operator’s instruction manual - hire one ltdhireone.net/images/product_downloads/490-569 - 5-10...

Tier

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Lim

ited

2007

T047

45 - 10 Tonne

Operator’sInstruction

Manual

Mach 564 – 6 Tonne Powerswivel Mach 565 – 6 Tonne Front Tip

Introduction

Safety symbols• Attention!• Bealert!• Yoursafetyisinvolved!

• Correctaction • Incorrectaction/procedurewhich should NOT be carried out

Signal wordsSignalwordsareusedonthemachineandwithinthismanualtoidentifylevelsofhazardseriousness:

danger warnIng cautIon

thwaites Limited puts Safety FirstItisthepolicyofThwaitesLimitedtopromotesafetyintheoperationofitsmachinesandtocreateageneralawarenessofsitesafetyandsafeworkingpracticesfortheoperatorsofitsmachines.ThisOperator’sInstructionManualisintendedforbothnewand experienced machine operators. It should remain with themachineatalltimes.Alloperatorsshouldbeawareofitslocation and contents.Itisimportantthatalloperatorsarefullytrainedandfamiliarwiththemachineandthattheyhavereadandunderstoodtheinformationcontainedwithinthisbookbeforetheyattempttooperateinthesiteconditionsforwhichthemachinewasdesigned.ThisbookdetailspracticesandoperationswhichThwaitesLimitedrecommends.DONOToperatethismachineinwaysotherthanthosedetailedwithinthisbook.Thismachineisdesignedforcustomaryconstructionsiteoperations,andthetransportationofbulkmaterialscommonlycarried on such sites; that is their ‘intended use’. Under certain controlledconditionsthedumpermaybeusedfortowing

wheeled loads.Duetothevariednatureoftheoperationofsitedumpersandtheabsenceofanagreedteststandard,anyfiguresquotedbyThwaitesinrelationtovibrationvaluesandexposureareforreferencepurposesonly.Itistheresponsibilityoftheemployertoassessvibrationexposurebasedontheactualsiteconditions,andoperatingpractices,atthepointofuse.Hand arm Vibration-ThedailyexposureAction/LimitValuesofbetween2.5-5.0m/s2(A8)areunlikelytobeexceededinaneight-hourreferenceperiod.whole Body Vibration-Thedailyexposurecanonlybeaccuratelydeterminedatthepointofuse.ThisexposuremustbemanagedinrespectoftheAction/LimitValuesof0.5and1.15m/s2(A8)respectively.Employersshouldnotrelysolelyonpublishedvibrationfigureswhenundertakingriskassessments.Dependingonthesiteconditions,cycletimesmayneedtobeadjustedinorderto reduce operator exposure levels.VibrationvaluesbasedontypicaldutycyclesareavailableonrequestfromThwaites.Thesemaybeusedforreferencepurposesonly.

1

Complete checks in section before starting the engine

read operator’s instruction manual

Before operating this machine

1. ContactyourThwaitesrepresentativeincaseoffurtherquestions

2. Learn to operate this machine3. Ensureyouarefittooperate4. Wearcorrectsafetyclothingandensurethatsafety

equipmentisavailable

Distributor

1


Walk around the machine

Visually check the machine1 Arethechassislockandtheskiplockdisengaged?2 Arethecontrols,crushzoneorhydraulicrams

clean,andclearofanydebris?3 IstheRoll-OverProtectiveframe(ROPSframe)

secure,fullyuprightandundamaged?4 Istheseatbeltanchoragesecureandserviceable?5 Arethecoversandmudguardssecure?6 Arethehosesfreefromfluidleaks?7 Areallsafetydecalslegible?8 Arethetyresfreeofcutsorsplits?9 Areallboltstightandinposition?10 Have the daily maintenance tasks been

performed? (See rear cover)Reportallfaultsimmediately.


do not oPerate tHe MacHIne untIL aLL FauLtS HaVe Been rectIFIed

Incorrecttyrepressuresreducemachinestability.

warnIng

1


Mount the machine and check the controls1 Usethegrabrailsandfootstepsprovidedto

manoevre into seating position. Face the machine at all times when mounting and dismounting

