Winget TD650 Service manual

OPERATORS
HANDBOOK TD650
TRACKED DUMPER
WINGET LIMITED
PO BOX 41
EDGEFOLD INDUSTRIAL ESTATE
PLODDER LANE
BOLTON
LANCS
BL4 0LR
Tel: ++ 44 (0) 1204 854650
[email protected]
[email protected]
www.winget.co.uk
ISSUE12 2021

CONTENTS
1 Introduction
2 Declaration of Conformity
4 Warranty Terms & Conditions
6 Safe Working
11 Operation
13 Maintenance and Service
19 Technical Information
21 Parts Information Section

INTRODUCTION 1
The WINGET TD650 Tracked Dumper is based on the HONDA HP500H
Power Carrier donor unit and this Handbook must be read in
conjunction with HONDA HP500H Owners Manual.
The contents of this Handbook although correct at the time of
publication, may be subject to alteration by the manufacturers
without notice.
Winget Limited operate a policy of continuous product development.
Therefore, some illustrations or text within this publication may differ
from your machine.
WARNING: The operator must read both this handbook and the
Honda publication and be familiar with all the controls before
attempting to operate this machine.

DECLARATION
OF
CONFORMITY
UKCA
We: WINGET LIMITED
Of Edgefold Industrial Estate, Plodder Lane, Bolton, Lancs, England BL4 0LR
declare that the product type:-
Machine Type:- . 650Kg Tracked Dumper .
Model:- . TD650 .
Serial Number:- . 2156-2750 .
To which this declaration relates, with a net installed power of 3.6Kw and
having been tested in accordance with the Conformity Assessment Procedure
detailed in Schedule 9 of UKSI 2001/10701 and verified by;-
ANP Certification Limited
2 Parkfield Street
Manchester
M14 4PN
is in conformity with the provisions of the Noise Emission in the Environment
by Equipment for use Outdoors Regulations 2001”. Representative samples
of this equipment were tested and Sound Power Levels (Lwa) recorded of:-
97db
We guarantee under the provisions of the above Regulations that the Sound
Power Levels for this equipment will not exceed:-
99db

We also declare that the above equipment is also in accordance with the
following Standards & Regulations:-
EN ISO 12100:2010 EN ISO 13309:2010
ISO 3744:1995 UKSI 2018/764
Bolton 22.07.21 S. Hodge .
Place and date of issue
N
ame and signature or equivalent
marking of authorised person.
Joint Managing Director
Position
The above named person is also responsible for holding the Technical Documentation
applicable to the product to which this declaration relates and may be contacted at the
address which appears at the head of this declaration
Please take care of this document, as duplicate copies are not available.

WARRANTY TERMS & CONDITIONS 4
Winget Limited assures you that if any of the parts identified within
the Parts section of this manual become defective due to faulty
manufacture or materials within 12 months from the date of purchase,
the part will be repaired or replaced under warranty free of charge by
any authorised Winget Distributor.
Warranty repairs must be carried out by a Winget Distributor, unless
prior agreement has been agreed in writing with the Warranty
Department at Winget Limited.
This warranty is given to the first owner and may be transferred to
subsequent owners for the balance of the Warranty period.
Winget Limited’s liability only extends to the costs of repair or
replacement of the faulty parts and necessary labour charges
involved in the repairs. The company accepts no liability for any
consequential loss, damage or injury, resulting directly or indirectly
from any defect in the goods.
Items not covered by Warranty and considered to be the customers
responsibility include normal maintenance services; replacement of
service items and consumables; replacement required due to abuse,
accident, misuse or improper operation; replacement of wearable
items e.g. pins bushes etc.
All Warranty repairs on the Honda HP500H Power Carrier must be
carried out by an Authorised Honda Distributor.
The Warranty will not apply where the equipment is modified,
converted, or used for purposes other than those for which it was
designed, unless clearance for the modifications etc. have been
granted by Winget Limited in writing.
The Pre-delivery Inspection & Warranty Registration Document must
be completed correctly and returned to Winget Limited within 7 days
of the date of sale. Failure to do so could result in any subsequent
Warranty claim being rejected.
No claim will be considered if other than genuine Winget Limited
parts, which must be obtained via an authorised Winget distributor,

