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TEREX, Central Boulevard, ProLogis Park, Coventry CV6 4BX, EnglandTel.: +44 (0)2476 339400 - Fax: +44 (0)2476 339500

www.terexce.com - Email : [email protected] - [email protected]

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Diesel engine exhaust and some of its constituents are known tothe State of California to cause cancer, birth defects, and otherreproductive harm

CALIFORNIAProposition 65 Warning

Battery posts, terminals and related accessories contain lead andlead compounds, chemicals known to the State of California tocause cancer and reproductive harm. Wash hands afterhandling.

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Operators Instruction Book

TA9 & TA104.W.D. Dumpers, Perkins Engine

Dana AxlesPublication No. B0803GB-4 July 2011

Original Instructions

For machines with Newage Axles refer toPublication No. 0803GB-2 November 2009

1 - Table of ContentsTA9 and TA10Four Wheel Drive Dumper

Contents

1. Table of ContentsTable of Contents .......................................................................................................................................................1 - 1 to 1- 5

2. IntroductionIntroduction ....................................................................................................................................................................... 2-1

Safety Alert System ..................................................................................................................................................... 2-1Intended Use ................................................................................................................................................................ 2-1

Instruction Manual ............................................................................................................................................................ 2-1Service or Spares Enquiries ............................................................................................................................................... 2-2Warranty and Maintenance ............................................................................................................................................... 2-2Official Documents (European Community only) ............................................................................................................ 2-2

3 - SafetyGeneral Safety ................................................................................................................................................................... 3-1Safety Alert Symbol .......................................................................................................................................................... 3-1Hazard Classification ........................................................................................................................................................ 3-1General Safety Notes ......................................................................................................................................................... 3-1Personal Protective Equipment (PPE) ................................................................................................................................ 3-2General Safety Information ............................................................................................................................................... 3-3Seat Controlled Safety System .......................................................................................................................................... 3-4Seat Belt ............................................................................................................................................................................ 3-4ROPS .................................................................................................................................................................................. 3-4Hydraulic Fluid .................................................................................................................................................................. 3-5Fluid Levels ....................................................................................................................................................................... 3-5Frozen Battery Electrolyte.................................................................................................................................................. 3-5Fires .................................................................................................................................................................................... 3-5Water Cooled Engines........................................................................................................................................................ 3-5Lubricants .......................................................................................................................................................................... 3-6Hygiene .............................................................................................................................................................................. 3-6Storage................................................................................................................................................................................ 3-6Handling Oil ....................................................................................................................................................................... 3-6

New Oil ....................................................................................................................................................................... 3-6Old Oil ......................................................................................................................................................................... 3-6

First Aid - Oil .................................................................................................................................................................... 3-7Swallowing Oil ............................................................................................................................................................ 3-7Skin Contact ................................................................................................................................................................ 3-7Eye Contact ................................................................................................................................................................. 3-7

Oil or Fuel Spillage ........................................................................................................................................................... 3-7Fires .................................................................................................................................................................................... 3-7Gradients ........................................................................................................................................................................... 3-8

Slopes - Diagram A ..................................................................................................................................................... 3-8Maximum Slope Gradient - Diagram B ..................................................................................................................... 3-8

Gradients - continued ........................................................................................................................................................ 3-9Crossing Gradients - Diagram C ................................................................................................................................ 3-9Emergency Stopping on Slopes ................................................................................................................................... 3-9Responsibilities ............................................................................................................................................................ 3-9Overturning .................................................................................................................................................................. 3-9

Description of Symbols and Pictorials Used On Safety Signs ........................................................................................... 3-10Safety Sign Location (ISO) ................................................................................................................................................ 3-12Safety Sign Description (ISO)............................................................................................................................................ 3-13

4 - InstallationDelivery Checks ................................................................................................................................................................ 4-1Articulation Lock .............................................................................................................................................................. 4-1Pre-Start Checks ................................................................................................................................................................ 4-2

1-1 TA9 & TA10 Dumper 0803-4 July 2011

Contents

5. DescriptionTA9 Dumper ..................................................................................................................................................................... 5-1TA10 Dumper ................................................................................................................................................................... 5-1General Description .......................................................................................................................................................... 5-2

Skip ............................................................................................................................................................................. 5-2Engines ........................................................................................................................................................................ 5-2Chassis ........................................................................................................................................................................ 5-2Steering ....................................................................................................................................................................... 5-2Transmission ............................................................................................................................................................... 5-2Brakes ......................................................................................................................................................................... 5-2Handbrake ................................................................................................................................................................... 5-2Electric System ........................................................................................................................................................... 5-2ROPS .......................................................................................................................................................................... 5-2

Skip ................................................................................................................................................................................... 5-3Skip Props ......................................................................................................................................................................... 5-3Chassis ............................................................................................................................................................................... 5-4Torque Converter & Shuttle Gearbox ............................................................................................................................... 5-4Transfer Box ...................................................................................................................................................................... 5-4Hydraulic System .............................................................................................................................................................. 5-5Engine Air Intake .............................................................................................................................................................. 5-6Battery Isolator .................................................................................................................................................................. 5-7Circuit Breakers ................................................................................................................................................................ 5-8Dashboard Controls & Instruments ................................................................................................................................... 5-8Dash Decal - No Lights ..................................................................................................................................................... 5-9Dash Decal - Site Lights ................................................................................................................................................... 5-10Dash Decal - Road Traffic Lights ..................................................................................................................................... 5-11Dash Panel Symbol Description ........................................................................................................................................ 5-12Dash Panel Symbol Description - continued .................................................................................................................... 5-13Dash Panel Switch Descriptions ....................................................................................................................................... 5-14Start/Stop Switch ............................................................................................................................................................... 5-15Forward / Reverse Switch ................................................................................................................................................. 5-15

Forward/Reverse Positions and Actions ..................................................................................................................... 5-15Direction Indicator Switch - if fitted ................................................................................................................................. 5-16Audible Warning, Hourmeter and Reverse Bleeper ......................................................................................................... 5-16

Audible Warning (A) .................................................................................................................................................. 5-16Hourmeter (B) ............................................................................................................................................................. 5-16Reverse Bleeper - if fitted ........................................................................................................................................... 5-16

Road Traffic Lighting ....................................................................................................................................................... 5-17Brake Lights ................................................................................................................................................................ 5-17Number Plate Lights .................................................................................................................................................... 5-17

Flashing Beacon ................................................................................................................................................................ 5-18Storage Instructions .................................................................................................................................................... 5-18

Accessory ‘Jack Plug’ Socket ........................................................................................................................................... 5-19Foot Brake and Accelerator Pedals ................................................................................................................................... 5-20 Gearlever ........................................................................................................................................................................... 5-20Parking Brake .................................................................................................................................................................... 5-21

Apply ......................................................................................................................................................................... 5-21Release ....................................................................................................................................................................... 5-21

Engine Canopy Doors ....................................................................................................................................................... 5-22Tow Hitch .......................................................................................................................................................................... 5-22ROPS ................................................................................................................................................................................. 5-23

6. InspectionGeneral Inspection ............................................................................................................................................................ 6-1Daily Operator Checks ...................................................................................................................................................... 6-2

TA9 & TA10 Dumper 0803-4 July2011 1-2

Contents

7. Operating InstructionsOperating Instructions ....................................................................................................................................................... 7-1Pre-Start Checks ................................................................................................................................................................ 7-1Access / Egress .................................................................................................................................................................. 7-2Operators Seat - Grammar.................................................................................................................................................. 7-3

Angle Adjustment ....................................................................................................................................................... 7-3Seat Movement ............................................................................................................................................................ 7-3Weight Adjustment ..................................................................................................................................................... 7-3

Operators Seat - Grammar.................................................................................................................................................. 7-4D - Seat Belt ................................................................................................................................................................ 7-4

Operators Seat - Milsco ...................................................................................................................................................... 7-5Seat Controls ................................................................................................................................................................ 7-5Fore and Aft Movement ............................................................................................................................................... 7-5Weight Adjustment ...................................................................................................................................................... 7-5Backrest Angle Adjustment ......................................................................................................................................... 7-5

Operators Seat - Milsco ...................................................................................................................................................... 7-6Seat Belt ....................................................................................................................................................................... 7-6

Folding ROPS .................................................................................................................................................................... 7-7Folding Procedure ....................................................................................................................................................... 7-7

Starting and Stopping the Engine ...................................................................................................................................... 7-8Starting the Engine ...................................................................................................................................................... 7-8Stopping the Engine .................................................................................................................................................... 7-8

To Move the Machine ....................................................................................................................................................... 7-9To Change Gear ................................................................................................................................................................. 7-10Gradients ........................................................................................................................................................................... 7-11

Descending Gradients ................................................................................................................................................. 7-11Stopping and Moving off on a gradient ...................................................................................................................... 7-11

To Tip The Skip ................................................................................................................................................................ 7-11To Lower The Skip ............................................................................................................................................................ 7-11Towing Or Recovery ......................................................................................................................................................... 7-12

Towing ........................................................................................................................................................................ 7-12

8. TransportationTransportation ................................................................................................................................................................... 8-1

Loading onto Lorry / Trailer ....................................................................................................................................... 8-1Unloading .................................................................................................................................................................... 8-1

Articulation Lock .............................................................................................................................................................. 8-1Securing Dumper to a Lorry or Trailer Bed ...................................................................................................................... 8-2

9. MaintenanceMaintenance and Lubrication ............................................................................................................................................ 9-1

Safety Signs ................................................................................................................................................................. 9-1Hydraulic Oil Under Pressure ..................................................................................................................................... 9-1

Cleaning ............................................................................................................................................................................. 9-2Vehicle/Machine Battery - End of Life Disposal ............................................................................................................... 9-2Working Under A Raised Skip .......................................................................................................................................... 9-3

Fitting Skip Props ........................................................................................................................................................ 9-3Removing Skip Props .................................................................................................................................................. 9-3

Battery ............................................................................................................................................................................... 9-4Battery Isolator ............................................................................................................................................................ 9-4Battery Access ............................................................................................................................................................. 9-4Battery Removal .......................................................................................................................................................... 9-4

Battery Maintenance .......................................................................................................................................................... 9-5‘Jump Starting’ .................................................................................................................................................................. 9-6Engine Air Cleaner Servicing ............................................................................................................................................ 9-7

Air Cleaner Daily Maintenance .................................................................................................................................. 9-7Air Cleaner Servicing .................................................................................................................................................. 9-7Air Filter Cleaning ...................................................................................................................................................... 9-7

Engine Oil .......................................................................................................................................................................... 9-8Engine Oil Level Checking ......................................................................................................................................... 9-8

1-3 TA9 & TA10 Dumper 0803-4 July 2011

Contents

9. Maintenance (Continued)Engine Oil ......................................................................................................................................................................... 9-9

Engine Oil Draining .................................................................................................................................................... 9-9Engine Coolant .................................................................................................................................................................. 9-10

Radiator Pressure Cap (A) .......................................................................................................................................... 9-10Topping-Up Cooling System Level - Engine Cold .................................................................................................... 9-10Coolant ........................................................................................................................................................................ 9-10Radiator Cap Access ................................................................................................................................................... 9-10

Hydraulic System .............................................................................................................................................................. 9-11Always ........................................................................................................................................................................ 9-11Never ........................................................................................................................................................................... 9-11Hydraulic Filters ......................................................................................................................................................... 9-11

Hydraulic System............................................................................................................................................................... 9-12Hydraulic Oil Level - Checking .................................................................................................................................. 9-12Hydraulic Oil - Adding ............................................................................................................................................... 9-12

Hydraulic System............................................................................................................................................................... 9-13Hydraulic Oil - Replacing ........................................................................................................................................... 9-13Return Filter Renewal ................................................................................................................................................ 9-13

Fuel System ....................................................................................................................................................................... 9-14Diesel Fuel Level ........................................................................................................................................................ 9-14Fuel/Water Seperator .................................................................................................................................................. 9-14

Brakes ................................................................................................................................................................................ 9-15Brake Arrangement ..................................................................................................................................................... 9-15Brake Maintenance ..................................................................................................................................................... 9-15Brake Fluid - Checking Level ..................................................................................................................................... 9-15

Brakes ................................................................................................................................................................................ 9-16Parking Brake ............................................................................................................................................................. 9-16Parking Brake Lever .................................................................................................................................................... 9-16Brake Calliper ............................................................................................................................................................. 9-16Parking Brake Test....................................................................................................................................................... 9-16

Front and Rear Axles ........................................................................................................................................................ 9-17Axle Description ......................................................................................................................................................... 9-17Axle Oil - Checking Level .......................................................................................................................................... 9-17Axle Oil - Changing .................................................................................................................................................... 9-17

Hubs ................................................................................................................................................................................... 9-18To Check the Oil Level................................................................................................................................................ 9-18

Gearbox and Transfer Box ................................................................................................................................................ 9-19General ........................................................................................................................................................................ 9-19Oil Changes ................................................................................................................................................................. 9-19Transfer Box ............................................................................................................................................................... 9-19

Gearbox and Transfer Box ................................................................................................................................................ 9-20Power Shuttle Gearbox ............................................................................................................................................... 9-20Checking Oil Level ..................................................................................................................................................... 9-20Changing Oil ............................................................................................................................................................... 9-20

Wheels and Tyres .............................................................................................................................................................. 9-21Centre Pivot ....................................................................................................................................................................... 9-22

General ........................................................................................................................................................................ 9-22Pivot Pin Locking Screws ........................................................................................................................................... 9-22Protective Caps ........................................................................................................................................................... 9-22Lubrication .................................................................................................................................................................. 9-22

ROPS ................................................................................................................................................................................. 9-23Introduction ................................................................................................................................................................. 9-23Attachments and/or Modifications .............................................................................................................................. 9-23Maintenance ................................................................................................................................................................ 9-23Repair .......................................................................................................................................................................... 9-23

Seat Belts ........................................................................................................................................................................... 9-24Important Facts about Seat Belts ................................................................................................................................ 9-24

Seat Belt Maintenance Guidelines .................................................................................................................................... 9-24Service Schedule ............................................................................................................................................................... 9-25Lubrication Schedule ........................................................................................................................................................ 9-26Lubrication Points ............................................................................................................................................................. 9-27

TA9 & TA10 Dumper 0803-4 July2011 1-4

Contents

9. Maintenance (Continued)Long Term Storage............................................................................................................................................................. 9-28Scrapping............................................................................................................................................................................ 9-28Antifreeze ........................................................................................................................................................................... 9-29

10. SpecificationsDimensions ........................................................................................................................................................................ 10-1

Data - Engine, Alternator and Battery ......................................................................................................................... 10-2Data - Dumper Speeds and Brakes .............................................................................................................................. 10-2Data - Fluid Capacities - litres (pints) ......................................................................................................................... 10-2Data - Load Capacities ................................................................................................................................................ 10-2Data - Wheels and Tyres ............................................................................................................................................. 10-2Data - Noise Levels ..................................................................................................................................................... 10-3Data - Antifreeze / Water Ratio Properties ................................................................................................................. 10-3Noise Emissions ........................................................................................................................................................... 10-3Vibration ...................................................................................................................................................................... 10-3

Electric Circuits ................................................................................................................................................................. 10-4Hydraulic Circuit ............................................................................................................................................................... 10-9

1-5 TA9 & TA10 Dumper 0803-4 July 2011

Contents

TA9 & TA10 Dumper 0803-4 July2011 1-6

2 - IntroductionTA9 and TA10Four Wheel Drive Dumper

Introduction

Introduction

TEREX appreciates your choice of our product for yourapplication. Our number one priority is user safety which is bestachieved by our joint efforts. We feel you can make a majorcontribution to safety if, you as the machines user:• Comply with all the relevant National Laws and Local

Regulations.• Read, Understand and Follow the instructions in this and

any other manuals supplied with this machine.• Use Good, Safe Work Practices in a common sense way.• Only Use Trained Operators to operate the machine who

are directed by informed and knowledgeable supervision.