2 Istheenginecoversecureandlocked?3 Adjusttheseatpositionforcomfortandeasy

access to controls4 Fastentheseatbelt.Adjustaccordinglyforsafety

andcomfort5 IsthehandbrakeON?6 Set the transmission to neutral7 Doesthefootbrakefeelfirm?8 Donotoperatethemachinewithoutunderstanding

allitscontrolsasdescribedinthefollowingpages

AseatbeltMUSTBEWORNwhenoperatingmachinesfittedwithaROPSframe

warnIng


1


control locations and functions1 Steering wheel2 Direction indicator selector - Forward=leftturn-back=rightturn*3 Lights - twist 1 = sidelights ON - twist2=dippedheadlightsON*4 Up=flash.Down=mainbeam*5 Hazardwarninglightswitch*6 Beaconswitch7 Footbrakepedal8 Throttlepedal9 Parkingbrakelever10 Engine oil pressure warning light11 Water temperature warning light12 Transmission oil pressure warning light13 Headlightmainbeampilotlight*14 Directionindicatorpilotlight*15 Transmission oil temperature warning light16 Lowbrakefluidwarninglight*17 Batterychargingwarninglight18 Hornpush19 Bucketraise/lower/rotatelever20 Gearlever(powershuttleonly)21 Dump valve pedal22 Circuitbreakers(pushtoreset)23 Handbrakewarningbuzzer24 Ignition switch25 Forward/neutral/reverselever(powershuttle) Gear/forward/reverselever(powershift)26 Maxifuse(underenginecover)* Optional items

CB1 Fuel/directionsolenoidsCB2 Instrumentation/warningCB3 L/Hsidelights*CB4 R/Hsidelights*CB5 IgnitionfedlightsCB6 Batteryfedlights

Layout of controls

1


Seatbelt• Adjustlengthofbeltwhenseated• Pressbucklebladeintobucklelock• Pullbeltwebbingthroughbucklebladetoremoveslack

Seatbelt should not be worn loose. It should pass comfortably across hip bones and not the abdomen

throttle pedal - right foot• Applypressuretoincreasespeed• Releasepressuretoreducespeed

Foot brake - right foot Applypressuretosloworstopthemachine

dump valve pedal - left footPressdownbeforeeachgearchange-selectgear,thenrelease

control functions - in depthSeat adjustmentA– TurnknobtosetdriverweightB– Lifttoslideseatassemblyforwards/backwardsC– Lifthandletoadjustbackrest

1


control Functions - in depthForward/neutral/reverse lever (Fnr lever) (powershuttle) - left hand• Pushforwardstotravelinaforwarddirection• Levercentred=neutral• Pullbacktotravelinareversedirection

Hand brake lever - right hand• Useonlywhenthemachineisstationary(orinanemergency)• Pullleveruptoapply• Pushbuttonandlowerlevertorelease

An audible warning device is fitted to your machine. This will sound if the parking brake is engaged whilst forward or reverse is selected.

gear lever (powershift) - left hand• Upchanges-anti-clockwiseselectsgears1to4• Downchanges-clockwiseselectsgears4to1

Warning - Overspeed time delay sensor fitted

gear lever (powershuttle only) - left hand forward-left forward-right firstgear thirdgear neutral back-left back-right second gear fourthgear

1


control functions - in depth

tipping control lever (front tip models) - left hand• Pushforwardtoraiseskip• Pushbackwardtolowerskip

tipping control lever (powerswivel models) - left hand• Raiseskip100mm(4”)todisengagepivotcentringlock• Rotateskiptoacentralposition(fullylowered)toautomaticallyengagecentringlock

• Raiseskipandpushlevertotherighttorotateskipclockwise• Raiseskipandpushlevertothelefttorotateskipanti-clockwise• Increasedenginespeedreducescycletimes

Movement of the bucket is disabled if the steering wheel is moved (steering is given priority)

Steering wheel - both hands• Turnthewheelclockwisetoturnmachinetoright• Turnthewheelanti-clockwisetoturnmachinetoleft

