UK
Introduction
Thwaites Limited put Safety First.
It is the policy of Thwaites Limited to promote safety in the operation of its machines and to create a general awareness of site safety and safe working practices for the operators of its machines.
This Operator Manual is intended for both new and experienced machine operators. It should remain with the machine at all times. All operators should be aware of its location and contents.
It is important that all operators are fully trained and familiar with the machine and that they have read and understood the information contained within this book before they attempt to operate in the site conditions for which the machine was designed.
This book details practices and operations which Thwaites Limited recommend. DO NOT operate this machine in ways other than those detailed within this book.
This machine is designed for customary construction site operations, and the transportation of bulk materials commonly carried on such sites; that is their ‘intended use’. Under certain controlled conditions the dumper may be used for towing wheeled loads.
Safety Symbols.
• Attention!
•
•
Become Alert!
Your Safety Is Involved!
Correct action.
Incorrect action/ procedure which should NOT be carried out.
Signal words:
Signal words are used on the machine and within this manual to identify levels of hazard seriousness.
DANGER WARNING CAUTION
1
Before You Operate This Machine
Read Operator Instruction Manual.
1.
Questions - contact:
Thwaites representative.
2.
3.
4.
Learn to operate this dumper.
Ensure you are fit to operate.
Wear correct safety clothing and ensure safety equipment is available.
Complete Checks in Section
1
Befor e Star ting The Engine
1
Before You Operate This Machine
W alk Around The Machine
Visually Check The Machine
1 Chassis/Skip Locks - Disengaged.
2 Controls - Clean/Clear debris.
3 Roll Over Protective (ROPS) frame -
Secure/Fully upright/Undamaged.
4 Seatbelt Anchorage - Secure/Serviceable.
5 Covers and Mudguards - Secure.
6 No Fluid Leaks.
7 All Labels - Legible.
8 Tyres - No Cuts/Splits.
9 Bolts - Tight/In Position.
10 Perform Daily Maintenance Tasks.
(See Rear Cover)
11. Report all faults immediately.
DO NOT OPERATE UNTIL ALL
FAULTS HAVE BEEN RECTIFIED.
Complete Checks in Section
1
Befor e Star ting The Engine
1
Before You Operate This Machine
Mount Machine & Check Controls
1
4
5
6
2
3
7
8
Use grabrails and footsteps provided to reach machine seat.
(Mount and dismount facing machine).
Engine Cover - Secure/Locked.
Seat - Adjust for Comfort/Reach.
Wear Seatbelt - Adjust.
Check Parking Brake - ON.
Controls - to Neutral.
Foot Brake - Pressure.
Learn and check all control functions explained in the following pages.
WARNING
Seatbelt MUST BE WORN when operating machines fitted with Roll Over Protective frame.
Complete Checks in Section
1
Befor e Star ting The Engine
1
Controls Function - Layout
22
21
20
19
18
17
16
23
1011 12
15 14 13
20
CB1 Fuel/Direction Solenoids.
CB2 Instrumentation/Warning.
CB3 L/H Sidelights.*
CB4 R/H Sidelights.*
CB5 Ignition Fed Lights.*
CB6 Battery Fed Lights.*
CB1 CB3 CB5
CB2 CB4 CB6
1
2.3.4
5.6
7
8
9
Controls Location & Functions
1. Steering Wheel.
2. Direction Indicator Selector -
Forward = Left turn - Back = Right turn.*
3. Lights - Twist 1 = Sidelights ON - Twist 2 =
Dipped headlights ON.*
4. Up = Flash. Down = Main beam.*
5. Hazard Warning Light Switch.*
6. Beacon Switch.
7. Foot Brake Pedal.
8. Throttle Pedal.
9. Parking Brake Lever.
10. Engine Oil Pressure Warning Light.
11. Water Temperature Warning Light.
12. Headlamp Main Beam Pilot light.*
13. Direction Indicator Pilot Light.*
14. Heat/Start Pilot light.
15. Battery Charging Warning Light.
16. Horn Push.
17. Bucket Raise/Lower/Rotate Lever.
18. Gear Lever.
19. Clutch Pedal (Start Inhibitor).
20. Circuit Breakers (Push to reset).
21. Ignition & Parking Brake Warning Buzzer.
22. Ignition Switch.
23. Maxi Fuse (under engine cover).
* Optional items
Complete Checks in Section
1
Befor e Star ting The Engine
1
Controls Function - Explained
Seat Adjustment
A Push down to set driver weight (seat empty).