If there is anything in this manual which is not clear or there isinformation which you think should be added, contact theManufacturers Service Department who will deal with yourproblem or request.

We reserve the right to make improvements to these machineswithout incurring any need to change these operatinginstructions.

Any modification to this machine which has not been approvedby the Manufacturer in writing immediately invalidates theManufacturers warranty.

Safety Alert System

Intended Use

The machine has been designed and tested to carry out thefunction of transporting various free flowing materials. If usedcorrectly, it will provide an effective means of transportationand meet the appropriate performance standards andregulations.

Use of this product in any other way is prohibited and contraryto its intended use.

Instruction Manual

Read this instruction manual carefully before operating themachine. Ensure this instruction manual is kept with themachine at all times and is in good condition - replace themanual immediately if it becomes dirty, damaged or has beenlost. The manual holder for this manual is located behind theseat.

The Safety Alert Symbol is used to alert youto potential personal injury hazards. Obey allsafety messages that follow this symbol toavoid possible injury or death.

Machine LEFT and RIGHT HANDAll references in this manual to LEFT and RIGHTare as viewed from the Operat ing Posit ion(Operators Seat) with Operator facing the skip.

A

A

0803-2-001

2-1 TA9 & TA10 Dumper 0803-3 Devcember 2010

Introduction

Service or Spares Enquiries

Please state the vehicle type and the Vehicle IdentificationNumber when making enquiries or orders and in all writtencorrespondence.

The Vehicle Identification Number is stamped on a plate (A)located on the front of the right hand wing.

Warranty and Maintenance

The warranty period for the machine, under normalcircumstances, covers the first 12 months. This period beginsthe day the machine is handed over or put into operation.

The machine must be used correctly and serviced to themanufacturers recommendations.

The correct grades of fuels, lubricants and coolants must beused at all times and must be new and clean when added to themachine. Failure to follow these rules may lead to failure of themachine.

Servicing and repairs should be carried out by the dealers staffwho will be trained and experienced in the necessary skills forsuccessful maintenance of the machine.

Only genuine TEREX spare parts must be used when themachine is serviced or repaired.

All claims during the warranty period will only be accepted ifthe recommended maintenance and service work has beencarried out at the specified intervals.

It is important regular maintenance and service work is carriedout after the warranty period has expired to ensure the machineis in good working condition and does not cause unnecessarydowntime and expense.

Modifications to this machine and/or changes to thespecification which have not been approved by the factory, willinvalidate the machines warranty and possibly your owninsurance cover.

Official documents (European Community only)

CE markThe Machinery Safety directive is intended to harmonise all themachinery safety regulations throughout the community so thatthere will be no technical barriers to trade.

Compliance with the essential safety requirements of the EECdirectives 2006/42/EC (machinery), 2000/14/EC (Noise) and2004/108/EC, permits companies to CE mark their products.

The directive affects almost every equipment supplier and userin the community and in particular, applies to this type ofmachine.

The regulations require that potential hazards from machineryare properly addressed and guarded against.

The EC declaration of conformity is a requirement of CEmarking. The declaration for this machine follows.

0801-2-002

A

TA9 & TA10 Dumper 0803-3 December 2010

Introduction

EC declaration of conformity

TEREXContents of the EC Declaration of Conformity

2006/42/EC Machinery Directive

Manufacturer: Terex United Kingdom Limited

Central Boulevard

Prologis Park

Keresley End

Coventry

CV6 4BX

United Kingdom

Name of Person to Compile Technical File: David Maslin

Address of Person to Compile Technical File: Terex United Kingdom Ltd

Generic Denomination: Dumper

Machine Function: Earth-moving machinery

Model / Type :

Serial/VIN number:

TA9

TA10

Commercial Name: Same as Model/ Type

Terex United Kingdom Limited hereby declares that the above piece of machinery is in conformity with the relevantprovisions of Machinery Directive 2006/42/ EC.

Terex United Kingdom Limited hereby declares that the above piece of machinery is in conformity with the provisionsof the following other EC-directives: Noise - Equipment Used Outdoors (2000/14/EC), Emissions - Non-Road Engines(97/68/EC) and Electromagnetic Compatibility (2004/108/EC).

Terex United Kingdom Limited hereby declares that the following European harmonised Standards have been used:

EN474-1 & EN474-6

Place of Issue: Coventry, United Kingdom

Date of Issue:

Empowered signatory:

Wayne Berry

Sales Administration Manager

2-3 TA9 & TA10 Dumper 0803-3 Devcember 2010

Introduction

TA9 & TA10 Dumper 0803-3 December 2010

3 - SafetyTA9 and TA10Four Wheel Drive Dumper

Safety

General Safety

This manual is designed as a guide to the Machines Controls,Operation and Maintenance.

It Is NOT A Training Manual

Safety Alert Symbol

The Safety Alert Symbol is used to alert you to potentialpersonal injury hazards. Obey all safety messages that followthis symbol to avoid possible injury or death..

Hazard Classification

A multi-t ier hazard classification system is used tocommunicate potential personal injury hazards.

The following signal words used with the safety alert symbolindicate a specific level of severity of the potential hazard.

Signal words used without the safety alert symbol relate toproperty damage and protection only.

All are used as attention getting devices throughout this manualas well as on decals and labels fixed to the machinery to assistin potential hazard recognition and prevention.

General Safety Notes

Consult manufacturers or dealers for details of training courses.

All the time you are working on or with the machine you mustbe thinking what hazards there may be and how to avoid them.

bSafety Alert Symbol

DANGER - Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNING - Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION - Indicates a hazardous situation which, if not avoided, may result in minor or moderate injury.

NOTICE - IndIcates a property damage message. This signal word shall not be used with a safety message. The safety alert symbol shall not be used with this signal word.

This manual is designed as a guide to the MachinesControls, Operation and Maintenance

IT IS NOT A TRAINING MANUAL

bThis manual must not be removed from the machine andshould be kept in the place provided in a useablecondition.If the manual becomes unusable new copies may beordered from the manufacturer by quoting the PublicationNumber

bALL Operators of the machine must be authorised,mentally and physically capable of operating this machineand fully trained in its operation.The Operator must have read and understood this manualbefore operating this machine.

bOnly authorised persons should be allowed to operatethis machine.Unauthorised use of this machine may invalidate theinsurance.

bIf you are unsure of anything concerning machine or job-

ASK

3-1 TA9 &TA10 Dumper 0803-3 December 2010

Safety

Personal Protective Equipment (PPE)

The following symbols indicate the personal protectiveequipment that must be used as necessary.

Protective Helmet A protective helmetmus t be worn toprevent injury fromfalling objects

Face MaskA face mask must beworn when conditionsdictate to prevent eyeor facial injury fromflying objects

Protective Gloves Wear p ro tec t i veg loves to p reven tin ju ry f rom sharpobjects

Dust Mask A dust mask must beworn when s i teconditions dictate

Respirator A respirator must beworn when s i teconditions dictate

Protect iveClothing

Protective clothingmust be worn whensite conditions dictate

Safety Glasses Safety glasses mustbe worn at all times toprevent eye in juryfrom flying objects

High Visibility Clothing

High visibility clothingmust be worn whenopera t ing th i sequipment.

Ear DefendersEar protection mustbe worn whenoperating or near thisequipment

Safety Harness A seat belt must beworn a t a l l t imeswhen operating thisequipment

Safety Boots Safety boots must beworn when operatingthis equipment

TA9 &TA10 Dumper 0803-3 December 2010 3-2

Safety

b General Safety Information

Operators and maintenance personnel must always comply with the following precautions. These precautions are given here for yourprotection. Review them carefully before operating the machine and before performing general maintenance or repairs. Supervisingpersonnel should develop additional precautions relating to the specific work area and local safety regulations.

• Before operating the machine ensure you have had propertraining and are fully conversant with the machine and itsoperation - If in Doubt ASK!

• Read this instruction manual carefully before operating themachine. Ensure this instruction manual is kept with themachine at all times and is in good condition - replace themanual immediately if it becomes dirty, damaged or lost.

• Safety signs are fitted to machine for safety purposes andMUST be replaced immediately if they are unreadable orlost. If the machine is repaired and parts have been replacedon which decals were fixed ensure new decals are fittedbefore the machine is put into service.

• Always make sure there is adequate ventilation around themachine. Never run the engine in an enclosed area withoutgood ventilation or next to combustible materials.

• Stop the engine before refuelling, if there is a spillage mop itup and do not start the engine until it has been done.

• The exhaust gets extremely hot. Do not place anything ontop of it and keep all combustible materials clear. Do notattempt any maintenance on a hot engine.

• Be familiar with all prohibited work areas such as excessiveslopes and dangerous terrain conditions.

• Check your local laws and regulations, the engine mayrequire a spark arrester etc.

• Do not inspect or clean the machine with the engine running.• Before carrying out maintenance on the hydraulic system

ensure the hydraulic fluid is cool and there is no residualpressure in the hydraulic circuit - hydraulic fluid leakingunder pressure can penetrate the skin.

• Make sure you, and anyone else who uses the machine, havebeen trained to operate it correctly.

• Personal Protective Equipment must be used as necessary.• Establish a training programme for all operators to ensure

they are fully familiar with its operation.• Do not operate the machine unless thoroughly trained and

are physically and mentally fit.• Do not operate the machine if it is damaged, improperly

adjusted or not completely and correctly assembled.• Always use driveways approved by site management when

driving around the site.• Do not work under a raised skip unless the props are fitted

and locked in position.• Do not drive the machine with the skip raised.

• Do not operate the machine if you are unfit to do so becauseof alcohol or drugs etc.

• Before performing any maintenance on the machine, place awarning tag on the machine to prevent accidental start-upand/or remove the start key and battery isolator. Put thelocking bar into position to prevent the front and rear chassismoving and creating a crushing zone.

• Ensure the ROPS/FOPS is not damaged.• The operator must get off machine when loading the dumper

skip.• Do not carry passengers.• Keep footplates and steps free from dirt, oil, snow, ice etc.• Check seat belts daily. ALWAYS WEAR A SEAT BELT

WHEN OPERATING THE MACHINE.• Do not remove the radiator cap when the engine is hot. Do

not add coolant to a hot engine.• Always park machine correctly on firm, level ground where

it will not cause an obstruction or danger - chock the wheelsif necessary. DO NOT LEAVE THE ENGINE RUNNING orthe start key in the start switch.

• Before taking the machine on public roads ensure themachine complies with all road traffic regulations and obeyall driving laws.

• Tyre Changes and repairs to Punctured Tyres MUST only becarried out by fully trained Operatives using the correctequipment. The manufacturer of this machine recommends acompetent firm is employed to carry out these tasks.

• If the machine is fitted with ROPS/FOPS and the machineshould roll over, the Operator must grip the steering wheelfirmly allowing the seat belt to restrain him/her in the seatuntil the machine comes to rest.

bIf any site personnel has any concerns with anysafety aspect of the machine, the machine must notbe used until the safety concerns have beenrectified or an authorised person has checked andsatisfied the site personnel the machine is safe touse.


Safety

b Seat Controlled Safety System

To help prevent accidents a safety system prevents the enginebeing started unless the operator is sat on the seat.

An inhibitor switch in the seat is operated by the weight of theoperator and the seat must be adjusted for the drivers weight.

b Seat Belt

A seat belt is provided for operator safety, it must be worn at alltimes the machine is in use. It is important that the seat belt isinspected and checked regularly See Maintenance Section.

b ROPS

A ROPS (Roll Over Protective Structure) is provided foroperator safety.

Although ROPS seem to be relatively maintenance-free, regularperiodic inspections to ensure ROPS are damage free and thuscapable of functioning in a rollover cannot be over emphasized.

Through periodic inspections, cracks, loose bolts, damage, andother normal wear and tear related problems can be eliminatedbefore they become serious.

Proper inspection and maintenance procedures can ensure thatROPS will perform the life saving function they are designedfor and expected to do.

Details on the inspection and maintenance of the ROPS will befound in the Maintenance Section.

bFailure to properly inspect and maintain a seat belt can

cause serious injury or loss of life in the event of an accident.

bThe seat belt MUST be worn at all times when operating

this equipment.

bDo NOT modify or attach items to the ROPS without the

manufacturers approval.Do NOT use the ROPS as an attachment point for towing

or pulling equipment.


Safety

b Hydraulic Fluid

Fine jets of hydraulic fluid under pressure can penetrate theskin.

Do not use your fingers to check for small leaks or exposeuncovered areas of your body to leaks.

Check for leaks using a piece of cardboard.

b Fluid Levels

Ensure Machine is on level Stable Ground, gear lever is inneutral and the engine is stopped when checking ALL fluidlevels.

b Frozen Battery Electrolyte

• Batteries with frozen electrolyte may explode if used orcharged.

• Never 'jump start' a machine with a frozen battery.• To help prevent freezing, keep the battery fully charged.

b Fires

Using water to extinguish an oil fire could spread the fire or giveyou a shock from an electrical fire.

Use a carbon dioxide, dry chemical or foam extinguisher whilstwaiting for the fire brigade.

Keep fire extinguisher seviceable and have it checked regularly.

b Water Cooled Engines

Water cooled systems operate under pressure to increase theboiling point of the coolant. Therefore, the coolant temperaturemay be greater than boiling water at standard atmosphericpressure (100ºC).

bIf skin is penetrated with Hydraulic Fluid, Get Immediate

Medical Help

0605-1-3000a

bDo Not Use a Machine with Frozen Battery

Electrolyte

bDo Not Use Water to Extinguish a Machine Fire

bNever Maintain Cooling System when the Engine is

HOT!


Safety

b Lubricants

It is essential that anyone concerned with lubricants read andunderstand the following text.

b Hygiene

Lubricants are not a health risk when used correctly for theirintended purposes.

However, excessive or prolonged skin contact can remove thenatural fats from the skin, causing dryness and irritation.

Low viscosity oils are more likely to do this, therefore particularcare is necessary in handling used oils which can be diluted withfuel contamination.

Whenever handling oil products, maintain good standards ofcare plus personal and plant hygiene.

For details of these precautions we advise you to read therelevant publications issued by your local health authority.

b Storage

ALWAYS keep lubricants out of reach of children.

NEVER store lubricants in open or unlabelled containers.

b Handling Oil

See also First Aid - Oil on Page 3 - 7.

New Oil

There are no special precautions needed for the handling or useof new oil other than the normal care and hygiene practices.

Old Oil

Observe the following precautions.• Avoid prolonged, excessive or repeated skin contact with

used engine oil.• Apply a barrier cream to the skin before handling used

engine oil.• Note the following when removing engine oil from the skin.

- Wash skin thoroughly with soap and water. Using a nailbrush will help.

- Use special hand cleansers to help clean dirty hands.- Never use petrol, diesel fuel or kerosene.- Avoid skin contact with oil soaked clothing.- Do not keep oily rags in pockets.- Wash dirty clothing before reuse.- Throw away oil soaked shoes.

bUsed engine crankcase lubricants contain harmful

contaminants. In laboratory tests it was shown used petrol engine oils can cause skin cancer.


Safety

b First Aid - Oil

Swallowing Oil

If oil is swallowed, do not induce vomiting.

Get Medical Advice

Skin Contact

In the case of excessive skin contact, wash with soap and water.

Eye Contact

In the case of eye contact, flush with water for 15 minutes. If theirritation persists, get medical attention.

