OPERATIONS/

MAINTENANCE MANUAL

MODEL: TS4065
MANUAL ISSUE 4.01

47 Moor Road 1 McCloskey Road,

Coalisland Keene, Ontario
Co. Tyrone Canada
N. Ireland K9J 0G6
BT71 4QB
tel: +1 705 295 4925
tel: +44 (0)28 8774 0926 fax: +1 705 295 4777
fax: +44 (0)28 8774 7242 mail:
mail: mccloskey@mccloskeyinternational.com
salesuk@mccloskeyinternational.com

1
CONTENTS TS4065
WARRENTY START UP INFORMATION 4

ORIENTATION 5

SECTION 1 INTRODUCTION 6

SECTION 2 SAFETY 8
2.1 Warning & Safety. 8
2.2 Safety Rules – Do’s & Don’ts 10
2.3 Description 12

SECTION 3 OPERATIONAL PROCEDURES 13

3.1 Starting Machine 13
3.1.1 Starting Engine 16
3.1.2 Stopping Engine 17
3.1.3 Track Control using Umbilical 17
3.2 Machine Set Up Procedure 18
3.2.1 Unfold Conveyor Top Section 18
3.2.2 Raise Conveyor Feedboot 20
3.2.3 Raise Conveyor Frame 20
3.3 Operating Functions 21
3.3.1 Pre-Start Checks 21
3.3.2 Start-up Sequence 22
3.3.3 Operating Control Valves 22
3.4 Emergency Stops 23
3.4.1 To stop a Machine in an Emergency 23
3.4.2 Re-starting after an Emergency Stop Is Pushed 23
3.5 Preparing Machine for Transport 24
3.5.1 Lower Conveyor Frame 24
3.5.2 Lower Conveyor Feedboot 25
3.5.3 Fold Conveyor for Transport 25
3.5.4 Loading Machine onto a Trailer 26

SECTION 4 SPARE PARTS 27

4.1 Regular Spares 27

SECTION 5 MAINTENANCE 28
5.1 Safety 28
5.2 General 28
5.3 Maintenance Schedule 29
5.4 Greasing Information 32
5.5 Engine Maintenance 33
5.6 Track Maintenance 34
5.7 Recommended Lubricants 34
5.8 Servicing Terminology 35

SECTION 6 SPECIAL PROCEDURES 36

6.1 Tension and Alignment of Conveyor Belt 36
6.2 Servicing Filters 37
6.2.1 Air Filter 38
6.2.2 Hydraulic Oil Filter 39
6.2.3 Engine Oil & Fuel Filter 39

SECTION 7 FAULT FINDING 40

7.1 Fault Finding Table 40

2
SECTION 8 MACHINE TECHNICAL SPECIFICATIONS 41
8.1 TS4065 41

SECTION 9 TRACK OPERATION 42

9.1 General Information 43
9.1.1 Undercarriage Identification 43
9.1.2 General Safety and Accident Prevention 43
9.1.3 Daily Safety Checks 44
9.1.4 Operating Precautions 45
9.2 Hydraulic Installation 46
9.2.1 Hydraulic Connections to the Track Drives with A2FE Fixed Displacement Motors 46
9.2.2 Hydraulic Schematic 47
9.2.3 Hydraulic Ports 48
9.2.4 Hydraulic Specifications 48
9.3 Basic Maintenance 49
9.3.1 Correct Maintenance Procedure 49
9.3.2 Checking Track Tension 49
9.3.3 Adjustment of Track Tension 50
9.3.4 Removing the Track 52
9.3.5 Rejoining the Track 53
9.3.6 Fitting of Repair Link 53
9.3.7 Track Drive Units 54
9.4 Trouble Shooting 55
9.4.1 Track Tension 55
9.4.2 Loss of Drive 56
9.4.3 Leaks and Seizures 57

SECTION 10 APPENDIX 58
10.1 TS4065 Elevation View 58
10.2 TS4065 Plan View Head Section Folded 59
10.3 TS4065 Plan View Head and Tail Section Folded 60
10.4 Bolt Torque Table 61

3
 Warranty Start-Up Information

IMPORTANT: WARRANTY CAN NOT BE ACTIVATED UNTIL THIS FORM IS RECEIVED. PLEASE FILL OUT COMPLETELY AND
RETURN.
Customer Name

Company Name

Address

Phone

Fax

Email

Federal ID#
(US customers only)

Machine Purchased through

Dealer
Model #
Serial #
Control Panel Serial #
Track Serial # RH LH
Purchase Date

Hour Meter Reading At Time of Purchase Control Panel Serial No.

Signing Officer
Please Print

Please Sign

Date Month Day Year

Please complete this form and send it to:

McCloskey International Ltd., McCloskey International Ltd.,
47 Moor Road, 1 McCloskey Road,
Coalisland, Keene,
Co. Tyrone, Ontario,
Northern Ireland. Canada.
BT714QB K9J 0G6
tel: (+44)-28-8774-0926 tel: +1 705 295 4925
fax: (+44)-028-8774-7242 fax: +1 705 295 4777
Web: www.mccloskeyinternational.com mail: mccloskey@mccloskeyinternational.com

4
Orientation TS4065

Front

Left

Right

Back

NOTE: THE LEFT AND RIGHT OF THE MACHINE ARE ASSIGNED

BY STANDING AT THE HOPPER END OF THE MACHINE
LOOKING TOWARDS THE TAIL CONVEYOR DISCHARGE.

5
INTRODUCTION SECTION 1
Thank you for your purchase of the TS4065. This manual is designed to help you safely operate and
maintain your new machine. Following the information in this manual will ensure years of safe, reliable
service and production. Please ensure that all owners, operators or any other persons working near or on
the TS4065 read and understand this manual. Following the procedures and maintenance schedules as
outlined in this manual will help to:

 Avoid dangers
 Reduce costly repairs and downtime
 Increase the reliability of the TS4065

The TS4065 is a machine that has been designed and built to the highest standards using quality materials
and components. McCloskey International has taken the greatest care to insure that you have received a
safe and reliable machine that will provide you with years of production.

The T4065 is designed with the highest regard for safety. Nonetheless any misuse of this machine may
result in serious injury, death, damage to the machine as well as void the manufacturer’s warranty.

This operating manual should always stay with the machine.

Machine’s Designated Use

The T4065 is a portable, self-contained conveyor for stockpiling material. Typical materials include sand
and gravel, rock, soil, coal and landfill. If you need to stockpile any other material not listed please consult
with the manufacturer.

McCloskey International cannot be held liable for any damages resulting from misuse.

Contacting McCloskey International Ltd.

If you have any questions regarding your TS4065, please contact us at the following number:

UK: Canada:
+44 28-8774 0926 +1 705 295 4925
Toll Free: 1 877 TROMMEL
By phoning this number you can reach anyone of the following departments; service, sales, production,
accounting and engineering.

Section Overview
The following briefly outlines each section and its contents.

Warranty Startup Information

Warranty activation form to be completed and returned to McCloskey International.

Orientation
Machine left, right, front and back directions.

6
Safety
Safety information related to all aspects of the machine including safety stickers and warnings, do’s and do
not’s, and machine components.

Operation Procedures
Basic operating procedures including unloading from transport, on site setup, operation, and travel and
transport preparation.

Recommended Spare Parts

List of recommended parts to stock to minimize down time.

Maintenance Procedures
Schedules and general maintenance checks including:
 Oil & filter changes (all)
 Belt tensioning maintenance
 Idler maintenance

Special Procedures
Belt tightening and filter replacement.

Fault Finding
Fault/solution chart.

Technical Specifications
Dimensions and weight of machine.

Tracks
Track maintenance and trouble shooting.

