Thwaites MACH 2071 2022 Operator'S Instruction Manual Download | Manualshive

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5

Maintenance Tasks

Safe Working Practice:

Before lubrication and maintenance tasks:

•

Machine must be on firm level ground.

•  Apply parking brake.
•  Stop engine and remove ignition key.
•  Isolate the battery (See section 1 - Battery isolator)
•  Allow engine to cool.
•  Place FNR/gear lever in neutral.
•  Fit chassis locking bar
•  Chock the wheels
•  Prop bucket when working beneath
•  Lock skip safety prop(s)

WARNING - FUEL HANDLING

• Diesel fuel is FLAMMABLE.

• Never refuel or service the fuel system while smoking or

near naked flames.

• Never refuel the machine while the engine is running.

Refer to service manual for further reference

Daily (10 hour) maintenance check list:

•  Diesel fuel level
•  Engine oil level
•  Engine coolant level
•  Hydraulic tank oil level
•  Hand brake function
•  Foot brake resistance
•  Steering wheel and column condition
•  Tyre pressure
•  Air cleaner indicator

Weekly (50 hour) maintenance check list:

•

Wheel nut torque

• Brake oil level
• Fan belt
•

Sufficient lubricant in all grease points

Recommended maintenance tasks:

• Turn ignition switch ‘

ON

’ without starting engine, and wait

2 seconds for all warning lamps to turn off.

• Note any lamp that remains lit and correct system fault

identified before operating the machine.

• Turn ignition switch ‘

OFF

’.

First (100 hours) - New machine - change:

• Axle oil (Refer to service manual for procedure)

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Summary of Contents for MACH 2071 2022

Page 1: ...MACH 2071 2076 2077 2080 2081 Operator s Instruction Manual 2 0 3 0 Tonne hydrostatic Mach 2077 2 3 Tonne Powerswivel Mach 2071 2 0 Tonne Hi Swivel Thwaites Limited T0607 Version 3 ...

Page 2: ...within this book This machine is designed for customary construction site operations and the transportation of bulk materials commonly carried on such sites that is their intended use Under certain controlled conditions the dumper may be used for towing wheeled loads Due to the varied nature of the operation of site dumpers and the absence of an agreed test standard any figures quoted by Thwaites ...

Page 3: ...g this machine 1 Contact your Thwaites dealer in case of further questions 2 Learn to operate this machine 3 Ensure that you are fit to operate 4 Wear correct safety clothing and ensure that safety equipment is available Distributor Read this operator s instruction manual ...

Page 4: ...5 max 25 max 16 max 20 max 16 max 4 1 25 max A B C D E G F J K L M N P R S 5 1 4 1 5 1 20 max 25 max 25 max 20 max 4 1 25 max 5 1 20 max 5 1 20 max H Complete checks in section before starting the engine Safety label identification ...

Page 5: ...understand the content and position of the labels Ensure labels are clean and in good condition do not clean labels with solvents Replace lost or damaged safety labels There are also other labels in addition to the safety labels handle these labels in the same way Orientation of labels may vary from those shown Item Description Qty J Crushing of whole body Stay a safe distance from articulation ar...

Page 6: ...clean and clear of any debris 3 Is the Roll Over Protective frame ROPS frame secure fully upright and undamaged 4 Is the seatbelt anchorage secure and serviceable 5 Are the covers and mudguards secure 6 Are the hoses free from fluid leaks 7 Are all safety decals legible 8 Are the tyres free of cuts or splits 9 Are all bolts tight and in position 10 Are the steering wheel and the steering column un...

Page 7: ... machine at all times when mounting and dismounting 2 Is the engine cover secure and locked 3 Adjust the seat position for comfort and easy access to controls 4 Fasten the seatbelt Adjust accordingly for safety and comfort 5 Is the hand brake ON 6 Set the transmission to neutral 7 Does the foot brake feel firm 8 Do not operate the machine without understanding all its controls as described in the ...

