitations and potential hazards. Be thoroughly familiar with the controls and their proper operation. Know how to stop the machine and disengage the controls quickly. safety goggles or safety glasses with side shields when operating. Wear appropriate hearing protection. Always keep hands and feet away from all moving parts during operation. Moving parts can cut or crush body parts. Always keep hands and feet away from all pinch points. Make sure to read and understand all the instructions and safety precautions as outlined in the Engine Manufacturer's manual packed Do not touch parts that might be hot from operation. Allow parts to cool before attempting to maintain, adjust, or service. separately with your unit. Do not attempt to Stay alert, watch what you are doing, and use operate the machine until you fully understand common sense when operating the machine. how to properly operate and maintain the engine and konw how to avoid accidental injuries and/or property damage. Do not overreach. Do not operate the machine while barefoot or when wearing sandals or similar lightweight footwear. Wear protective If the unit is to be used by someone other than footwear that will protect your feet and original purchaser, or is to be loaned, rented, improve your footing on slippery surfaces. or sold, always provide this manual and any Keep proper footing and balance at all times. needed safety training before operation. This enables better control of the machine in The user can prevent and is responsible unexpected situations. for accidents or injuries that may occur to themselves, to other people, or to property. Do not force the machine beyond its limits. Use the correct machine for your application. Inspect Your Machine Check your machine before starting it. Keep guards in place and in working order. Make sure all nuts, bolts, etc., are securely tightened. Personal Safety Never operate the machine when it is in need Do not permit children to operate this machine of repair or is in poor mechanical condition. at any time. Replace damaged, missing, or failed parts Keep children, pets, and other people not using the unit away from the work area. Be before using it. Check for fuel leaks. Keep the machine in safe working condition. alert and shut off the unit if anyone enters Do not use the machine if the engine's switch work area. Keep children under the watchful does not turn off the engine when running. care of a responsible adult. Any gasoline powered machine that can't be Do not operate the machine while under the influence of drugs, alcohol, or any medication controlled with the engine switch is dangerous and must be replaced. that could affect your ability to use it properly. Regularly check to see that keys and adjusting Dress properly: Wear long, heavy pants, work boots, and work gloves. Do not wear loose clothing, short pants, or jewelry of any kind. Secure long hair so it is above shoulder level. wrenches are removed from the machine area before starting it. A wrench or a key that is left attached to a rotating part of the machine may result in personal injury. Keep your hair, clothing, and gloves away Avoid accidental starting. Be sure the engine's from moving parts. Loose clothes, jewelry, or switch is off before transporting the machine long hair can be caught in moving parts. or performing any maintenance or service 4 MINI TRACKED DUMPER on the unit. Transporting or performing To avoid sparking or arcing, keep grounded GB maintenance or service on a machine with its conductive objects such as tools away switch on invites accidents. from exposed, live electrical parts and If the machine should start to vibrate abnormally, stop the engine (motor) and connections. These events could ignite fumes or vapors. check immediately for the cause. Vibration is Always stop the engine and allow it to cool generally a warning sign of trouble. before filling the fuel tank. Never remove Engine Safety This machine is equipped with an internal combustion engine. Do not use on, or near, forest-covered or brush-covered land unless the exhaust system is equipped with a spark arrester meeting applicable local, state, or the cap of the fuel tank or add fuel while the engine is running or when