Appendix
Elevation/plan views and bolt tightening table.

Problems, Errors and Omissions

We believe this manual will provide you with the necessary information to operate and maintain your
machine for many years of service. If you believe that this manual contains an error, or you encounter a
problem while following the guidelines in this manual, or if you believe this manual may be missing
information, please contact us so we may rectify any problems immediately.

Copyright
This document is copyrighted to McCloskey International Ltd. Any information, text, drawings or
technical data contained in this document cannot be copied, distributed, altered, stored on electric media,
revealed to others or used for the purpose of competition.

7
SAFETY SECTION 2
2.1 Warnings and Symbols
Most accidents involving product operation, service and transportation are caused by failure to observe
basic safety rules and precautions. Recognizing all possible safety hazards before acting can often prevent
accidents. The machine operator must always observe each situation for potential hazards. In addition, the
operator must possess the required knowledge, skill and equipment required to perform these tasks
appropriately. The warnings printed on the machine and in this publication are NOT inclusive. McCloskey
International Ltd cannot anticipate every possible situation that can be potentially hazardous. For any
function performed not recommended by McCloskey International Ltd, you must satisfy yourself that it
is safe for you and for others. Also, the action must not compromise the safety or function of the product
for future use. If in doubt, contact McCloskey International Ltd. for clarification.

Improper operation, service or transportation can result in injury or death. Do not operate this product
unless you have been factory trained. Do not attempt to operate, service or transport the product without
carefully reading and fully understanding the proper safety, operation, service and/or transportation section
of this manual (see Section 3).

Safety precautions and warnings are provided in this document and labelled on the product. Failure to
observe these hazards can result in injury or death. Hazards are symbolized by signal words such as
Danger, Warning, Caution and Attention. There are several warning labels printed on the product. The
warning labels are grouped into three categories:

Danger
This indicates an extremely dangerous situation. If proper precautions are not taken, it will result in serious
injury or death.

Warning or Caution
This indicates a hazardous situation. If proper precautions are not taken, it may result in serious injury or
death.

Push Emergency stop switch towards the machine to

completely shut down the engine. For locations see
Section 3.4.1.

When operating any moving part of the machine

ensure hands and feet are clear of all moving parts.
Never approach the tipping grid when the machine is
in operation. Always wear EN/ANSI approved safety
clothing. See Fig 1.

8
 To avoid accidental start-up, Lockout/Tagout the
machine during any maintenance. The lockout
controls are located inside the left hand power unit
door beside the oil cooler.

Attention
This indicates a potentially hazardous situation. If proper precautions are not taken, it may result in injury
and or damage to the machine.

9
2.2 SAFETY RULES: THE DO’S AND DON’TS

2.2.1 DO NOT

DO NOT:
 Remove obstruction or attempt any maintenance while engine is running

 Operate machine without reading manuals thoroughly

 Stand within a 15m (50 ft.) radius of the machine when it is in operation. The only exceptions to
this rule are authorized and trained operators and/or technicians who are involved in the machine
operation or maintenance.

 Increase pressure in system as this may cause damage to pump seal, hoses, hose fittings and to the
actual machine structure

 Start or stop (unless in an emergency) the machine with control levers in the operating position, as
this could stall the engine, shear keys and couplings, blow seals and cause damage to the actual
machine structure

 Operate machine with guards missing

 Remove any guards

 Open inspection doors while machine is operating

 Block burst hydraulic hoses, pipes or fittings with hands, as hydraulic oil under pressure will
penetrate the skin and cause serious injury

 Enter loading area while machine is functioning. The only exceptions to this rule are authorized
and trained operators and/or technicians who are involved in the machine operation or
maintenance.

 Stand beneath conveyors

 Stand beneath any head drum

 Use machine near power lines

 Touch hot surfaces

 Wear loose fitting clothing near machine

10
2.2.2 DO

DO:
 Change filters and oil regularly

 Grease machine regularly

 Inspect machine regularly

 Check conveyor belt alignment before running belt

 Read all manuals from start to finish before operating machine

 Obey all warning labels

 Replace unreadable or missing labels with new ones before operating this machine

 Use a qualified and knowledgeable serviceman

 Grease ALL exposed hydraulic cylinder rods every 8 weeks to prevent corrosion

 Always wear correctly fitting (EN/ANSI approved) protective clothing. Protective clothing
includes hard hat, safety glasses, ear protection, close fitting overalls, steel toed boots a high
visibility vest and gloves (Fig 1).

Fig. 1

11
2.3 DESCRIPTION

Fig. 2

1) Hopper – A wide hopper with extension plates to receive the material feed.

2) Conveyor – A 1000mm (40inch) three-ply belt delivers material from hopper to the discharge point
end of the conveyor.

3) Rear Support legs – Adjustable legs to raise and lower the hopper end of the conveyor frame for a
range of operating positions.

4) Main Support legs – Adjustable legs to raise and lower the conveyor frame from transport position
to a range of operating positions.

5) Tracks – Hydraulic drive crawler tracks for on site movement of machine.

6) Powerunit – Encloses the engine, hydraulic tank and machine operational controls.

12
OPERATIONAL PROCEDURES SECTION 3
3.1 STARTING MACHINE
Operation

Do NOT attempt to start the machine until you have been properly trained by a McCloskey International
technician. Ensure that the operator has read this manual and is fully aware of its operation. Ensure all
precautions are taken so that the machine is only operated in a safe and reliable manner. Follow all
government laws, codes or bylaws regarding safety matters. Only operate the machine ensuring all safety
devices are in place and working properly, including all guards, safety devices, safety and warning stickers,
emergency shut-off switches, tank caps and exhaust elements. Always operate internal combustion engine
equipped machines out-doors, or in properly ventilated area. Always wear safety boots, glasses and hard
hats while operating the machine. Avoid wearing loose fitting clothing, neckties or scarves.

Machine Setup

Before setting up the machine walk around the machine and check the following:
1. Scan the area around the machine for potential hazards, overhead wires or structures, hills or
slopes, poles or trees etc, address each situation before continuing. The machine must be set-up on
firm level ground for safety, and maximum performance.
2. Establish a buffer zone around the machine. All un-authorized personnel and foreign objects are
not permitted in the buffer zone while the machine is in operation.

While setting up the machine check the following:

1. Ensure all safety precautions have been made before starting the machine (see machine pre-start)
2. Keep all non-operator personnel outside the buffer zone while jacking machine and unfolding
radial conveyor.
3. Stabilize the machine from rolling by blocking transport wheels where applicable, lowering
jacking legs and raising the jack axle (if equipped).
4. Level the machine front to back, side to side using secure blocks.
5. Unfold the conveyors in accordance to the operation procedure listed for your machine. Secure all
supports.

Machine Pre-Start

Do NOT attempt to start the machine until you have been properly trained by a McCloskey International
technician. Different countries and states have distinct legislation relating to the safe operation of
machinery. Therefore it is the user’s responsibility to ensure their operation complies with their laws.
Before starting your McCloskey conveyor walk around and check the following:

1. Check that the machine is in good mechanical condition and that there is no component damage or
loss. Ensure all safety devices, guards, bolts & fittings have been properly installed and tightened.
2. All conveyors are fully unfolded with supports properly in place.
3. Ensure the feed hopper and conveyor belts are free of material.
4. Check for any obstructions that would inhibit the movement of the conveyors.
5. Ensure all hydraulic valves are in the neutral position.
6. Ensure all safety pins are in the appropriate position.
7. Know where all emergency stops are located.
8. Ensure the machine is blocked, level and stable. All jacking legs are properly pinned.
9. Ensure all non-operator personnel & equipment is outside the buffer zone.

