Moffat 500 TC manuals

Moffat 500 TC Specifications (336 pages)

Brand: Moffat | Category: Engine | Size: 3.41 MB |

English

Table of contents

544G, 544G LL, and

1

544G TC Loaders

1

624G Loader

1

644G Loader

1

(Serial No. 557739-)

1

Introduction

2

TX,DH2121 -19-08JUN96

5

TX,DH2283 -19-02OCT92

6

HELP!! HELP!! HELP!! HELP!!

7

Contents

10

T100127 –19–21FEB96

14

RECOGNIZE SAFETY INFORMATION

15

UNDERSTAND SIGNAL WORDS

15

FOLLOW SAFETY INSTRUCTIONS

15

TX,05,DH1525 –19–21JUN91–1/1

16

TX,05,DH1573 –19–18MAR91–1/1

17

TX,05,DH2478 –19–26SEP92–1/1

18

T82,BHSA,CL –19–14MAR90–1/1

18

USE HANDHOLDS AND STEPS

19

PREVENT MACHINE RUNAWAY

19

USE SEAT BELT PROPERLY

19

MAINTAIN SEAT BELT

20

SECONDARY EXITS

20

TRAVEL SAFELY

21

T6964AD –UN–20DEC88

21

DRIVE MACHINE SAFELY

21

T6582AS –UN–25OCT88

21

OPERATE MACHINE WITH CAUTION

22

T6642EF –UN–18OCT88

22

OPERATING ON SLOPES

22

T7050AB –UN–03AUG89

22

CARRYING LOADS

23

AVOID POWER LINES

23

BEWARE OF EXHAUST FUMES

23

KEEP RIDERS OFF MACHINE

24

PREPARE FOR EMERGENCIES

24

HANDLE STARTING FLUID SAFELY

25

CLEAN TRASH FROM MACHINE

25

PROTECT AGAINST FLYING DEBRIS

25

WEAR PROTECTIVE CLOTHING

26

PROTECT AGAINST NOISE

26

USE SAFETY LIGHTS AND DEVICES

27

N36564 –UN–10FEB89

27

KEEP THE OPERATOR PROTECTIVE

28

STRUCTURE (OPS) IN PLACE

28

WARN OTHERS OF SERVICE WORK

28

T7447AO –19–22APR91

28

PRACTICE SAFE MAINTENANCE

29

TS218 –UN–23AUG88

29

SUPPORT MACHINE PROPERLY

30

TS229 –UN–23AUG88

30

DX,PAINT –19–03MAR93–1/1

31

DX,TORCH –19–03MAR93–1/1

31

AVOID HIGH-PRESSURE FLUIDS

32

CLEAN THE MACHINE REGULARLY

32

T6642EJ –UN–18OCT88

32

SERVICE COOLING SYSTEM SAFELY

33

STORE ATTACHMENTS SAFELY

33

DISPOSE OF WASTE PROPERLY

33

Safety Signs

34

T7939AI –19–22MAR93

35

T7773CV –UN–31AUG92

35

A-Warning Decal

35

T8417AD –19–09FEB95

36

T7593AC –19–30AUG91

37

T6976AE –UN–30JAN89

37

T7939AK –19–22MAR93

38

T8029AF –UN–15JUN93

38

T7934AM –19–01FEB93

39

T100703 –UN–22MAR96

39

Left Side Shown

39

T8029AR –19–16JUN93

40

T8029AQ –UN–21JUN93

40

T7829AT –19–17SEP92

41

A-Warning Decal, If Equipped

41

Right Side of Machine

41

T7916AC –19–06JAN93

42

T7773AZ –UN–10AUG92

42

T7748CU –19–14OCT92

42

T7773CA –UN–10AUG92

42

T7829AQ –19–31AUG92

43

T100702 –UN–22MAR96

43

T7829AU –19–17SEP92

44

T7839BB –UN–17SEP92

44

Operator’s Station

45

T8375AN –UN–02DEC94

46

STOP INDICATOR AND ALARM

47

T7673AM –UN–06JAN92

47

T6201BL –UN–18OCT88

48

DIGITAL DISPLAY

48

T7747AT –UN–19MAY92

48

FUEL GAUGE

49

ENGINE OIL PRESSURE INDICATOR

50

ALTERNATOR VOLTAGE INDICATOR

50

ENGINE AIR FILTER RESTRICTION

50

INDICATOR

50

RIGHT TURN SIGNAL INDICATOR

52

BRAKE OIL PRESSURE INDICATOR

52

PARK BRAKE INDICATOR

52

FASTEN SEAT BELT INDICATOR

53

ETHER INJECTION INDICATOR

53

LEFT TURN SIGNAL INDICATOR

54

T7747AM –UN–19MAY92

55

T7747AN –UN–19MAY92

55

T7747AO –UN–19MAY92

56

PARK BRAKE SWITCH

56

NEUTRAL LOCK

57

T7747BI –UN–19MAY92

57

HORN BUTTON

57

T7747BJ –UN–19MAY92

57

TURN SIGNAL SWITCH

58

VANDAL SHIELD—IF EQUIPPED

58

WASHERS—IF EQUIPPED

59

ADJUSTING STEERING WHEEL TILT

59

OPENING SIDE WINDOW

59

CAB DOOR RELEASE

60

OPERATING LIGHTS

61

HEATING AND AIR CONDITIONING

62

CONTROLS

62

ADJUSTING SUSPENSION SEAT

63

SEAT BELT

64

T8415AA –UN–09FEB95

64

STORAGE COMPARTMENT

64

T8029AK –UN–15JUN93

64

Break-in

65

AFTER THE FIRST 100 HOURS

66

Pre-Start Inspection

67

Operating the Engine

68

T7747BU –UN–19MAY92

70

WEATHER STARTING AID)