Oil or Fuel Spillage

Absorb with sand or a locally approved brand of absorbentgranules. Scrape up and dispose of in a chemical disposal area.

b Fires

Extinguish with carbon dioxide, dry chemical or foam.


Safety

b Gradients

Slopes - Diagram A

When ascending or descending a gradient, especially when theskip is loaded, the skip MUST ALWAYS face the top of theincline.

Gradients

Maximum Slope Gradient - Diagram B

Maximum Gradient X = 20% (11º, 1 in 5)

bALWAYS Reverse Down Inclines

�

��

bONLY Fill Swing Skip with Free Flowing Materials

X

B

pic-035


Safety

b Gradients - continued

Crossing Gradients - Diagram C

Muddy, slippy ground conditions will adversely affect theascending and descending capabilities of the dumper.

However, these ground conditions can be even more dangerouswhen crossing a gradient. Greater care must be taken whencrossing a gradient to prevent the machine sliding sideways outof the operators control.

X (Maximum Crossing Gradient) = 20% (11º, 1 in 5)

Emergency Stopping on Slopes - (Running Out of Fuel)

Where possible park the machine at a slight angle across theslope (less than 8.5º (15%), chock the wheels and refuel. If nearthe bottom of the gradient the vehicle can be allowed to rollbackwards to the bottom of the gradient, however caution mustbe exercised as the vehicle has no engine braking, and heavysteering.

Responsibilities

Site management should identify possible dangers and makearrangements to eliminate them.

Site management are responsible for planning drivewaysaround the site which will prevent the machine fromexperiencing excessive slopes, soft ground or having to driveover edges especially at an angle etc. The driveways should alsoavoid any other possible dangers e.g. overhead cables, workareas etc.

The operator should ensure the machine is driven correctly at alltimes especially with regards to speed, overloading, using thewrong machine for the intended task, driving dumpers with alift-skip in the raised position etc.

If these instructions are followed the risk of overturning is verymuch reduced.

Overturning

If the machine should overturn and it is fitted with ROPS andseat belt the risk of injury to the operator is reduced if they arewearing the seat belt.

When the machine begins to overturn the operator should gripthe steering wheel firmly allowing the seat belt to restrain him/her in the seat until the machine comes to rest. The operatorshould not try to jump clear of the machine when it isrolling.

bDo Not Drive on Land which may cause the Dumper

to Exceed Maximum Gradient Limits Shown

�

��

�


Safety

Description of Symbols and Pictorials Used on Safety Signs

Read and understand Operators Manual and all safety messages before operating or maintaining the machine.

Falling Hazard. Falling from machine canresult in serious injury or death.

No passengers on machine. It is dangerousand forbidden to carry passengers on thismachine

No passengers/hangers on machine. Do notallow passengers stand or ride on the machine

Rollover hazard. Incorrect skip position whenoperating can result in serious injury or death.

Crush Hazard. Crushing can result in seriousinjury or death

Transport Lock. Secure Lock before lifting.

Lift Point.

Entanglement Hazard. Contact with rotatingparts can result in serious injury. Keep awayfrom fan and belt when engine is running.

Stop Engine and Remove Start Key beforeservicing.

Crush Hazard. Machine movement can causeserious injury or death

Stay away from machine. Contact withmoving machine can cause serious injury ordeath

Improper towing may cause damage. Readinstruction book before towing.

Fasten the seat belt before operating themachine and keep it secure at all times.

Crush Zone. Machine movement can causeserious injury or death.

Skip Prop. Secure lifting cylinder lockingdevice before service.

?000KG


Safety

Description of Symbols and Pictorials Used on Safety Signs

Oil Injection Hazard. Escaping fluid underpressure can penetrate skin

Do Not Use Hand to Check For Leaks. Use apiece of paper or cardboard.

Read Instruction Manual before performingmaintenance or repair.

Keep clear of rotating parts. Contact withrotating parts will result in injury or death.

Stop engine when working in this area.


Safety

Safety Sign Location (ISO)

P�

P�

30A

421

3

15A

N�

III

8002-2072

2.2

Bar

�32

PSI

� 8002-2315

3.8

Bar

�55

PSI

� 8002-2562

8002-2340

8002

-230

6�80

02-2

900�

8002

-290

2�80

02-2

903�

8002

-290

4�80

02-2

905�

MAX

MAX

8002-2907

1 in

5�

∞11

�20

%�

1 in

5�

∞11

�20

%�

8002-2286

8002

-289

9�

8002-2281

8002

-290

1�80

02-2

906�

8002

-230

5�

8002

-289

9�

8002-2289

8002-2285

8002

-270

1�

13

12

14 1516 17

18

19

2021

22

23

14

11

10

7, 8

& 9

12

34

5

6


Safety

Safety Sign Description (ISO)

Item Decal Description Notes

1 Read Instruction Manual -

2 Remove start key before doing any maintenance work -

3 No passengers -

4 Beware high pressure oil leaks -

5 Gradient instructions -

6 Do Not Use On Public Highway (Only fitted with item 7) Dashboard

7 Dashboard Decal - No Lights Dashboard

8 Dashboard Decal - Site Lights Dashboard

9 Dashboard Decal - Road Lights Dashboard

10 Instruction Manual Location. -

11 Straight Skip control valve lever positions -

12 Vehicle Sound Power Level -

13 Keep Clear of Fan/Wait Until Moving Parts Have Stopped Completely -

14 Keep Clear of Machine - Crush Zone -

15 Read Manual Before Towing -

16 Hydraulic Oil Filler Point On Tank

17 Diesel Fuel Filler Point On Tank

18 Tyre Pressure Rear -

19 Tyre Pressure Front -

20 Always use Seatbelt when operating the machine -

21 Crush Zone - Keep Clear -

22 Remove Start Key And Fit Articulation Lock Before Maintenance -

23 Fit skip prop BEFORE doing maintenance under the skip -

Safety Signs

IMPORTANTALL safety signs listed must be fitted to the machine and must be legible. Use mild soap and water to clean safety signs - DO NOT use solvent based cleaners because they may damage safety sign material.Safety signs are fitted to the machine to warn of possible dangers and MUST be replaced immediately if they become unreadable or lost.If the machine is repaired and parts have been replaced on which safety signs were fixed, ensure new safety signs are fitted before the machine is put into service.


Safety

Blank Page


4 - InstallationTA9 and TA10Four Wheel Drive Dumper

Installation

Delivery Checks

Immediately on taking delivery of your new dumper and beforeputting it into service:• Read this handbook completely -- it could save a great deal

of unnecessary expense. Put this Instruction Manual in itsholder (A) on the back of the seat.

• Read the engine handbook supplied with the dumper.• Check general condition of the machine, - has it been

damaged during delivery?• Raise ROPS and install all pins and locking rings.• Fit flashing beacon to ROPS.• Check fluid levels - see Pre Start Checks on page 4-2.

Articulation Lock

If the machine has been delivered by lorry or trailer thearticulation lock (B) may have been fitted. This must bereleased before the machine is used. Failure to release thearticulation lock will make the steering inoperative and causeserious damage to the machine.

A

A

0803-2-001

B

0515-055

4-1 TA9 & TA10 Dumper 0803-3 December 2010

Installation

Pre-Start Checks

Before putting the machine into service:• Check the following fluid levels:

- Oil levels in engine and both axles.- Hydraulic oil and fuel levels using tank top level gauges.- Brake fluid level in reservoir located under floor plate.- Battery electrolyte level.- Coolant level in radiator.

Recommended lubricants are detailed in the Maintenancesection of this manual.• Check tyres are inflated to correct pressure.• Check all instruments alarm buzzers and warning lights

function correctly.• Check all lights and road traffic indicators (if fitted) function

correctly.

Note: When filling fuel tank make sure the tank is filled whenthe engine is cold and the machine is in a well ventilated area,with the engine stopped using clean fuel and container. It isadvisable to fill the tank at the end of a working session toprevent condensation forming in the tank during long periods ofinactivity, e.g. overnight.

Check for adequate ventilation if the machine is to be started orrun in a building etc.

bWhen Refuelling Beware of Naked Flames, Grinding

Sparks etc.

TA9 & TA10 Dumper 0803-3 December 2010 4-2

5 - DescriptionTA9 and TA10Four Wheel Drive Dumper

Description

TA9 Dumper

TA10 Dumper

0803-5-001

0803-5-002

5-1 TA9 & TA10 Dumper 0803-2 November 2009

Description

General Description

This range of site dumpers have been designed to provide the greatest degree of component standardisation possible, thus providingthe user with simplified servicing requirements.

This section of the manual must be read in conjunction with the Safety section located at the beginning of the manual.

Skip

All models in the range are 4 wheel drive dumpers having a loadcarrying skip located over the front axle, and ahead of thedriver.

Engines

Engines on all machines are Perkins multi-cylinder diesel.

All machines are fitted with electric starting of the engine.

A separate key operated start switch is provided and is locatedadjacent to the steering wheel.

A battery isolator switch is provided in engine compartment.

Chassis

The chassis of the dumpers is of the two part articulating typehaving a centre pivot joint which articulates in both vertical, andhorizontal planes.

Steering

Steering of the dumper is by an 'Orbitrol' hydrostatic steeringunit, powering a single ram connecting the front and rear chassisunits.

Hydraulic power is supplied via an engine driven pump to thesteering unit, which on turning the steering wheel meters oil tothe steering ram and thus provides movement in either directionof the vehicle.

In the event of a hydraulic failure the vehicle can still be steered.Under these circumstances steering loads are high and thedumper should only be driven at slow speeds.

Transmission

The transmission of the dumpers have torque converters andPowerShuttle four speed gearboxes.

Brakes

The vehicle braking is provided by means of totally enclosed oilimmersed brakes located within the drive axles. These brakesare self adjusting, multi-plate discs which are hydraulicallyoperated by means of a tandem master cylinder. This providesthe feature of totally independent front and rear systems. In theevent of failure of one system, braking will still be available onthe alternative axle.

Handbrake

The vehicle is fitted with an overcentre type handbrake.

Electric System

All models are available with full lighting to comply with EU/ISO road traffic regulations.

ROPS

Machines are fitted with a ROPS (Roll Over ProtectiveStructure) to protect the operator should the machine turn over.

General Description

TA9 & TA10 Dumper 0803-2 November 2009 5-2

Description

Skip

The dumper vehicle is basically a load carrier and can be usedfor a multitude of building/contracting site functions, butessentially it is used for carrying materials from excavations ordemolitions and commonly carrying materials to generalbuilding activities. The carrying of soil, sand, gravel, debris,bricks etc. requires that the materials can be placed accuratelyat the place point and in some cases without damage to thematerials themselves.

It is for this reason that the load carrying skip is power lifted andlowered by means of double acting hydraulic cylinders mountedbetween the front chassis and the underside of the skip whichare controlled from the drivers seat by a double acting hydrauliccontrol valve (A).

To elevate the skip move lever (A) forwards.

To lower the skip move lever (A) backwards.

The power for the system is provided by an engine drivenhydraulic pump and the circuit is described in detail in theHydraulic System section.

The skip in the lowered or loading position is located such thatthe driver has a good view ahead, therefore when loading theskip get off the machine and do not allow the load to be heapedin such a fashion as to impair the drivers view

Skip Props

Skip props (A) are provided to enable personnel to work safelyon the machine with the skip in the raised position. The prop isretained in the stored position by a pin (B) secured by a grip clip(C).

The same pin and grip clip are used to secure the prop in theworking position..

bNever Elevate Skip Unless the Dumper Is On Level Ground

0515-082a

A

bNever work under a raised skip unless the skip props are

LOCKED in position.

0515-047b

A

A

B C


Description

Chassis

The two part chassis is of the centre pivot articulating type andis of a design which enables both front and rear axles to beattached directly to the chassis members.

The front and rear frames are connected in the middle by avertical pivot in spherical bearings and a horizontal link, whichconnects between the spherical bearing of the vertical pivot andan additional spherical bearing located in the rear frame.

This arrangement is illustrated in the diagram below and showsfull movement of the chassis in both horizontal and verticalplanes, thus ensuring maximum wheel adhesion at all times.

Chassis

Torque Converter & Shuttle Gearbox

The dumpers are fitted with an ITL PowerShuttle gearbox withintegral 4 speed synchronised transmission and a Borg WarnerTorque Converter.

This system provides 4 forward and 4 reverse speeds.

Transfer Box

The transfer box transmits the drive from the gearbox/torqueconverter to the front and rear axles.

pic-008

9º

30º


Description

Hydraulic System

The hydraulic system provides power to operate the vehiclesteering and to power the skip elevation.

The system comprises an engine driven hydraulic pumpdrawing oil from a tank located inside the chassis. The tank isfitted with a suction strainer, an oil level gauge, and a filler/breather cap.

The pump generates a maximum pressure of 200 bar (2900psi):

Hydraulic Circuit.

The system is protected by a relief valve in the control valvewhich is set at the same pressure. A return line filter is fitted tothe circuit and is of the replaceable cartridge type.

Steering of the dumper is by means of a single hydraulic ramconnecting the front and rear frames, the oil supply to the ram iscontrolled by an Orbitrol hydrostatic steering unit. The unitreceives oil via a carry over port in the 3 way control valve andmeters oil to the steering ram as the steering wheel is turned, atall times.

A - Skip Ram E - Hydraulic Tank

B - Skip Ram F - Hydraulic Pump

C - Steering Ram G - Control Valve

D - Orbitrol

G

E

D

C

B

A

F


Description

Engine Air Intake

The engine air intake (A) is located on the left hand side of theseat support and it is important this intake is never blocked. Seeillustration below.

Do not hang clothing etc. on the access handle (B).

If the engine air intake (A) is blocked it will adversely affect therunning of the engine and may cause engine damage.

NOTICE

NEVER Block Engine Air Intake (A)

0515-068a

A

B


Description

Battery Isolator

The battery isolator serves both as a maintenance aid and Anti-Vandalism device.

When carrying out any maintenance on the machine, the batteryisolator key must be removed to prevent the engine from beingstarted or the electric circuit being activated.

When parking or leaving the machine, remove the batteryisolator key to prevent unauthorised people from using orstealing the machine..

When the isolator key (B) is not being used, the rubber cap (A)should be used to cover the switch.

When the isolator key is to be used, the rubber cover should beinserted into the side of the key

.

The isolator key is inserted into the switch with tag vertical (C).

Turning the isolator key clockwise to position (D), allows thebattery to supply power to the machine. When the isolator keyis in position (D) the machine may be used normally.

It is accessible through left hand engine canopy door.

B

0515-078a

A

0515-079a

bBefore performing maintenance tasks on the machine,turn isolator key to the (OFF) vertical position (C) andremove key from the isolator switch. The engine cannotbe started.Disconnect battery before major maintenance work.

C

0515-077a

0515-076a

D


Description

Circuit Breakers

A - Engine Starter System (20amps)

B - Lights (30amps)

In the event of a fault occurring, the circuit breaker will trip out,this being indicated by the button protruding out beyond itsnormal position.

Should this occur, the reason for the overload must be found andthe components at fault replaced or repaired.

When the repair has been completed the circuit breaker shouldbe reset by pressing the button until it locks in position thusrestoring the electrical supply.

On machines with full lighting, one extra 30amp circuit breakeris fitted on the left hand side of the dashboard.

Dashboard Controls & Instruments

The layout of the dumper dashboard is dependant on equipmentand options fitted and various examples are illustrated on thefollowing pages.

