Winget 4B2000 Operator's Handbook Manual
DUMPER
4B2000
OPERATORS HANDBOOK
Manual MANS524 March 2013
WINGET LIMITED, P.O. Box 41, Edgefold Industrial Estate, Plodder Lane, Bolton, BL4 0LR, England
Tel: +44 (0) 1204 854650 Fax: +44 (0) 1204 854663
E mail: parts@winget.co.uk, service@winget.co.uk
www.winget.co.uk
INTRODUCTION I
Dumper
4B2000
The contents of this Handbook, although correct at the time of publication, may be
subject to alteration by the Manufacturers without notice.
Winget Limited operate a policy of continuous product development. Therefore, some
illustrations or text within this publication may differ from your machine.
II INTRODUCTION
CONTENTS
Section Page
INTRODUCTION
Contents II
Introduction to the Handbook III
Machine identification III
Warranty Terms & Conditions IV
SAFE WORKING
Machine modification 1.1
Training 1.1
Running-in 1.1
Driving 1.1
Skips and loading 1.3
Towing 1.3
Gradients 1.3
Hydraulics 1.4
Servicing 1.4
Decal identification 1.6
OPERATION
Controls layout 2.1
Running-in a new engine 2.3
Pre-start checks 2.3
Driving the dumper 2.3
Starting and stopping the engine 2.4
Gradients 2.10
Braking 2.10
Engage gear lever 2.10
Stopping the dumper 2.10
Leaving the dumper 2.10
Skip operation 2.11
Towing 2.12
Section Page
SERVICE
Safe working 3.1
Service schedule chart 3.2
Engine 3.4
Fuel System 3.6
Air Cleaner 3.9
Gearbox 3.10
Transfer box 3.11
Propeller shafts 3.12
Battery 3.13
Hydraulic system 3.14
Greasing 3.19
Braking systems 3.20
Wheels & Tyres 3.22
Axles 3.23
TECHNICAL INFORMATION
Dimensions 4.1
Specifications 4.2
General dumper
Lubricants & fluids
Adjustments
Pressures
Tyres
Load capacities
Machine weight
Vibration declaration
Electrical circuit, without road lights 4.5
Electrical circuit, road lights 4.6
PARTS SECTION
INTRODUCTION III
THE HANDBOOK
WARNING The Operator must read all the Handbook and fully understand its contents
before attempting to operate the machine.
THE HANDBOOK MUST NOT BE REMOVED FROM THE MACHINE.
The Handbook should be kept clean and in good condition. Additional copies of the
Handbook can be obtained from your Distributor.
The contents of this Operators Handbook are designed as a guide to the machine’s
controls, operation, working capacities and maintenance. It is not a training manual.
Only trained operators should use this machine. Consult your Distributor for details of
authorised training courses.
In this Handbook are WARNING notes. They are preceded by this symbol:
WARNING These notes are used to indicate that the procedure being described in the
Handbook must be followed to avoid serious injury or death to yourself or
others; or damage to the machine.
The warnings are also used to protect the machine from unsafe servicing
practices.
Pay particular attention to the warnings given in the Handbook.
If you have any doubts about any aspect of the machine’s capability or servicing
procedures, you must consult the manufacturer.
MACHINE IDENTIFICATION
Please record the model and serial numbers of your machine in the spaces provided and
quote them when ordering parts.
Model - Year
Dumper serial no.
Front axle
Rear axle
Key, start
Engine
Gearbox
Transfer box
Ram steering
Ram, tipping, L.H.
Ram, tipping, R.H.
Tyre manufacturer & size
IV INTRODUCTION
WARRANTY TERMS & CONDITIONS
The Manufacturer assures you that if any part of the machine becomes defective due to
faulty manufacture or materials within 12 months from the date of purchase, the part will
be repaired or replaced under warranty free of charge by any authorised Winget
Distributor. Warranty repairs must be carried out by Winget Distributors.
This Warranty is given to the first owner and may be transferred to subsequent owners
for the balance of the Warranty period.
The Manufacturer’s liability only extends to the costs of repair or replacement of the
faulty parts and necessary labour charges involved in the repairs. The Company
accepts no liability for any consequential loss, damage or injury, resulting directly or
indirectly from any defect in the goods.
Items not covered by Warranty and considered to be the customer’s responsibility
include normal maintenance services; replacement of service items and consumables;
replacement required due to abuse, accident, misuse or improper operaton; replacement
of wearable items e.g. pins, bushes, brake linings, clutch linings etc.
The Warranty will not apply where the equipment is modified, converted, or used for
purposes other than those for which it was designed, unless clearance for the
modifications etc. have been granted by the Manufacturer, in writing.
The Pre-Delivery Inspection and Warranty Registration Document must be completed
correctly and returned to the Manufacturer within 7 days of sale date. Failure to do so
may result in the claim being subsequently rejected.