Ensure the non-steering hand is on the engine cover grabrail when using the spinner knob for low-speed single handed steering

opening and closing the engine cover • Insertignitionkeyandturnanti-clockwisetounlock• Pullhandletoreleaseandraisecover• Lowercover,secureandlockbeforedriving

1


Lowering and raising the roPS frame• Removelinchpinsandwithdrawframelockpins• Lowerframeandinsertlockpinsandlinchpinsinnewposition• Reversetheproceduretoraisetheframe• Ensureallpinsaresecurebeforedriving

Beacon stowage• Unplugandremovebeacon• Securebeacononbracketprovidedbeneathbonnet

Battery isolator (beneath engine cover)• Turnkeyanti-clockwisetoisolatethebatterypowersupply

control Functions - in depth

Tipping lever lock (if fitted)• Placeyokeovertippingleverandsecurewithlinchpin

2

Complete checks in section before loading the machine

to start the engine• Depressacceleratorpedalfullyandturnthe keyclockwisetothestartposition‘S’.

All panel lights self-test (illuminate) and should extinguish on start-up.

• Allowtheenginetoturnforamaximumof15seconds

If the engine does not start within 15 seconds return key to ‘O’ and wait 30 seconds. Turn to ‘S’ again

• Whentheenginefires,releasekey.Itwillautomaticallyspringto‘R’(runposition).

The engine is fitted with an automatic device to ensure ample fuel supply under cold start conditions and economic running.

Position ‘H’ should only be used below -15ºC• Reduceacceleratorpedalpressuretopreventover-

revving.

to stop the engine• Turnkeytoposition ‘o’.

How to Start and StoP the engine

cautIonIfapanellightremainsonswitchengineoff(turnkeyto‘O’)andinvestigatetheproblem.

cautIon• Donotuseunauthorisedstartingaids• Donottoworbumpstart

2


Function checks - engine onBrakes• Doesthefootbrakefeelfirm?• Carryoutthehandbraketest (described on next

page)• Ifthehandbrakeison,andagearisselected,abuzzerwillsoundandthedrivemaybedisconnected.

Note: hand brake microswitch must be disconnected to carry out hand brake test (described on next page)

Steering• Rotatesteeringwheelclockwiseandanti-clockwiseElectrics• Doesthehornsound?• Doesthereversealarmsound?(optional)• Doesthebeaconflash?• Doalllightswork?(optional): side main brake

indicators hazardTipping lever• Raiseandlowerskip• Rotateskipclockwiseandanti-clockwise(swivel

model only)

Preliminary checks

2


1 Applyhandbrake2 Disconnectmicroswitch;connecttestsocket2 Start engine and allow a 1-minute warm-up3 Depress dump valve pedal4 Selectthirdgear(NatAsp)/fourthgear(turbo)

Note: Please check the vehicle identification plate (located on the side of the machine) to identify engine power.

5 Release dump valve pedal6 Applyfirmpressureonthefootbrakepedal7 Selectforwarddrive(thebuzzerwillsound)8 Slowlyreducebrakepedalpressure9 Ifthemachinehasnotmoved,usethethrottle

pedaltograduallyincreasetheenginespeedtofullrevs(20secondsmax)The machine should not move during these tests

10 Reduce engine speed to idle11 Select neutral12 Reconnect microswitch to original position

How to test the hand brake

warnIngDo not operate a machine that has moved during the aboveparkingbraketest.

warnIngBeforetestingthehandbrakeensurethemachineisonfirmlevelgroundandthattherearenopeoplearoundthemachine.Releasethrottleandapplyfootbrakeifthemachinemovesduringthefollowingtest.