0515-073a

BA


Description

Dash Decal - No Lights

A - 20A Circuit Breaker - Engine H - Warning Light - Handbrake ‘ON’

B - Instruction - Parking Brake / Coolant Temp. Audible I - Warning Light - Battery Charge

C - Instruction - Forward/Reverse Switch J - Warning Light - Transmission Oil Pressure

D - Instruction - Gear Lever Positions K - Warning Light - Engine Water Temperature

E - Horn Button M - Instruction - Start Inhibitor

F - Warning Light - Engine Oil Pressure Q - Instruction - Engine Start Key Switch

G - Warning Light - Transmission Oil Temperature

NIII

20A

30A

P

P

24

3 1

8002-2666

A

C D

E

F G H

M

Q

I J K

B


Description

Dash Decal - Site Lights

A - 30A/20A Circuit Breakers H - Warning Light - Handbrake ‘ON’

B - Instruction - Parking Brake / Coolant Temp. Audible Warning I - Warning Light - Battery Charge

C - Instruction - Forward/Reverse Switch J - Warning Light - Transmission Oil Pressure

D - Instruction - Gear Lever Positions K- Warning Light - Engine Water Temperature

E - Horn Button M - Instruction - Start Inhibitor

F - Warning Light - Engine Oil Pressure P - Switch - SITE Machine Lighting

G - Warning Light - Transmission Oil Temperature Q - Instruction - Engine Start Key Switch

NIII

20A

30A

P

24

3 1

8002-2666

P

A

C D

E

F G H

M

Q

I J K

P

B


Description

Dash Decal - Road Traffic Lights

A - 30A/20A Circuit Breakers J - Warning Light - Transmission Oil Pressure

B - Instruction - Parking Brake / Coolant Temp. Audible Warning K - Warning Light - Engine Water Temperature

C - Instruction - Forward/Reverse Switch L - Warning Light - Direction Indicators

D - Instruction - Gear Lever Positions M - Instruction - Start Inhibitor

E - Horn Button N - Instruction - Indicator Switch

F - Warning Light - Engine Oil Pressure O - Switch - Hazard Warning Lights

G - Warning Light - Transmission Oil Temperature P - Switch - RTA Machine Lighting

H - Warning Light - Handbrake ‘ON’ Q - Instruction - Engine Start Key Switch

I - Warning Light - Battery Charge

NIII

20A

30A

P

P

24

3 1

8002-2666

A

C D

E

F G H

M

Q

I J K L

N

O

P

B


Description

Dash Panel Symbol Description

A - Circuit breaker - Electric CircuitA - 20A Engine Starter SystemB - 30A Lights (if fitted)Circuit breakers protect the machines electrical system.

B - Instruction - Audible Warning

Instructs if the audible warning sounds either the handbrakehas been left on or the engine coolant temperature hasreached an unacceptable high temperature.If the cause is excessive engine coolant temperature -

STOP THE ENGINE IMMEDIATELYDo not use the machine until the fault has been rectified.

C - Switch Instruction - Forward / Reverse Positions

Indicates the direction to move the forward/reverse switchfrom the neutral position to obtain the required direction oftravel.

D - Instruction - Gear Lever Positions Instructs the operator to the position of the gearlever withregards to the desired gear

E - Horn ButtonThe horn is used to warn others and should only be used forthis purpose. Excessive use may cause others to ignore agenuine warning.

F - Warning Light - Engine Oil Pressure

This warning light will illuminate when the start switch isturned to the RUN position.When the engine starts, the light should extinguish. If thelight fails to extinguish or illuminates when the engine isrunning -


G - Warning Light - Excessive Transmission Oil Temperature

This warning light will illuminate if the transmission oiltemperature reaches an unacceptable level.If the light illuminates when the engine is running -


H - Warning Light - Handbrake ‘ON’This warning light will illuminate when the handbrake is in the‘ON’ position and the start key switch is in the ‘RUN’ position.The machine should not be driven when the l ight isilluminated - release the handbrake first.

I - Warning Light - Battery Charge

The battery charge warning light should only be illuminatedwhen the start switch is ON and the engine is not running.When the engine starts and full RPM is selected the chargewarning light extinguishes. The warning light should stay offwhile the engine is running.If the light fails to go out when the engine is running -

STOP THE ENGINE IMMEDIATELYCheck the fan belt, alternator, wiring etc.Do not use the machine until the fault has been rectified.

20A

30A

�

�

4

3

2

1

P

� �


Description

Dash Panel Symbol Description - continued

J - Warning Light - Transmission Oil Pressure

When i l luminated th is warn ing l ight ind icates thetransmission oil pressure is LOW

K - Warning Light - Engine Coolant Temperature

The water temperature warning l ight should only beilluminated when the start switch is in the ON position andshould go out when the engine is cranked.If the warning light illuminates when the engine is running thewater temperature is too high, a warning buzzer will alsosound.If engine temperature warning light is Illuminated whenengine is running -

STOP THE ENGINE IMMEDIATELYDo not use the machine until the fault has been rectified

L - Warning Light - Direction Indicator

If fitted, this light will flash when the indicator switch is movedinto the left or right turn position.If the light fails to perform this function, do not use themachine until the cause has been rectified.

M - Instruction - Start Inhibitor

This instruction informs the operator they will have to sit onthe seat before the engine will start.A start inhibitor is fitted to the seat which is disabled when theoperator sits on the seat. It is therefore important theoperator adjusts the seat to match their weight.

N - Switch Instruction - Direction Indicator

If fitted, this instruction informs the Operator which way tomove the switch in order to operate the LEFT and RIGHTdirection indicators

O - Switch - Hazard Warning Lights

If fitted, the hazard warning light switch will cause all fourindicator lights to flash and is used to warn others themachine is experiencing problems and should be givenspecial attention.

P - Switch - RTA Machine Lighting - if fitted

This switch will turn the headlights and front, rear side lightson and off.

P - Switch - Site Lights - if fitted This switch will turn the site lights on and off.

Q - Instruction - Engine Start Key Switch This instruction shows the start key position to use when theengine cold start aid is required.


Description

Dash Panel Switch Descriptions

Hazard Light SwitchPressing the button will cause all four direction indicatorlights to begin flashing and will continue to do so until thebutton is pressed again

Horn Button When pressed, this button will cause the horn to sound.

Site Light Switch

Turning this switch clockwise (A to B) will cause the site lightsto i l luminate. To turn the site l ights off , turn switchanticlockwise (B to A).Site lights are fitted to provide illumination when driving offthe public highway.

RTA Light Switch

Turning the switch clockwise from the OFF position willcause the front and rear side (marker) lights to illuminate.Turning the switch to the next position will cause the mainheadlights to illuminate too.When the machine is fitted with the full lighting set and istaxed and insured for public road use, the machine may bedriven on the public highway at night.

AB

A

BC


Description

Start/Stop Switch

The Start/Stop Switch (A) is operated by removable key. Theengine will not start unless the operator is sitting on the seat.

The switch has 4 positions:-- O - Off/Neutral- 1 - Run- 2 - Heat- 3 - Start

Forward / Reverse Switch

When the machine is not being used or driven the Forward/Reverse Switch (A) should always be in position '0' to preventaccidental movement.

Forward/Reverse Positions and Actions

0 = Neutral1 = Forward2 = Reverse

If the handbrake is ‘ON’ when forward or reverse is selected awarning buzzer will sound.

If a reverse alarm option is fitted this will also sound whenreverse is selected regardless of the handbrakes status. See“Audible Warning, Hourmeter and Reverse Bleeper” section onpage 5-18.

0 1

2

3

A

0515-074b

bEnsure handbrake is applied whenever machine is

stationary

0515-053a

1

2

A0


Description

Direction Indicator Switch - if fitted

This switch is used to illuminate the LEFT or RIGHT, front andrear indicator lights to inform others of the operators intentionto turn the machine to the Left or Right.

Moving indicator lever (A) forwards (1) will illuminate the lefthand indicator lights. Moving the lever (A) backwards (2) willilluminate the right hand indicator lights.

These instructions are shown graphically on the dashboarddecal (B).

Audible Warning, Hourmeter and Reverse Bleeper

Audible Warning (A)

The Audible Warning (A) alerts the Operator that the handbrakeis ‘ON’ or the engine coolant temperature is too high.

Hourmeter (B)

The Hourmeter (B) is located in the control panel to the right ofthe steering column. The meter is activated whenever the startswitch is in position 1 or above and its purpose is to determinewhen a service schedule is due i.e. every 10, 50, 250, 500 and1000 hours etc.

Reverse Bleeper - if fitted

This warning device is activated whenever the Forward/Reverse switch is put into the REVERSE position. Its purposeis to warn people the machine is reversing.

1

2

A

0515-052a

B

B

0515-056a

0515-053b

A


Description

Road Traffic Lighting

A 3 position switch (A) Controls the side and head lights.

Brake Lights

The brake light switch is activated when the brake pedal ispushed down, this illuminates the brake lights (4).

When the pedal is released the brake light switch is de-activatedand the brake lights (4) are extinguished.

Number Plate Lights

If full lighting is fitted, lights (1a) are provided for illuminatingthe vehicle rear registration plate.

Full Lighting

Switch Position Lamp Description

0 0 OFF

1 1 Side Light

1 1a Rear Number Plate Light

2 2 Head Light

Indicator Switch 3 Indicator Light

Brake Switch 4 Brake Light

- 5 Reflector0515-062b

1

0 2

A

0515-066a

3

2

1

1a1a

5

3

1

4

0515-115a


Description

Flashing Beacon

The beacon is provided to warn people of the dumpers presence.

The Flashing Beacon (A) is fitted to the machines ROPS (D)and is controlled by switch (B).

The Flashing Beacon is easily removed to prevent theft orvandalism by slackening nut (C) and lifting the beacon of itsmounting stem (E).

When the beacon has been removed, the top of the mountingstem is covered by pulling the rubber stem cap (F) over themounting stem (E).

Storage instructions

To help prevent damage, theft and vandalism the flashingbeacon (G) can be removed from its working position on theROPS and stored inside the lockable engine compartment whennot required.

It is held in position on the pin by tightening nut (H).

Flashing Beacon

0506-070a

B

C

A

DE

FE

0506-071a

0803-5-008

HG


Description

Accessory ‘Jack Plug’ Socket

A 12v ‘jack plug’ socket (A) is fitted by the battery isolator (B).

This socket may be used for inspection lamps, 12v electrictools, 12v compressors etc. The rating of the equipmentconnected to the socket must not exceed 5 amps.

The ‘jack plug’ is accessible through the left hand enginecanopy door. To use the socket (A), lift the plug cover up andinsert the special ‘jack plug’.

A

B

0803-5-003


Description

Foot Brake and Accelerator Pedals

The range of dumpers have a common driving position andcontrols for all models.

The driver is centrally positioned. The footbrake (A) andaccelerator (B) pedals are located in standard automotiveformat.

Note: There is no clutch pedal fitted to this machine.

Gearlever

The gearlever (C) allows any of the gearboxes 4 speed ratios tobe selected. The lever moves in a conventional H pattern.

An interrupt button (D) on the gear lever knob (E) is depressedand held while changing gear. This button is the equivalent of aclutch pedal on a conventional dumper.

0803-5-009

B

A

C

0515-050a

4 2

3 1

0515-051b

D

E


Description

Parking Brake

The dumper has a parking brake system which is integral withthe disc and calliper, fitted to the gearbox output shaft, and isoperated by a parkung brake lever (A) located to the right of thedrivers seat.

The parking brake lever (A) is fitted with a lever (B) to preventthe parking brake being released if the parking brake lever (A)is accidentally knocked forwards.

Apply

Pull the parking brake lever (A) upwards to the vertical ‘ON’position to apply the parking brake.

Release

To release the parking brake lever (A) pull release lever (B)against the parking brake handle (A), this will release lever (A)allowing it to return to the ‘OFF’ position (C).b

The parking brake may not hold machine on gradientssteeper than 8.5º (15%). Always park on flat level ground.(If the dumper is parked on a slope it must not exceed 8.5º(15%) and the dumper must be parked across the slopeand the wheels chocked). DO NOT stop or park on a slopethat is liable to collapse.

0515-059a

A

B

P

P

0515-060a

C

P

P


Description

Engine Canopy Doors

The engine canopy door (C) hinges, are fitted vertically causingthe door to open forwards.

The door (C) is opened by lifting the catch handle (A) from edge(D). To close the door (C), firmly push the door (C) into theclosed position.

A lock (B) is fitted to prevent unauthorised access to the enginecompartment.

Tow Hitch

The dumper has not be designed for, and we do notrecommend its use as a towing vehicle but if so used alwaysmake sure the weight of any trailer and its load does notexceed half the rated payload of the dumper.

It is important that if used for towing:• .The skip is loaded with half the rated payload to provide

adhesion when braking.• The machine is NEVER driven down gradients as “jack

knifing” may occur.• Only first gear is used and the machine is never driven on or

across inclines.• The grip clip (B) must be positioned through the towing pin

(C) when the trailer etc. has been attached to the bracket (A).

0803-5-006

A

B

D C

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B

C

A


Description

b ROPS

A Roll Over Protective Structure (ROPS) is fitted to protect the operator should the machine over turn. For more information on ROPSsee ‘Safety’ section of this manual

The ROPS Identification Plate (D) is located on the top of theROPS.

The ROPS comprises of two sections (A & B) and is pivoted atseat level to allow the ROPs to be tipped backwards to reducethe transportation height - not the working height. A gas strut(C) is fitted to assist in raising the ROPS.

The ROPS is secured in the raised position by a locking pin (E)and a linch pin.

bUnder No Circumstances Modify the ROPS in Any Way

bOnly Lower the ROPS when Transporting the Dumper on a

Lorry / Trailer etc.Beware of trapping fingers etc. in ROPS pivot areas.

0803-5-004

D

0803-5-005

E

0803-5-007

C

A

B


Description

Blank Page


6 - InspectionTA9 and TA10Four Wheel Drive Dumper

Inspection

General Inspection

Before each days operation of the dumper the operator mustperform the General Inspection as outlined in the Check List onthe following page.

The purpose of the Operators Inspection is to keep the dumperin proper working condition and to detect any signs ofmalfunction during normal operation between scheduledmaintenance intervals.

Read the Safety Section of this manual before performing theinspection.

While it may not be the operators responsibility to performmechanical maintenance the operator must be thoroughlyfamiliar with the machine and its proper care since their ownsafety is involved.

bBefore Carrying Out Checks Read Safety Section Of This

Manual


Inspection

Daily Operator Checks

15 9 7 6 5 4

12 1 2 1 8 12 11 13

16

3

10

14

16

0803-6-001

1 Steering Ram Pins Check for wear and retention

2 Steering Ram and Hoses Check for leaks

3 Skip Pivot Pins Check for wear and retention

4 Instruction Manual Present and Legible

5 Seat Belt Working and Undamaged

6 ROP’s Frame Check for Damage

7 Seat Inhibitor Switch Check for Correct Function

8 Battery Check Electrolyte Level

9 Air Cleaner Clear and unobstructed

10 Engine Coolant Check Level (ONLY with Engine Cold)

11 Engine Oil Check Level

12 Tyres Check for Correct Inflation and Damage

13 Fuel Check Level

14 Hydraulic Tank Check Level

15 Skip Rams and Hoses Check Condition and Signs of Leakage

16 Lighting (If Fitted) Check Operation

Various Safety Decals Check if Present and Legible


7 - Operating InstructionsTA9 and TA10Four Wheel Drive Dumper

Operating Instructions


Before using this equipment the operator must read and fullyunderstand this instruction manual and pay particular attentionto Section 3 - Safety and Section 5 - Description whichdescribes the major components of the machine and the layoutand function of all the controls.