Tyres and tubes are not covered by Warranty, but are covered by the tyre
manufacturer’s own warranty system which provides against defects in material or
workmanship.
Engines are covered separately by the engine manufacturers, and engine warranty
repairs must be handled by the relevant engine manufacturers’ distrubutors.
No claim will be considered if other than genuine Winget Limited parts, which must be
obtained from Winget Limited via an authorised Distributor, are used to effect a repair, or
if lubricants other than those recommended by Winget Limited are used.
The equipment must be serviced in accordance with the service schedules laid down by
Winget Limited. Evidence that these have been complied with may be required before
Warranty Claims are reimbursed.
The Manufacturer’s policy is one of continuous improvement. Winget Limited reserve the
right to change specifications without notice. No responsibility will be accepted for
discrepancies which may occur between specification of machines and the descriptions
contained in publications.
SAFE WORKING 1.1
Safety is the responsibility of all persons working with this machine. Think
“safety” at all times. Read and remember the contents of this handbook.
The safe working recommendations for specific tasks are found with the
instructions for the relevant operation in this Handbook.
MACHINE MODIFICATION
WARNING Any modifications to the machine will affect its working parameters and
safety factors. Refer to the Manufacturers before fitting any non-standard
equipment or parts.
The Manufacturers accept no responsibility for any modifications made after
the machine has left the factory, unless previously agreed by the
Manufacturers in writing; the Manufacturers will accept no liability for damage
to property, personnel or the machine if failure is brought about due to such
modifications, or fitment of spurious parts.
TRAINING
WARNINGOnly trained operators should use this machine.
Operators should hold an appropriate full motor vehicle driving licence and
undergo both a safety awareness course and a driver training course for Site
dumpers run by the C.ITB or equivalent body leading to the award of a CTA.
It is strongly recommended that operators read the H.S.E. publication “Safe
Working with Small Dumpers” which is available from government
bookshops (HMSO) or from other bookshops quoting the following number
ISBN O11 8836935. Another useful publication is British Standard number
BS 6264, “Procedure for Operator Training For Earth Moving Machinery”
available from the British Standard Institution.
RUNNING-IN
WARNINGWhile a gradual ‘running-in’ of a new engine is not necessary, it is extremely
important that the instructions given in Section 1 “Operation” on “Running-in
a new engine” should be followed very closely during the first fifty hours of
operation.
DRIVING
WARNING NEVER use the machine for purposes other than those for which it was
designed. This machine was designed to carry loads such as soil, clay,
sand, wet concrete, stone or other similar materials. It was not designed to
carry loads which may move around in the skip uncontrollably, nor to carry
any loads or materials which overhang the skip in any way. If in any doubt
as to the suitability of this machine for a particular task, contact your nearest
Distributor or the Manufacturer for advice.
1.2 SAFE WORKING
ALWAYS be aware of local and national regulations governing the use of the
machine.
NEVER commence work with the machine until the “Daily (or every ten
hours)” service checks have been made. (See Service Section for details)
ALWAYS check wheel nut tightness daily.
NEVER carry passengers.
Ensure that the seat is securely fixed to the machine. Where seat belt
restraints are fitted as part of Rops/Fops protection they must be worn.
Check that the seat belt is in good condition, free from cuts and frayed
edges.
ALWAYS remain in the driving seat whenever the engine is running. Never
attempt to operate any controls unless seated.
ALWAYS apply the parking brake before leaving the driver’s seat.
NEVER dismount with the engine running, and never leave the machine
unattended with the key in the starter switch.
When Battery Isolators are fitted they must be activated only when the
engine is turned off except in cases of emergency.
Activating a Battery Isolator when the engine is running can result in damage
to the electrical components and circuits.
NEVER fill the fuel or hydraulic tanks with the engine running.
ALWAYS drive only on surfaces that are known to be stable.
ALWAYS keep the floor plates and walkways clean.
NEVER drive the machine close to the edge of any excavation. Always use
effective wheel stops to prevent the machine running close to the edge.
Make sure that the stops are in proportion to the size of the wheels and are
set sufficiently far enough back from the edge of any excavation to prevent
the weight of the load causing a collapse.
NEVER adjust the tyre pressures in an attempt to improve traction on soft
ground or obtain a softer ride on hard ground. Incorrectly adjusted tyres can
affect the steering and handling characteristics.
NEVER attempt to free a machine which is ‘bogged down’ by pushing with
the bucket of a backhoe loader, tracked excavator or other similar machine.
NEVER make unnecessary “crash stops” when travelling at speed, especially
in forward direction.
NEVER work under an unpropped skip. If the skip was supplied with a
special skip support always ensure that it is used.
SAFE WORKING 1.3
SKIPS AND LOADING
WARNINGNEVER exceed the rated payload. The weights of all loads above skip water
level must be checked.