Powershuttle

Powershift

2


Moving from rest and stopping• Depressdumpvalvepedal• Selectfirstgear• Releasedumpvalvepedal• Selectforwardorreverse• Releasehandbrakefully (machinemaymove)• Slowlydepressacceleratorandmoveaway• Holdsteeringwheelwithbothhands• Removefootfromacceleratorpedal• Brakegentlytoahaltusingfootbrake

changing speed/direction• Depressdumpvalvepedal• Selectnextgear• Releasedumpvalvepedal• Themachinemustbestationaryandthehandbrakemustbeengagedbeforechangingdirection

after operating - park safely• Alwaysleaveskipemptywhennotinuse• Ensuremachineisonfirmlevelground• Applyhandbrake• Engagetransmissiontoneutral• Fullylowerskip,inacentralposition• Setdrivetoneutral• Stopengineandremovekey• Ensuremachinecannotbestarted

driving procedure and safe parking

cautIon• Noviceoperatorsshouldalwaysstartwithforward

motion on clear, level ground• Alowgearshouldalwaysbeselectedwhenadriverisunfamiliarwithmachinetype

3

Attention! Section correct and incorrect working practices

danger IMMEDIATEHAZARDSWHICHwILL RESULTINSEVEREPERSONALINjURYORDEATH

Swivel Skip

Forward tip

worKIng on gradIentSDO NOT exceed maximum stated gradients

DO NOT turn across gradients

DONOTbrakesuddenlyinwet,muddy,icyconditionsorwhenoperatingonloosesurfaces

DO NOT run downhill with controls in neutral

Travel straight up, down or along a gradient

Keepspeedtoaminimumandusethefootbraketoreducespeedwhen travelling down gradients

Alwaysengagehandbrakewhenstoppedonslopinggroundtopreventmovement,andinaddition,chockwheelssecurelywhenleaving the machine unattendedAlwayspositionswivelskipincentrallock

3


danger IMMEDIATEHAZARDSWHICHwILL RESULTINSEVEREPERSONALINjURYORDEATH

VISIBILItYCheckaheadandbehindmachinebeforeoperation

cruSH ZoneStayclearofarticulationareawhentheengineisrunning

worKIng under a raISed SKIPLockbothskipsafetypropsduringmaintenance

Beawareoflow-visibilityareaswhenoperating

Beforeoperating,soundthehorntowarnpeopleintheimmediate area

Never operate the machine’s controls when standing on eithersideofmachine

Neverworkunderanunproppedskip

Whenusingskipsafetypropengagetippingleverlock(Iffitted)

3

Attention! section correct and incorrect working practices

warnIng HAZARDSORUNSAFEPRACTICESWHICHcouLd RESULTINSEVEREPERSONALINjURYORDEATH

LoadIng tHe MacHIneApplyhandbrake,settransmissiontoneutraL, turn engine oFF,disembarkthemachine and Stand cLeardo not exceed the machine’s rated capacityCleardebrisfromcontrols

EnsureSAFESTABLELOWloadwhichallowsgoodvisibilityMaterialscarriedmustbefree-flowing

unLoadIng tHe MacHInedo not dischargeloadwhenworkingonsloping grounddo notdischargeloadtothesideofthemachineifmaterialcarriedisnotfree-flowingDischargeloadforwardsifmaterialcarriedisnotfree-flowingDischarge load on level ground

Use StoPBoardS and SuPPort walls on trenches

3



DO NOT drive with thebuckettipped(bulldozing)

drIVIng

NEVERdismountfroma moving machine

DONOTcarrypassengers

Sitehazardstoavoid:adverse weather conditions,icysurfaces,people

Avoidconfinedworkareas-exhaustfumesand noise can be a hazard

DO NOT operate withtheROPSframefoldeddown

3

Attention! section correct and incorrect working practices


towIng a traILerPlaceballastloadinskip.Thisloadshouldbeaminimumof25%ofthemachine’sratedpayload

tranSPortatIonReversemachineslowlyontoasuitabletrailer

AlwaysuseaThwaites-approvedtowingpin

The gross weight to be towed plus the ballast load MuSt notexceedratedpayloadofmachine

do not exceed maximum tow bar pull or vertical load

Towing must not be carried out on sloping ground

do notdrivethemachineforwardwhenloading

ApplyhandbrakeStop engineChockwheels(To prevent movement)EngagechassislockingbarSecure to trailerEnsure legal load (Height/weight of trailer)

3


cautIon HAZARDSORUNSAFEPRACTICESWHICHcouLd RESULT IN MINOR PERSONALINjURYORPRODUCTORPROPERTYDAMAGE

uSIng a crane to LIFt tHe MacHIneTipskipfullyforward(except9and10Tonne)EngageskipsafetypropEngagechassislockingbarLiftusingcentreeyeprovided

Hand BraKedo notapplyhandbrakeifmachineismoving(exceptinanemergency)

SLoPIng SurFaceSdo notstepontherearmudguards’slopingsurfaces.Usetreadgriparea(iffitted)toraiseorlowerhingedROPS.