the engine is hot. Do not operate the machine with known leaks in the fuel system. Loosen the fuel tank cap slowly to relieve any pressure in the tank. federal laws. Never overfill the fuel tank. Because engine In the state of California, a spark arrester is required by law. Other states have similar laws. A spark arrester, if used, must be maintained in effective working order by the operator. heat can cause fuel to expand, never fill the tank to more than 1/2" below the bottom of the filler neck. This will provide space for fuel expansion. Never start or run the engine inside a closed area. The exhaust fumes are dangerous, containing carbon monoxide, an odorless and deadly gas. Operate this unit only in a well- Replace all fuel tank and container caps securely and wipe up spilled fuel. Never operate the unit without the fuel cap securely in place. ventilated outdoor area. Avoid creating a source of ignition for spilled Do not tamper with the engine in an effort to get it to run at higher speeds. The maximum engine speed is preset by the manufacturer and is within safety limits. See engine manual. Keep a Class B fire extinguisher on hand when operating this machine in dry areas as a precautionary measure. fuel. If fuel is spilled, do not attempt to start the engine. Instead, move the machine away from the area of spillage and avoid creating any source of ignition until fuel vapors have dissipated. When fuel is spilled on yourself or your clothes, wash your skin and change clothes immediately. Fuel Safety Fuel is highly flammable, and its vapors can explode if ignited. Take precautions when using to reduce the chance of serious personal injury. When refilling or draining the fuel tank, use an approved fuel storage container while in a clean, well-ventilated outdoor area. While adding fuel or operating the unit, do not smoke, and stay away from sparks, open flames, or other sources of ignition near the area of operation. Never fill the fuel tank Store fuel in containers specifically designed and approved for fuel storage. Store fuel in a cool, well-ventilated area, safely away from sparks, open flames, or other sources of ignition. Never store fuel or a machine with fuel in the tank inside a building where fumes may reach a spark, open flame, or any other source of ignition (such as a water heater, furnace, or clothes dryer). Allow the engine to cool before storing in any enclosure. indoors. MINI TRACKED DUMPER 5 GB Specific Safety Rules On soft ground, drive at the first forward/ reverse gear. Do not rapidly accelerate, turn Thoroughly inspect the area to be worked. sharply or stop. Keep the working area clean and free of debris to prevent tripping. Operate on flat, level ground. Pay the utmost attention when working on frozen ground, as the machine may tend to skid. Never place any part of your body where it would be in danger if movement should occur during assembly, installation, operation, maintenance, repair, or relocation. Do not operate the machine in confined areas where there may be a risk of crushing the operator between the machine and another object. Keep all bystanders, children, and pets at least 23m away. If you are approached, stop the unit immediately. Do not mount anything on the hopper and never carry passengers. Never park the machine in a place with unstable ground that could give way, particularly when it is full. Never operate the machine on slopes where angle is over 20°. When operating on a slope, whether moving forward or in reverse, always make certain that the weight is evenly balanced. Always operate the machine straight up or down slopes, never drive sideways or across the slope. Do not shift gears on slopes. Disengage clutch lever before starting the engine. Start the engine carefully according to instructions and with feet away from the moving parts. Never leave the operating position when the engine is running. When dumping the contents of the hopper, the center of gravity will change continuously and the ground conditions will be essential for the stability of the machine. Use extra caution and control when dumping the hopper on unstable ground, such as wet clay or soil. Always hold the unit with both hands when operating. Keep a firm grip on the handlebars. Be aware that the machine may unexpectedly bounce upward or jump forward if the machine should strike buried obstacles such as large rocks or roots. Walk, never run with the machine. Do not overload the machine capacity. Always drive at a safe speed, and adjust the speed to the slope of the land, the surface conditions of the road, and the weight of the load. Use extreme caution when in reverse or pulling the machine towards you. Exercise extreme caution when operating on or crossing gravel drives, walks, or roads. Stay alert for hidden hazards or traffic. 