NEVER remain on the machine when loading the skip with excavators or
loaders. Stop the engine, apply the parking brake, dismount, and stand well
clear.
ALWAYS ensure that the load is evenly distributed in the skip.
NEVER carry loads or heap materials in such a manner as to affect the
forward vision.
ALWAYS take extra care when tipping non free running loads, particularly
with Rotary Skips and High Discharge machines.
NEVER use the skip in a tipped position to bulldoze heaped materials level
or to backfill material into excavations.
NEVER leave the machine with the skip raised or rotated.
TOWING
WARNINGNEVER attempt to tow a dumper before first reading ‘Towing the dumper’
(see Contents page).
Dumpers are not designed as towing vehicles, but loads (including weight of
trailer) not exceeding the rated payload of the dumper may be towed on dry,
level ground in first gear, providing the dumper skip is loaded with half the
rated payload to ensure tyre adhesion when braking.
NEVER attempt to start the engine of a dumper by towing or pushing.
ALWAYS use a purpose made towing pin.
NEVER tow loads up, down or across gradients.
GRADIENTS
WARNINGNEVER operate on any gradients which exceed 25% (1 in 4), or across
gradients which exceed 16% (1 in 6).
ALWAYS remember that slippery or loose surface conditions can adversely
affect safe machine operation, including braking, particularly on gradients.
ALWAYS choose routes that avoid steep, slippery or loose gradients.
NEVER coast down gradients. Always negotiate gradients in first gear.
ALWAYS drive forwards up gradients when loaded.
ALWAYS reverse down gradients when loaded.
ALWAYS keep the load facing uphill.
NEVER park on a gradient. If this is unavoidable, ALWAYS chock the
wheels.
NEVER attempt to turn on a gradient
NEVER tow up, down or across a gradient.
NEVER operate high discharge or rotating skips on gradients.
1.4 SAFE WORKING
HYDRAULICS
WARNINGALWAYS “Dump” residual pressure from the system before leaving the
machine or before carrying out any maintenance or adjustments.
If maintenance work requires the skip to be in the raised position, then it
must be raised and supported before dumping the pressure.
Dump pressure by switching off the engine, then moving the hydraulic control
lever several times in each direction.
NEVER leave the machine unattended with pressure in the system.
ALWAYS purge hydraulic rams before commencing work. With the engine
running operate the hydraulic control to fully extend and retract the rams.
ALWAYS practise the greatest cleanliness in maintaining hydraulic
components.
SERVICING
WARNING ALWAYS report any defect at once, before an accident or consequential
damage can occur.
ALWAYS conform to service schedules except where:
1 Warning lights or warning indicators call for immediate attention.
2 Adverse conditions necessitate more frequent servicing.
ALWAYS wear correctly fitting protective clothing. Loose or baggy clothing
can be extremely dangerous when working on running engines or machinery.
ALWAYS, where possible, work on or close to engines or machinery only
when they are stopped. If this is not practical, remember to keep tools, test
equipment and all parts of your body well away from the moving parts.
ALWAYS “Dump” pressure from the hydraulic system before carrying out any
kind of maintenance or adjustment. (see Service - Hydraulic system).
ALWAYS avoid contact with exhaust pipes, exhaust manifolds and silencers
when the engine is running; these can be very hot.
ALWAYS work out of doors, or in a well-ventilated area.
NEVER run an engine in an enclosed space. Exhaust fumes in enclosed
areas can kill.
ALWAYS disconnect battery cables and remove battery before using an
external charger, carrying out welding repairs or to prevent unauthorised
usage when unattended or during a repair.
NEVER allow unqualified personnel to attempt to repair, remove or replace
any part of the machine, or anyone to remove large or heavy components
without adequate lifting tackle.
NEVER attempt to modify or repair Rops Frames or Fops Canopies by
welding, drilling or any other means. Attempts to do so will invalidate
Rops/Fops Certification.
SAFE WORKING 1.5
ALWAYS obtain advice before mixing oils; some are incompatible. If in doubt
drain and refill.
NEVER allow oils and fuels to come into regular contact with skin. This can
lead to serious skin diseases including, medical evidence suggests, skin
cancer. ALWAYS wear protective gloves when handling oils and fuels
whether topping up, draining or refilling. ALWAYS wash hands if oils or fuels
come into contact with the skin.
Many liquids used in this machine are harmful if taken internally or splashed
into the eyes. In the event of accidentally swallowing oils, fuels, anti-freeze,
battery acid etc, DO NOT encourage vomiting, seek qualified medical
assistance immediately.
ALWAYS dispose of waste oils and fuels into waste oil storage tanks. If
storage tanks are not available consult your distributor or local authority for
addresses of local designated disposal points. It is illegal to dispose of waste
oil into drains or water courses or to bury it.
Equipment which includes friction materials will sometimes contain asbestos.