HInged roPSUsegrabhandles,treadgrips(iffitted)andstepswhenstandingonthemachinetolowertheROPSframe.Avoidwetsurfaces.

4

Always check panel warning lights, tripped circuit breakers or blown maxi fuse

troubleshootingProblem reason SolutionEnginewillnotstart isolatorswitchisturnedoff switchisolatorswitchon FNRlevernotinneutral shifttransmissiontoneutral batteryvoltagetoolow checkbatteryandconnections faultyfuelsupply checkfuellevelandconnections electricalstoponfuelpumpdefective checkconnections circuitbreakertripped reset(pushtoreset)Completelossofelectricalfunctions maxifuseblown rectifyelectricalfaultandreplacefuseStartermotorwillnotoperate faultybattery replaceMaxifuseblown faultystartermotor/solenoid replacestartermotor/solenoidandmaxifuse (currentdrawnbysolenoidexceeds25A) (onlyreplacewitha30ampfuse) shortcircuitonmainfeedorstartersolenoidcables locateandrepairEnginestopssoonafterstart-up blockedfuelorairfilter replacefuelorairfilter airinfuelsystem checkfuellineconnectionsBlackenginesmoke airfilterclogged(Indicatorred) replaceorcleanairfilter fuelsystemdefect contactThwaitesdealer wrongfuel replacefuelandfilterMachinewillnotmovewhenFNRlever handbrakeapplied–machinefittedwithisolator releasehandbrakelever is selected

Engine oil pressure low oil level top up engine oilHighenginetemperature radiatorchoked cleanradiator Low coolant level top up coolantIrregularalternator defectiveorloosealternatorbelt adjust,or,ifnecessary,replacealternatorbeltTransmissionoiltemperature oilcoolerchoked cleanoilcooler over/underfilledwithoil correctoillevelTransmissionoilpressure lowtransmissionfluidlevel topuptransmissionfluidLowbrakeoil checkoillevel/leaks topupbrakeoilWarningbuzzersounds handBrakeON releasehandbrake

4 data chart – Powerswivel

dimensions (mm) 5t 6t 9t

A. Length ...............................................................................4780 ..... 4780 ......5011B. Width .................................................................................2135 ..... 2280 ......2435C. Height(ROPSframe&Beacon)........................................3320 ..... 3300 ......3415D. Bucketlipheight ...............................................................1615 ..... 1670 ......1820E. Widthovertyres ...............................................................2100 ..... 2240 ......2440F. Wheelbase ........................................................................2480 ..... 2480 ......2660G. Ground clearance ...............................................................320 ..... 370 ........447H. Bucketloadheight ............................................................1795 ..... 1850 ......2002I. Axletorear .......................................................................1200 ..... 1200 ......1220J. Tipping ground clearance ................................................1050 ..... 1100 ......1134K. Tippingtyreclearance ........................................................540 ..... 550 ......1131L. Heighttipped(skip) ..........................................................3650 ..... 3694 ......4000M. MaxheightwithoutROPSframe .....................................2190 ..... 2230 ......2630N. Tipping side clearance .......................................................140 ....... 100 ........378P. Tyreclearancediameter(m) .............................................12.0 ...... 12.0 .......13.4Q. Height(ROPSframefolded) .............................................2170 ..... 2230 ......2630

weight (kg) 5t 6t 9t

unladenFront axle .......................................................1680........1780........2130Rear axle ........................................................2420........2490........3150Total ...............................................................4100........4270........5280