Page 8: ... Foot brake pedal 6 Throttle pedal 7 Hand brake lever 8 Engine oil pressure warning light 9 Water temperature warning light 10 Direction indicator pilot light 11 Heat start pilot light 12 Battery charging warning light 13 Horn push 14 Raise skip lever hi swivel model only 15 Tip skip lever Fwd tip model Tip skip and rotate skip lever powerswivel and hi swivel models 16 Ignition hand brake warning ...

Page 9: ... in section before starting the engine 1 Maxi fuse 2 Isolater switch 3 Hour meter CB1 Transmission CB2 Power CB3 Lights Becon Horn CB4 Hazard Lights CB5 LH side lights CB6 RH side lights Optional items Layout of battery ...

Page 10: ...ckle blade into buckle lock Pull belt webbing through buckle blade to remove slack Seatbelt should not be worn loose It should pass comfortably across hip bones and not the abdomen Control functions explained Seat adjustment A Turn knob to set driver weight B Lift to slide seat assembly forwards backwards C Lift handle to adjust backrest ...

Page 11: ...to right Raise bucket and push lever to the left to rotate skip to left Push forward to tip skip Push backwards to return skip Increased engine speed reduces cycle times Movement of the skip is disabled if the steering wheel is moved Priority Steering Raise skip lever Hi swivel model only Push forward to raise skip Push backwards to lower skip Tip skip lever forward tip model Push forward to tip s...

Page 12: ...lockwise for HIGH speed travel Twist lever clockwise for LOW speed travel If green beacon option is fitted seat belt must be buckled for lever to function Hand brake lever right hand Use only when the machine is stationary or in an emergency Pull lever back to apply lift collar pull back and releace collar to lock Lift collar and lever will move forward to release An audible warning device is fitt...

Page 13: ...cover grabrail when using the spinner knob for low speed single handed steering Control functions explained Throttle pedal right foot Apply pressure to increase speed Reduce pressure from the pedal to reduce speed Foot brake pedal inching pedal right foot Apply pressure to slow or stop the machine Use left foot when inching is required Push down while pressing throttle pedal with right foot and re...

Page 14: ...ath engine cover Turn key anti clockwise to isolate the battery power supply Raising and Lowering the folding ROPS frame Remove linch pins and withdraw frame lock pins Lower frame and insert lock pins and linch pins in new position Reverse the procedure to raise the frame Ensure all pins are secure before driving Tip skip lever lock optional Place yolk over tip skip lever and secure with linch pin...

Page 15: ... Allow the engine to turn for 15 seconds max If the engine does not start within 15 seconds return key to position O and wait 30 seconds before turning to S again When the engine fires release key The key will spring back to Run position R To Stop The Engine Turn key to position O How to START and STOP the engine CAUTION Do not use unauthorised starting aids Do not TOW or BUMP start WARNING DO NOT...

Page 16: ...nnected Steering Rotate steering wheel clockwise and anti clockwise Electrics Does the horn sound correctly Does the reverse alarm sound correctly Are the beacons flashing Are the lamps working correctly optional Side lights Head lights Stop Indicators Hazards Tip skip lever Rotate skip lever Discharge park skip Rotate right to left Left to Right powerswivel and hi swivel models Raise skip lever R...

Page 17: ... Changing speed direction Select high gear Before changing direction forward reverse stop the machine and engage the hand brake After operating park safely Always leave skip empty when not in use Ensure machine is on firm level ground Apply hand brake Using the FNR lever select neutral Hydraulic system at rest in a safe condition Stop engine and remove key Lock engine cover Driving procedure and p...

Page 18: ...dients DO NOT brake suddenly in wet muddy icy conditions or when operating on loose surfaces DO NOT run downhill with controls in neutral Travel straight up down or along a gradient Keep speed to a minimum and use the foot brake to reduce speed when travelling down gradients To prevent movement always engage hand brake when stopped on sloping ground Chock wheels securely when leaving the machine u...

Page 19: ...rking practices CRUSH ZONE Stay clear of articulation area when the engine is running Never operate machine controls when standing on either side of machine WORKING UNDER A RAISED SKIP Lock skip safety prop during maintenance When using skip safety prop engage tip skip lever lock if fitted Never work under an unpropped skip ...