6 MINI TRACKED DUMPER UNPACKING THE CONTAINER Use the screwdriver and hammer to open all the side locks. QTY: 1 GNC1M1WaWA3rD.:t:5o1E2nX70I74SN7..i060zC.ek5kH:ggXIN8A7.8 cm 300 QTP300B CZ Mini-Dumper GB Mini Tracked Dumper DE Miniraupendumper IT Minitrasporter RU FR Brouette motorisée sur chenilles 1 2 3 4 GB Remove all the plywood plates, and remove all the loose parts on the bottom pallets. MINI TRACKED DUMPER 7 GB CONTENTS SUPPLIED 1. Main Frame 2. Handlebar Assembly The mini tracked dumper comes partially assembled and is shipped in carefully packed package. After all the parts have been removed from the package, you should have: 3. Tipping Handle 4. Engine Guard 5. Panel (Rear) 6. Extendable Left Side 7. Extendable Right Side 8. Panel (Bottom) 9. Gas Spring (Optional) 10. Tools for Spark Plug Assembly 11. Operator's Manual & Engine Manual 1 12. Hardware Bag, Including 2 M10 X 20 X 4 A M8 X 25 X 2 M16 X 238 M16 4 X 35 X1 F X2 B X 2 M8 X 35 X 2 3 M8 X 30 C X 2 X6 D M8 X 35 X2 E 4 5 6 7 8 9 10 11 12 8 MINI TRACKED DUMPER ASSEMBLY Tipping Handle & Engine Guard GB Place the engine guard inside the mounting Following the assembly directions below, you bracket and align with the mounting bracket will assemble the machine in a few minutes. holes. Secure panel left side with two M8x30 Handlebar Assembly Align the holes of the handlebar with the mount bracket and secure each with a spring washer, flat washer and a M10x20 bolt . Fasten each hex bolts, four washers and two nuts. Mount the tipping handle on panel right side. Align holes and fasten with two M8x35 hex bolts, four washers and two nuts. handlebar support onto the engine deck with a spring washer, flat washer and a M8x25 hex bolt. 1 2 M8 X 35 3 1 M8 X 30 3 M10 X 20 M8 X 25 X 4 A X 2 Panel (Bottom) Position the bottom panel inside the mounting bracket. Align the holes with the mounting bracket. Insert a long pin through holes and secure each side with a flat washer and cotter pin. M8 X 35 M8 X 30 X 2 C X 2 Panel (Rear) & Extendable Left/Right Side Insert the extendable sides into mounting slots located on the bottom panel and fasten each at the bottom with two L pins and locknuts. 1 2 1 2 M16 X 238 M16 4 X 35 X1 F X2 B X 2 MINI TRACKED DUMPER 9 GB Plow Blade (Optional) Mount the mounting bracket to the blade using M8X30 hex bolts, washers and nuts. M8×30 (×4) M8 X 30 X4 a X6 D Gas Spring (Optional) Lift up the hopper and insert a support rod for safety purpose. Align the holes in the gas spring with the holes in both guide brackets and insert M8x35 bolts, washers and nuts to tighten. Guide Bracket Position the pivot bracket inside the mounting bracket and align with mounting bracket holes. Secure with M20X95 hex bolt, washers and nut. M20×95 (×1) Pivot Bracket Gas Spring Support Rod Danger Area M20 X 95 X1 b Insert the shorter control lever into the longer lever. Align holes and fasten with M8X40 hex bolt, washers and nut. M8×40 (×1) M8 X 35 10 MINI TRACKED DUMPER X2 E M8 X 40 X1 c Attach control lever to the guide tube. Line up Engine Oil GB holes and fasten with M8X35 bolt, washers and nut. OIL HAS BEEN DRAINED FOR Insert the handle grip into the holder. SHIPPING. Secure the support bracket into the control lever with pin 10x60 and bridge clip. Handle Grip Failure to fill engine sump with oil before starting engine will result in permanent damage and void engine warranty. Control Lever Add oil according to Engine Manual packed separately with your tiller. 