WARRANTY TERMS & CONDITIONS 5
are used to effect a repair, or if lubricants other than those
recommended by Winget Limited are used.
The equipment must be serviced and maintained in accordance with
the service schedules laid down in this handbook by Winget Limited.
Evidence that these have been complied with may be required before
Warranty claims are reimbursed.
Winget Limited have a policy of continuous product improvement
and reserve the right to change specifications without notice. No
responsibility will be accepted for discrepancies, which may occur
between the specification of machines and the descriptions
contained in publications.

SAFE WORKING 6
Safety is the responsibility of all persons working with and around
this machine. Think “SAFETY” at all times. Read and remember the
contents of this and the Honda Operators Handbook.
Any modifications to the machine will affect its working parameters
and reduce built in safety factors. Refer to Winget Limited before
fitting any non-standard equipment or parts. Winget Limited accepts
no responsibility for any modifications made after the machine has
left the factory, unless previously agreed in writing. Winget Limited
will accept no liability for damage to property, persons or the
machine if failure is brought about due to such modifications, or
fitment of spurious parts.
Never use this machine for purposes other than those for which it
was designed. This machine was designed to carry loads such as
soil, clay, sand, wet concrete, light stone, garden rubbish or other
similar materials. It was not designed to carry any loads or materials
that may over hang the skip in any way, nor was it designed to carry
loads that may move around in the skip uncontrollably. If in doubt as
to the suitability of this machine for a particular task refer to Winget
Limited or Honda Power Equipment.
Never commence work until the daily service checks have made
carried out.
Always report faults as soon as they are discovered.
Never fill fuel or hydraulic tanks whilst the engine is running.
Never leave the machine unattended with the engine running.
Never ride on the machine and do not carry others as passengers.
Never use this equipment in areas of poor lighting.
Always operate on surfaces that are known to be stable.
Never drive or operate the machine close to the edge of any
excavation, always use effective track stops to prevent the machine
running close to the edge. Ensure the stops are in proportion to the
size of the tracks and are set sufficiently far back from the edge of
any excavation to prevent the weight of the load causing a collapse.

SAFE WORKING 7
Never work under an unsupported or unpropped skip.
Always ensure that any load is evenly distributed in the skip.
Never carry loads or heap material in such a manner as to effect
forward vision.
Always take care when tipping non free running loads, be aware that
wet concrete when carried in a skip can settle and stick in the skip
when tipped thereby affecting the centre of gravity and stability.
Never use the skip in a tipped position to bulldoze heaped materials
level or backfill material into excavations.
Never tip the skip to discharge materials unless on firm level ground.
Never tip the skip unless the machine is stationary and the clutch
levers have been released.
Never exceed the rated payload, this machine is designed to carry
650kg on level ground, this should be reduced to 350kg when
operating on gradients.
Never operate on any upward gradient which exceeds 20oor on any
downward gradient which exceeds 15o Be awareof the change in the
centre of gravity when negotiating gradients.
Always walk behind the machine when negotiating downward
gradients, never in front of it; do not reverse down gradients.
Always remember that slippery or loose surface conditions can
adversely affect the safe operation of this machine.
Never attempt to turn on or across a gradient and do not park or stop
on gradients.
Never smoke whilst filling the fuel tank, mop up any fuel spills
immediately and in any event before running the engine and allow
time for any vapours from the spilled fuel to disperse before starting
the engine.
Never run the engine in an enclosed or confined area, exhaust fumes
in enclosed areas can kill.