When removing friction material dust from components, such as when
servicing brakes or clutches, do not blow out with an airline; it could be
harmful to inhale the dust. Remove the dust with a vacuum cleaner or wipe
clean with a damp rag. Waste should be placed in a sealed container,
marked, and disposed of in accordance with local or national regulations.
The accumlated dust found in clutch housings may contain lead/antimony.
No food should be eaten at a work place contaminated by this dust. Hands
must be washed before eating. Do not blow out dust with an airline.
NEVER work under an unpropped skip. If the skip was supplied with a
special skip support always ensure that it is used.
ALWAYS ensure that when using a starting handle that it is clean and in
good condition. Keep the engine starting dog and the part of the starting
handle that mates with it lightly lubricated (Refer to the Engine Handbook).
The battery negative terminal is
1.6 SAFE WORKING
DECALS
Attached to the dumper are several pictorial warning decals
Ensure that all decals fitted to the dumper are legible. If any should become detached,
they must be replaced immediately
For detailed information on how to safely use the items described by the decals, see the
“Safe working, Operation and Servicing” sections of this Handbook.
Descriptions of the decals are as follows:
Fuel tank filling point.
Hydraulic oil filling point.
Remove starting handle.
Wear ear protection.
The Battery Isolator is situated close to
this decal.
Read Operators Handbook, or
Operators Handbook storage place.
Attach lifting hooks to this eye.
connected to earth.
SAFE WORKING 1.7
CE (EC machines only)
Always reverse down gradients when
loaded
Forks and buckets are not to be used to
push or lift the dumper.
Beware of electrical hazards
These surfaces may be hot.
The figures shown on these decals are
the maximum loads for the skips onto
which the decals are fastened.
Keep hands away from moving parts.
ISO Skip Support, when used, is pinned
around the tipping ram rod to prevent the
ram from closing.
Always wear eye protection.
Stand clear of the articulation area of the
dumper
1.8 SAFE WORKING
OPERATION 2.1
CONTROLS AND SERVICE POINTS
1 Hydraulic oil filler cap
2 Skip control, tip/return
3 Clutch
4 Gear lever
5 Steering wheel
6 Seat
7 Foot Brake
8 Accelerator
9 Parking brake
10 Fuel filler cap
11 Key start switch (where fitted)
12 Engine starting handle (stowage)
2.2 OPERATION
ROAD LIGHTS SWITCH PANEL
20 Horn
21 Switch: Side and head lights
22 Switch: Hazard warning lights
23 Flasher unit
24 Fuse box
25 Switch: Direction indicators
26 Warning light: Direction indicators
OPERATION 2.3
DRIVING THE DUMPER
Safety warnings
Read also the “Safe Working” Section
before operating the dumper.
WARNINGALWAYS wear correctly fitting
protective clothing. Loose or
baggy clothing can be
extremely dangerous when
operating or servicing
machinery.
Only skilled personnel are
permitted to work with this
machine.
ALWAYS be aware of local
and national regulations
governing the use of this
machine.
Starting the engine
WARNINGNEVER use ether type
starting aids.
ALWAYS stop the engine if
the battery charge warning
light (where fitted) fails to
cancel.
Running-in a new engine
While a gradual ‘running-in’ of a new
engine is not necessary, it is
EXTREMELY IMPORTANT that the
following instructions should be followed
very closely during the first fifty hours of
operation.
1 Avoid overloading the engine.
2 Use the lower gears when operating
with heavy loads, and avoid continuous
operation at constant engine speeds.
3 Check the instruments frequently, and
keep the oil compartments and the
hydraulic reservoirs filled to their
recommended levels.
4 Do not operate the engine at high
speeds without a load.
5 Do not allow the engine to run at idle
speeds for long periods; this may cause
bore glazing and an increase in oil
consumption.
Operating in this way throughout the
machine’s life will prove beneficial to its
overall performance and efficiency.
Pre-start Checks
ALWAYS stop the engine if
warning lights illuminate.
Detect the fault before
continuing.
DO NOT PROCEED IF A
FAULT IS EVIDENT
NEVER attempt to start the
dumper by pushing or towing.
NEVER operate controls
unless you are seated on the
machine, and ALWAYS
remain in the driving seat
whenever the engine is
running.
WARNING NEVER commence work with
the machine until the checks
detailed in “Every 10
operating hours, or daily”
have been carried out. (See
Service Schedule).
Check that all controls are clean and not
slippery, and that they all function
correctly.
Check that the areas around pivot points,
rams and linkages are all free from mud,
ice and debris.
Check that all grab handles, steps and
platforms are clean and dry.
Check the machine for any obvious
damage or faults.
Check that all decals can be clearly read.
2.4 OPERATION
DRIVING THE DUMPER
Petter PH2 engines (UP TO 1988)
To start Petter PH2 engines:
Ensure the parking brake is in the raised
“ON” position.
Ensure gear lever is in the neutral
position.