While Operating

1. Always pay attention to the job at hand.

2. At the first sign of malfunction shutdown and lockout the machine (see Lockout/Tagout
Procedure).
3. Stay clear of all discharge ends of machine components such as tail conveyor, side conveyors,
tipping grid discharge and screenbox. Material discharging from these components can cause
serious injury or death

13
 4. Read and follow all warning labels.
5. Only operate the machine with all guards and safety devices in place.
6. Keep hands and fingers away from moving objects such as the screen, conveyors & scrapers,
conveyor pivot assemblies, and the engine compartment.
7. Do not climb in or on the machine while in operation.
8. Do not fold the conveyor while in operation.
9. Do not transport the machine while in operation.
10. All personnel must be notified prior to the using the remote control.

Lockout/Tagout Procedure

1. Follow proper shut down procedures, (see Machine Shut Down in the Operations section).
2. Turn the ignition key to the off position and remove the key.
3. Close the control panel door on the engine and lock it using a key.
4. Activate at least one emergency stop button.
5. Isolate the machine by turning off the battery isolator.
6. Lock out the battery isolator switch using a padlock or lock-out tag-out kit and remove the key.
7. It is suggested that a Maintenance / Repair Tag be secured to the control panel to notify all
personnel that the machine has been immobilized. Only once the problem has been repaired and
inspected, the tag can be removed.
8. Follow proper safety precautions before restarting the machine (see Machine Start up in this
section).

Maintenance

Maintenance and/or repairs on the machine must be performed by competent individuals. Maintenance
and/or repairs should only be carried out once the machine is on sturdy and level ground and is secured
against inadvertent movement or buckling. Always assess the situation for potential hazards before action is
taken. Ensure the following safety precautions are met at all times.

1. Lockout the machine before any action is taken.

2. Never stand or work under a suspended load.
3. Never use machine assemblies or parts as a work area or climbing aid. Only use proper safety
platforms or ladders when working on the machine.
4. When moving large and/or heavy machine assemblies for the purposes of removing, replacing or
performing work, ensure all parts are secured with proper rigging and all standard rigging
practices are followed.
5. Always use proper safety harnesses when working more than 7 ft from the ground.
6. Never perform maintenance with tools that may cause sparks or provide an ignition source for the
fuel.
7. Only carry out grinding, welding or flame cutting if the manufacturer has authorized it. There
may be risk of explosion and fire.
 Ensure the machine and its surroundings are clear from dust and any other flammable
sources to prevent the risk of an explosion.
 The premises upon which the work will be performed must be properly ventilated.
 You must turn the battery isolator switch to the off position. Using your lockout/tagout
procedure. This will help prevent damage to any sensitive electronics on the machine.
8. Any work to be performed on the electrical system must be carried out by a qualified electrician in
compliance with standard practices and any laws, codes or bylaws.
 Before any work is performed on the electrical system always disconnect the battery
leads, check all de-energized parts for power and ground or short circuit them.
 The electrical system must be inspected and checked at regular intervals. Check for
defects such as loose connections, frayed, burned or damaged cables.
9. Any work to be performed on the hydraulic system must be carried out by a qualified hydraulic
specialist in compliance with standard practices and any laws, codes or bylaws.
 Never use your hands or other body parts to check for hydraulic leaks. Use a piece of
cardboard or paper. Before performing any service or maintenance work on the hydraulic
system ensure it is de-pressurized.
 Any equipment that is raised and lowered hydraulically must be secured in place before
any service work is performed.

14
  Inspect all lines, hoses, fittings and connections for leaks and any damage. Any problems
should be fixed immediately.
10. Never remove the filler cap or refuel while the engine is running.
11. Keep all safety devices; platforms, work areas and ladders clear from oil, dirt, snow, ice, water or
other medium that may cause harm.
12. All inspection, maintenance, and service schedules must be strictly followed.

Transportation

Make sure that all of material has been run off the conveyors and the machine has been properly shut down
(see Machine Shut Down in Operations section). Always perform machine pre-start check starting the
machine (see section 3.1.1). Clear the area of all personnel & obstructions before folding the conveyors.
Refer to operation section for proper procedures for folding the radial conveyor and loading of the machine.

Do NOT move the machine without all transportation fitments securely in place and safety pins in position.

Ensure that:

1. All travel stays/chains, jacks and tow bars are secured in the travel position.
2. All parts are properly secured, cleaned and free of hardware, rocks, dirt or any debris that can fall
off the machine and cause damage to other motorists.
3. All necessary parts are removed before transport.
4. Check the condition (if applicable) of the wheels and tires for any potential problems, i.e.: cuts,
excessive rusting, missing rubber, wheel damage, loose or missing wheel nuts and proper tire
inflation.
5. The brake system has been thoroughly checked and is fully operational.
6. All lights (running, turning and brake) are operational.

The machine must be transported in accordance with all local laws, codes and bylaws. Check that your
specific transportation configuration meets all load capacities. Make note of the travel dimensions for your
machine before planning your route (see Weights & Dimensions in the Operations Section). Take caution
when crossing under overhead wires, underpasses, bridges, etc. to ensure enough clearance. Loading and
unloading procedure must be followed as outlined in this manual (see Operational Procedures Section).

15
3.1.1 STARTING ENGINE

1. Check that control levers are in neutral position, and all emergency stops are released
2. Make sure no one, other than the operator, is standing within 15m (50ft) of machine.
3. Set throttle lever to idle.
4. Insert key (Fig. 3).
5. Turn key clockwise (position 11), the charge, Emergency Machine stop and oil pressure light will
illuminate.
6. Turn key clockwise again position 13, the fuel light will illuminate, and alarm will sound, hold for
10 seconds until engine cranks.
7. Release key after immediately the engine starts.

Fig. 3: Engine Starter Panel

1 Charge 9 Preheat (optional)

2 Oil pressure 10 Hour clock
3 Coolant temperature 11 Off position
4 Coolant level 12 Run position
5 Air filter blockage lamp 13 Preheat position (optional)
6 Hydraulic oil level (optional) 14 Ignition key
7 Machine run lamp 15 Crank position
8 Fuel

Note: The engine will start but will stop after 20 minutes if the air filter blockage lamp
is illuminated.

16
3.1.2 STOPPING ENGINE

1. Make sure conveyor is clear of all material.

2. Stop the machine in the following sequence (See section 3.3.3)

1. Additional coupled conveyor (where fitted).

2. Conveyor belt.

3. Before stopping the engine, slow engine to idle speed for a few minutes before turning ignition switch
off.

3.1.3 TRACK CONTROL USING UMBILICAL CORD HANDSET

1. Connect the umbilical handset to the socket mounted above engine control panel.
2. Refer to (Fig. 4) showing umbilical handset.
3. Ensure E-stop button (item 1) is released. Twist to unlock.

Fig. 4

4. Start the engine (see 3.1.1).

5. Push track control levers down to activate track hydraulic circuits see Fig 4.
6. Change switch (Fig. 4 item 2) from AUX to TRACK to activate handset the siren will sound.
There will be a 10 sec delay before the machine will move.
7. To move the machine with hopper end moving forward, toggle and hold both switches (Fig. 4
items 3 & 4) towards the E-stop button. To move the machine in the opposite direction toggle and
hold the switches away from the E-stop button.
8. To turn the machine toggle and hold one of the switches (Fig. 4 item 3 OR 4).
9. To stop engine in an emergency, while using umbilical handset, push E-stop button (Fig 4 item 1).