Laden (including driver at 80 kg)Ratedpayload ................................................5000........6000........9000Front axle .......................................................6240........7420......10030Rear axle ........................................................2940........2930........4330Total ...............................................................9180......10350......14360

towbar (Max)Pull load .........................................................3750........4500 .......6750Verticalload .....................................................300..........500..........500

tyre PressureBar(psi)front ............................................. 4.9(71)... 3.9(57).... 3.2(46) rear ............................................... 2.5(36)... 2.5(36).... 1.6(24)

noise

Airborne(10m)

Naturallyaspirated

Turbo

Operator

Hydmainlinepressure-170bar

4

dimensions (mm) 5t 6t 7t 9t 10t

A. Length ........................................................4438 ..4440 ....4450 ..... 4635 ......4650B. Width ..........................................................2165 ..2354 ....2354 ..... 2485 ......2485C. Height(ROPSframe&beacon) .................3320 ..3390 ....3390 ..... 3335 ......3415 D. Bucketlipheight ........................................1600 ..1610 ....1610 ..... 1740 ......1740E. Widthovertyres ........................................2100 ..2240 ....2240 ..... 2440 ......2440F. Wheelbase .................................................2480 ..2480 ....2480 ..... 2615 ......2615G. Ground clearance ........................................330 ....370 ......370 ....... 447 ........447H. Bucketloadheight .....................................1700 ..1740 ....1780 ..... 1975 ......2135I. Axletorear ................................................1200 ..1200 ....1200 ..... 1220 ......1220J. Tipping ground clearance ...........................310 ....340 ......340 ....... 436 ........436K. Tippingtyreclearance .................................574 ....520 ......520 ....... 642 ........768L. Heighttipped(skip) ...................................2479 ..2505 ....2505 ..... 2840 ......2860M. MaxheightwithoutROPSframe ..............2190 ..2230 ....2230 ..... 2440 ......2540P. Tyreclearancediameter(m) ..................... 12.4 .. 12.6 .... 12.6 ..... 13.5 .......14.0Q. Height(ROPSframefolded) ......................2190 ..2230 ....2230 ..... 2555 ......2630

weight (kg) 5t 6t 7t 9t 10t

unladenFront axle .......................1390........1490........1530........1740........1760Rear axle ........................2480........2590........2590........2860........2920Total ...............................3870........4080........4120........4600........4680

Laden (including driver at 80 kg)Ratedpayload ................5000........6000........7000........9000......10000Front axle .......................5525........6525........7455........8740........9600Rear axle ........................3425........3635........3745........4940........5160Total ...............................8950......10160......11200......13680......14760

towbar (Max)Pull load .........................3750........4500........5250........6750........7500Verticalload .....................500..........500..........500..........500..........500

tyre pressureBar(psi)front ............. 4.0(58).... 3.5(51).... 3.9(57).... 3.2(46).... 3.2(46) rear ............ 2.5(36).... 2.7(39).... 3.0(44)... 1.6(24) ... 1.6(24)

Hydmainlinepressure-170bar

data chart – Front tip

noise

Airborne(10m)

Naturallyaspirated

Turbo After-cooled

Operator

4

This machine must be serviced after first 100 hoursNormal service intervals: 250 hours 500 hours 1000 hours 2000 hoursContactlocalThwaitesDistributorfordetailsorwww.thwaitesdumpers.co.ukNote:failuretouseThwaites-approvedlubricantsmayinvalidateyourwarranty

daily/weekly checks

aXLe oIL (centre case + Hubs) 1 tracteLF SF3

engIne oIL 2 BP Vanellus c5 global 15w 40

tranSMISSIon oIL 3 autran MBX

HYdrauLIc oIL 4 energol HLP HM32

droPBoX oIL 5 energear Hypoid gear + transmission 80w-90

cooLant LeVeL 6 H²o+33% anti-freeze

FueL LeVeL 7 diesel

greaSe 8 Fill all points

aIr cLeaner 9 check indicator

BraKeS 10 test hand brake & foot brake

BraKe oIL 11 BP Bartran HV32

wHeeL nutS 12 330 nm

tYre PreSSure 13 See data chart

Fan BeLt 14 check condition/tension

operator’s instruction manual - hire one ltdhireone.net/images/product_downloads/490-569 - 5-10...

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