WARNINGIf a starting handle is to be
used, see that the shaft is
greased. Make sure the
starting handle can be freely
withdrawn.
On the engine, lift the overload stop (A)
and move the fuel pump rack (D) in the
direction of the arrow to the fully open
position.
Operate the fuel pump priming lever (C)
approximately six times. (This is
unnecessary with a warm engine.)
Lift the decompression lever (B) to the
vertical position. Crank the engine as fast
as possible or use the starter motor.
When the engine is turning at a good
speed, knock down the lever (B). The
engine should now fire.
If the engine does not fire, lift the
decompressor lever (B) and slowly turn
the engine a few times before attempting
to start again. Do not operate the starter
motor for more than 20 seconds at a time.
.
Note:If it is necessary to bleed and prime
the fuel system, consult the PH2
Engine Operators Handbook.
To stop PH2 engines:
WARNING NEVER stop the engine by
using the decompressor lever.
This will lead to damaged
valve seats and cylinder head
joints.
DO NOT stop the engine by
allowing the tank to run dry.
This will make it necessary to
bleed and prime the system.
DO NOT remove or alter the
setting of the overload stop.
It is advisable to run on light load for a
few minutes before stopping.
Raise the priming lever (C) to the vertical
position, or move and hold the fuel pump
rack (D) away from the fly wheel until the
engine stops.
OPERATION 2.5
DRIVING THE DUMPER
Lister ST2 engines (UP TO 1988)
To hand start Lister ST2 engines:
Ensure the parking brake is in the raised
“ON” position.
Ensure gear lever is in the neutral
position.
Move the decompressor lever over
towards the flywheel (F).
Pull the control lever outwards and allow it
to rotate anticlockwise so that it abuts
against the top stop and is in a vertical
position (G).
IMPORTANT: Ensure that the starting
handle is of the correct type and is fully
servicable. Lightly oil the end of the
starting shaft and the starting handle.
Check the arrow on the handle for correct
rotation, then turn the handle in the
opposite direction to that required to start
engine. This is done in order to check that
the clutch pin will disengage from the
keyway, and does not bind on the starting
shaft.
ENSURE THERE ARE NO BURRS ON
THE SHAFT.
IMPORTANT: With the starting handle, turn the engine slowly from 3 to 20 turns according to the temperature and period of standing unused, in order to prime the combustion chamber and the lubricating oil system.
Turning the starting handle in the correct
rotation, crank the engine really fast and
when maximum cranking speed is
reached move the decompressor lever
away from the flywheel (H). Retain a firm
grip on the starting handle and continue to
crank until the engine fires. Remove the
starting handle from the shaft.
WARNING It is dangerous to allow the
handle to rotate on the
running shaft.
IMPORTANT: As soon as the engine
reaches normal speed, turn the control
lever clockwise to the horizontal position
so that it abuts the horizontal stop (J).
2.6 OPERATION
DRIVING THE DUMPER
To key (Electric) start Lister ST2
engines:
Ensure the parking brake is in the raised
“ON” position.
Ensure gear lever is in the neutral
position.
Depress and hold down the accelerator.
Pull the control lever outwards and allow it
to rotate anticlockwise so that it abuts
against the top stop and is in a vertical
position (G).
Turn the starter key and release
immediately the engine fires. Do not
motor the engine continuously for more
than 20 seconds.
Release the accelerator pedal.
IMPORTANT: As soon as the engine
reaches normal speed, turn the control
lever clockwise to the horizontal position
so that it abuts the horizontal stop (J).
Cold Starting Below -10oC (14oF)
A cup and plunger is fitted to the
combustion air intake port on ST engines.
Operate as follows:
Withdraw the plunger (K) and fill one
third of the cup (L) with the same type
of lubricating oil as used in the engine.
Replace the plunger and inject the oil
just before starting the engine.
The device must not be used more than
three times in succession. When hand
starting, turn the engine 20 revolutions
with the fuel on after injecting the oil,
before attempting to start.
To stop engine
Turn the control lever clockwise in the
direction of the arrow (M) and hold it until
the engine stops.
OPERATION 2.7
DRIVING THE DUMPER
TS/TR2 engines
Description
A Dipstick
B Lubricating oil filler
C Engine control
D Decompressor levers
F Cold start oil cup
G Fuel lift pump
Automatic Exess Fuel Device
The engine is fitted with an automatic
excess fuel device which becomes
operative, ready for the next start, when
the engine is stopped.
If the engine stops other than by the
operation of the engine control, the control
(C) must be turned anti-clockwise to the
‘STOP’ position and released before the
device can operate.
As the engine runs up to speed the
excess fuel device will automatically reset
to the normal running position.
Cold Starting Below -10oC (14oF)
A cup and plunger is normally fitted to the
combustion air intake port on TR and TS
engines.
With the fuel turned on, turn the engine
for up to 20 revolutions to prime the fuel
and lubrication systems.