Page 20: ... operation of the machine The machines are compliant with the visibility requirement given in EN 474 1 with regards to the rectangular boundary and a test object of 1 2m high and 0 3m wide and the 12m circular boundary Check all around the machine before operation Be sure all mirrors are adjusted before operating the machine if fitted All cameras and mirrors must be kept clean if fitted Be aware o...

Page 21: ...m 1m 1m 1m 1m 1 2m 4 7m 0 45m Mach 2077 3 DANGER IMMEDIATE HAZARDS WHICH WILL RESULT IN SEVERE PERSONAL INJURY OR DEATH Attention Section correct and incorrect working practices Operators field of vision Blind spots Operators field of vision Blind spots ...

Page 22: ...1m 1m 1m 1m 1 2m 6 2m Mach 2080 0 6m DANGER IMMEDIATE HAZARDS WHICH WILL RESULT IN SEVERE PERSONAL INJURY OR DEATH 3 Attention Section correct and incorrect working practices Operators field of vision Blind spots Operators field of vision Blind spots ...

Page 23: ...city UNLOADING THE MACHINE Use STOPBOARDS and SUPPORT walls on trenches Reduce payload if materials being carried are not free flowing DO NOT discharge load when working on sloping ground Clear any debris from controls Ensure SAFE STABLE LOW load which allows good visibility DO NOT tip skip if load is sticking Activate the hand brake set drive to neutral turn the engine off disembark the machine a...

Page 24: ...incorrect working practices DRIVING DO NOT operate with the ROPS frame folded down DO NOT drive with the skip tipped bulldozing DO NOT carry passengers NEVER dismount from a moving machine Avoid confined work areas exhaust fumes and noise can be a hazard Site hazards to avoid adverse weather conditions icy surfaces people ...

Page 25: ... ballast load MUST NOT exceed rated payload of machine DO NOT exceed maximum tow bar pull or vertical load Towing must not be carried out on sloping ground Always use Thwaites approved towing pin TRANSPORTATION When transporting or storing machine with the ROPS frame folded down remove beacons and secure beneath the bonnet Reverse machine slowly onto a suitable trailer DO NOT drive the machine for...

Page 26: ...ESULT IN MINOR PERSONAL INJURY OR PRODUCT OR PROPERTY DAMAGE SCISSOR LIFT Insert locking pin when working beneath skip LIFTING Tip skip fully forward Engage skip safety prop Engage chassis locking bar Lift using centre eye provided HAND BRAKE DO NOT apply hand brake if machine is moving except in an emergency ...

Page 27: ...HINGED ROPS Use grab handles tread grips if fitted and steps when standing on the machine to lower the ROPS frame Avoid wet surfaces ELECTRICAL SYSTEM DAMAGE When pressure washing the machine avoid electrical system or component damage DO NOT aim directly at electrical components housed beneath the engine cover or located within the instrument panel Never modify structure ...

Page 28: ... be towed 1 5 time more than the gross weight Tow the machine using the front tie down points or around the rear axle Tow the machine in neutral with the engine running Moving a disabled machine Towing or pushing a disabled machine can only be done after the following has been carried out The hydrostatic pump is opened Handbrake emergency release procedure WARNING If rear axle brakes and pump are ...

Page 29: ... opened To open the pump follow this procedure At the left side of the pump below the floor plate there is one high pressure control valve at the top and another at the bottom To activate the hydrostatic transmission bypass release lock nut 2 screw in grub screw 1 until flush with top of nut 2 tighten nut 2 Reverse procedure prior to machine being placed back into service WARNING The maximum towin...

Page 30: ...e in contact the internal pusher plate After tightening the screws alternatively for of turn on each side with a wrench until they are completely tightened RESET OF FAILS SAFE BRAKE FUNCTION Loosen again the screws 3 alternatively for of turn on each side and fit in the spacer 4 between the screw head and the axle cover Tighten the screws 3 completely against the spacer with torque of 95 115 N m T...