10×60 (×1) M8×35 (×1) Support Bracket M8 X 35 10 X 60 2 X 11 X 35 X 1 X1 d X 1 Install the already assembled plow blade to the trackbarrow as shown. M10×25 (×2) M12×40 (×2) M10 X 25 M12 X 40 X 2 e X 2 MINI TRACKED DUMPER 11 GB Engine Switch Throttle Control Right Steering Lever Clutch Control Lever Left Steering Lever Hopper Tipping Handle Gear Selection Lever Track Gearbox KNOW YOUR MACHINE Features and Controls Gas Spring Assistance (Optional) 12 MINI TRACKED DUMPER GB Recoil Starter Handle Throttle Control Choke Control Fuel Shut-Off Valve Gear Selection Lever The gear selection lever has 4 positions: 3 forward speeds and 1 reverse. To change speeds, move the speed shift lever to the desired position. The lever locks in a notch at each speed selection. Always release the clutch control lever before changing speeds. Failure to do so will result in damage to the power trackbarrow. Slower speeds are for heavier loads, while faster speeds are for transporting light loads or an empty hopper. It is recommended that you use a slower speed until you are familiar with the operation of the power trackbarrow. If the engine slows down under a load or the tracks slip, shift the machine into a lower gear. If the front of the machine rides up, shift the machine into a lower gear. If the front continues to ride up, lift up on the handles. Left/Right Steering Lever Operate the lever to turn left/right. Operate the steering levers only at a reduced speed. Gas Spring Assistance (Optional) The gas spring assistance provides support when lifting and lowering the hopper. Engine On/Off Switch The engine switch has two positions. OFF engine will not start or run. ON - engine will start and run. Recoil Starter Handle The recoil starter handle is used to start the engine. Fuel Shut-Off Valve The fuel shut-off has two positions: CLOSED ( ) - Use this position to service, transport, or to store the unit. OPEN ( ) - Use this position to run the unit. Throttle Control The throttle control regulates the speed of the engine, and moves between FAST , SLOW , and STOP positions. The throttle control will shut off the engine when it is moved to the STOP position. Choke Control The choke control is used to choke the carburetor and assist in starting the engine. The choke control slides between the CHOKE CLOSED and CHOKE OPEN positions. MINI TRACKED DUMPER 13 GB 1. The engine must be off and allowed to cool Never use choke to stop engine. at least two minutes before adding fuel. Clutch Control Lever Squeeze the control lever, clutch engaged. Release the lever, clutch disengaged. 2. Remove the fuel filler cap and fill the tank. (See engine manual for fuel capacity, fuel recommendation, and location of fuel cap.) IMPORTANT: DO NOT OVERFILL! Operation Add Oil To Engine The engine is shipped without oil. Do not start the engine before adding oil. Please refer to your engine manual for the proper grade of oil to add. 1. Make sure the power trackbarrow is on a flat, level surface. 2. Remove the oil fill cap/dipstick to add oil. OPEN CLOSED 3. Using a funnel, add oil up to the FULL mark on the dipstick. (See engine manual for oil capacity, oil recommendation, and location of fill cap.) DO NOT OVERFILL. Check engine oil level daily and add as needed. This equipment and/or its engine may include evaporative emissions control system components, required to meet EPA and/ or CARB regulations, that will only function properly when the fuel tank has been filled to the recommended level. Overfilling may cause permanent damage to evaporative emissions control system components. Filling to the recommended level ensures a vapor gap required to allow for fuel expansion. Pay close attention while filling the fuel tank to ensure that the recommended fuel level inside the tank is not exceeded. Use a portable gasoline container with an appropriately sized dispensing spout when filling the tank. Do not use a funnel or other device that obstructs the view of the tank filling process. 