17
3.2 MACHINE SET-UP PROCEDURE

MAKE SURE MACHINE IS

CLEAR OF ALL NON-
WARNING AUTHORIZED PERSONNEL
BEFORE START UP

3.2.1 UNFOLD CONVEYOR TOP SECTION

1. Before unfolding the conveyor top section, check that there are no loose items on the upper
conveyor frame. Any loose items on the upper conveyor frame may fall off causing injury and/or
damage to the machinery.
2. Start engine (See section 3.1.1).
3. Run engine at idle speed.
4. The hydraulic control panel shown in Fig. 5 is located on right hand side inside the powerunit see
Item 1, Fig. 6. Note that there will be a 4th lever in Fig. 5 if you have the optional hydraulic tail
fold.

Fig. 5

18
 STEPS 5 and 6 MUST be
followed in order!
WARNING Failure to do so may cause the
machine to tip!

5. The tail section must be fully extended BEFORE the conveyor head section is extended (Fig. 6). If
your machine contains the optional tail hydraulics, use lever 4, from the hydraulic control panel, to
slowly raise the tail section clear of the transport brackets, and then fold into the working position.

Fig. 6

6. Using lever Item 2, Fig. 5 slowly raise the conveyor head section clear of the transport brackets
Items 3, Fig. 6 and then fold into the working position (Fig. 7).

Fig. 7

Opening the conveyor head

WARNING section before the tail section

may cause the machine to tip!

19
3.2.2 RAISE CONVEYOR FEEDBOOT

1. Start engine (See section 3.1.1).

2. Run engine at idle speed.
3. Remove pin Item 2, Fig. 8.
4. The hydraulic control panel shown in Fig. 5 is located on right hand side inside the powerunit see
Item 1, Fig. 6.
5. Using lever Item 1, Fig. 5 slowly raise the conveyor feedboot end to desired position by extending
the rear support arms Item 1, Fig. 8.
6. Replace pin Item 2, Fig. 8.

Fig. 8

3.2.3 RAISE CONVEYOR FRAME

1. Start engine (See section 3.1.1).

2. Run engine at idle speed.
3. Remove pin Item 2, Fig. 9.
4. The hydraulic control panel shown in Fig. 5 is located on right hand side inside the powerunit see
Item 1, Fig. 6.
5. Using lever Item 3, Fig. 5 slowly raise the conveyor frame to desired position by extending the
main support arms Item 1, Fig. 9.
6. Replace pin Item 2, Fig. 9.

Fig. 9

20
3.3 OPERATING FUNCTIONS

MAKE SURE MACHINE IS

WARNING CLEAR OF ALL NON-

AUTHORIZED PERSONNEL
BEFORE START UP

3.3.1 PRE START UP CHECKS

1. Check engine oil. Fill if necessary. 1

2. Check hydraulic oil level, Item 1, Fig. 10, fill if
necessary
3. Check diesel water separator for water and drain if
necessary.
4. All control valves must be in the neutral (mid)
position. Item 2, Fig. 10.
5. Throttle should be in the idle position (i.e. in lower
position) see Item 3, Fig. 10.
6. Ensure the electrical isolator switch is turned on.
Item 4, Fig. 10.
7. Turn the ignition key on the starter panel to the
crank position and hold. Item 5, Fig. 10. A warning
siren will sound for 10 seconds after which the
engine will crank. Once started release the ignition
key. For warning lights on starter panel see trouble
shooting. Also see section 3.1.

8. 3 2
5 4

Fig. 10

21
3.3.2 START UP SEQUENCE

Increase the engine speed by pulling the throttle. The throttle will lock in the slot on the throttle assembly
slide.

To start the conveyor belt pull the control valve towards you (see Fig. 11).

3.3.3 OPERATING CONRTROL VALVES

Hydraulic fluid directed by a series of control valves is used to power the machine. Control valve labels
provide functional information. Control valves in the powerunit may include dials. These dials control the
output flow from the valve which will speed up or slow down the operation. See Fig. 11.

Fig. 11

22
3.4 EMERGENCY STOPS

IN THE EVENT OF AN EMERGENCY IT IS IMPORTANT TO KNOW HOW TO STOP

THE MACHINE QUICKLY. BECOME FAMILIAR WITH LOCATION AND
OPERATION OF ALL EMERGENCY STOPS ON THE MACHINE (see Fig. 12).

3.4.1 TO STOP MACHINE IN AN EMERGENCY

If an emergency arises, stop machine quickly, by pressing emergency stop (see Fig. 12).

1. Switch off engine ignition switch.

2. Set all hydraulic control levers to neutral positions.

Fig. 12

3.4.2 RESTARTING AFTER AN EMERGENCY STOP

1. Ensure all control levers are in neutral position.

2. (i) If the emergency stop is of a twist type, simply twist clockwise to reset.
(ii) If emergency stop is of a key type, insert key and turn key clockwise.
3. Start engine (See section 3.1.1).

23
3.5 PREPARING MACHINE FOR TRANSPORT

ENSURE HOPPER AND

DANGER CONVEYOR ARE EMPTY (FREE

FROM MATERIAL)

3.5.1 LOWER CONVEYOR FRAME

1. Start engine (See section 3.1.1).

2. Run engine at idle speed.
3. Remove pin Item 2, Fig. 13.
4. The hydraulic control panel shown in Fig. 5 is located on right hand side inside the powerunit see
Item 1, Fig. 6.
5. Using lever Item 3, Fig. 5 slowly lower the conveyor frame to desired position by extending the
main support arms Item 1, Fig. 13.
6. Replace pin Item 2, Fig. 13.

Fig. 13

24
3.5.2 LOWER CONVEYOR FEEDBOOT

1. Start engine (See section 3.1.1).

2. Run engine at idle speed.
3. Remove pin Item 2, Fig. 14.
4. The hydraulic control panel shown in Fig. 5 is located on right hand side inside the powerunit see
Item 1, Fig. 6.
5. Using lever Item 1, Fig. 5 slowly raise the conveyor feedboot end to desired position by extending
the rear support arms Item 1, Fig. 14.
6. Replace pin Item 2, Fig. 14.

Fig. 14

3.5.3 FOLD CONVEYOR FOR TRANSPORT

1. Before starting to fold over conveyor head section first lower conveyor to lowest position.
2. Before unfolding Conveyor Top Section check that there is no loose items on the upper conveyor
frame that could fall off.
3. Start engine (See section 3.1.1).
4. Run engine at idle speed.
5. The hydraulic control panel shown in Fig. 5 is located on right hand side inside the powerunit see
Item 1, Fig. 6.

STEPS 6 and 7 MUST be

followed in order!
WARNING Failure to do so may cause the
machine to tip!
6. Using lever Item 2, Fig. 5 slowly raise the conveyor head section clear of the transport brackets
Items 3, Fig. 6, then fold into the transport position ensuring that the frame locates into transport
brackets Items 3, Fig. 6.
7. (Optional) If your machine contains the optional tail hydraulics, use lever 4, from the hydraulic
control panel, to slowly raise and fold the tail section into the transport position.

The machine is now ready to be loaded on a trailer.

25
3.5.4 LOADING MACHINE ONTO A TRAILER

LOADING SHOULD ONLY BE

DANGER UNDERTAKEN BY COMPETENT

TRAINED PERSONNEL

The machine should be loaded on a trailer in either configuration figure 15 or configuration figure 16.
There should be adequate clearance beneath the frame so the machine chassis will not come in contact with
the ground. Continually check ground clearance during loading to ensure clearance is maintained.

NOTE: After loading check overall height does not exceed local transport height restrictions.

approximately

Fig. 15

approximately

Fig. 16

26
RECOMMENDED SPARE PARTS SECTION 4
During the working life of a McCloskey TS4065, it may be necessary to replace parts due to normal wear
and tear. This section identifies which parts typically require replacement and when those parts may need
replacing.