Push fully down and release to reset (seat empty).
B Lift to slide seat assembly forwards/backwards.
C Lift to slide cushion forward and set backrest.
Seatbelt (If Fitted)
Adjust length of belt when sitting on machine.
Press buckle blade into buckle lock.
Pull belt webbing through buckle blade to remove slack.
Seatbelt should not be worn loose, it should pass comfortably across hip bones and not the abdomen.....
(8)- Throttle Pedal - Right Foot
Press down pedal, to increase speed.
Lift pressure from the pedal to reduce speed.
C B
A
(7) - Foot Brake Pedal - Right Foot
Push down on the pedal to slow/stop the machine.
(8)
(19) - Clutch Pedal - Left Foot
Press down before each gear change - select gear and release.
Start inhibitor fitted - press down clutch pedal before starting engine.
(19)
(7)
Complete Checks in Section
1
Befor e Star ting The Engine
2
1
Controls Function - Explained
3
1
(18) Gear Lever - Left Hand
Forward Left
Third Gear
Neutral
Back Left
Second Gear
Forward Right
First Gear
Back Right
Reverse
ÿ
R
(9) Parking Brake Lever - Right Hand
When the machine is stationary (or in an emergency):
Pull up to apply.
Pull catch and lower to release.
An audible warning device is fitted to your machine.
This will sound when the parking brake is engaged.
Complete Checks in Section
1
Befor e Star ting The Engine
1
Controls Function - Explained
(1) Steering Wheel - Both Hands
Turn the wheel to the right (clockwise) to turn machine to right.
Turn the wheel to the left (anticlockwise) to turn machine to left.
When using the spinner knob for low speed single handed steering ensure the non steering hand is on the engine cover grab rail.
(17) Tipping Control Lever (Forward Tip Models) - Left Hand
Push forward to raise skip.
Push backwards to lower skip.
(17) Tipping Control Lever (Swivel Skip Models) - Left Hand
Raise skip 100 mm (4”) to disengage pivot centring lock.
Rotate skip, fully lowered, to automatically engage centring lock.
Raise skip and Push lever to the right to rotate skip to right.
Raise skip and push lever to the left to rotate skip to left.
Increased engine speed reduces cycle times.
Movement of the bucket is disabled if the steering wheel is moved
(Priority Steering).
Engine Cover Open/Close
Insert ignition key and turn anticlockwise to unlock.
Pull handle to release and raise cover.
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Lower cover, secure and lock before driving.
Complete Checks in Section
1
Befor e Star ting The Engine
1
Controls Function - Explained
Folding Roll Over Protective Frame - Lower & Raise
Remove linch pins and withdraw frame lock pins.
Lower frame and insert lock pins and linch pins in new position.
Reverse the procedure to raise the frame.
Ensure all pins are secure before driving.
Tipping Lever Lock (If fitted)
Place yolk over tipping lever and secure with linch pin.
Beacon Stowage
Unplug and remove beacon.
Secure beacon on bracket provided beneath bonnet.
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Battery Isolator (Beneath engine cover)
Turn key anticlockwise to isolate the battery power supply.
Complete Checks in Section
1
Befor e Star ting The Engine
2
How to START and STOP the engine
Warning
DO NOT START THE ENGINE UNLESS YOU
ARE SITTING IN THE DRIVERS SEAT.
Caution
If a panel light remains ON switch off engine
(key to ‘O’) and investigate problem.
ÿ
ÿ
To Start The Engine
• Depress Clutch Pedal.
(Start Inhibitor fitted).
• Depress accelerator pedal fully and turn the key clockwise to the start position (S).
All panel lights self test (illuminate) and should extinguish on start-up.