SAFE WORKING 8
Always avoid contact with the exhaust muffler, this can get very hot
when the engine is running and remains so for some time afterwards.
Always “dump” residual hydraulic pressure from the system before
leaving the machine. Lower the skip; stop the engine, then move the
hydraulic control lever several times in each direction.
Never leave the machine unattended with pressure in the hydraulic
system.
Always, where possible, work on or close to engines or machinery
when carrying out servicing or any maintenance, only when they are
stopped, if this is not practical, remember to keep tools, test
equipment and all parts of your person well away from moving parts.
Always wear correctly fitting clothing when carrying out servicing,
loose or baggy clothing can be extremely dangerous when working
on running engines or machinery.
Always “dump” pressure from the hydraulic system before carrying
out any kind of maintenance or adjustment.
Never allow unqualified personnel to attempt to repair, remove or
replace any part of the machine.
Always obtain advice before mixing oils; some are incompatible, if in
doubt completely drain, flush and refill.
Many liquids used in this machine are harmful if taken internally or
splashed into the eyes. In the event of accidentally swallowing oils or
fuels, seek qualified medical assistance and advice.
Always dispose of waste oils and fuels into designated waste oil
storage tanks. If storage tanks are not available, consult your
distributor or local authority for the addresses of local designated
disposal points. Improperly discarded waste oils pose a threat to
wildlife. It is illegal to dispose of waste oil into drains, or water
courses or to bury it. The Environment Agency have the power to
impose heavy fines for breaches of the above advice.
Never allow oils and fuels to come into regular contact with skin.
This can lead to serious skin diseases, including, medical evidence

SAFE WORKING 9
suggests, skin cancer. ALWAYS wear protective gloves when
handling oils and fuels whether topping up, draining or refilling.
ALWAYS wash your hands if oils or fuels come into contact with the
skin.
Always store fuels in small quantities in the correct specially
designed containers, which can be securely fastened. Store fuel in a
cool, well ventilated store away from sources of ignition.
Always ensure that any Warning, Safety or Advisory Decals attached
to the machine are legible and clean, replace if damaged, defaced or
missing.

SAFE WORKING 10
The following warning and advisory decals are applied to the dumper
‘CE’ Decal Wear Eye Protection Do Not Work Under Skip
Hydraulic Control Safety Reminder Hydraulic Oil
Keep Hands Clear Reads Ops Book Load Carrying Capacity
Take Care With Non Free Running Loads

OPERATION 11
Never commence work until the daily service checks have been
carried out.
Only tip or Discharge the skip on level ground.
The hydraulic system control valve and operating lever is mounted
on top of the hydraulic tank on the left-hand side of the machine.
The operating lever has three positions, forwards for ‘Dump’ or
‘Tip’, centre for ‘Neutral’ or ‘Hold’ and rearwards for ‘Return’.
The hydraulics will not operate until the engine is running, refer to
the Honda HP500H Operators Handbook for instructions on starting
the engine.
With the engine running and the engine speed set to fast idle push
the lever forwards as indicated on the ‘Dump/Return’ Decal located
top of the fuel tank. The rate of oil delivered to the skip tipping ram
and therefore the speed at which the skip tips is proportional both to
the distance the lever is moved and the speed at which the engine is
set.
Holding the lever forwards until the skip reaches the maximum travel
of the ram will cause the relief valve located in the control valve to
‘blow off’ allowing the oil to return to tank. Do not hold the lever
forward when the ‘relief valve’ blows, this will cause the hydraulic oil
temperature to increase and may cause damage to components.
Once the ram reaches the end of its travel release the lever to the
neutral or hold position.
Releasing the operating lever will allow it to automatically return to
neutral position and movement of the skip will stop, even if the ram
has not reached the full extent of its travel, or the skip is not seated
on the stops. In this way once you are used to the controls, the
speed at which the skip will tip can be finely controlled.
Once the skip is empty pull the lever to the rear and allow the skip to
return down on to the skip stops. Do NOT allow the skip to return
onto the stops with any force, control the speed of its return using
the operating lever and gently bring the skip back onto to stops. This
is particularly important if you have not completely emptied the skip.