4.1 REGULAR SPARES

The following parts should be kept in stock for the operation and maintenance of the McCloskey TS4065:

 Oil filters
 Fuel filters
 Air filters
 Flashing
 Rollers
 Idlers

For specific part numbers and quantities reference the TS4065 Parts Book.

ENSURE THAT MACHINE IS LOCKED

OUT BEFORE ANY MAINTENANCE IS
WARNING PREFORMED OR OBSTRUCTIONS ARE
REMOVED

27
MAINTENANCE SECTION 5

5.1 SAFETY

5.2 GENERAL
Maintenance of the McCloskey conveyor is carried out using five schedules:

 Schedule ‘A’ – daily

 Schedule ‘B’ – after first 50 hours

 Schedule ‘C’ – weekly

 Schedule ‘D’ – monthly

 Schedule ‘E’ – 600 HOURS or 3 months

 Schedule ‘F’ – annually

28
5.3 MAINTENANCE SCHEDULES

SCHEDULE ‘A’ DAILY MAINTENANCE

ITEM OPERATION REMARKS

1 Defects Attend to any defects reported by the operator.
2 Electrical System Examine all visible cables and connections.
3 Hydraulic Power a) Check oil level and replenish.
Unit b) Visually inspect for leaks, damaged hoses and
fittings. Replace defective items.
c) Visually inspect filter indicators

4 Conveyor Belt a) Visually inspect for cuts, rips and tears. Report See Section 6. 1
to maintenance manager if necessary.
b) Check alignment, adjust as necessary.
c) Check tension, adjust as necessary.

5 Guards a) Ensure all guards are securely fitted.

b) Report defective guards to maintenance
manager.
c) Replace defective guards.
6 Fasteners Visually inspect for loose bolts and screws, tighten
if necessary
7 Track a) Check idler oil leakage
maintenance b) Check lower roller for loose nuts/bolts
c) Check lower roller oil leakage
d) Check sprockets loose nuts/bolts
e) Check track drive loose nuts/bolts
f) Check track drive oil leakage
g) Check track group for damage to track links,
pins or shoes
h) Check track group loose nuts/bolts
i) Check track group tight/seized track joints
8 Fuel level a) Check fuel level and replenish.
b) Visually inspect for leaks, damaged hoses and
fittings. Replace defective items.
9 Engine oil level Check oil level and replenish
10 Hoses Visually inspect for leaks, damaged hoses and
fittings. Replace defective items.
11 Seals Visually inspect for damaged seals

12 Engine Air filter Change filter if light illuminates

29
 SCHEDULE ‘B’ MAINTENANCE AFTER FIRST 50 HOURS
ITEM
1 Schedule ‘A’
2 Return line hydraulic filters
3 Diesel pre-filter
SCHEDULE ‘C’ WEEKLY MAINTENANCE OR EVERY 50 HOURS
ITEM
1 Schedule ‘A’
2 Conveyor Belt Scraper
3 Greasing of bearings
4 Bolt tightness
5 Diesel pre-filter
6 Track maintenance
OPERATION REMARKS
Ensure that the work detailed in this
schedule has been carried out.
Change filter after the first 50 hours
Drain pre-filter after first 50 hours
OPERATION REMARKS
Ensure that the work detailed in this
schedule has been carried out.
a) Remove Material Build Up.
b) Check adjustment and adjust as
necessary.
c) Replace worn or damaged parts.
Grease as per recommendations See Section 5.4
Check bolt tightness around screen
box and engine compartment
Drain diesel pre-filter
a) Track drive oil quality
b) Track group track tension
30
 SCHEDULE ‘D’ MONTHLY MAINTENANCE OR EVERY 200 HOURS
ITEM
1 Schedule ‘A’and‘C’
2 Bearings
3 Hydraulic oil filters
4 Hydraulic tank
5 Engine air intake pipe
6 Track
SCHEDULE ‘E’ ANNUAL MAINTENANCE OR EVERY 500 HOURS
ITEM
1 Engine oil change
SCHEDULE ‘F’ ANNUAL MAINTENANCE OR EVERY 2500 HOURS
ITEM
1 Schedule ‘A’,‘C’ and ‘D’
2 Hydraulic Oil
OPERATION REMARKS
Ensure that the work detailed in
these schedules has been carried
out.
a) Inspect for loose bolts and
tighten if necessary.
b) Inspect for loose fit on shaft
and any damage, replace if
necessary.
c) Lubricate screen box outer
bearings
Return line oil filter should be Change element frequently
changed every 1000 hours or when when operating in excessively
indicator turns from green to red dusty conditions
Hydraulic tank filter/breather cap
should be cleaned.
a) Check engine air intake pipe
for signs of weakness, holes or
wear.
b) Replace where necessary.
Check track system for structural
damage or failure
OPERATION REMARKS
Engine oil, oil filter and fuel filter
OPERATION REMARKS
Ensure that the work detailed in these
schedules has been carried out.
a) Analyze oil sample, check for
condition and contamination.
b) Change only as necessary.
31
5.4 GREASING INFORMATION

Conveyor Bearings
Conveyor bearings require 2 grease gun strokes every 40 hours.

HYDRAULIC SYSTEM

IMPORTANT: The utmost cleanliness must be observed at all times when changing or topping up
hydraulic oil or changing filter elements. Impurities in the oil will destroy the system. Check the condition
of all hydraulic system components weekly.

IMPORTANT: If the performance of the McCloskey machine has decreased (i.e. conveyor speed has
slowed down) switch the machine off immediately. Check the
hydraulic system before restarting.

Note: Immediately contact an agent approved by McCloskey International Ltd., if the

hydraulic system requires any major repairs.

32
5.5 ENGINE MAINTENANCE
For engine maintenance refer to the engine manual. Engine servicing should only be carried out by a
qualified Service person.

Maintenance Interval Schedule

The normal oil change is every 500 service hours or 12 months. Be sure to conduct controlled oil sampling
at every 250 service hours or 6 months. The oil change interval may need to be reduced for some
applications based on the controlled oil sampling results. Verify the proper oil change interval for the
engine after satisfactory completion of the controlled oil sampling.

When Required
Battery Replace
Engine Clean
Engine Air Cleaner Element Clean/Replace
Engine Crankcase Breather Clean

Daily
Cooling System Coolant Level Check
Driven Equipment Check
Engine air Cleaner Service Indicator Inspect
Engine Oil Level Check
Walk Around Inspection

Every 50 Service Hours or Weekly

Fuel Water Separator and Filter Drain

Every 250 Service Hours or 6 Months

Engine Oil Sample Obtain

Every 250 Service Hours or 1 Year

Radiator Clean

Every 500 Service Hours

Alternator and Fan Belts Inspect / Adjust / Replace
Battery Electrolyte Level Check
Cooling System Coolant Test / Add

Every 500 Service Hours or 6 Months

Engine Protective Devices Check
Fuel System Secondary Filter Replace
Fuel Transfer Pump Strainer Clean
Hoses and Clamps Inspect/Replace

Every 500 Service Hours or 1 Year

Engine Oil and Filter Change

Every 1000 Service Hours

Engine Valve Lash Inspect Adjust

33
Every 2000 Service Hours
Alternator Inspect

Every 2000 Service Hours or 1 Year

Engine Mounts Inspect
Fuel Injection Nozzles Test/Exchange

Every 2000 Service Hours or 2 Years

Cooling System Coolant Extender (ELC) Add

Every 3000 Service Hours or 2 Years

Cooling System Coolant Change
Cooling System Water Temperature Regulator Replace
Starting Motor Inspect
Water Pump Inspect

Every 6000 Service Hours or 6 Years

Cooling System Coolant (ELC) Change

5.6 TRACK MAINTENANCE

See section 9.3.