3. Reinstall the fuel cap and tighten. Always clean up spilled fuel. Starting Engine 1. Move the engine switch to the ON position. Add Gasoline To Engine Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. Use extreme care when handling gasoline. OFF ON 2. Open the fuel shut-off valve. Fill the fuel tank outdoors, never indoors. Gasoline vapors can ignite if they collect inside an enclosure. Explosion can result. OFF ON 14 MINI TRACKED DUMPER 3. Move the choke lever to the CLOSED turn. When the machine is fully loaded, more GB position. pressure is required. If the engine is hot, closing the choke is not necessary. The power trackbarrow has a maximum load capacity of 660 LBS. However, it is advisable to assess the load and adjust it according to the ground on which the machine will be used. CLOSED OPEN It is, therefore, advisable to cover uneven or rough terrain using a low gear, and to take extra precautions. In such situations, the machine should be kept in low gear for the entire stretch. 4. Move the throttle lever slightly to the FAST speed. FAST SLOW 5. Pull the recoil starter until the engine starts. Return the recoil to the home position after each pull. Repeat the steps as needed. Once engine has started, set the throttle to the FAST position before you operate the unit. Rapid retraction of the starter cord (kickback) will pull your handand arm toward the engine faster than you can let go. Broken bones, fractures, bruises, or sprains could result. Avoid sharp turns and frequent changes of direction while driving on rough, hard terrains full of sharp, uneven points with a high degree of friction. Even though the unit has rubber tracks, remember to be careful when working in adverse weather conditions (ice, heavy rain and snow) or on types of ground that could make the power trackbarrow unstable. Please note that as this is a tracked vehicle, it is subject to a considerable pitching movement when passing over bumps, holes and steps. When the clutch control lever is released, the machine will stop and brake automatically. If the machine is stopped on a steep slope, a wedge should be placed against one of the tracks. Idle Speed Operating After the engine warms up, move the throttle lever to accelerate engine speed. Engage the required gear and slowly squeeze the clutch control lever. If the gear does not engage immediately, slowly release the clutch lever and try again. In this way the power trackbarrow will start moving. The power trackbarrow has the steering levers on the handlebars, which makes steering very easy. To turn right or left, simply pull the corresponding right or left steering lever. Set the throttle control lever to the SLOW position to reduce stress on the engine when work is not being performed. Lowering the engine speed will help extend the life of the engine, as well as conserve fuel and reduce noise level. STOP ENGINE To stop the engine in an emergency, simply turn the engine switch to the OFF position. Under normal conditions, use the following procedure: 1. Move the throttle lever to the SLOW ( ) position. The sensitivity of the steering increases in 2. Let the engine idle for one or two minutes. proportion to the speed of the machine and the load. With an empty machine, a light 3. Turn the engine switch to the OFF position. pressure on the lever is all that is needed to 4. Turn the fuel valve lever to the OFF ( ) position. MINI TRACKED DUMPER 15 GB Sudden stopping at a high Adjusting Clutch speed under a heavy load is not When the clutch begins to show wear, the recommended. Engine damage may handle reach will become wider, making it result. more difficult to reach. Follow these steps to return the clutch lever back to its original position. Do not move the choke control to CLOSE to stop the engine. Backfire or engine damage may occur. 1. Loosen the jam nut by turning it counter clockwise with 10mm wrench. 2. Tighten or loosen the cable by turning the cable adjustment nut clockwise or counter MAINTENANCE clockwise with 10mm wrench until you have reached your required tightness. Maintaining your mini tracked dumper will ensure long life to the machine and its components. 3. Once tightness is set, return the jam nut against the handle to hold the cable in place. Preventive Maintenance 1. Turn off the engine and disengage all command levers. The engine must be cool. 1 Jam Nut 2. Keep the engine's throttle lever in its SLOW position and remove the spark plug wire from the spark plug and secure. 3. Inspect the general condition of the power trackbarrow. Check for loose screws, misalignment or binding of moving parts, cracked or broken parts, and any other condition that may affect its safe operation. 