• Allow the engine to turn for 15 seconds max.
If the engine does not start within 15 seconds return key to position O and wait 30 seconds before turning to S again.
• When the engine fires, release key.
(Springs back to 'Run' position (R)).
• Reduce accelerator pedal pressure to prevent over revving.
Cold Start Aid -
Turn key to position (H). When panel Light extinguishes
start engine (as above).
To Stop The Engine
• Turn key to position (O).
Caution
Do not use unauthorised starting aids.
Do not TOW or BUMP start.
2
Befor e Loading The Machine
2
Check the following Control Functions
Function Checks - Engine ON
Brakes
• Foot Brake pedal for firm feel.
• Parking Brake.
Carry out Park Brake Test (Described on next page).
Steering
• Rotate steering wheel left to right - right to left.
Electrics
• Horn Sounds.
• Reverse Alarm sounds (Optional).
• Beacon Flashes.
• Lights (Optional)Side
Main
Stop
Indicators
Hazards
Tipping Lever
• Raise/Lower Bucket.
• Rotate - Right to left/Left to Right.
(Swivel model only).
2
Befor e Loading The Machine
2
How to Test the Parking Brake
3
ÿ
Warning
Before testing Parking Brake ensure the machine is on firm level ground and the area is clear of people.
• Apply parking brake .
• Depress clutch pedal and start engine.
• Select 3rd gear.
• Use the throttle pedal to gradually increase engine speed to full revs.
• Gradually release the clutch pedal.
• Release throttle and apply clutch and foot brake if the machine moves forwards.
You should be able to stall the engine before the machine moves.
• Select neutral.
• Turn ignition key to off position.
Warning
Do Not Operate a machine that has moved during the above parking brake test.
2
Befor e Loading The Machine
2
Driving Procedure and Safe Parking
1
Caution
Novice operators should always start with forward motion on clear, level ground.
Low gear should always be selected where a driver is unfamiliar with machine type.
Moving From Rest and Stopping
• Depress clutch pedal.
• Select gear- One.
• Slowly depress accelerator pedal, release clutch pedal and parkbrake lever and move slowly.
• Hold steering wheel with both hands.
• Remove foot from accelerator pedal.
• Brake gently to a halt, using foot brake pedal, and press clutch pedal to prevent stalling.
• Apply park brake and select neutral.
Changing Speed/Direction
• Release accelerator pedal.
• Depress clutch pedal.
• Select next gear.
• Release clutch pedal and press accelerator pedal.
• STOP motion and engage parking brake before changing direction (forward/reverse).
After Operating - Park Safe
• Always leave bucket empty when not in use.
• Ensure machine is on firm level ground.
• Apply parking brake.
• Engage neutral.
• Hydraulic system at rest in a safe condition.
• Stop engine and remove key.
• Lock engine cover.
2
Befor e Loading The Machine
3
Swivel Skip
IMMEDIATE HAZARDS WHICH
DANGER WILL RESULT IN SEVERE PERSONAL INJURY OR DEATH
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WORKING ON GRADIENTS
DO NOT exceed maximum stated gradients.
ÿ
ÿ
DO NOT turn across gradients.
ÿ
Forward Tip
ÿ
DO NOT brake suddenly in wet, muddy, icy conditions or when operating on loose surfaces.
DO NOT run down hill with controls in neutral.
ÿ
ÿ
ÿ
ÿ
ÿ
ÿ
Travel straight up, down or along a gradient.
Keep speed to a minimum and use the foot brake to reduce speed when travelling down gradients.
Always engage parking brake when stopped on sloping ground and in addition chock wheels securely when leaving the machine unattended to prevent movement
.
3
Always position swivel bucket in central lock.
Corr ect and Incorr ect
W orking P
3
IMMEDIATE HAZARDS WHICH
DANGER WILL RESULT IN SEVERE PERSONAL INJURY OR DEATH
VISIBILITY
Check ahead and behind machine before operation.
Be aware of low visibility areas when operating.
Sound the horn to warn people in the immediate area before operating.
CRUSH ZONE
Stay clear of articulation area when the engine is running.