Pre-Start Checks

• Ensure the machine has been cleaned to enable leaks etc. tobe noticed easily during the pre-start check and duringnormal operation.

• Check general condition of machine - missing parts, loosefixings, fuel lines for damage, hydraulic hose end fittings forleakage, hose outer covers for ballooning, etc.

• Check engine and hydraulic oil levels - make sure the engineand hydraulic tank are filled using clean oil and a cleancontainer.

• Check fuel tank is full - make sure the tank is filled when theengine is cold and the machine is in a well ventilated area,with the engine stopped using clean fuel and container. It isadvisable to fill the tank at the end of a working session toprevent condensation forming in the tank during longperiods of inactivity, e.g. overnight.

• Check battery and battery cable condition.• Check for adequate ventilation if the machine is to be started

or run in a building etc.• If a folding ROPS is fitted ensure it is in the “work” position

and pins and retaining clips are fitted.

bALL Operators of this machine must be authorised,mentally and physically capable of operating this machineand fully trained in its operation.

bWhen Refuelling Beware of Naked Flames, Grinding

Sparks etc.



Access / Egress

The Operator must use footsteps (A) and handles (B) whenmounting or dismounting the machine to avoid personal injuryor damage to the machine.

When mounting or dismounting, the Operator must always facethe machine to help avoid personal injury.

The handles (B) and footsteps (A) are situated either side of themachine.

Before dismounting, ensure the machine is parked correctly onfirm, level ground. The handbrake is firmly ON, the directionlever is in NEUTRAL and the engine has been stopped.

Access / Egress

bDo Not use steering wheel, handbrake etc. when mountingor dismounting. Use Footsteps (A) and Handles (B)provided

BB

B

A

A

A0803-7-001

bEnsure the steps, handles and Operators footplate are

kept clean from mud, oil, ice etc.

bDO NOT jump from the machine, ALWAYS face the

machine and use handles and steps provided



Operators Seat - Grammar

Angle Adjustment

The seat back rest is adjustable for angle, this is achieved bylifting lever (A) at the front of the seat cushion and sliding theseat cushion forwards/backwards.

Release the lever and ensure the seat runners engage in one ofthe preset locking positions.

Seat Movement

On all machines the operator is able to adjust the seat in the fore/aft direction by lifting knob (B) and sliding seat to the requiredposition, then releasing the knob to lock the seat into position.

Grammar Seat Operating Instructions

Weight Adjustment

The seat may be adjusted for drivers weight by sliding lever (C)downwards to the relevant weight position, as indicated by thescale (D) on the side of the seat.

To return lever to the top of the scale push the lever (C) fullydownwards to the bottom of the scale (D) and then lift the lever(C) to the top.

The engine will not stop when the Operator leaves the seat.

bDo Not Adjust the Seat While the Machine Is Moving

0506-053a

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The Engine will not start unless Operator is sitting on the Operators Seat.

0803-7-003

C

D



Seat Belt• Sit on the seat, place the seat belt across the lap and insert the

inner buckle 'A' into outer buckle 'B' until it locks firmly intoposition.

• To remove the seat belt, press the button ‘C' and pull innerbuckle 'A' away from outer buckle 'B'.

bSeat Belt must be locked in position across the Operators hips BEFORE operating the machine if ROPS/FOPS fitted

0803-7-002

B

C

A



Operators Seat - Milsco

The seat is adjustable for Operator comfort. The adjustmentsallow the seat to be moved forwards and backwards, the back ofthe seat may be tipped forwards and backwards and the seatsuspension may be adjusted to the weight of the Operator.

Seat Controls

A - Fore and aft movement.

B - Weight adjustment.

C - Back rest angle adjustment.

D - Seat belt.

Fore and Aft Movement

Lifting lever (A) allows the seat to be move forwards orbackwards to suit the leg length of the Operator.

When the lever (A) is released the seat is locked in the selectedposition.

Weight Adjustment

This control is used to adjust the seat characteristics to theweight of the Operator.

Turning knob (B) clockwise adjusts the seat for the largerperson and anticlockwise for the smaller person.

When the knob (B) is turned, the pointer (E) moves to allow theOperator to select the correct weight from the scale (F)..

The engine will not stop when the Operator leaves the seat.

Back Rest Angle Adjustment

Lifting lever (C) allows the back of the seat to be pushedforwards or backwards to suit the preference of the Operator.

When the lever (C) is released the seat is locked in the selectedposition.

The Engine will not start unless Operator is sitting on the Operators Seat.

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Seat Belt• Sit on the seat, place the seat belt across the hips and insert

the inner buckle (B) into the outer buckle (A) until it locksinto position.

• Adjust by pulling the belt through buckle (B) until it is afirm, comfortable fit across the hips.

• To remove the seat belt, press the button (C) and pull innerbuckle (B) away from outer buckle (A).

bSeat Belt must be locked in position across the Operators hips BEFORE operating the machine if ROPS/FOPS fitted

0504-003a

A

B

C



Folding ROPS

The optional Folding ROPS comprises of two sections (A&B)and is pivoted at seat level to allow the ROPS section (A) to betipped backwards to reduce the transportation height - not theworking height.

Folding Procedure• Ensure the machine is parked on firm, level ground.• Remove the flashing beacon• Remove both linch pins (G) and remove locking pins (D).• Pull the handle (C) upwards, tipping ROPS section (A)

backwards, until holes (E-E) are in line.• Fit locking pins (D) through holes (E) and refit linch pins

(G). The ROPS is now securely stored in transport position.

To re-instate the ROPS to its operational position reversethe above procedure. A gas strut (F) is fitted to assist raisingthe ROPS.

Ensure the locking pins (D) and linch pins (G) have beenrefitted before using the machine.

bOnly Lower the ROPS when Transporting the Dumper on a

Lorry / Trailer etc.Beware of trapping fingers etc. in ROPS pivot areas.DO NOT use the machine when the ROPS has been

folded.

0515-086a

G

��

F

C

D

B

A

E

E

bNEVER use the dumper with the ROPS in the transport

(lowered) position

0803-7-004

A

C

D

G

0515-087a

C



Starting and Stopping the Engine

Starting the Engine

Before attempting to start the engine ensure:-• There are no obvious faults with the machine.• The Operator is Sitting on the Operators Seat.• The handbrake is applied and Forward/Reverse switch (A) is

in neutral (0) and ALL warning lights on the dashboard areilluminated when the start key (B) is turned to the RUNposition (1).

• Turn the start key (B) to the HEAT position (2) and hold for10 seconds.

• Turn the start key switch (B) to the START position (3),release immediately the engine starts and allow the key toreturn to the RUN position (1).

• When engine has started, ensure ALL warning lights on thedashboard are no longer illuminated except the handbrake‘ON’ light. If any are still illuminated stop the engine andhave the fault rectified before using the dumper.

Stopping the Engine• Before stopping the engine the machine must be on firm,

level, stable ground, it must not be in a dangerous position orcausing an obstruction to others, the handbrake must beapplied and the forward / reverse switch (A) and gear levershould be in neutral.

• The engine is stopped, in normal use, by the Operatorturning the start switch (B) anticlockwise to the OFFposition (0).

Do Not Use Starting Sprays to Assist Engine Starting

Do Not Crank Engines for More than 10 Seconds- Allow 30 Second Delay Before Further Starting Attempt

NOTICENever Engage the Starter Motor Whilst Engine is Running

0515-053c

A0

NOTICEAllow the engine to ‘idle’ for 30 seconds before stopping engine especially if the engine has been ‘worked hard’

bIf leaving the machine unattended, remove the start keyand turn the battery isolator to the OFF position andremove the isolator key. This will help prevent themachine from being used by unauthorised people.

0 1

2

3

B

0515-074a



To Move the Machine

To Change Gear

The procedure is as follows:-• Select Forward or Reverse as required using the Forward/

Reverse switch.• Depress the Drive Interrupt Button (A) on the gear lever and

hold whilst moving the gear lever into first gear. This buttonis the equivalent of a clutch pedal on a conventional dumper.

• Release the button.• Release the handbrake.• Press the accelerator pedal down slowly, drive will be

progressively taken up through the torque converter and thedumper will move off.

Changing gear, up or down the range, is effected by depressingthe drive interrupt button on the gear lever and moving the gearlever into a higher or lower gear position.

Action See Section Remarks

Check condition of machine is satisfactory andthe surrounding area is clear.Sit on operators seat.

Safety

Start Inhibitor

The engine will not start unless operator issitting on the machine.

Ensure the handbrake is ON, theForward / Reverse switch is in NEUTRAL andgearlever is in NEUTRAL.

HandbrakeForward / Reverse Switch

Torque Convertor & Shuttle Gearbox-

Turn start key switch to RUN - position 1.Check all warning lights etc. on the dashboardare illuminated before proceeding.

Starting the Engine

Dash Panel Symbol Descriptions-

If the engine is cold turn start key switch toHEAT - position 2 - before proceeding. Starting the Engine If the engine is ‘Hot’ this procedure should

not be required.

Turn start key switch to START - position 3.When the engine starts release key and allowit to return to RUN - position1.Ensure all warning lights have extinguishedexcept the handbrake ‘ON’ warning light

Starting the Engine

Dash Panel Symbol Descriptions

Do not crank for more than 10 seconds. Wait for 30 seconds before attempting the starting procedure again.

Select forward or reverse.Using the gearlever select first gear.Release handbrake and depress acceleratorpedal gently until the machine begins to move.

Forward / Reverse SwitchHandbrake

Torque Convertor & Shuttle Gearbox-

As machine speed increases, if conditionsallow, change into successive higher gears Torque Convertor & Shuttle Gearbox -

0803-7-005

A



Gradients

Ascending, descending or crossing gradients should be donewith extreme care.

See Gradients in Safety section in this manual for furtherinformation.

Descending Gradients

The operator must select a suitable low gear for descending thegradient. If the operator is in any doubt as to the gear to beselected, first gear must be selected.

Stopping and Moving off on a gradient steeper than the handbrake capability • Stop the vehicle on the footbrake, continue to apply the

footbrake and apply the handbrake, and select neutral on theforward reverse switch.

• To move off select 1st gear then forward/reverse, hold thevehicle on the handbrake, release the footbrake and apply thethrottle to drive against the handbrake.

• When the vehicle starts to move in the desired directionrelease the handbrake and move off.

To Tip The Skip

• Position the machine where the load is to be discharged.• Ensure the area is clear of bystanders.• Move the control lever (A) forwards.

The skip will elevate and the load will be discharged.

To Lower The Skip

Move the control lever (A) rearwards.

The skip will lower.

NOTICEEnsure the machine has stopped before moving the

forward/reverse switch to the opposite direction

bNEVER Elevate The Skip Unless The Dumper Is On Level

Ground

bDo Not Use Raised Skip as a Bulldozer Blade.

0515-082a

A



Towing Or Recovery

When towing or recovering the machine it is essential that thetop driveshaft between the transfer box and the gearbox isdisconnected to prevent damage to the gearbox.

Note that the parking brake will be inoperative when the driveshaft is disconnected. Before removing the driveshaft it will benecessary chock the wheels of the machine to preventmovement.

A suitable rope or chain attached; using a ‘D’ link, to one of thefront lashing points or the rear tow hitch (A) should be used fortowing the dumper.

Towing

The machine may be towed for a maximum distance of 1 mile(1.6 kilometres) at speeds not exceeding 15 mph (25kph).

NOTICETo prevent oil starvation and possible seizure of thetransmission whilst towing vehicle, it is imperative thatthe top drive shaft is disconnected. Failure to observe thisprecaut ion may resu l t in ex tens ive damage totransmission.

bWhen the driveshaft is disconnected the parking brake

will not operate. The wheels must be chocked to prevent movement.

bThe rope, chain etc. must be of adequate strength for the weight of the dumper and its load. All bystanders must be

kept well clear when towing or recovering.

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B

C

A


8 - TransportationTA9 and TA10Four Wheel Drive Dumper

Transportation

b Transportation

Loading onto Lorry / Trailer

When loading dumper onto a trailer or lorry, strong loadingramps should be used. See Specification section for machineweights.

Ensure trailer or lorry will not move during loading by applyingtheir brakes and also chocking their wheels if necessary.

The angle of the ramps must not exceed the gradeability of themachine and in wet or muddy conditions may need to be less

Fit articulation lock - see Articulation Lock.

Secure the dumper to the lorry chassis using chains, straps orropes of sufficient strength attached to the machine.

See Securing Dumper in the next section.

Unloading

When unloading from a lorry/trailer, strong loading lamps;capable of taking the weight of the dumper, must be used.

Ensure trailer or lorry will not move during loading by applyingtheir brakes and also chocking their wheels if necessary.

Release the articulation lock before moving the machine.

b Articulation Lock

1. When the machine has been positioned on the lorry ortrailer to prevent both chassis halves swinging relative toeach other the articulation lock (A) must be used.

2. To fit the lock remove grip clip (C) and pin (B) from frontstorage position.

3. Pivot the locking bar (A) around until the holes in the barare in line with the holes in rear chassis locking bracket.

4. Fit the pin (B) through the holes and secure with the gripclip (C).

bRamp Gradeability Will Be Reduced In Slippy Conditions.

Ensure the Skip is Empty when Transporting.

bTo prevent both chassis halves swinging relative to each

other the articulation lock must be fitted when the machine is on lorry/trailer. See Articulation Lock section.

bKeep all bystanders well clear while loading or unloading

the machine.

bKeep all bystanders well clear while loading or unloading

the machine.

0515-054a

A

C

B

A

B

C

0515-055a


Transportation

b Securing Dumper to a Lorry or Trailer Bed

When the machine has been placed in an acceptable position onthe lorry or trailer, the handbrake should be securely applied andthe skip fully lowered. The articulation lock should be fitted.

If the dumper has a folding ROPS this should be lowered toreduce the transport height of the machine.

Once the machine has been positioned on the Lorry / Trailerbed, chocks should be nailed firmly in the positions shown inthe diagram below.

The chains, straps, ropes etc. should be attached to the machinesfront lashing points (A) and rear towing hitch or over axles.

Ropes may also be placed over the wheels as shown in diagram.

The loose ends of the chains, straps, ropes etc. must then besecurely attached to the lorry / trailer bed.

bChocks MUST be Placed on All Four Wheels.

Secure the dumper to the lorry/trailer chassis usingChains, Straps or Ropes of Sufficient Strength.

pic-013

bWhichever Lashing Method is Used it MUST be SECURE

A

0803-8-001


9 - MaintenanceTA9 and TA10Four Wheel Drive Dumper

Maintenance

Maintenance and Lubrication

Before carrying out any service or maintenance work ensurethat the following precautions have been taken.• Place the machine on firm level ground.• Stop engine and chock the wheels.• Remove Start key to prevent accidental starting.• Place a warning tag on the machine to prevent accidental

start up.• Only jack or raise the dumper using the correct equipment.

• Refer to the Service Schedule on Page 9 -27• When checking fluid levels the machine must be placed on a

firm, level surface, in a well ventilated position away fromnaked flames, grinding sparks etc.

• Ensure strict cleanliness is observed especially when dealingwith hydraulic systems.

• Isolate electrical system by using the isolator switch or bydisconnecting the battery.

• Ensure all guards and covers removed during maintenanceare replaced before the machine is put back into work.

Safety Signs

All safety signs fitted to the machine must be legible.Use mildsoap and water to clean safety signs -DO NOT use solvent basedcleaners because they may damage the safety sign material. Allsafety signs MUST be replaced immediately they becomedamaged or unreadable.