4. Use a soft brush, vacuum or compressed air to remove all contaminants from the machine. Then use high quality light oil to lubricate all moving parts. 5. Check the spark plug wire regularly for signs of wear, and replace when needed. Never use a "pressure washer" to clean your unit. Water can penetrate tight areas of the machine and its transmission case and cause damage to spindles, gears, bearings, or the engine. The use of pressure washers will result in shortened life and reduce serviceability. Jam Nut Adjustment Nut 2 3 Adjustment Nut Jam Nut Adjusting Steering If steering becomes difficult to engage, follow these steps to adjust the cable tension. 1. Loosen the jam nut by turning it counter clockwise with 10mm wrench. 2. Tighten or loosen the cable by turning the cable adjustment nut clockwise or counter clockwise with 10mm wrench until you have reached your required tightness. 3. Once tightness is set, return the jam nut against the handle to hold the cable in place. 16 MINI TRACKED DUMPER Adjustment Nut 1 GB Jam Nut Lock Nut Jam Nut Lock Nut 2 Adjustment Nut 3 Jam Nut Belt Cover M8×20 (×3) Lock Nut Gearbox Pulley M6×20 If the above adjustment does not create enough cable tension, follow the steps below: 1. Loosen the jam nut by turning it counter clockwise with 12mm wrench. 2. Tighten or loosen the cable by turning the cable adjustment nut clockwise or counter clockwise with 10mm wrench until you have reached your required tightness. 3. Once tightness is set, return the jam nut against the handle to hold the cable in place. Drive Belt Belt Cover for Gearbox Pulley You may need to loosen the belt guide bracket and slide back before removing belt. Lubrication General Lubrication Lightly lubricate all moving parts of the machine at end of the season or every 25 operating hours. Jam Nut 1 Adjustment Nut 2 3 Adjustment Nut Lock Nut Jam Nut Gearbox Lubrication The gearbox is pre-lubricated and sealed at the factory. Unless there is evidence of leakage or service has been performed on the gearbox, no additional lubricate should be required until 50 hours use. After first 50 hours use, change all the gear oil. Capacity is 1.5L. For future use, check the oil level after every 50 hours of use. If you remove the oil level plug and no oil flows out, please add oil and then screw the oil level plug. Jam Nut Gear oil GL-5 or GL-6, SAE80W-90 is recommended. Do not use synthetic oil. Replacing Drive Belt Remove belt covers as shown and pull out the belt. When replacing gear oil, the engine must be stopped and still warm. Unscrew the filter cap and the drain plug. When oil is drained, replace the drain plug, fill up with fresh oil, and then replace the filter cap. MINI TRACKED DUMPER 17 GB Oil Filler Oil Outlet If the distance is greater, proceed as follows. 1. Use the tipping handle to tip the hopper and set it on blocks or supports rated for the weight of the box. 2. Loosen locknut A. 3. Tighten bolt B until the correct tightness is restored. 4. Secure bolt B by tightening locknut A thoroughly. 5. Return the hopper to its original position. Tightening Tracks With use, tracks tend to loosen. When operating with loose tracks, they tend to slip over the driving wheel causing it to jump its housing, thus damaging wear to the housing. To check track tightness, proceed as follows. 1. Set the machine on a flat surface with compact ground, or on asphalt or pavement. 2. Lift the machine and set it on blocks or supports rated for the weight of the machine so that the tracks are approximately 4" off the ground. 3. Measure the track midline vs. the horizontal line. The reading must not be more than 10cm~15cm. Jam Nut A A B B Adjusting Bolt Do not over-tighten your track. The adjustment of the track and the brakes are linked. The braking power will lessen the more the track is tightened. If the adjustment bolt has no more adjustment left, the tracks may have to be replaced. 10cm ~ 15cm Replacing Tracks Check the condition of the tracks periodically. If any track is cracked or frayed, it should be replaced as soon as convenient. 18 MINI TRACKED DUMPER 1. Lift up the hopper and insert a support rod 4. Pull out the whole track. GB for safety purposes. 