Withdraw the plunger (H) and fill one
third of the cup (J) with the same type
of lubricating oil as used in the engine.
Replace the plunger and inject the oil
just before starting the engine.
WARNING The device must not be used
more than three times in
succession during the same
attempt to start the engine.
2.8 OPERATION
DRIVING THE DUMPER
Hand starting TS/TR2 engines
Ensure the parking brake is in the raised
“ON” position.
Ensure gear lever is in the neutral
position.
Always use the correct starting handle
which has been designed for the
engine.
Ensure there are no burrs on the handle.
Before attempting to use the handle,
clean and lightly oil that part of it which
fits onto the engine.
WARNINGDo not attempt to use a
handle if it is damaged in any
way.
Turn the engine control lever
anti-clockwise to the “STOP” position (L)
and release it.
Move the decompressor lever towards the
flywheel (M).
Insert the correct handle into the starting
housing.
Turn the engine slowly for up to 20 turns
to prime the combustion chamber and
lubricating oil system.
Maintaining a firm grip on the starting
handle, crank the engine really fast and
when sufficient speed is obtained move
the decompressor lever away from the fly
wheel (N) and continue to crank until the
engine fires.
Retain a firm grip on the handle and
remove it from the engine.
OPERATION 2.9
DRIVING THE DUMPER
Key Starting TS/TR2 engines
Ensure the parking brake is in the raised
“ON” position.
Ensure the gear lever is in the neutral
position.
Fully depress and hold down both clutch
and accelerator pedals.
Check that the decompressor lever, (if
fitted) is away (N) from the flywheel.
Turn the engine control lever
anti-clockwise to the “STOP” position (L)
and release it.
Turn the start key clockwise to position
(1), the battery charging light (P) will
illuminate.
Turn the key and hold at the “START”
position (2) until the engine fires and then
release it immediately.
If the engine fails to start within 20
seconds, release the key and attempt to
restart after allowing sufficient time for all
moving parts to stop.
Stopping the engine
WARNING Never stop the engine by
operating the decompressor
lever or valve damage may
occur
Key start engines: Turning
the starter key to the “OFF”
(0) position will not stop the
engine.
It is advisable to run on light load for a
few minutes before stopping.
Turn the engine control anti-clockwise to
the “STOP” position (L) and hold it there
until the engine comes to rest.
Key start engines: After the engine has
stopped, turn the starter key to the “OFF”
(0) position.
2.10 OPERATION
DRIVING THE DUMPER
Gradients
IMPORTANT: Read the notes in “Safe
Working” and also remember the
following:
Slippery or loose surface conditions can
adversely affect safe machine
operation, particularly on gradients.
ALWAYS choose routes that avoid
steep, slippery or loose gradients.
NEVER park the machine on a
gradient.
NEVER attempt to turn on, or drive
across, a gradient.
ALWAYS drive forwards up gradients
when loaded.
ALWAYS reverse down gradients when
loaded.
NEVER tow up or down gradients.
NEVER operate on a gradient which
exceeds 25% (1 in 4), or across
gradients which exceed 16% (1 in
6). This should be reduced where
surfaces are wet or unstable.
NEVER operate high discharge or
rotating skip options on gradients.
Stopping the dumper
IMPORTANT: Never make unnecessary
‘crash’ stops when travelling at speed,
especially in forward direction.
Release accelerator and brake to a halt
progressively.
Select neutral gear.
Apply parking brake when stationary.
Stop the engine. Turn the starter key to
the ‘OFF’ position, and remove the key.
Leaving the dumper
Ensure the machine is parked on firm,
level ground. Do not park on a gradient.
Check that the parking brake is applied.
Ensure that the skip is fully lowered.
With the engine stopped, operate the skip
hydraulic control lever fully in each
direction several times to ‘dump’ hydraulic
pressure from the system.
Remove starter key (where fitted) from
switch.
Electric start dumpers: If unattended for
Braking
Dumpers with hydraulically operated
brakes
The brake pedal operates a hydraulic
master cylinder that supplies oil to brakes
within the front axle. (Brakes fitted within
the rear axle are an option.)
The handbrake operates a caliper that
acts upon a disc mounted on the
transmission.
some time, remove earth cable from
battery, or activate the Battery Isolator,
(where fitted).
Engaging gear lever
When changing gear, always depress the
clutch pedal before moving the gear lever
from one gear to another.
OPERATION 2.11
DRIVING THE DUMPER
Skip operation
Loading
Never remain on the dumper when using
excavators or loaders to load the skip.
Stop the engine, apply the parking brake,
dismount, and stand well clear.
Ensure that the load is evenly distributed
in the skip. Never carry loads in such a
manner as to affect the forward vision.
Never exceed the rated payload. The
weights of all loads above skip water level
must be checked.
Tipping
Only discharge on level ground.