71

COLD WEATHER WARM-UP

75

STOPPING THE ENGINE

75

Driving the Machine

77

GENERAL DRIVING PRECAUTIONS

78

SHIFTING THE TRANSMISSION

79

TRAVEL SPEEDS

81

STOPPING THE MACHINE

82

PARKING THE MACHINE

83

Operating the Machine

85

TWO LEVER DESIGN

86

QUICK SHIFT SWITCH

87

T7773CE –UN–21AUG92

87

PIN DISCONNECT SWITCH—544G TC

89

BOOM DOWN SWITCH

89

T7773AT –UN–30JUL92

90

T100664 –UN–12MAR96

90

T6601AI –UN–21OCT88

91

ADJUSTING RETURN-TO-DIG

92

T6599AD –UN–21OCT88

92

GENERAL OPERATING TIPS

93

T7208AV –UN–30JAN90

94

USING THE LOADER BUCKET

94

T7747BB –UN–19MAY92

94

T7747BC –UN–19MAY92

95

T7208AR –UN–30JAN90

95

T7747BD –UN–19MAY92

95

BACKDRAGGING

96

T7747BG –UN–19MAY92

96

BACKFILLING

96

T6603AO –UN–20OCT88

96

TRUCK LOADING

97

T7511CN –UN–27JUN91

97

TOWING PROCEDURE—ENGINE

100

OPERATIONAL

100

T6629AM –UN–20OCT88

100

TOWING PROCEDURE—ENGINE NON

101

Transporting

102

LIFTING THE MACHINE

104

T7477AV –UN–19MAR91

104

Fuels and Lubricants

105

FUEL TANK

107

DIESEL ENGINE OIL

108

T101239 –19–22MAY96

108

T100663 –19–10MAY96

109

T8358AI –19–27MAR95

110

LUBRICANT STORAGE

111

MIXING OF LUBRICANTS

111

Periodic Maintenance

112

LOCKING MACHINE FRAME

114

BOOM LOCK

115

SERVICE DOORS

115

OPENING GRILLE DOOR

116

MAINTENANCE AND REPAIR RECORD

117

KEEPING SYSTEM

117

T7511CO –UN–27JUN91

117

OILSCAN

118

*includes 544G LL and 544G TC

119

Maintenance—As Required

121

TIRE PRESSURES

122

TX,55,JC1157 –19–03JUN96–1/1

123

TX,55,JC1158 –19–03JUN96–1/1

124

TX,55,JC1159 –19–03JUN96–1/1

125

TX,55,DH2551 –19–16JUN93–1/1

125

CLEAN OR REPLACE AIR CLEANER

126

ELEMENTS

126

T6119AF –UN–01NOV88

126

T6119AG –UN–01NOV88

126

CLEAN DUSTY PRIMARY ELEMENT

127

INSPECT ELEMENT

128

T90684 –UN–10NOV88

128

CHECK AIR INLET COVER

129

T6779BQ –UN–19OCT88

129

INSPECT SERPENTINE BELT—644G

131

T7405BG –UN–15NOV90

131

DRAIN FUEL TANK

131

T7773CN –UN–21AUG92

131

(WATER SEPARATOR)—544G, 624G

132

T8387AD –UN–17DEC94

133

(WATER SEPARATOR)—644G

133

T100696 –UN–22MAR96

133

T8295AA –UN–10AUG94

134

LUBRICATE PIVOTS

135

CHECK ENGINE OIL LEVEL

135

544G Shown

136

624G Shown

136

644G Shown

136

CHECK HYDRAULIC OIL LEVEL

137

T7773CB –UN–10AUG92

138

T8029AM –UN–15JUN93

138

CHECK TRANSMISSION OIL LEVEL

139

T7773CP –UN–21AUG92

139

Maintenance—Every 100 Hours

140

LUBRICATE BOOM, BUCKET, AND

141

CYLINDER PIVOTS—544G TC

141

T7829BH –UN–17SEP92

142

Five Points

142

CHECK CAB FRESH AIR FILTER—IF

144

EQUIPPED

144

T7829AC –UN–31AUG92

145

Maintenance—Every 250 Hours

146

CHANGE ENGINE OIL AND REPLACE

147

T7853AI –UN–08OCT92

148

CHECK RADIATOR COOLANT LEVEL

150

T6642EK –UN–01NOV88

150

Maintenance—Every 500 Hours

151

AND TERMINALS

152

TS203 –UN–23AUG88

152

T6758AA –UN–21OCT88

154

CHECK COOLANT

155

T101279 –19–14MAY96

155

TS281 –UN–23AUG88

155

SEPARATOR)