Hydraulic Oil Under Pressure• Release any pressure in the hydraulic circuit before carrying

out any repairs to the hydraulic system or components.• Fine jets of hydraulic fluid under pressure can penetrate the

skin.• Do not use your fingers to check for small leaks or expose

uncovered areas of your body to leaks.• Check for leaks using a piece of cardboard.

bAlways use Axle Stands or other acceptable rigid supportof ample capacity to support the dumper when raisedclear of the floor.

bRefer to the SAFETY Section of this manual before

performing any maintenance tasks on this machine.

bNever work under a raised skip unless the skip props are

LOCKED in position.

bIf skin is penetrated with Hydraulic Fluid, Get Immediate

Medical Help

0605-1-9000

BEWAREOf Hydraulic OilUnder Pressure


Maintenance

Cleaning

• Clean the dumper thoroughly, this will make it easier to findoil leaks and loose fittings etc.

• Take care to clean the oil, fuel and water tank filler necks.• Drain plugs should also be cleaned.

• Using water or a pressure washer to wash down the exteriorof the dumper with or without detergent is generally all thatis required.

• When cleaning the dumper it is preferable to use abiodegradable cleaner. Do not use solvents or like productswhich can damage rubber and plastics.

Vehicle/Machine Battery - End of Life Disposal

When the battery reaches the end of its useful life it must beremoved from the machine and recycled in an approved way inaccordance with local environmental regulations.

This service is usually offered by battery vendors.

Machine users that cannot find a suitable battery recyclingfacility should contact Terex for assistance.

NOTICEAvoid Spraying Electrical Equipment with Pressure

Washers

bContaminated Water / Fluids / Oils Must Be Disposed of

Legally


Maintenance

b Working Under A Raised Skip

NEVER work under, or in front of, a raised skip unless skipprops have been fitted.

Fitting Skip Props• Once the skip has been fully elevated, remove the upper grip

clips (C) from both skip prop pins (B) in turn.• Remove pins (B) and allow props (A) to swing downwards

and enter the lock positions (D) on the front chassis.• Position the pins (B) through the holes in the front chassis

(E) and through the corresponding holes in the props (A).When pushed fully through, push the grip clips (C) securelythrough the locking pins (B).

Removing Skip Props• Remove the grip clips (C) from the locking pins (B).• Remove the pins (B) from the props and chassis.• Raise the props (A) to the storage position on the skip.

• Secure in place with pins (B) and Grip clips (C).

0515-047a

A

A

B C

D

bBefore Attempting to Carry out Any Work Under a Raised Skip, the Skip Props Must be Placed in LOCKED Position.

B

C

A

0515-045a

E


Maintenance

Battery

Battery Isolator

See Battery Isolator on Pages 5-8 and 5- 9 of this manual.

Battery Access• Remove the four bolts (B) securing the hose cover to the

steering column.• Remove the four bolts (A) fixing the floor plate to the rear

frame.• Lift the floor plate clear of the machine.

Battery

Battery Removal

Read Battery Maintenance section before continuing.

• Disconnect NEGATIVE cable (B) first.• Disconnect POSITIVE cable (A).• Loosen the battery clamp strip nuts (C) and remove the

clamp strip (E).• Lift battery from the machine using lifting handles (D).

bBefore Attempting Any Major Maintenance Disconnect

Battery

bUse Isolator for Emergency Battery Isolation

AA

A

A

B

B

0803-9-001

bDisconnect Negative Battery Lead Connection First

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C

B

E

C

A

D


Maintenance

b Battery Maintenance

• Always wear protective glasses when working on battery.• If battery leads are removed, clean battery terminals and

connections. When reassembled smear terminals withgrease.

• Remove start key and all electrical loads beforedisconnecting. Always disconnect Negative (-) battery lead(B) before disconnecting the Positive (+) battery lead (A).

• Remove start key and all electrical loads beforereconnecting. Always connect Positive (+) battery lead first(A) when reconnecting battery.

• Never allow metal objects to touch both battery terminals atsame time or allow metal objects to touch Positive (+)terminal (A) and frame.

Battery Maintenance

• When charging the battery hydrogen gas is produced. Ensurethe area is well ventilated to prevent the risk of explosionfrom a build up of hydrogen.

• Do not smoke, weld, cut, grind etc. in vicinity of a batterybeing charged.

• If the skin is exposed to battery electrolyte, the affected skinmust be washed immediately with running water.

• If eyes are exposed to battery electrolyte, wash eyes withrunning water and obtain immediate professional medicalattention.

bDisconnect Negative Battery Lead Connection First

bNEVER Charge a FROZEN BATTERY!


Maintenance

b ‘Jump Starting’

When connecting a slave battery (A), to boost a dischargedbattery (D), on the machine ensure that: • The slave battery (A) is of the same nominal voltage as the

machine’s battery.• The interconnecting cables (B & C) are of sufficient capacity

to carry starting current.• The cables are connected between battery terminals in the

following order,

1st - Slave Battery Positive (B+) to Machine Positive (D+)

2nd - Slave Battery Negative (C-) to Machine Earth1 (E-)

• IMPORTANT - It is essential to avoid sparks whenconnecting cables to a discharged battery. The batterygenerates inflammable gases and may pose as a fire risk.

• The engine speed is reduced to minimum idle speed beforedisconnecting the jumper cables.

• The machines battery cables must never be removed whilethe engine is running.

A - Slave Battery D - Machines Battery

B - Positive Jump Lead E - Negative Jump Lead to Chassis

C - Negative Jump Lead F - Machine Chassis

A

C-

B+

D

E

F

1. Machine Earth - Earth point should be made on the engine orchassis (F), away from the discharged battery (D).

bA frozen battery may explode if charged or the machine is‘jump started’ and the engine run. To prevent the batteryelectrolyte freezing, keep the battery fully charged


Maintenance

Engine Air Cleaner Servicing

Air Cleaner Daily Maintenance

The air cleaner is located in the engine compartment,approximately under the Operators seat.

Check the filter blockage indicator (F). If the indicator isshowing RED, the air cleaner requires servicing.

Air Cleaner Servicing• To service air cleaner first clean its surrounding area and

then loosen clamps (E) holding the sediment cup (A) to aircleaner body (D).

• Pull the Primary (B) and Secondary (C) air filter elementsfrom the air cleaner body (D).

• Renew, or clean the element (B) by carefully usingcompressed air to blow dust out of the filter. Secondary aircleaner (C) must not be cleaned - it must be renewed whennecessary.

• Thoroughly clean air cleaner body (D) and sediment cup(A). Reassemble by reversing the above procedures.

Air Filter Cleaning

Air cleaner elements should be cleaned by blowing gently withan airline from inside, or tapping gently against a firm object.

NOTICECheck Air Inlet System Daily for Air Leaks

A

E

B

C

D

F

��

NOTICEMaximum engine protection against dust is possible onlyif the air cleaner is serviced at regular intervals. No hardand fast rules apply to the regularity of servicing becauseoperating conditions vary so much. The only way todetermine if an air cleaner requires cleaning or replacingis to physically check it.Site Conditions Will Dictate the Frequency of ElementReplacement. In Dusty Conditions - Check the Air CleanerFrequently.

��


Maintenance

Engine Oil

Always use the Engine Manufacturers Handbook forinstructions when checking or servicing the engine, e.g. oillevel, filters, fan belt etc.

If this is not available the following procedures should befollowed for checking and changing the engine oil.

Engine Oil Level Checking• Park the machine on firm, level ground.• Stop the engine and let the machine stand for a few minutes

to allow the oil to drain into the engine sump.• Remove engine dipstick (A), located behind the oil filter,

wipe clean with paper, replace the dipstick. Remove andcheck the oil level on dipstick.

• If the oil level is below the MIN level (E), remove the engineoil filler cap (C) and add clean, fresh oil of the correct gradeto the engine. While adding oil, check the level frequently toensure it does not go over the MAX level (D). Replace thefiller cap (C).

bThe Dumper MUST be On Firm Level Ground when

Checking or Changing the Oil

0803-9-003

A

NOTICEToo much engine oil may cause damage to the engine

D

E

��

A

0803-9-004

C


Maintenance

Engine Oil

Engine Oil Draining• Drain the engine oil when the engine is warm - NOT HOT!.• Park the machine on firm, level ground. Access to remote

drain plug is from underneath the machine.- Engage parking brake.- Select neutral position for the transmission.- Remove the starter key.- Remove the battery isolator key.

• Place a suitable container under the remote drain plug (B),remove the drain plug (B) from the hose (A) and allow theold oil to drain into the container.

• When the oil has finished draining, replace the drain plug(B) into hose (A) and securely tighten.

• See Checking Engine Oil Level section for refillinginstructions.

• Start the engine and check for oil leaks.

NOTICEThe engine oil filter should be replaced when changing

the engine oil

B

A

0803-9-011


Maintenance

b Engine Coolant

Radiator Pressure Cap

The cooling system is pressurised to increase boiling point ofcoolant, therefore extreme caution should be taken whencarrying out maintenance on cooling system to preventscalding.

Topping-Up Cooling System Level - Engine Cold

This operation should only be performed by topping-up theplastic expansion tank (B) to maintain coolant level within theMaximum (D) and Minimum (E) marks on expansion tank.

Only fill radiator via the orifice at (A), after draining the systemor on regular servicing check. See Radiator Cap Access section.

NEVER Overfill the Expansion Tank

Coolant

The coolant used to top up the cooling system should be a pre-mixed solution of antifreeze and water in the correct ratio for thetemperature range the machine is to be used in.

DO NOT USE Anti-Leak AdditivesWhen topping-up the system, always check the water hoses

for damage or wear and for any obvious leaks

Radiator Cap Access • Lift and turn handle (F) on the radiator cap cover plate (G) to

release the catch.• Lift cover plate (G) to access the radiator cap (A).

• Ensure radiator cap (A) has been replaced and tightenedbefore closing cover plate (G) and returning the handle (F) tothe locked position.

bNEVER Remove Radiator Cap (A) or Expansion Tank Cap(C) when Engine is HOT. Allow tanks to vent residualpressure before completely removing caps.

0803-9-002

D

E

BC

bNEVER Remove Radiator Cap (A) when Engine is HOT

bNEVER start engine without coolant in the cooling system.

NEVER remove radiator cap when the engine is running.

Antifreeze is TOXIC. If accidentally swallowed, medical advice must be sought Immediately.

Antifreeze is corrosive to the skin. If accidentally spilledon to skin, it must be washed off immediately. Protectiveclothing and eye protection should be worn whenhandling antifreeze.

0515-075a

A

F

G


Maintenance

Hydraulic System

During ANY hydraulic maintenance extreme care should betaken to ensure the cleanliness of the hydraulic circuit. Byobserving strict hydraulic cleanliness the machine will benefitfrom fewer hydraulic failures through contamination. Forexample:

Always• Thoroughly clean machine before any maintenance. Use

paper roll, not rag, to wipe parts.• Use fresh, clean hydraulic oil from a sealed container.• Ensure old gasket particles and excess sealing compound

etc. do not enter the system. If they do clean them out.• Ensure new parts and fittings are kept in sealed bags etc. and

they are stored away from any contamination.• Remove flaking paint from around the area being

maintained. Inspect the inside of new tanks for plastic debrisetc.

Never• Fit new hoses if both ends are not fitted with plastic caps.• Fit new valves, pumps, motors, filters etc. if all the ports are

not plugged.• Use dirty containers for oil storage.• Use dirty containers or funnels for filling hydraulic system.• Store hydraulic components on the floor, in areas where

welding or grinding is done, in a dirty environment etc.

Hydraulic Filters

A description of the hydraulics, and circuit diagrams iscontained in this manual under the section headed HydraulicSystem on page 5-6. The system components are maintenancefree other than the suction strainer and return line filter.

Whilst removing these parts it is recommended the system isdrained and refilled with clean new hydraulic oil as specified onthe lubrication chart on page 9-28.

NOTICEWhen renewing these filters, the area around the filtershould be cleaned before removing old filters to preventingress of dirt into the hydraulic system

bWaste Oil MUST be Disposed of Legally


Maintenance

Hydraulic System

Hydraulic Oil Level - Checking

To check the hydraulic oil level, • Stop the engine and unscrew the dipstick/breather (A) and

remove from the tank. Do not lose the sealing ring (B).• Wipe all traces of oil from the dipstick (A) with clean paper

and replace.• Remove the dipstick (A) again and check the position of the

oil level.• There are two marks Max (C) and Min (D) on the dipstick,

never allow the oil level to go below the Minimum mark -Min (D) or above the Maximum mark - Max (C).

Hydraulic Oil - Adding

When adding oil, • Ensure a clean container and clean, fresh, new oil is used.• See Lubrication Schedule in this manual for correct grade of

hydraulic oil.• Remove the filler/dipstick (A). Pour new oil through the

filler/dipstick (A) hole. • Use the dipstick (A) to check the level frequently, until oil

level is at the upper mark Max (C) on the dipstick.

bAlways Position Machine on Firm, Level Ground when

Checking Fluid Levels

p0515-008

C

D

B

A��

p0515-009a

A

E


Maintenance

Hydraulic System

Hydraulic Oil - Replacing• Before draining the hydraulic oil, ensure the oil is warm not

hot.

• Loosen the hydraulic tank drain plug (A) at the bottom of thehydraulic tank.

• Place a suitable receptacle, of sufficient capacity, under thehydraulic oil tank drain plug (A) to catch the oil.

• Remove the drain plug (A).• When the oil has finished draining, clean the drain plug (A)

and replace the sealing washer (B). Refit the drain plug (A)and tighten.

• Refill the hydraulic tank with the correct grade and quantityof hydraulic oil. See ‘Lubrication’ and ‘Hydraulic Oil -Adding’ sections.

Return Filter Renewal • Unscrew the cap (A) from top of return filter body (E). Take

care not to lose spring (B).• Pull the return filter (D) and casing (E) out from the filter

body (G).• Clean casing (E) and inside of the filter body (G).• Renew rubber sealing ring (F) and replace casing (E) into

filter body (G).• Insert a new filter (D).• Renew the rubber sealing ring (C) and lubricate with clean

hydraulic oil.• Position the cap (A) and spring (B) in filter housing (G) and

fully tighten cap (A).• Check oil level and test for leaks before returning the

machine to work.

bPosition Machine on Firm Level Ground

B

A

��

B

C

D

E

F

G

A

��

��


Maintenance

Fuel System

Diesel Fuel Level

• Check the diesel fuel level reaches the indicated maximumlevel on the tank mounted level gauge (A). The gaugemarkings indicate when the tank is Empty, half full or Full.

• To refill, remove the large filler cap (B) and pour therecommended grade of fuel through the fuel strainer insidethe filler neck. NEVER overfill the fuel tank.

• When refuelling never leave the engine running • Ensure the engine is cool, the machine is in a well ventilated

area and always use clean fuel from a clean container.

Fuel/Water Separator

To drain the separator (A)• Remove the bleed screw (B) and discard the washer.• Place a receptacle of suitable capacity under the tap (C) of

the separator, open the tap and allow contaminated fuel todrain.

• Close the tap (C) and re-fit the bleed screw (B) using a newwasher.

bWhen Refuelling Stop the Engine and Beware of Naked

Flames, Grinding Sparks etc.

0803-9-005

AB

0803-9-006

A

C

B


Maintenance

b Brakes

Brake Arrangement

The machines use axles with oil immersed totally enclosedmulti-plate brakes. The dumpers have braking on both front andrear axles, see Specifications section.

The brake system is charged with mineral oil, NOT BRAKEFLUID, via a fluid reservoir (B) which is remote from the brakemaster cylinder. For correct mineral oil refer to LubricationSchedule on page 9-28.

Brake Maintenance

Normally adjustment of the brakes is unnecessary due to theautomatic compensation which is built into the brake design,but bleeding of the system may be necessary on occasions ifpipe work is damaged causing system leakage.