OPERATION 12
Allowing the skip to return onto the stops with force will damage the
machine.
Holding the lever to the rear until the skip is fully lowered will cause
the relief valve located in the control valve to ‘blow off’ allowing the
oil to return to tank. Do not continue to hold the lever rearward when
the ‘relief valve’ blows off, this will cause the hydraulic oil
temperature to increase and may cause damage to components.
Once the skip is seated on the stops release the operating lever to
the neutral position.

MAINTENANCE AND SERVICE 13
SERVICE SCHEDULE
IMPORTANT; The Honda HP500H Power Carrier will require
additional daily checks, services and adjustments in addition to
those listed below, refer to the appropriate section of the HP500H
Operators Handbook for details.
Daily or every 10 operating hours check, or carry out the following:-
Hydraulic oil level & condition of hoses
Oil leaks, loose items and fixings
All levers, controls and cables for correct operation, (binding)
Lubricate (oil) control lever pivots and linkages as necessary
Grease the front skip pivot pin
Lubricate (oil) skip ram pivots
First 100 hours of operation:-
Change the hydraulic oil, clean the hydraulic oil filter strainer.
Every 500 hours of operation (more frequently in dusty/dirty
conditions)
Change the hydraulic oil, clean the hydraulic oil filter/strainer.
Clean the hydraulic oil filler strainer/breather assembly.
Note:- the oil level should only be checked when the engine is
switched off, the skip is at rest on the stops and any residual
hydraulic pressure remaining in the system has been ‘dumped’ as
described under ‘Safe Working’. Wear suitable gloves to protect the
skin.
On the rear vertical face of the hydraulic tank there is a small sight
glass, the hydraulic oil level is correct when the oil is visible in the
centre of the glass. If the oil level is to low, clean the area around the
filler/breather on top of the hydraulic tank. Remove the cap and
carefully top up the level until it reaches the centre of the glass.
Refer to the Technical Information section of this manual for the
correct grade of hydraulic oil.
CHECKING HYDRAULIC OIL LEVEL

CHANGING THE HYDRAULIC OIL AND
CLEANING THE SUCTION STRAINER AND
FILLER STRAINER/BREATHER
MAINTENANCE AND SERVICE 14
Note:- the oil should only be changed when the engine is switched
off, the skip is at rest on the stops and any residual hydraulic
pressure remaining in the system has been ‘dumped’ as described
under ‘Safe Working’. Wear suitable gloves to protect the skin.
Run the engine and operate the hydraulics until the hydraulic oil is
warm, stop the engine, dump any residual pressure.
Place a suitable container below the hydraulic tank, clean the area
around the filler/breather and remove the cap. Carefully undo the
drain plug located under the tank, remove and allow the oil to collect
in the container.
Replace the drain plug, fitting a new sealing washer if required.
Undo the suction hose connection on the rear vertical face of the
tank, remove the hose from the tank and allow any oil to drain into
the container.
Remove the four nuts and washers retaining the square cover to the
face of the tank, take care not to lose the small sealing washers.
Carefully pull the cover away from the tank body taking care not to
damage the gasket between the two, pull the cover to the rear until it
clears the four studs and continue until the suction strainer located
on the back of the cover is clear of the tank.
Allow any oil to drain from the filter, carefully unscrew the strainer
and wash out in solvent. Examine the strainer for damage, if
punctured it should be replaced, as it will no longer be effective.
Refit the strainer in the reverse order replacing the gasket and four
small sealing washers if necessary. Take care not to strip the
threads on the studs when securing the cover in place. Refit the
suction hose.
Remove the three small slotted screws securing the filler/breather
body into the top of the tank, carefully lift the assembly clear of the
tank taking care not to damage the cork gaskets. Wash the filler