2. Lift the machine and set it on blocks or supports rated for the weight of the machine so that the tracks are approximately 4" off the ground. Support Rod Danger Area When removing or installing the tracks, be careful not to get your fingers caught between the track and pulley. Support Object 3. Loosen the adjusting bolts and pull the steering wheel axle toward the engine, then track will be loosen. Steering Wheel Engine Maintenance Refer to the Engine Manual included in your unit for the information on engine maintenance. Your engine manual provides detailed information and a maintenance schedule for performing the tasks. Steering Wheel Axle Jam Nut A A B B Adjusting Bolt MINI TRACKED DUMPER 19 GB STORAGE If the mini tracked dumper will not be used for a period longer than 30 days, follow the steps below to prepare your unit for storage. 1. Drain the fuel tank completely. Stored fuel containing ethanol or MTBE can start to go stale in 30 days. Stale fuel has high gum content and can clog the carburetor and restrict fuel flow. 2. Start the engine and allow it to run until it stops. This ensures no fuel is left in the carburetor. Run the engine until it stops. This helps prevent gum deposits from forming inside the carburetor and possible engine damage. 3. While the engine is still warm, drain the oil from the engine. Refill with fresh oil of the grade recommended in the Engine Manual. 4. Use clean cloths to clean off the outside of the machine and to keep the air vents free of obstructions. Do not use strong detergents or petroleum based cleaners when cleaning plastic parts. Chemicals can damage plastics. 5. Inspect for any loose or damaged parts. Repair or replace damaged parts and tighten loose screws, nuts or bolts. 6. Store your unit on flat ground in a clean, dry building that has good ventilation. Do not store the machine with fuel in a non-ventilated area where fuel fumes may reach flame, sparks, pilot lights or any ignition sources. 20 MINI TRACKED DUMPER TROUBLE SHOOTING GB Problem Engine fails to start. Cause 1. Spark plug wire disconnected. 2. Out of fuel or stale fuel. 3. Choke not in open position. 4. Blocked fuel line. 5. Fouled spark plug. 6. Engine flooding. Remedy 1. Attach spark plug wire securely to spark plug. 2. Fill with clean, fresh gasoline. 3. Throttle must be positioned at choke for a cold start. 4. Clean the fuel line. 5. Clean, adjust gap, or replace. 6. Wait a few minutes to restart, but do not prime. Engine runs erratically. 1. Spark plug wire loose. 2. Unit running on CHOKE. 3. Blocked fuel line or stale fuel. 4. Vent plugged. 5. Water or dirt in fuel system. 6. Dirty air cleaner. 7. Improper carburetor adjustment. 1. Connect and tighten spark plug wire. 2. Move choke lever to OFF. 3. Clean fuel line. Fill tank with clean, fresh gasoline. 4. Clear vent. 5. Drain fuel tank. Refill with fresh fuel. 6. Clean or replace air cleaner. 7. Refer to Engine Manual. Engine overheats. 1. Engine oil level low. 1. Fill crankcase with proper oil. 2. Dirty air cleaner. 2. Clean air cleaner. 3. Air flow restricted. 3. Remove housing and clean. 4. Carburetor not adjusted properly. 4. Refer to Engine Manual. One of the two tracks is blocked. Foreign bodies have worked their way between the track and the frame. Remove the foreign body. Machine does 1. Gear is not properly selected. not move while engine is running. 2. Driving tracks not tight enough. 1. Ensure gear lever is not in-between two different gears. 2. Tighten driving tracks. MINI TRACKED DUMPER 21 GB PARTS SCHEDULE 22 MINI TRACKED DUMPER GB Gearbox (50) MINI TRACKED DUMPER 23 GB Box (88) 24 MINI TRACKED DUMPER PARTS LIST GB No. Description Q'ty No. Description Q'ty 1 Tensioner Pulley Cable 1 39 Key 5x35 1 2 Safety Control Handle 1 40 Belt Protect Frame 1 3 Screw M6x16 1 41 Bolt M8x30 3 4 Screw M5x20 2 42 Fixed Bracket 1 5 Nut M5 2 43 Washer 8 2 6 Handle Sleeve 2 44 Bolt M10x60 2 7 Throttle Cable 1 45 Belt Pulley 1 8 Throttle Lever 1 46 Screw M5x12 1 9 HOOP 1 47 Tensioner Pulley 1 10 ON/OFF Switch 1 48 Circlip 15 1 11 Handle Frame Assembly 1 49 Bearing 6202-2RS 2 12 Lower Handle 2 50 Gear Box 1 13 Washer ø6 11 51 Circlip 35 1 14 Screw M6x35 1 52 Large Belt Pulley Cover 1 15 Screw M6x60 1 53 