156

T100705 –UN–22MAR96

158

REPLACE HYDRAULIC RESERVOIR

158

BREATHER FILTER

158

OIL LEVEL—IF EQUIPPED WITH

160

DIFFERENTIAL LOCK AXLE

160

Maintenance—Every 1000 Hours

161

T7853AB –UN–06OCT92

162

REPLACE AIR CLEANER ELEMENTS

163

CHANGE TRANSMISSION OIL AND

165

REPLACE FILTER

165

T7853AA –UN–23SEP92

166

T7853AC –UN–06OCT92

166

CHECK PARK BRAKE

167

T7773AG –UN–11JUN92

168

ADJUST PARK BRAKE

168

T7747BR –UN–19MAY92

168

T100701 –UN–22MAR96

169

LUBRICATE FRAME HINGE PIVOTS

170

T100690 –UN–22MAR96

170

Maintenance—Every 2000 Hours

171

T6233AG –19–27JAN89

172

T6233AH –19–27JAN89

172

ADJUST ENGINE VALVE LASH

173

(CLEARANCE)—644G

173

T6105BF –UN–24FEB89

173

T6233AI –19–27JAN89

174

T6233AJ –19–27JAN89

174

Maintenance—Every 3000 Hours

176

FILTER(S)—IF EQUIPPED

177

Maintenance

180

T7829AN –UN–31AUG92

181

544G, 624G Shown

181

T100709 –UN–22MAR96

181

DIESEL ENGINE COOLANT

182

FILLING THE COOLING SYSTEM

183

TEST THE COOLANT FREEZE—

183

PROTECTION LEVEL

183

T85402 –UN–10NOV88

183

DO NOT ADJUST INJECTION PUMP

184

T6523BW1 –UN–20OCT88

185

T7833AJ –UN–10SEP92

186

BLEEDING FUEL SYSTEM—644G

187

SERVICE BATTERIES CAREFULLY

189

CHECKING ELECTROLYTE SPECIFIC

191

USING BATTERY CHARGER

193

TS204 –UN–23AUG88

193

REPLACING BATTERIES

193

REMOVING BATTERIES

194

REPLACING FUSES

194

FUSE (BLADE-TYPE) COLOR CODES

194

RESETTING CIRCUIT BREAKERS

195

REPLACING HALOGEN BULBS

195

T6249AU –UN–19OCT88

196

CHECKING NEUTRAL START SYSTEM

197

BELT TENSION—IF EQUIPPED

199

WELDING ON MACHINE

199

INSPECTING PARK BRAKE PADS

200

T7853AU –UN–08OCT92

201

T6523BZ –UN–25OCT88

202

T6138AZ –UN–25OCT88

202

T8137AC –UN–03DEC93

202

CHECKING BRAKE ACCUMULATOR

203

T100704 –UN–22MAR96

203

CHECKING RIDE CONTROL

204

ACCUMULATOR—IF EQUIPPED

204

BLEEDING BRAKES

205

X9811 –UN–23AUG88

205