Brake Fluid - Checking Level

The master cylinder reservoir is located under the seat support,to the rear of the accelerator pedal. • To access reservoir (B) remove cover plate (C) by removing

bolt (D) and lifting the cover plate away from seat support.• Thoroughly clean the area around reservoir filler cap (A). • If the fluid is not level with the base of the filler neck,

unscrew reservoir cap (A) and fill as necessary.

• Replace the filler cap (A) and the cover plate (C).

bUnder NO circumstances allow conventional BRAKEFLUID to be added to the system and NEVER purge thesystem and refill with brake fluid, otherwise damage willoccur to all rubber sealing components in the brakesystem. Refer to Lubrication Section.

bBrakes on the machines provide means of effectivebraking with minimum maintenance. But it is vital duringmachine maintenance that the general condition ofsystem. i.e. pipe work, pedal operation, fluid level andgeneral oil t ightness is checked and deficienciescorrected immediately.

Failure to do so Could Result in Brake Failure

bOnly use MINERAL OIL

��

A

B

��

D

C


Maintenance

b Brakes

Parking Brake

The parking brake is mounted on the output end of gearbox.

Wear can occur either by stretching of the brake cable, or wearon the disc pads themselves, causing a reduction in efficiency.

Parking Brake Lever

To adjust the cable:-• Release the parking brake (lever horizontal). Remove plastic

handgrip and slacken locking grub screw( B).• Turn handle nut (C) to bring the pin (D) central in the slot.

Retighten grub screw and replace plastic grip.Parking Brake

Brake Caliper

To adjust the brake caliper:-• Slacken the locknuts (E) on the brake cable (F). Tighten the

lower nut until the linings contact the brake disc (G) andprevent the disc from turning easily.

• Slacken the nut (E) off until the brake disc (G) turns freelywithout any friction on the brake disc. Tighten the locknuts(E) and check the brake disc (G) still turns freely.

Any further adjustment should be done at the parking brakelever.

Parking Brake Test

When adjusted correctly the parking brake should hold thevehicle at full engine revs in 4th gear. Test as follows:-• Ensure all personnel are clear of the area and the area is free

of obstructions.• Apply parking brake.• Select Forward and 4th Gear.• Increase engine speed gradually up to maximum R.P.M

If vehicle moves abort test immediately re-check adjustment.

bBefore adjusting the parking brake make sure that themachine is on level ground. Chock all four wheels toprevent machine moving. Set battery isolator to OFF.

bThe Parking Brake Lever (A) fitted, is of the over centretype, and if incorrectly adjusted can place excessive loadon the brake cable

C

D

B

A

0801-9-044

bEnsure All Personnel are Clear of the Area Before

Performing Brake Test

A

E

F G

pic-012


Maintenance

Front and Rear Axles

Axle Description

Totally enclosed sealed multi-plate brake axles are fitted, whichhave automatic compensation for wear of the friction discs.

Normal servicing is limited to lubrication as detailed in theschedule in the Maintenance section, details of procedures formajor repairs may be obtained from the manufacturer.

Over a period of time wear may necessitate replacement of thefriction discs and/or the slave cylinder seals.

These parts should be replaced as required and the system bled.

Axle Oil - Checking Level• Position the machine on level ground.• Clean dirt from around the plugs.• Remove the oil level plug (B).• The oil level should be level with the bottom of the oil level

plug hole.• Add the specified oil, as required, through the filler plug (A)

until the oil begins to run out of oil level plug hole. SeeLubrication Points and Lubricants section for correct oil.

• Refit and tighten the filler plug (A) and level plug (B).

Axle Oil - Changing• Ensure axle oil is warm - Not Hot, to facilitate draining.

Position the machine on level ground.• Clean dirt from around drain plugs.• Place a suitable container of adequate size under the drain

plug (C).• Remove the filler plug (A) level plug (B) and remove the

drain plug (C). Allow the oil to drain.• Refit and tighten the drain plug (A).• Refill the axle through the filler hole (A) until the oil in axle

is level with the bottom of the level plug hole (B). SeeLubrication Points and Lubricants section for correct oil.

• Refit and tighten the filler plug (A) and level plug (B).

bAlways Position Machine on Firm, Level Ground when



Legally

C

B

A

0803-9-008


Maintenance

Hubs

The hubs on the axles have separate oil cavities and the oil andlevels should be checked at the recommended intervals.

To Check The Level• Position the machine on level ground with the words “OIL

LEVEL” (A) the correct way up and the line (B) horizontal.• Clean dirt from around the plug (C).• Remove the oil level plug.• The oil level should be level with the bottom of the oil level

plug hole.• Add the specified oil, as required, through the plug hole

until the oil begins to run out of the plug hole. SeeLubrication Points and Lubricants section for correct oil.

• Refit the plug and tighten.

A

BC

Hub Level


Maintenance

Gearbox and Transfer Box

General

NO adjustments are necessary to any of these units, all that isrequired is adherence to the lubrication schedule on page 9-28.

Oil Changes

An initial oil change and flush is recommended after thetransmission is placed in actual service. This change should bemade at any time following 50 hours in service, but should notexceed 100 hours. An oil change and flush should be scheduledfor every subsequent 500 hours of operation. When changingthe oil it is essential to renew the oil filter and clean out thesuction strainer. The object in draining the oil is to eliminatepossible bearing surface abrasion and attendant wear. Minuteparticles of metal, the result of normal wear in service aredeposited in and circulated with the oil. Oil changes are bestcarried out when the transmission is thoroughly warm - NOTHOT!

Transfer Box• Position the machine on firm, level ground.• Clean dirt from around filler plug (A).• Fill the transfer box through the filler/level hole (A), with the

correct grade of oil, until the oil begins to flow from thelevel/filler hole (A).

• Replace the plug (A) and tighten.

Refer to Lubrication Schedule for correct grade of oil.

NOTICEAlways Position Machine on Firm, Level Ground when


A

0803-9-010


Maintenance

Gearbox and Transfer Box

Power Shuttle Gearbox

To ensure proper lubrication and operating temperatures it ismost important that appropriate lubricants are used and that thecorrect oil level is maintained. Refer to Lubrication Schedulefor correct oil.

The only routine maintenance required is weekly checking ofgearbox oil level using the dipstick (A) accessed through theright hand engine cover, and changing oil and filter at thespecified intervals, as detailed in the Lubrication Schedule.

Do not overfill the transmission as this may result in oilbreakdown due to excessive heat and aeration from thechurning action of the gears.

Early breakdown of the oil will result in heavy sludge depositsthat block oil ports and build up on splines and bearings. Overfilling may also cause oil leaks.

Checking Oil Level

Drive the machine for approximately one minute. Stop theengine and check the gearbox oil level within one minute ofstopping the engine.

Changing Oil

When draining gearbox oil the oil should be warm but not hot!Ensure container used to drain the oil into is of sufficientcapacity to hold the oil.

Drain oil by removing the strainer (B). Clean strainer (B) usinga suitable solvent.

When refitting strainer (B), renew gasket (C) and apply Loctite242 to bolts (D).

Before fitting a new filter (E), smear seal (F) with transmissionoil. Screw the new filter onto the gearbox and tighten usinghands only.

0803-9-007

A

A

C

BD

F

E

0515-072a

��

E


Maintenance

b Wheels and Tyres

Check the tyres regularly for damage by cuts and embeddedparticles, i.e. nails, steel, glass etc. and check / adjust thepressures weekly using valve (A).

See Specifications section for tyre pressures.

bWheel Nut Torques Must be Checked Regular ly.See the Serv ice Schedule and the Techn ica lSpecIfications Sections for Details

A

0803-9-009


Maintenance

Centre Pivot

General

Ensure Articulation Lock (F) is fitted when working in the areaof the Centre Pivot.

Pivot Pin Locking Screws

To prevent centre pivot pin from turning it is important to keepthe Locking Screws (A) correctly tightened.

Protective Caps

Two protective caps (B) are fitted over the pivot bearinghousing’s and these should be replaced in the event of damageto avoid ingress of dirt and moisture to the bearings.

Seals (C) should be replaced in the event of damage.

Lubrication

Lubrication of the three centre pivot bearings (D) and the pin(E) in the assembly is important and should be carried out every50 hours in accordance with the Service and lubricationschedules.

NOTICEKeep Centre Pivot Lock Screws (A) Tight

0515-032b

F

��

A

A

C

C

B

B

NOTICEEnsure Centre Pivot Bearings are Lubricated Weekly

bEnsure Articulation Lock is in Position when Working in

Crush Zone

E

0515-067b

��

D

D

D


Maintenance

ROPS

Introduction

There are in-service factors which tend to degrade a ROPS/FOPS systems energy absorbing or load carrying capability.

A few of these factors are:• Structural damage from vibrations and/or loadings during

some operations.• A corrosive environment.• Continued use of the machine after rollover or accident

involving structural damage.• Unauthorized modification.• Worn or deteriorated isolation mounts.• Bolt replacement with less than the correct grade or neglect

in maintaining proper bolt torque.• Improper installation.

Any of these factors may cause a dangerous condition to existas well as exposing all concerned parties to liability damages.The following guidelines will be helpful if followed.

Attachments and/or Modifications

Generally ROPS/FOPS structures are not intended as externalload carrying members and must not be used to mountattachments such as pull hooks, winches, side booms, etc.without the manufacturers approval.

Non external load transmitting attachments such as mirrors,fans, heaters, lights, etc. should be installed following themanufactures guidelines. Typically these attachments arelocated in non critical areas such as roof sheets, enclosure sheetmetal, or the middle portion of the ROPS legs.

Modifications to basic design such as increasing canopy height,or relocating ROPS legs is not permitted.

Maintenance

Inspection - A scheduled, frequent visual check of mountinghardware by operation or service personnel is recommended.As most ROPS are different and function in different serviceenvironments, no specific inspection interval can berecommended. Inspection in conjunction with regular serviceintervals is suggested. The inspection should check for:

Worn, damaged or missing resilient mounts. Excessive motionor rattling during operation are indications of a problem. Themounts should be disassembled and repaired if required.

Missing or damaged mounting hardware (bolts, nuts, washers,etc.) should be replaced. Bolts should be checked for correcttorque settings.

Cracks in ROPS/FOPS structure and mounting system. Themachine should be cleaned and disassembled as necessary toallow inspection for cracks in the structure and mountingsystem. Cracks are usually associated with weld details andusually show as a line of rust before it will be clear as a crack.Rust lines should be taken as indications of cracks and verifiedby inspection following the manufacturers procedures. Onlysome cracks will badly affect the ROPS/FOPS function. Cracksin enclosure sheet metal generally are not structurallyimportant. The manufacturer can identify the appropriatemeasures. If in doubt, consult the manufacturer.

Water drainage paths. The check should verify clear waterdrainage paths so that entrapped water will not freeze and crackor deform the structure.

Corrosion. Extensive paint peeling and rusting should be notedand corrective action taken.

Other Inspection. The structure must be inspected following arollover, collision or fire.

Repair

Replace al l missing or damaged hardware with themanufactures specified hardware. Re-torque all threadedfasteners to the manufacturers specifications.

Replace worn or damaged resilient mounts to prevent furtherdamage and vibration problems.

Determine the repair ability of cracks in ROPS/FOPS structureson the basis of the crack details and effect on the particulardesign. The manufacturer must be consulted at this step. Somegeneral guidelines which may be helpful are:

Enclosure sheet metal cracks are repairable.

Small cracks may be repairable. Consult the manufacturer.

If damaged by a rollover, collision or fire consult themanufacturer.

In all cases, when doubt exists, consult manufacturer.


Maintenance

b Seat Belts

Important Facts about Seat Belts

The potential exposure of this seat belt to severe environmentalconditions make it crucial to inspect the seat belt systemregularly.

It is recommended that the seat belt system is inspected at leastonce a year or more often if the vehicle is exposed to severeenvironmental or vocational conditions,

Any seat belt system that shows cuts, fraying, extreme orunusual wear, significant discoloration due to UV exposure,dusty-dirty conditions, abrasion to the seat belt webbing, ordamage to the buckle, latch plate, retractor, hardware or anyother obvious problem should be replaced immediately.

Once replacement of the seat belt has been determined, becertain that it is only replaced with the original equipmentmanufacturer recommended replacement seat belt. See yourauthorized spares and service centre for replacement. Yourrestraint system has been developed and tested specifically foryour machine.

If the inspection indicates that any part of the seat belt requiresreplacement, the entire belt must be replaced. It is vitallyimportant that all components be mounted back in the sameposition as the original components which were removed. Thiswill maintain the design integrity of the mounting points for theseat belt assembly.

Seat Belt Maintenance Guidelines

Follow Maintenance Guidelines 1-4 to properly inspect seat beltand tethers to determine if replacement is necessary.

The following maintenance guidelines detail how to Inspectseat belt for “cuts, fraying, extreme or unusual wear of thewebbing, etc., and damage to the buckle, retractor, hardware orother factors” which indicate that seat belt replacement isnecessary,• Check the webbing. Pull the webbing completely out of the

belt retractor and inspect the full length of the webbing forcuts, wear, fraying, dirt and stiffness. If a belt shows anycuts, fraying, extreme or unusual wear, the system should bereplaced.

• Check the buckle and latch for proper operation and todetermine if latch plate is excessively worn, deformed orbuckle is damaged or casing broken.

• Check retractor web storage device operation by extendingwebbing to determine it locks properly and that it spools outand retracts webbing properly - fitted.

Check web in areas exposed to ultraviolet rays from the sun orextreme dust or dirt. If the original colour of the web in theseareas is extremely faded and/or the web is packed with dirt, thephysical strength of this web may have deteriorated. If thiscondition exists replace the system.

bFailure to properly inspect and maintain a seat belt cancause serious injury or loss of life in the event of anaccident.

It is critical that any time the machine is involved in anaccident, the entire seat belt system must be replaced.

The seat belt should be considered to have a finite lifeand must be replaced as required throughout the life ofthe machine.

The seat belt must be inspected daily for requiredmaintenance.

If replacement of any part of the seat belt is indicatedthrough maintenance guidelines below, the entire beltmust be replaced, both retractor and buckle sides.

Web cut or frayed or extremely worn

Buckle casing broken

��


Maintenance

Service Schedule

The following service schedules are for guidance only. Under extreme operating conditions the service schedules should be adjusted accordingly to allow for the local working environment. Before carrying out any service or maintenance work ensure ALL safety precautions have been taken. Always follow the instructions given in the engine manufacturers handbook when servicing, adjusting and especially when starting and stopping the engine.

ALL Faults MUST be Reported Immediately and Corrected BEFORE the Machine is Used

10 Hours

Check tyre condition and pressures.Check ROPS for damage etc. Report ALL faults immediately. Check seat belt. Check the air cleaner blockage indicator. Remove air filter and clean in dusty environments.Check fuel tank level - NEVER allow the fuel tank to empty. Fill at the end of each shift. Check engine oil level and top up as necessary. Check hydraulic oil level.Check all warning lights and gauges are working correctly. Check alternator belt. Check engine coolant level - expansion tank. Check brake fluid reservoir level. Check operator platform and steps are clean and free from damage and obstructions. Check start inhibitors are functioning correctly. Check skip prop is working satisfactorily. Visually check machine for fluid leaks, damage, missing parts, unreadable safety signs etc.

50 Hours

As for 10 hours and including:-Drain fuel filter sediment bowl.Check coolant level in radiator - ensure engine is cold.Lubricate the centre pivot. Lubricate all other grease nipples - see lubrication chart. Check transfer box oil level.Oil all control pivots, e.g. throttle, tipping, ram links. Check handbrake adjustment. Check wheel nut torque. Check, clean and grease battery connections.Check for air leaks on the air inlet/filter system. Repair as necessary.