It is recommended that only free flowing
materials be tipped. Take extra care when
tipping non free running loads.
Skip control lever
The control lever has three positions; they
are, Tip (or Dump), Hold and Return.
To tip the skip:
Move the lever to DUMP.
To return the skip:
Move the lever to RETURN.
If the lever is released when in the DUMP
or RETURN position, it will automatically
return to the central HOLD position and
movement of the skip will stop. In this
way, the speed at which the skip is tipped
can be finely controlled.
However, if the skip is raised and the
engine is switched off, DO NOT operate
the control lever as the skip will rapidly
lower to the chassis
Rotating skip (manual rotation)
Rotating skip (hydraulic rotation)
The skip is operated by a joystick control
valve; the lever of which is moved through
a gate.
Because of the gate it is not possible to
move the lever diagonally, therefore it is
not possible to tip and slew the skip
simultaneously.
WARNING Before attempting to slew the
skip; the dumper must be
stationary, on level ground,
with the front and rear chassis
in-line (not articulated) and
with the parking brake applied
When the skip is fully lowered, the rear of
the skip locates into a recess in the
chassis. This is to ensure that there is no
rotary movement of the skip while the
dumper is travelling.
To slew the skip:
Look at the rear of the skip where it is
recessed into the chassis.
With the joystick lever, gently tip the
skip forward just sufficiently to raise the
rear of the skip clear of the recess.
Allow the lever to “self-centre”.
Move the lever in the direction that you
wish to turn the skip.
Allow the lever to “self-centre”.
Move the lever forwards to tip the skip.
Reverse the procedure to return the
skip to the travelling position.
After releasing the turntable locking catch,
rotate the skip manually, then tip by using
the hydraulic control lever.
When returned to the carrying position,
ensure that the turntable catch is locked.
WARNING Be sure that the rear of the
skip has fully seated in its
recess in the chassis before
travelling.
2.12 OPERATION
DRIVING THE DUMPER
Towing with the dumper
Dumpers are not designed as towing
vehicles, however, trailers may be towed
providing that:
1 The combined weight of the trailer and
its load does not exceed the specified
maximum dumper payload.
(see"specifications")
2 Trailers may be towed in first gear on
level dry ground, provided a purpose
made towing pin is used.
3 The dumper skip must be loaded with
half the rated payload to ensure tyre
adhesion when braking.
Never tow loads up, down or across
gradients.
Towing the dumper
The dumper should only be towed if
recovery is needed of a broken-down unit,
or to free a “bogged down” machine.
Always ensure that ropes, chains, etc.
used to tow the dumper have sufficient
safe working load capability.
When towing the dumper, always ensure
that the speed is kept to an absolute
minimum.
Always tow the dumper with the gear
lever in neutral.
Never attempt to start the dumper by
pushing or towing.
SERVICE 3.1
SAFE WORKING
WARNINGRead the safety notes in
“Safe Working”, Section 1
of this book.
Also note the following :
Safe handling of oils, filters and
filter elements
WARNINGDo not allow oils to come into
regular contact with skin. This
can lead to serious skin
diseases. Medical evidence
suggests they may include
skin cancer.
Always wear protective gloves
when handling oils for
topping up, draining, or
refilling.
Dispose of waste oil into
waste oil storage tanks. if
storage tanks are not
available, consult your
Distributor or local authority
for addresses of local
designated disposal points.
It is illegal to dispose of waste
oil into drains or water
courses or to bury it.
The materials used in the
manufacture and treatment of
some filters and elements
may cause irritation or
discomfort if they come into
contact with the eyes or
mouth and they may give off
toxic gases if they are burnt.
After handling any filters or
oils the users hands should
be thoroughly washed,
particularly before eating.
Used filter elements contain
some of the filtered oil and
should be handled and
disposed of with care.
3.2 SERVICE
SERVICE SCHEDULE
IMPORTANT: The engine will require additional services or adjustments in addition to
those listed below (See the appropriate Engine Operator’s handbook or Workshop
Manual).
WARNING Warning lights and indicators
REQUIRE IMMEDIATE ACTION.
SERVICE OPERATION REFERENCE PAGE
Every 10 operating hours, or daily, the above and the following
Engine oil level Engine 3.4
Fuel tank level Engine 3.6
Air cleaner Engine 3.9
Wheel nut tightness Wheels & tyres 3.22
Axle oil seals Axles 3.23
Hydraulic oil level & hose condition Hydraulic system 3.16
Every 50 operating hours, or weekly, the above and the following
Axle nuts Axles 3.23
Axle oil levels Axles 3.23
Tyre pressures & condition Wheels & tyres 3.22
Fuel tank filler strainer Engine 3.6
Battery electrolyte level Battery 3.13
Grease nipples Greasing 3.19
Gearbox / Transfer box oil levels Gearbox / Transfer box 3.10
Parking brake
Check function of the parking brake and adjust if necessary.