5.7 RECOMMENDED LUBRICANTS

Conveyor Bearings and general purpose grease EP2 Grease

Engine 15W/40 Engine oil

Track Gearbox and track adjustment See section 9

Hydraulic Oil ISO VG 46

Cold Weather Operation Ambient Temp -150C (50 F)

Engine Oil 10W/30 Engine Oil

Hydraulic Oil ISO VG 32

34
5.8 SERVICING TERMINOLOGY
Definitions of terms are as follows:

Check or inspect: carry out a survey to ensure the condition of the item is not impaired by one or more
of the following:

 External damage
 Insecurity of attachment
 Cracks or fractures

Check or inspect: carry out a survey to ensure the condition of the item is not impaired by one or more
of the following:

 Corrosion, deterioration or contamination

 Distortion
 Loose or missing fasteners
 Faulty or broken locking devices
 Chafing, fraying, scoring, wear, cuts or tearing
 Leaks from pipelines and hoses
 Discolouration due to overheating or leaking fluids

Operate: Ensure that an item or system functions correctly, as far as possible, without the use of test
equipment or reference to measurement.

OEM: Original Equipment Manufacturer

Fit: Correctly attach one item to another

Remove: Separate an item from its support (completely)

Refit: Fit an item which has previously been removed

Replace: Remove an item and replace it with a new or serviced item

Replenish: Refill a container to a pre-determined level or quantity and where necessary:

1. Remove caps from filter orifices

2. Clean orifices
3. Fill container as directed
4. Inspect caps and gaskets
5. Refit caps

35
SPECIAL PROCEDURES SECTION 6

PROCEDURES IN SECTION 6 MUST

BE CARRIED OUT BY A QUALIFIED
WARNING AND COMPETENT SERVICE PERSON

BEFORE ATTEMPTING ANY PROCEDURES IN THIS SECTION ENSURE

ENGINE IS SWITCHED OFF AND CAN NOT BE RESTARTED BY ANYONE
OTHER THAN THE SERVICE PERSON. ISOLATE THE MACHINE BY
TURNING OFF THE ISOLATOR SWITCH SEE 3.3.1 Fig. 22 AND LOCKOUT
THE MACHINE. NOTE: THE SERVICE PERSON MUST BE IN CHARGE OF
THE KEYS.

6.1 TENSIONING AND ALIGNMENT OF CONVEYOR BELT

1. Insure that engine is switched off and cannot be

started by anyone other than the service person.
2. Turn off the battery isolator switch item 1 Fig. 22.
Push in one e-stop Fig. 12.
3. Clean build up of material from all idlers and
rollers.
4. Turn tensioning bolts (item 1 Fig. 17), alternately
and evenly, until belt feels tight.
5. Release emergency stops.
6. Check that all unauthorised personnel are clear of
machine, restart the engine.
7. Run engine at full throttle.
8. Pull the lever to run the conveyor being adjusted Fig. 17
(see 3.3.2).
9. If the conveyor belt is running to the right tighten the right hand adjuster.
10. If the conveyor belt is running to the left then tighten the left hand adjuster.
11. Observe the belt to see if it running true to centre, if not repeat procedure ‘10’ or ‘11’ until the belt
is centred.
12. Run the machine with belts loaded and unloaded until you are satisfied that the belt is tensioned
and aligned.

36
 6.2 SERVICING FILTERS

4 1

2 3

Fig. 18: FILTER LOCATIONS

1 – Air filter
2 – Primary fuel filter\Water separator
3 – Fuel filter
4 – Hydraulic oil return line filter
5 – Filler cap

37
6.2.1 AIR FILTER

1. Turn off engine

2. Remove air filter cap by loosening

clips items 1 Fig. 19. The filter
elements are shown in Fig. 20.

3. When removing the filter element

Item 3, Fig. 20 be careful not to
disturb the safety element item 4,
Fig. 20.

4. When re-assembling the filter

ensure that the filter are fully in-
place before fitting the cap.

5. Ensure all clips are tight.

6. Reset air filter button.

Fig. 32

Fig. 19

Fig. 33: Air filter Components 1. Fixed outer housing

2. Cap
3. Outer filter element
4. Safety element
Fig. 20: Filter Elements 5. Clip

38
6.2.2 HYDAULIC FILTER

1 1) Lock out machine

2) Clean the exterior of the hydraulic oil filter housing with a
clean rag.
2) Remove filter cap by removing bolts (Fig. 21 item 1)
3) Remove hydraulic filter element (Fig. 21 item 2)
4) Replace filter element

2 NOTE: Do not allow dirt to enter the tank.

NOTE: The complete filter housing does not have to be removed

as shown. Only the cap and lid need to be removed.

Fig. 21

1) The hydraulic fill Item 5 Fig. 18 has

a strainer to stop large debris. The strainer should be kept
1 clear.

2) To remove strainer remove filler cap and pull out strainer

(Fig. 22).

Fig. 22

6.2.3 ENGINE OIL & FUEL FILTER

See Engine Maintenance Section 5.5.

39
SECTION 7 FAULT FINDING
7.1 FAULT FINDING TABLE

HYDRAULICS BELT HYDRAULIC

HEATING UP STALLING OIL FOAMING

OIL COOLER BLOCKED OR FAN NOT

WORKING

RETURN FILTER CLOGGED

STOP VALVES TURNED OFF

LOW OIL LEVEL IN TANK

HOSE COLLAPSE

HOSES BLOCKED

LOW PRESSURE TO MOTOR

OIL SYSTEM OBSTRUCTED

BELT SLIPPING ON DRIVE DRUM

AIR IN / ENTERING SYSTEM

PUMP PRESSURE LOW

PUMP DAMAGE (PRESSURE TEST)

DAMAGED FITTINGS

MOTOR DAMAGED

HOSES HOLED

MOTOR / PUMP KEY HAS SHEARED

SHEARED COUPLING

40
TECHNICAL SPECIFICATIONS SECTION 8
8.1 TS4065

TRANSPORT HEIGHT……………………………...……… 2440mm (8’ – 0”)

TRANSPORT WIDTH……………………………………… 2230mm (7’ – 4”)

TRANSPORT LENGTH……………………………………. 13150mm (43’ – 2”)

WORKING HEIGHT……...………………………………... 8063mm (26’ – 5”)

WORKING LENGTH………………………………………. 18640mm (61’ – 2”)

WORKING WIDTH………………………………………… 2230mm (7’ – 4”)

WEIGHT……………………………………………………. 10,500 kg (23,150 lbs.)

41
TRACK OPERATION SECTION 9

42
SECTION 9.1 GENERAL INFORMATION
9.1.1 UNDERCARRIAGE IDENTIFICATION

The picture below (Fig. 23) illustrates the position of the serial numbers on the track systems. The serial
number of the track system is located on the identification plate and stamped on the skid place of each track
frame. Note that the serial number will be required for track service and support.

Fig. 23

9.1.2 GENERAL SAFETY AND ACCIDENT PREVENTION

Please ensure all safety precautions and instructions are adhered to when installing, operating and/or
performing maintenance on the track systems.

1. Protective Equipment: Always wear protective clothing and footwear as required by job conditions
when working around this product. Wear protective glasses when in risk of splintering debris. Use welder’s
gloves, facial/eye protection and other protective clothing appropriate to welding job being performed.
Avoid loose clothing.

2. Unauthorized Modifications: It is important not to carry out modifications to the track system which
could compromise proper operation and safety. McCloskey International is not responsible for any injury or
damage caused by unauthorized modifications.

3. Pressurized Items: Avoid welding near pressurized hydraulic pipelines, track tensioners, track recoils
or other flammable materials. Excessive heating near to pressurized hydraulic pipelines can cause failure,
generating a flammable spray with the possibility of severe injuries to nearby persons.