250 Hours

As for 50 hours and including:-Drain engine and refill with fresh, clean oil. Replace engine oil filter.Check front and rear axle and hub oil levels - top up as necessary.Check tightness of centre pivot lock screws. Check hose lines for chaffing, adjust as necessary. Check steering lock bar is fitted and works.

500 Hours

As for 250 hours and including:-Replace fuel filter element. Drain and clean fuel tank. Drain gearbox oil and refill with fresh, clean oil.Replace gearbox filter element.Change hydraulic filter(s). Drain hydraulic tank and clean hydraulic suction strainer. Renew return line filter. Refill hydraulic system with clean, fresh oil. Drain and replace brake fluid.Drain front and rear axles and hubs and refill with clean, fresh oil. Check engine coolant antifreeze / water ratio - especially in sub zero conditions.

1000 Hours

As for 500 hours and including:-Drain and replace engine coolant. Check axle location bolts. Check centre pivot pin nut torque setting.

Only Perform the Applicable Service Checks AboveThoroughly Clean the Machine BEFORE Performing ANY Service or Maintenance Tasks


Maintenance

Lubrication Schedule

Item Key International Specification Service HoursCheck Change

A Skip Pivot Pins

Multi Purpose Grease EP2 Lithium Grease - Gr Li, NL GI 2 50 -B Skip Ram Pins

C Steering Ram Pins

D Gearbox Shell Donax TF - 250 500

E Rear Axle & Hubs Shell Donax TD - 50 500

F Hydraulic Tank Shell Tellus T46 High VI Hydraulic Oil - HV ISO VG46 - -

G Radiator Shell Glycoshell / Water MixtureRefer to Antifreeze Table Extended Life Antifreeze 10 Autumn

H Engine Sump Shell Rimula R3 X 15W/40 API:CH-4, CG-4, CF-4, CF ACEA:ES, E3 SAE15/W40 10 250

J Fuel Tank Diesel DERV to EN590 10 500

K Brake Reservoir Shell Tellus T46 High VI Hydraulic Oil - HV ISO VG46 10 500

L PedalsMulti Purpose Grease EP2 Lithium Grease - - Gr Li, NL GI 2 50 -

M Handbrake

N Propshaft - (6 off) Multi Purpose Grease EP2 Lithium Grease - - Gr Li, NL GI 2 50 -

P Transfer Box Shell Spirax A 80W/90 - 250 500

R Centre Pivot Starplex All Purpose Grease EP2 Lithium Complex Grease - Gr Lic, NLGI 2 50 -

S Front Axle and Hubs Shell Donax TD - 50 500


Maintenance

Lubrication Points

A

R

N

M

S

P

K

J

H

L

G

C

D

B

E

F


Maintenance

Long Term Storage

If the machine is to be stored for a long period of time thefollowing procedures must be applied:-• Thoroughly wash down the exterior of the machine and

remove any build up of dirt etc.• Repair all damaged paint work to prevent further corrosion.• Grease all greasing points.• Start and warm up the engine. Drain the engine oil and refill

with clean fresh oil. Refer to engine manufacturershandbook for further information on prolonged enginestorage with regards to anti-corrosion oils and fluids.

• Check hydraulic oil level and top up as required.• Drain, and refill cooling system with water/antifreeze

mixture (see Specifications section).• Store the machine on solid level ground which is not liable

to flooding, standing water or airborne contamination.• Chock the wheels securely to prevent the dumper moving.• Smear exposed metal parts with grease.• Remove the battery and keep fully charged.• Leave the parking brake in the OFF position.

Scrapping the Machine

The appropriate lifting equipment, chocks and stands must beused to maintain a stable machine as components are removedand the machines centre of mass changes.

Care must be taken when dealing with flammable liquids andthe machine parts that contained those liquids. Any process thatcould ignite flammable materials must not be used oncomponents that have contained flammable liquids in them orhave residual flammable liquids on them.

Fire extinguishers must be readily available if cutting/weldingequipment is to be used.

Fluids must be drained off into suitable containers and ifposs ib l e r ecyc led o r o the rwise d i sposed of in anenvironmentally friendly way in accordance with localregulations.

Where possible recyclable materials should be separated outand processed in accordance with local regulations using anauthorised agent.


Legally

bAt the end o f i ts l i f e the mach ine shou ld bedisassembled by a competent person using safeworking practices, wearing the appropriate PersonalProtective Equipment and working in accordance withlocal regulations.


Maintenance

Antifreeze

The following table gives the freezing and boiling temperaturesfor the recommended antifreeze/water of 50%.

If the machine is to be used in temperatures outside this range,consult the engine manufacturers or their handbook.

It is advisable to change the antifreeze/water mixture annually,before winter. if it is not changed, the concentration must bechecked and additional antifreeze added as necessary tomaintain the correct concentration.

Antifreeze (Ethylene Glycol)

Concentration Freeze Protection Boil Protection

50% -36ºC (-33ºF) 106ºC (223ºF)


Maintenance


10 - SpecificationsTA9 and TA10Four Wheel Drive Dumper

Specifications

DimensionsDimensions and Specification

Dimensions = mm (ins) A B C D E F G H

ROPs Beacon

Iacross tyres

Jacross

skip

Weight (wet)

kg (lbs)

TA9 2,670(105.1)

1,722(67.8)

420(16.5)

2,450(96.5)

4,330(170.5)

338(13.3)

2,532(99.7)

3,282(129.2)

3,537(139.3)

2,380(93.7)

2,500(98.4)

4,875(10747)

TA10 2,695(106.1)

1,760 (69.3)

440(17.3)

2,450 (96.5)

4,450 (174)

338 (13.3)

2,630 (103.5)

3.375 (132.9)

3,630(142.9)

2,380(93.7)

2,550(100.4)

4,920(10847)

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p0515-002

10-1 TA9 & TA10 Dumper 0803-4 July 2011

Specifications

Data - Engine, Alternator and Battery

Data - Dumper Speeds and Brakes

Data - Fluid Capacities - litres (pints)

Data - Load Capacities

Data - Wheels and Tyres

Model Engine kW (hp) @ rpm Alternator Output Amps

Battery Cold Start Amps

TA9Perkins 1104D-44T 74.5(99) @ 2200 Belt Driven 65 900CCA 90 AH

TA10

Gearbox TransferBox

1st Gear 2nd Gear 3rd Gear 4th Gear Reverse FrontBrakes

RearBrakes

ITL PowerShuttle TG300 5.6 kph(3.5 mph)

8.9 kph(5.5 mph)

16.4 kph(10.1 mph)

28.8 kph(17.9 mph)

as forward Yes Yes

EngineSump

Gearbox TransferBox

Axles (including Hubs)Front Rear

Fuel Tank Hydraulic Tank

BrakeReservoir

Coolant

10.00 (21.1) 13.00 (27.5) 0.45 (0.95) 9.7 (20.5) 9.7 (20.5) 67.00 (141.6) 50.00 (105.7) 1.20 (2.5) 20 (42.3)

Model Payload - kg Payload - lbs Water Level - litres (yd.3) Struck Level - litres (yd.3) Heaped - litres (yd.3)

TA9 9000 19,800 2,070 (2.7) 3,965 (5.1) 4,615 (6.0)

TA10 10,000 22,000 2,450 (3.2) 4,140 (5.42) 5,053 (6.61)

Model Tyre Specification/CapacityTyre Pressures

Wheel Nut TorqueFront Rear

TA9500/60 x 22.5 3.8 bar (55 psi) 2.2 bar (32 psi) 630 Nm

TA10

TA9 & TA10 Dumper 0803-4 July 2011 10-2

Specifications

Data - Antifreeze / Water Ratio Properties

Noise Emissions

Vibrations:

Note: these values are for guidance only. Actual work site, operation and operator characteristics will have a large influence on actualvalues for specific circumstances.

Ratio ºC ºF 16ºC (60ºF) 27ºC (81ºF) 38ºC (100ºF)

20% 1 : 5 -9 15.8 S.G. 1.032 S.G. 1.030 S.G. 1.028

25% 1 : 4 -12 10.4 S.G. 1.041 S.G. 1.037 S.G. 1.033

33.3% 1 : 3 -19 -2.2 S.G. 1.054 S.G. 1.049 S.G. 1.044

50% 1 : 2 -37 -34.6 S.G. 1.080 S.G. 1.074 S.G. 1.068

Use good quality Ethylene Glycol - Check concentration regularly

Model

Declared Single-Number Noise EmissionValues to ISO 4871

A- rated sound pressure level at operator station A - rated sound power of machine

LpAd LWAd

TA9 86.0 dB 102 dB

TA10 86.0 dB 102 dB

Operation Value Uncertainty

Hand Arm Vibration asdefined in EN474-1 All Operations <2.5 m/s2 N/A

Whole body vibrationvalues as defined in

ISO/TR 25398Work Cycle 0.529 rms 0.264 m/s2

10-3 TA9 & TA10 Dumper 0803-4 July 2011

Specifications

Electric Circuit

10000 - Electric Circuit, Key and Colour Codes

Item Description Cable Colour Codes

1 Warning Light - Transmission oil temperature B Black

2 Warning Light - Transmission oil pressure G Green

3 Switch - Transmission oil temperature K Pink

4 Switch - Transmission oil pressure LG Light Green

5 Audible warning N Brown

6 Switch - Parking brake O Orange

7 Warning Light - Engine coolant temperature P Purple

8 Warning Light - Parking brake ‘ON’ R Red

9 Switch - Engine coolant S Slate

10 Solenoid - Cold start U Blue

11 Switch - Cold start T Turquoise

12 Hourmeter W White

13 Warning Light - Battery charge Y Yellow

14 Warning Light - Engine oil pressure

15 Switch - Engine oil pressure

16 Solenoid - Engine fuel

17 Engine glow plug

18 Alternator

19 Starter

20 Solenoid - Starter

21 Switch - Engine key start

22 Circuit breakers

23 Battery - 12v

24 Battery isolator

8005-0833A

TA9 & TA10 Dumper 0803-4 July 2011 10-4

Specifications

Electric Circuit

B

P P

BW

32

W32

17

3

NR

32

3015/5

4

21

0

19

W32

GY

32

BY

32

N32

N32

YN

32

B32

8730R

2 83

Y32

GY

32

W32

N84

WN

32

NY

32

W32

W28

NU

28N

U28

W28

BY

32

GY

32

GU

32

WR

44

NW

44

W28

N84

W32 1 2

16 21 R6

N84

R84

YP

32

YP

32

YG

32

B32

R28

50a

NR

32W

28

NW

44W

R44

RR

B+

D+

W

87a

30

R4 86

RR

RR

31

B65

36 8586 R1

R1

30 87

15A

30A

20

5250

4846

4442

4038

3634

3230

2826

2422

2018

1614

1210

86

4

8005

-083

3A

GU

32

NY

32

20R6

4 3

1

2 3

4

56

7

8

9

10

11 12

13

14

1516

17

18

19

20

2122

24

23

10-5 TA9 & TA10 Dumper 0803-4 July 2011

Specifications

Electric Circuit


1 Switch - Site Light (A=OFF - B=ON) B Black

2 Front - Site lights G Green

3 Rear - Site lights K Pink

4 Button - Horn LG Light Green

5 Horn N Brown

6 Button - Transmission dump O Orange

7 Switch - Seat Interlock P Purple

8 Switch - Direction (A=Forward - B=Neutral - C=Reverse) R Red

9 Reverse alarm S Slate

10 Solenoid - Reverse drive U Blue

11 Solenoid - Forward drive T Turquoise

12 Accessory socket W White

13 Beacon Y Yellow

14 Switch - Beacon

15 Fuse - Inline 10amp



18 Fuel Pump

8005-0833B

TA9 & TA10 Dumper 0803-4 July 2011 10-6

Specifications

Electric Circuit

BB

N32

W32

NU

28

B32

B32

RR

WW

RU

32

WP

32

8586 56R7

60R7

30 87 B32

4

4 3

32

21

1

PR

32

W32

P32

WO

32

WB

32

WP

32

PG

32P

W32

8586 42R4

R3

88

30 87a

R3

7086 85

NU

28

W32

8005

-083

3B

5860

6264

6668

7072

7476

7880

8284

8688

9092

9496

9810

010

210

410

654

56

8586 18R2

PB

32

W32

NU

28N

U32

U32

U32

U32

U32

U32

U32

PG

32

N32

N32

W32

W32

W32

A B

A B C

1

2

3

45

6

7

89

10

11

1215 13

1416

17

18

10-7 TA9 & TA10 Dumper 0803-4 July 2011

Specifications

Electric Circuit


1 Switch - Hazard lights B Black

2 Switch - Direction Indicator (A = Left B = OFF C = Right) G Green

3 Rear indicator lights K Pink

4 Front indicator lights LG Light Green

5 Front head lights N Brown

6 Brake lights O Orange

7 Number plate lights P Purple

8 Rear marker lights R Red

9 Front marker lights S Slate

10 Switch - Vehicle lights (A = OFF B = Marker Lights C = Head Lights) U Blue

11 Switch - Brake pressure (brake lights) T Turquoise

12 Flasher unit W White

13 Warning Light - Direction indicator Y Yellow

8005-0833C

TA9 & TA10 Dumper 0803-4 July 2011 10-8

Specifications

Electric Circuit

W32

W32

BB

GP

32G

P32

GP

32G

P32

GP

32G

P32

GP

32G

P32

R5

R5

138

138

8686 8585

NU

28N

U28

W32

W32

R5

R5

129

129

30308787

B32

B32

R32

R32

R32

R32

R32

R32

R32

R32

R32

R32

R32

R32

UR

32U

R32

UR

28U

R28

UR

28U

R28

NU

28N

U28

GN

32G

N32

GR

32G

R32

GW

32G

W32

YYR

R32

R32

RRRR

WW

W WW

RR

A AAA

AAAA

WW

49a

49a

C00

11

313130

b30

b4949 1515

3030LL

RR49

a49

a5858

UN

32U

N32

GN

32G

N32

R32

R32

GR

32G

R32

GW

32G

W32

W32 N

U28

NU

28

B32

B32

B32

B32

GP

32G

P32

110

110

108

108

160

160

158

158

156

156

154

154

152

152

150

150

148

148

146

146

144

144

142

142

140

140

138

138

136

136

134

134

132

132

130

130

128

128

126

126

124

124

122

122

120

120

118

118

116

116

114

114

112

112

8005

-083

3C

UR

32U

R32

UR

28U

R28

3149 49

6

7

8

9

13

10

11

12

1

A B C2

3

4

5

A B C

10-9 TA9 & TA10 Dumper 0803-4 July 2011

Specifications

Hydraulic Circuit

1 Engine

2 Gearbox

3 hydraulic Pump 26.6 cc/rev

4 Transmission Oil Cooler

5 Services Oil Cooler

6 Relief Valve 200 bar (2900psi)

7 Control Valve Skip Raise/Lower

8 Rams - Skip

9 Steering Unit

10 Ram - Steering Unit

11 Filter

12 Hydraulic Oil Reservoir

TA9 & TA10 Dumper 0803-4 July 2011 10-10

Specifications

Hydraulic Circuit

�

� �

LR

T P

�

�

�

� �

� �

� �

� �

� �

AB

C

T

P

1

2

3

4

5

6

7

8

9

10

11

12

10-11 TA9 & TA10 Dumper 0803-4 July 2011

Specifications

TA9 & TA10 Dumper 0803-4 July 2011 10-12