Propeller shaft
Tighten securing nuts. (See also Propeller Shaft Installation on page 3.12)
Brake pedal travel
Check the action of the brake pedal; it should have a short travel and firm
action. If travel is excessive, or the action spongy, have the brakes serviced
by your distributor.
First 100 operating hours
Hydraulic oil filter Hydraulic system 3.17
SERVICE 3.3
SERVICE SCHEDULE
SERVICE OPERATION REFERENCE PAGE
Every 125 operating hours, the above and the following
Air cleaner element Engine 3.9
Every 250 operating hours, the above and the following
Engine oil and filter Engine 3.5
Fuel filter Engine 3.7
Every 300 operating hours, the above and the following
Hydraulic oil filter Hydraulic system 3.17
Every 500 operating hours, the above and the following
Air cleaner element Engine 3.9
Fuel filter Engine 3.7
Frame assembly bolts Check all structural nuts & bolts for tightness.
Every 1000 operating hours, the above and the following
Hydraulic oil & filter Hydraulic system 3.17
Gearbox / Transfer box oil change Gearbox / Transfer box 3.10
Axle oil change Axles 3.23
Every 2000 operating hours, or 2 years, the above and the following
Brake system overhaul Braking system 3.20
Extra services
Dirty working conditions
Increase the frequency of all services during extremes of dirt, heat and cold,
especially those relating to clean air, cooling efficiency, lubrication and machine
cleanliness.
Laying-up protection
When a machine is to remain idle, remove the battery to the workshop. Seal all
openings: air intake, exhaust breathers. Grease bright parts and protect rubber
components from direct sunlight. Fill the fuel tank, check the tyre pressures
and exhaust any pressure from the hydraulic system.
3.4 SERVICE
ENGINE
Engines fitted in dumpers
Up to 1985: Lister ST2 and Petter PH2
1985 to 1989: Lister-Petter PH2
1985 to 1989: Lister-Petter TS2
Note: from 1989 the TS2 has been offered as an
option
1989 to date: Lister-Petter TR2
Engine lubrication oil
For engine oil grades and oil change
periods when operating in temperatures
above 30
o
C, see “Engine Handbook”.
IMPORTANT
To service the following engines,
Lister ST2
Petter PH2
Please refer to relevent Engine Operator’s
Handbook or Workshop Manual.
Lister-Petter TS/TR2
These engines will require additional
services and adjustments in addition to
those quoted in this handbook. Please
refer also to the relevant Engine
Operator’s Handbook or Workshop
Manual.
Every 10 operating hours, or
daily
Engine oil level
WARNING Lubrication oil cleanliness is
vital for the successful
operation of your engine. The
oil should be stored under the
cleanest possible conditions.
When changing or topping-up
oil, use only clean
receptacles.
Always wear protective gloves
when handling oils for
topping up, draining, or
refilling.
Oils and fuels can cause skin
irritation. Wear suitable
protective clothing to prevent
skin contact.
After handling oils the users
hands should be thoroughly
washed, particularly before
eating.
Check lubrication oil level as follows:
Stop the engine and allow the oil to
settle.
Remove and clean the dipstick (B),
then check that the oil is at the full
mark. If the level is low, top up through
the filler (C) to the full mark with clean
oil of the correct grade. DO NOT
OVERFILL.
For correct grade of engine oil, see
“Specifications”.
SERVICE 3.5
ENGINE
Every 250 hours
Engine oil
Drain and refill the oil sump as follows:
If possible run the engine immediately
before draining the oil.
Place a suitable container under the
drain plug. Remove the drain plug (D)
and drain oil.
Clean and coat the threads of the drain
plug with an appropriate sealant.
Replace the drain plug (D) taking care
not to overtighten it.
Fill the sump through the oil filler (C) to
the top mark on the dipstick (B).
Start the engine, run it for a few
minutes and check the drain plug does
not leak.
Stop the engine, allow the oil to settle
and check the level on the dipstick.
Add more oil if necessary.
Every 250 hours
Oil filter
Change oil filter element as follows:
Using a suitable strap wrench, unscrew
and remove the old filter (A).
Do not attempt to clean the old filter!
Dispose of it safely.
Thoroughly clean the crankcase filter
housing face.
Stop the engine, allow the oil to settle
and check the level on the dipstick (B).
Apply a small amount of clean engine
oil to the filter sealing joint.
Do not use a strap wrench to fit the
new element.
Screw on the new filter by hand, until
the sealing joint is just touching the
crankcase and then tighten a further
half turn.
Run the engine and check for any oil
leaks.
Add more oil if necessary.
Do not check oil level until the engine
has been stopped for 2 minutes.
Remove and clean dipstick then check
that the oil is at the full mark. If level is
low, top up through the filler to the full
mark with clean oil of the correct grade.
DO NOT OVERFILL.
For correct grade of engine oil, see
“Specifications”.
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