T6522BR –UN–20OCT88

206

CHECKING SECONDARY STEERING

207

SYSTEM—IF EQUIPPED

207

CLUTCH CUT-OFF ADJUSTMENT

207

T7817AL –UN–08SEP92

208

CYLINDERS, PUMPS OR MOTORS

208

KEEP ROPS INSTALLED PROPERLY

209

TS176 –UN–23AUG88

209

*Torque tolerance is

212

DX,TORQ1 –19–20JUL94–2/2

214

CHECK OIL LINES AND FITTINGS

215

T85401 –UN–24JAN89

215

BOSS FITTINGS

216

T6243AE –UN–18OCT88

216

T6520AB –UN–18OCT88

217

FACE O-RING SEAL FITTINGS

218

T6243AD –UN–18OCT88

218

T6890BB –UN–01MAR90

219

04T,90,K174 –19–01AUG94–2/2

221

Operational Checkout

222

– – –1/1

229

T7825BB –UN–21AUG92

229

T7825BD –UN–21AUG92

229

T7825BE –UN–21AUG92

229

LOOK: Machine MUST NOT move

231

Troubleshooting

256

ELECTRICAL SYSTEM

269

HYDRAULIC SYSTEM

277

Symptom Problem

283

Solution

283

POWER TRAIN

284

SERVICE BRAKES

290

DIFFERENTIAL AXLE

292

DRIVELINE

294

PARK BRAKE

295

AIR CONDITIONING

296

PREPARE MACHINE FOR STORAGE

297

T47764 –UN–09NOV88

297

T5813AM –UN–09FEB89

297

MONTHLY STORAGE PROCEDURE

298

T6191AA –UN–18OCT88

298

T6181AU –UN–18OCT88

299

Machine Numbers

300

RECORD HYDRAULIC PUMP SERIAL

301

Specifications

302

544G SPECIFICATIONS

304

544G LL SPECIFICATIONS

306

T7829AX –UN–10SEP92

306

544G TC SPECIFICATIONS

310

T7829AY –UN–21SEP92

310

624G SPECIFICATIONS

314

T6603AC1 –UN–20OCT88

314

644G SPECIFICATIONS

318

T6603AD1 –UN–20OCT88

318

Crime Prevention Tips

322

PARK INDOORS OUT OF SIGHT

323

TS158 –UN–23MAR89

323

WHEN PARKING OUTDOORS

323

TS144 –UN–23AUG88

323

REDUCE VANDALISM

324

T7223BB –UN–22FEB90

324

REPORT THEFTS IMMEDIATELY

324

TS146 –UN–09JAN89

324

Page Page

325

Checklists

331

PARTS CATALOG

333

OPERATOR’S MANUAL

333

TECHNICAL AND SERVICE MANUALS

333

TX,LIT1 -19-08JUN96

334

TS1643 -UN-12SEP95

335

DX,IBC,4 -19-12SEP95

335

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