MAINTENANCE AND SERVICE 15
strainer in solvent and examine for damage, as with the suction if
punctured it should be replaced as it will no longer be effective.
Refit in the reverse order taking care that the three small screws
correctly enter the tank and are not cross-threaded.
Wash the cap in solvent and dry off, ensure the vents in the cap are
not blocked.
Carefully top up the hydraulic oil until it reaches the centre of the
sight glass. Refit the cap.
Start the engine and operate the hydraulic operating lever in both
directions a number of times, raising and lowering the skip to purge
the system of air. Bring the skip back onto the stops. Stop the
engine, dump any residual pressure remaining in the hydraulic
system. Check the level of the oil in the sight glass and top up as
necessary. Check the tank for leaks and clean up any spilled oil.
Refer to the Technical Information section of this manual for the
correct grade of hydraulic oil.
Dispose of waste oil into designated waste oil storage tanks.

MAINTENANCE AND SERVICE 17
PUMP; the hydraulic pump is driven directly from the crankshaft of
the engine.
FILTER; the suction strainer filter is located in the base of the tank
as described above, hydraulic is drawn from the tank through the
strainer to the pump.
TIPPING CONTROL VALVE; the control valve receives oil from the
pump and when the operating lever is activated delivers oil to the
tipping ram. When the lever is in the neutral position the control
valve directs the hydraulic oil back to the tank. The rate of oil flow to
the tipping ram is directly proportional to the distance that the
operating lever is moved from the neutral position. The control valve
contains a safety device in the form of a preset relief valve, if the
operating lever is held fully in either the ‘dump’ or ‘return’ position
the relief valve will ‘blow off’ when the ram reaches the end of its
travel diverting oil back to the tank. This prevents excessive
pressure from damaging the hydraulic pump and other components.
TIPPING RAM; the single tipping ram is of the double acting type, oil
enters the lower part of the cylinder (full bore) when the operating
lever is moved forwards and pushes the piston and rod out of the
cylinder tipping the skip. When the lever is moved to the rear oil
enters the upper part of the cylinder (annulus) and pushes the
piston and rod into the cylinder lowering the skip. Oil displaced from
the opposite part of the cylinder as the piston and rod move in or
out is returned to the tank via the control valve.
Note; Only qualified experienced personnel should attempt to carry
out anything other than the basic checks, unless you have the
equipment and experience checking and adjusting hydraulic
pressures should be left to your local distributors service personnel.
If the hydraulic system fails to operate completely or does so
extremely slowly, check the following:-
Check that the hydraulic oil tank is full of oil to the correct level.
Check that the coupling between the engine and pump is still
HYDRAULIC SYSTEM CHECKS

MAINTENANCE AND SERVICE 18
transmitting drive and has not broken.
Check that the suction hose between the tank and pump is not
damaged or deformed and restricting the flow of oil.
Check that the system for leaks, loose hoses or fittings can allow air
to be drawn into the system, causing the pump to cavitate and
operate erratically.
Check that the suction strainer has been regularly cleaned in
accordance with the maintenance schedule, if not clean the filter.
Check the hydraulic pressure is correct as follows:-
Fit a 0-3000 psi (0-207bar) pressure gauge into the hydraulic system
at the base of the tipping ram, or if more accessible, at the hose
connection to the control valve using a tee-piece and short length of
suitable hydraulic hose. Start the engine, move the operating lever
to tip the skip and check the reading on the gauge when the ram is
fully extended and the relief valve ‘blows off’, see Technical
Information section for correct pressure.
If the reading is incorrect, adjust the relief valve setting to correct
the pressure.
If the above checks and procedures fail to rectify the fault contact
your local distributor.
If on releasing the operating lever to the neutral or hold position you
notice that the skip continues to either tip or lower, please refer the
fault to your local distributor, It is possible that a fault has
developed in the internal seals of the tipping ram or within the
control valve.