43
4. Lifting: Use a hoist when lifting components which weigh more than 23 Kg (50lbs). Ensure all hooks,
chains, slings etc., are in good condition and tested to an adequate safe working load, and be sure hooks or
slings are positioned correctly.

9.1.3 DAILY SAFETY CHECKS

The following checks should be made every day before operation. Check for:

• Loose bolts and nuts on lower rollers, sprockets and track shoes

• Track links if master pins are correctly located and tight

• Oil leaks from lower rollers, front idlers

• Oil leaks from track drive gearbox and motor

• Track tension within given limits (see Section 9.3.2)

• General damage and wear to all components

NOTE: Take corrective action immediately if track problems are evident; tighten bolts and nuts to
correct torque, replace damaged or worn components as required.

DO NOT operate the machine with

damaged or defective track system
components. Any persistent problem
should be reported to the machine
manufacturer.

44
9.1.4 OPERATING PRECAUTIONS

When traveling up a gradient (Fig. 24), the tracks should be driven forward (i.e. idlers first, drive sprocket
to the rear). When traveling down a gradient (Fig 25), tracks should be driven sprocket first.

Fig. 24 Fig. 25

ALWAYS:

 Park the machine on flat, level ground. If it is necessary to park the machine on a gradient, the tracks
should be solidly blocked.

 Ensure the terrain the machine is working on is firm enough to adequately support the machine.

 Ensure the machine is tracked at least 10m in either direction on a daily basis, to minimize risk of track
chain seizure.

 Ensure the track systems are free from debris before moving the machine.

 Ensure the tracks are not frozen to the ground before moving the machine.

NEVER:

 Attempt to track the machine if there is any build up of material around the tracks and drive sprockets.

 Attempt to track the machine if the tracks are frozen to the ground.

 Push or tow the machine when the machine becomes unable to free itself.

Failure to observe the above precautions could result in

danger to persons and damage to the track systems
which may invalidate the warranty.

45
SECTION 9.2 HYDRAULIC INSTALLATION

9.2.1 HYDRAULIC CONNECTIONS TO TRACK DRIVES

WITH A2FE FIXED DISPLACEMENT MOTORS

Basic Connections to the Track Drives and Motors

Highlighted below are the main connections to the standard track drive gearbox and fixed displacement
motor (Fig. 26), required for normal operation.

Fig. 26

Port Functions

Main Flow Ports, V1 & V2 - Flow and pressure of hydraulic oil is applied to these ports, main
drive is achieved. Torque and speed output is dependant on the
pressure and flow applied.

Case Drain Port, T - Allows any excess hydraulic oil to return to tank.

Under no circumstances should it be attempted to drive the

tracks without releasing the parking brake. This can cause
failure of the track drive and will invalidate the warranty.

46
 Direction of Rotation

When connecting to the track drives, it is important to check that the direction of rotation corresponds to
forward movement of the machine when positioned at the rear of the machine.

Fig. 27

The diagram above (Fig. 27) shows the direction of rotation of the track drive in relation to the input flow
to the motor.

9.2.2 HYDRAULIC SCHEMATIC

Below (Fig. 28) is a general hydraulic circuit for the track drive gearbox and fixed displacement motor
combination, with a motion control and brake release valve fitted (left and right track motors).

Left Track Right Track

Motor Motor

Fig. 28

47
9.2.3 HYDRAULIC PORTS

Port Size
A & B motor man flow ports ¾" SAE

T, motor case drain port M18 X 1.5

F, gearbox brake release port 3/4" BSPP

Fig. 29

9.2.4 Hydraulic Specifications

Operating Pressures/Flows

Maximum continuous pressure 230 bar

Maximum permissible case drain pressure at port T 2 bar
Brake release pressure 8 bar min/50 bar max
Variable speed control pressure at port X n/a
Maximum oil flow through ports A & B 120 L/min

Gearbox

Oil Volume 1.4 L/gearbox

Maximum permissible case drain pressure at port T 2 bar
Minimum operating oil temperature -25ºC
Maximum operating oil temperature 90ºC

48
SECTION 9.3 BASIC MAINTENANCE
9.3.1 CORRECT MAINTENANCE PROCEDURE
ALWAYS:

 Perform maintenance on a level and solid surface

 Ensure the undercarriage is solidly supported if work is necessary under the track systems

 Remove any build-up of grease, oil or debris

 Repair all damage and replace worn or broken parts immediately

 Check for oil leaks and damaged hydraulic hoses

 Use only specified lubricants, do not mix different brands or types

 Use great care when maintaining the hydraulic system since oil may be very hot when the machine

has just been working

 Use only McCloskey International supplied / approved replacement parts (NOTE: use of

unapproved parts will void the warranty)

 Dispose of lubricants in the proper manner

Please note that the maintenance intervals specified are for normal working conditions. If the
track system is used in severe working conditions perform maintenance and safety checks more
frequently.

9.3.2 CHECKING TRACK TENSION

Stop your machine on solid and level ground and drive 2 meters (minimum) in a forward direction.
Measure the sag on the top part of the track on the longest section of unsupported track as shown below
(Fig. 30). The sag of the track must be between 5mm and 15mm.

Fig.30
Sag must be checked on a new machine. Sag should also be periodically checked and corrected if
necessary, by adjusting the valve fitted to the end of the grease tensioner as described in Section 9.3.

49
9.3.3 ADJUSTMENT OF TRACK TENSION

Crawler track systems use a grease cylinder to keep each track chain in tension (Fig. 31). A grease fitting is
screwed into the end of the grease cylinder. This grease fitting enables grease (Lithium EP2) to be pumped
into the grease chamber and released from it, tightening and slackening the track.

NOTE: The grease inside the track tensioner is under pressure and care must be taken when
loosening the grease fitting.

Grease Fitting

Fig. 31

TIGHTENING THE TRACKS

1. Loosen three of the four screws and swing the access cover away from access aperture on the side of
the track frame (Fig. 32).

Fig. 32

2. Ensure the grease fitting and grease gun adaptor is clean. Ingress of dirt into the grease fitting can
result in track failure. Connect a grease gun to the grease fitting and add grease until the track tension
is within the specified values given in Section 9.3.2.

3. Drive 50 meters forwards and 50 meters backwards. If the track slackens, repeat steps 1 and 2 above.

4. Reattach the access cover.

50
SLACKENING THE TRACK

1. Loosen three of the four screws and swing the access cover away from access aperture on the side of
the track frame.

2. Loosen the grease fitting, by turning in an anti-clockwise direction, using gradual increments until the
grease begins to be expelled. Care must be taken not to loosen the grease fitting too quickly.

3. When the correct track tension has been obtained, tighten the grease fitting by turning in a clockwise
direction and clean away all trace of extruded grease. Be sure not to over tighten the grease fitting.

4. Reattach the access cover.

If the track fails to slacken after grease fitting has been loosened; DO NOT attempt to remove the tracks or
disassemble the track tensioner, and DO NOT remove the grease fitting from the tensioner. It is possible
that running the tracks a short distance in both directions with the grease fitting loosened may help to expel
the grease.

Should the tracks become slack on a regular basis, check and replace the following:

 Leakage on the outer face of the grease fitting – replace grease fitting
 Leakage at contact surface between the grease tensioner and grease fitting – replace bonded seal
 Swollen grease cylinder barrel – replace the complete tensioner unit

NOTE: Replacement parts will require the track serial number and should be ordered from
McCloskey International.

The above procedure involves working with grease

contained at high pressure and must only be carried out
by qualified fitters.