Nut M6 3 16 Right/Left Steering Lever Cable 2 54 Bolt M6x20 1 17 Screw M10x20 8 55 Wheel Axle Press Board 2 18 Washer10 26 56 Support Plate (right) 1 19 Washer10 22 57 Belt Plate 1 20 Bolt M8X16 6 58 Connecting Angle Block 1 21 Washer8 41 59 Bolt M6X25 2 22 Soleplate (left) 1 60 Bolt M8x40 4 23 Bolt M8X25 11 61 Bolt M10x65 w/glue 8 24 Washer8 7 62 Nut M8 14 25 Handle Mounting Frame 1 63 Cable Fixing Base 1 26 Bolt M8X20 3 64 Rubber Mat 2 27 Soleplate (right) 1 65 Support Plate (left) 1 28 Belt B32 1 66 Long Extension Spring 1 29 Pulley Cover Weldment 30 Lever Knob 31 Lock Nut M10 32 Screw M8x20 w/glue 33 Bolt M10X70 34 Brake Cable 35 Driving Wheel 36 Nut M8 37 Tensioner Pulley Bracket 38 Engine 1 67 Skeleton Oil Seal 4 1 68 Weight Supporting Wheel Weldment 4 11 69 Bearing 6204-2RS 8 12 70 Washer 10 6 1 71 Bolt M10X25 6 1 72 Axle Head Cover(47) 4 2 73 Track 180x60 2 25 74 Axle Head Cover(42) 2 1 75 Circlip 42 8 1 76 Bear 61905-2RS 4 MINI TRACKED DUMPER 25 GB No. Description 77 Guiding Wheel 78 Sealing Ring30X42X7 79 Nut M16 80 Bolt M16x110 81 Underframe Weldment 82 Guide Wheel Axle 83 Bolt M10X20 84 Support Bracket 85 Flat Gasket 16 86 Plain Shaft 87 Pin 4X35 88 Dumper Box 89 Operation Lever Frame 90 Handle Frame Weldment 91 Nut M12 92 Washer 12 93 Extension Spring 94 Handle Sleeve 95 Guiding Spring 96 Locating sleeve 97 Bolt M8X35 98 Pin 5x30 99 Gearshift Lever 100 Pin 3*30 101 Bolt M8*12 w/glue 102 Orientation Nut 103 Washer GroupwareD20 104 O-Ring 11.2x1.8 105 Lever Mount Bracket 106 Seal FB17X40X7 107 Spline Shaft I 108 Duplex Slip Gear 109 Gear 110 Bearing 6302 111 Gearshift Fork Guide Pin 112 Spring 113 Steel Ball 6 114 Gearshift Fork Q'ty 2 2 2 2 1 1 4 1 2 1 2 1 1 1 1 2 2 1 2 2 4 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 No. Description 115 Circlip 12 116 Rivet Assembly 117 Brake Disk 118 Joint Bolt 119 Plate 120 Brake Pull Plate 121 Washer6 122 Washer6 123 Bolt M6x16 124 Expansion Brake Cover 125 Stud 126 Vent-Plug Bushing 127 Vent-Plug 128 Screw M8X30 129 Expansion Brake Lock Bolt 130 Screw M8X130 131 Clutch Fork Shaft (L) 132 Bolt M6X20 133 Swing Plate 134 Gear III-4 135 Gear III-3 136 Large Belt Pulley 137 Bearing 6303 138 Gear II-5 139 Gear II-4 140 Gear II-3 141 Gear II-2 142 Gear III-2 Bush 143 Gear III-2 144 Gear Shaft III 145 Gear Box Case ( L) 146 Plug M14x1.5 147 Washer Groupware 14 148 Gear Box Case 149 Output Shaft 150 Gear II-1 151 Bush 2 152 Bush 1 Q'ty 1 1 1 3 1 1 4 2 4 1 1 1 1 3 3 6 1 3 2 1 1 1 5 1 1 1 1 1 1 1 1 2 2 1 2 1 1 1 26 MINI TRACKED DUMPER No. Description 153 Key C5x20 154 Spline Shaft II 155 Clutch Fork Shaft (R) 156 Gear Box Case ( R) 157 Pin 12x20 158 Seal FB16x22x4 159 Output Shaft Bush Gasket 160 Gasket 1 161 Clutch Spring 162 Spring Guide Bush 163 Clutch Sleeve 164 Spring Gasket 165 Steel Ball 5 166 Circlip 58 167 Output Gear 168 Intermediate Joint Bush 169 Intermediate Joint Bush Composite Bushing 170 Circlip 26 171 Joint Bush 172 Spring Gasket 173 Circlip 25 174 Washer 8 175 Output Shaft Bushing 176 Seal FB25x42x7 177 Output Shaft Composite Bushing 178 Guard Cover 179 Bolt M8x30 180 Panel (Front) 181 Plug 182 Shock Absorber pad 183 Extendable Side (Left) 184 Panel (Rear) 185 L Pin 186 Panel (Bottom) 187 Extendable Side (Right) Q'ty 2 1 1 1 2 2 2 4 2 2 2 2 70 2 1 1 2 2 2 4 2 10 2 2 4 1 2 1 6 12 1 1 6 1 1 GB MINI TRACKED DUMPER 27 Plow Blade (Optional) 09710UK00M100 Parts List No. Description Q'ty 1 Bolt M8X35 6 2 Shave Plate 1 3 Rubber Plate 1 4 Blade Weldment 1 5 Washer8 16 6 Nut M8 13 7 Landing Leg Weldment 2 8 Blade Fixed Bracket Weldment 1 9 Bolt M8X30 4 10 Bolt M20X95 1 11 Washer20 2 12 Nut M20 1 13 Blade Connecting Bracket Weldment 1 14 Bolt M12X40 4 15 Washer12 2 16 Washer12 3 17 Washer10 2 18 Washer10 2 19 Pin 10X60 1 20 Curved Support Bracket Weldment 1 No. Description 21 Bolt M8X50 22 Active Connecting Weldment 23 Nut M12 24 Bolt M10X25 25 Bolt M8X35 26 Adjusting Rod Weldment B 27 Bolt M8X40 28 Adjusting Rod Weldment A 29 Handle Sleeve 28 30 Limiter Rod Wedment 31 Bolt M24X110 32 Limiter Weldment 33 Washer24 34 Lock Nut M24 35 Spring 36 Bridge Pin 2X11X35 37 Pin 4x40 38 Handle Grip 2 39 Handle Sleeve 25 Q'ty 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1Adobe InDesign CS5 (7.0.2) Adobe PDF Library 9.9