WORKING UNDER
A RAISED BUCKET
Lock bucket Safety Prop during maintenance.
Never work under an unproped bucket.
Never operate machine controls when standing on either side of machine.
When using bucket Safety Prop engage Tipping Lever Lock.
(If fitted)
3
Corr ect and Incorr ect
W orking P
3
WARNING
HAZARDS OR UNSAFE PRACTICES WHICH COULD
RESULT IN SEVERE PERSONAL INJURY OR DEATH
LOADING
DO NOT exceed machines’ rated capacity.
Parking Brake ON, drive to NEUTRAL, engine OFF,
STAND CLEAR.
Clear debris from controls.
Ensure SAFE STABLE LOW load which allows good visibility.
Reduce payload if materials being carried are not free flowing.
UNLOADING
Use STOPBOARDS and SUPPORT walls on trenches.
DO NOT tip bucket if load is sticking.
DO NOT discharge load when working on sloping ground.
3
Corr ect and Incorr ect
W orking P
3
WARNING
DRIVING
HAZARDS OR UNSAFE PRACTICES WHICH COULD
RESULT IN SEVERE PERSONAL INJURY OR DEATH
DO NOT drive with the bucket tipped
(bulldozing)
NEVER dismount from a moving machine
DO NOT carry passengers
Avoid confined work areas - exhaust fumes and noise can be a hazard
Avoid hazardous site conditions people, weather,
ice etc.
DO NOT operate with the roll over protective structure folded down.
3
Corr ect and Incorr ect
W orking P
3
WARNING
þÿý
HAZARDS OR UNSAFE PRACTICES WHICH COULD
RESULT IN SEVERE PERSONAL INJURY OR DEATH
TOWING A TRAILER
Place minimum 25%, of machine's rated payload, ballast load in skip.
Gross weight to be towed, plus ballast load, MUST
NOT exceed rated payload of machine.
DO NOT exceed maximum tow bar pull or vertical load.
Towing must not be carried out on sloping ground.
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Always use Thwaites approved towing pin.
TRANSPORTATION
Reverse machine slowly onto a suitable trailer.
DO NOT drive forward up ramp when loading.
3
Apply parking brake.
Stop engine.
Chock wheels. (To prevent movement).
Engage chassis locking bar.
Secure to trailer.
Ensure legal load. (Height/weight).
Corr ect and Incorr ect
W orking P
3
HAZARDS OR UNSAFE PRACTICES WHICH COULD
CAUTION RESULT IN MINOR PERSONAL INJURY OR PRODUCT
OR PROPERTY DAMAGE.
LIFTING
Tip bucket fully forward.
Engage bucket safety prop.
Engage chassis locking bar.
PARKING BRAKE
Lift using centre eye provided.
DO NOT apply parking brake if dumper is moving.
Except in an emergency.
SLOPING SURFACES
DO NOT step on rear mudguards sloping surfaces.
3
Corr ect and Incorr ect
W orking P
4
Machine Fault - Checks you can make
ÿþþþþý
Problem
Engine will not start
Complete loss of electrical Maxi fuse blown functions
Maxi Fuse blown
Engine starts and stops
Black engine smoke
Reason
Isolator switch OFF
Clutch Pedal not pressed
Battery voltage too low.
Faulty fuel supply.
Electrical stop on fuel pump defective.
Circuit breaker tripped.
Faulty starter motor/solenoid
Solution
Switch on
Press Clutch Pedal.
Check battery and connections.
Check fuel level and connections.
Check connections.
Reset (Push to reset).
Rectify electrical fault and replace fuse
Replace motor/solenoid and maxi fuse
(Current drawn by solenoid exceeds 25A) (only replace with a 30 amp fuse)
Short circuit on main feed or starter solenoid cables locate and repair
Blocked fuel or air filter.
Air in fuel system.
Replace fuel or air filter.
Check fuel line connections.
Air filter clogged (Indicator red).
Fuel system defect.
Replace or clean air filter.
Contact Thwaites dealer.
Engine oil pressure
High engine temperature
Irregular alternator
Wrong fuel.
Low oil level.