51
9.3.4 REMOVING THE TRACK

To uncouple the track group the following

the steps below:

1. Jack up the machine and block safely

on firm, level ground.
2. Locate the master pin. This can be
identified by small circular
indentations, or by an X marked on
each of the end faces.
3. Rotate the track until the pin is in
approximate position (Fig. 33) and
place a block under the front of track.
This prevents the chain from dropping
once the master pin has been removed.
4. Release the tension on the tracks as
Fig. 33
described in Section 9.3.3; this should
only be carried out by a qualified
fitter.
5. The master pin can now be pressed out from the chain, separating the track. Note: The press type
mater pin identified by an X mark or centre drill mark (Fig. 33) requires a hydraulic press to remove
and replace.

Fig. 33: Press type

master pin

The more common, dowel type master pin (Fig. 34) can be removed and replaced with a copper
hammer.

Fig. 34: Dowel type

master pin

6. The track can now be pulled from under the machine.

When removing the master pin, do not use a

sledge hammer. This may cause splintering of
the metal which may lead to personal injury.

Care must be taken when pulling the track chain

from under the machine to avoid dislodging the
blocks or stands supporting the machine.

52
9.3.5 REJOINING THE TRACK

To rejoin the track group, the following procedure must be followed, but should only be carried out by
qualified fitters:

1. Position the pin collars into the counter bore of the mating links.
2. Ensure the pin holes and the bushings are aligned and insert a dummy pin.
3. With the master pin in position, set up the track press.
4. Press the master pin fully into the chain links, pushing the dummy pin through the link.

Sledge hammers must not be used to insert the master

pin. This may cause splintering of the metal with the
possibility of personal injury.

9.3.6 FITTING OF REPAIR LINK

A track repair link kit as shown in Section 9.4.6 consists of:

 1 no. Left hand track link

 1 no. Right hand track link
 1 no. Master bushing
 2 no. Master pin with collars
 4 no. Track shoe bolt
 4 no. Track shoe nut

NOTE: The kit is supplied with the master bushing pressed into
the left and right hand links.

To fit a repair link to a track chain, the following procedure

should be followed:

1. Position the pin collars into the counter bore of the open
mating links.
2. Insert the bushing end of the repair link into the open end of the track chain.
3. Ensure the pin holes and the bushings are aligned and insert a dummy pin.
4. With the master pin in position, set up the track press.
5. Press the master pin fully into the chain links, pushing the dummy pin through the link.

Repeat this procedure for the second join, inserting the dummy pin and pressing in the second master pin,
completing the chain.

Sledge hammers must not be used to insert the

master pin. This may cause splintering of the metal
with the possibility of personal injury.

53
9.3.7 TRACK DRIVE UNITS

Routine Checks

The first oil replacement for the gearbox is to be carried out after 100 operating hours. There after
replace the oil every 1000 hours or at least once each year. The oil level should be checked every 100
working hours or every month – whichever comes first.

Oil Filling
To fill, track the machine until the gearbox casing is level with a plug positioned at 12 o’clock (Fig. 35).
Unscrew the two plugs and fill from the upper hole until oil reaches the level of the lower hole.

Oil fill

Maximum level

Fig. 35

Oil Draining
To drain, track the machine until a plug is at 6 o’clock position (Fig. 36). Unscrew both plugs and allow all
oil to discharge into a suitable container. Dispose of waste oil in a safe and approved way.

Venting

Drain port

Fig. 36

54
SECTION 9.4 TROUBLE SHOOTING
9.4.1 TRACK TENSION

Crawler track systems use a grease cylinder to keep the track chains in tension. Loss of tension in the
tracks can result in the sprocket jumping in the track chain, and also allowing the track chain to run off the
idler/sprocket. This can hinder the tracking ability of the machine and damage many of the components of
the track systems if not resolved quickly.

The tension of the tracks should be checked on a regular basis according to the parameters set out in
Section 9.3 of this manual; General Maintenance. If the tension of the track is outside these parameters, and
the adjustment method given in paragraph 9.3.3 has no effect, please read below checks that can be made
and possible causes:

Check 1: With the greaser access plate removed (see Section 9.3.3), make a visual inspection of
the greaser, looking for any signs of leaking grease.

 If grease is leaking from the base of the grease fitting, where it screws into the
end of the tensioner, either the gasket has failed and needs replacing, or the
Possible Cause:
grease fitting is not screwed in properly and needs tightening.
 If grease is leaking from the end of the grease fitting where the grease gun
connects to it, the grease fitting valve has failed and should be replaced.

Check 2: When the machine is stationary and blocked, make a visual inspection of the track
below the adjusting end of the tensioner, looking for any signs of leaking grease. Also,
reach under the frame, feeling the adjusting end of the tensioner for any grease.

 If grease is leaking from the adjusting end of the cylinder, the seals may have
Possible Cause: failed. This requires the tensioner to be removed from the tracks frame, to be
either fitted with new seals, or replaced with a complete new grease tensioner.

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9.4.2 LOSS OF DRIVE

Crawler track systems are driven using hydraulic motors connected to planetary drive gearboxes. The
hydraulic motors are driven using the hydraulics fitted to the machine.

Begin by making a visual inspection of the tracks, particularly around the sprocket, idler and bottom rollers
where material / objects can sometimes lodge. Follow this by inspecting all hoses and connections,
ensuring there are no leaks or blocks. If there are no physical impedances in the tracks and no faults are
found with hoses and connectors, please read below checks that can be made and possible causes:

Check 1: Using pressure / flow testing equipment, measure the values of the flow and pressure
being applied to the hydraulic motors.

If the values of the flow and pressure passing to the hydraulic motors is less than that
Possible Cause: required to drive the tracks (see machine manufacturer’s separate publication), there
may be a fault in the machines hydraulic system.

Check 2: Test the pressure being applied to the brake release port on the gearbox. In order to
release the brake, this should be fed with a pressure between 12 to 50 bar.

Possible Cause: If the pressure is below 12 bar, do not attempt to drive the tracks. With a pressure
below 12 bar, the brake will not release when driving the tracks is attempted. This can
cause the brakes to seize requiring a replacement unit to be fitted.

Check 3: If a valve is fitted to the hydraulic motor flange, ensure there are no visible faults with
the valve, and none of the connections are damaged / leaking.

Possible Cause: If there are no visual faults with the valve, and all other checks identify any faults, the
valve block may need replacing.

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9.4.3 LEAKS AND SEIZURES

General Components

Many components fitted to crawler track systems such as rollers and idlers are lubricated with oil.
Regular checks should be made to ensure these components are not leaking and rotate freely when the
tracks are driven. Any items such as rollers which show signs of leaking, or fail to rotate when the tracks
are driven should be replaced immediately.

Track Chains

Track chains can seize in particular conditions if they remain stationary for more than a few days,
causing kinks in the chain.

This can be prevented by tracking the machine on a daily basis as outlined in Section 9.3 of this manual,
Basic Maintenance. However, should this problem occur, it may be possible to remedy by applying
penetrating fluid to the seized pin, leaving for several hours, then tracking the machine several meters
forward and back.

If lubricating the pin is unsuccessful, the problem can be resolved by cutting out the seized link
including the pin and bush, replacing it with a complete repair link (see Section 9.3.6).

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SECTION 10 APPENDIX
10.1 TS4065 ELEVATION VIEW

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10.2 TS4065 PLAN VIEW HEAD SECTION FOLDED

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10.3 TS4065 PLAN VIEW HEAD AND TAIL SECTION FOLDED

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10.4 BOLT TORQUE TABLE

If not otherwise specified, use the following torque settings. Suggested torque for normal applications
(10%), using bolts/nuts without lubricant. Bolts and nuts with lubricant reduce mean torque by 15%.

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