Radiator choked.
Low coolant level.
Defective or loose alternator belt.
Replace fuel and filter.
Top up engine oil
Clean radiator.
Top up coolant.
Adjust replace alternator belt.
Always investigate panel warning lights, tripped circuit breakers and blown maxi fuse.
4
Power Swivel - Data Chart
ÿ
ÿ
Dimensions (mm)
A. Length
B. Width
C. Height (ROPS & Beacon)
D. Bucket lip height
E. Width over tyres
F. Wheelbase
G. Ground clearance
H. Bucket load height
I. Axle to rear
J. Tipping ground clearance
K. Tipping tyre clearance
L. Height tipped (Bucket)
M. Max height without ROPS
N. Tipping side clearance
P. Tyre clearance diameter (m) 8.2
4010
1770
2964
1500
1760
1930
271
1600
1130
1150
475
3290
2013
260
Q. Height (ROPS folded)
3T
2460
4T
1130
1068
422
3408
2041
221
8.4
4107
1910
2993
1565
1859
1979
305
1713
2267
Weight (Kg)
Unladen
Front axle
Rear axle
Total
Rated payload
Laden
Front axle
Rear axle
Total
Towbar (Max)
Pull load
Vertical load
Tyre Pressure
Bar (psi) Front
Rear
Typical vibration levels - whole body 0.7 - 0.8 m/s². Hand/arm less than 2.5 m/s².
3T
750
1510
2260
3255
2005
5260
2250
580
3.4(50)
2.0(29)
4T
800
1615
2415
4500
1915
6415
3000
800
4.0(59)
2.5(37)
Noise
Airborne (10m)
Operator
ÿ
ÿ
4
Forward Tip - Data Chart
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Dimensions (mm)
A. Length
B. Width
C. Height (ROPS & Beacon)
D. Bucket lip height
E. Width over tyres
F. Wheelbase
G. Ground clearance
H. Bucket load height
I. Axle to rear
J. Tipping ground clearance
K. Tipping tyre clearance
L. Height tipped (Bucket)
M. Max height without ROPS
3T
3848
1930
2964
1447
1857
1930
312
1506
1131
175
620
2110
2013
P. Tyre clearance diameter(m) 9.3
Q. Height (ROPS folded) 2238
4T
3848
1980
2993
1467
1859
1980
342
1599
1131
365
422
3408
2042
9.5
2267
Weight (Kg)
Unladen
Front axle
Rear axle
Total
Rated payload
Laden
Front axle
Rear axle
Total
Towbar (Max)
Pull load
Vertical load
Tyre Pressure
Bar (psi)Front
Rear
Typical vibration levels - whole body 0.7 - 0.8 m/s². Hand/arm less than 2.5 m/s².
3T
725
1450
2175
3160
2015
5175
2250
580
3.4(50)
2.0(29)
4T
750
1585
2335
3990
2345
6335
3000
800
3.5(51)
3.0(44)
Noise
Airborne (10m)
Operator
ÿ
4
Daily/Weekly Checks
240/245/270/273
7
7
7
12
1
7 7
10H
50H
11
7 7
3
10
4
2
5
9
P
6
13
8 8
12
10 - 50hr CHECKS
AXLE OIL 1 Mobil Fluid 422
ENGINE OIL 2 SAE 10W 30
TRANSMISSION OIL 3 Mobil EP 90
HYDRAULIC OIL 4 Mobil DTE 24
COOLANT LEVEL
FUEL LEVEL
5
6
H²0 + 33% Antifreeze
Diesel
GREASE
AIR CLEANER
BRAKES
BRAKE OIL
7
8
9
10
Fill All Points
Check Indicator
Test Park & Foot Brake
Mobil DTE 24
WHEEL NUTS
TYRE PRESSURE
FAN BELT
11 271Nm (200lb ft)
12 See Data Chart
13 Condition/Tension
11
7 3 7 1
This machine must be serviced after first 50 hours
Normal service intervals:
250 hours
1000 hours
500 hours
2000 hours
Contact local Thwaites Distributor for details or www.thwaitesdumpers.co.uk