Page 31: ...ty battery Replace Maxi fuse blown Faulty starter motor solenoid Replace starter motor solenoid and maxi fuse Current drawn by solenoid exceeds 25A only replace with a 30 amp fuse Short circuit on main feed or starter solenoid cables locate and repair Engine starts and stops Blocked fuel or air filter Replace fuel or air filter Air in fuel system Check fuel line connections Black engine smoke Air ...

Page 32: ... mm 2T Hi Sw 2 3T 3T A Length 3726 3726 3934 B Width 1471 1471 1638 C Height ROPS Beacon 3053 3053 3180 D Bucket lip height 1479 1356 1456 E Width over tyres 1488 1488 1650 F Wheelbase 1850 1850 1950 G Ground clearance 282 282 337 H Bucket load height 1536 1416 1581 I Axle to rear 1042 1042 1042 J Tipping ground clearance 1236 728 751 K Tipping tyre clearance 525 475 546 L Height tipped skip 3152 ...

Page 33: ...ight tipped skip 2001 2131 M Height ROPS folded 1926 1981 P Tyre clearance diameter m 7 4 9 2 Weight Kg 2T 3T Unladen Front axle 590 620 Rear axle 1330 1420 Total 1920 2040 Rated payload including driver at 80 kg Laden 2000 3000 Front axle 2300 3160 Rear axle 1700 1960 Total 4000 5120 Towbar Max Pull load 1500 2250 Vertical load 500 500 Tyre Pressure Bar psi Front 3 5 51 3 6 52 Rear 2 3 33 2 0 29 ...

Page 34: ...is running Refer to service manual for further reference Daily 10 hour maintenance check list Diesel fuel level Engine oil level Engine coolant level Hydraulic tank oil level Hand brake function Foot brake resistance Steering wheel and column condition Tyre pressure Air cleaner indicator Weekly 50 hour maintenance check list Wheel nut torque Brake oil level Fan belt Sufficient lubricant in all gre...

Page 35: ...il level is between the MIN and MAX markers Fig 3 Top up to MAX marker if necessary through oil filler cap using recomended oil Machine initially filled with SAE15W40 Fig 2 B CAUTION COMPLIANT FUEL USAGE To avoid fuel system damage and to satisfy exhaust gas legislation fuel used in this machine MUST compley with one of the following approved low sulphur diesel specifications DIN 51628 EN 590 or B...

Page 36: ...utton has popped out Fig 4 B the filter requires changing CAUTION It is imperative that hydraulic oil is clean to avoid damage to hydraulic components Engine coolant level View level of coolant in expansion bottle The coolant level must always be between the MIN and MAX marks Fig 1 Top up at radiator cap if necessary Fig 2 WARNING HOT FLUID DO NOT attmept to remove the radiator cap until system ha...

Page 37: ...els and tyres Check tyre pressures Refer to data chart in section 4 Daily 10 Hour maintenance checks Check Air Cleaner Indicator When window Fig 2 indicates RED replace or clean filter as follows Pull release clip Fig 3 and remove the end cup Twist to remove primary element and secondary element Fig 4 Clean inside body Refit or replace elements twist to ensure correct seating Refit the end cup and...

Page 38: ...oved oil Fig 1 Should brake reservoir need frequent additions of oil machine must not be used A thorough check of brake system must be carried out Note Before removing filler cap clean area carefully to prevent contamination Check Fan Drivebelt Tension Isolate the battery Fig 2 Belt should have 10 15 mm of movement for correct tension Fig 3 Refer to service manual for adjustment procedure WARNING ...

Page 39: ...around the machine to improve operation of moving parts 1 Steering cylinder 2 Tipping cylinder 3 Kinglink assembly 4 Skip pivot pins 5 Propshafts 6 Engine cover hinges 7 Folding ROPS frame pins 8 Slew cylinders Powerswivel Only 9 Slew Ring Powerswivel Only 10 Central skip lock Powerswivel Only 11 Scissor frame pivot pins Hi Swivel Only ...

Page 40: ...hrs 50hrs first 100hrs 250hrs 500hrs 1000hrs 2000hrs Please refer to the Thwaites service manual for further maintenance information We reserve the right to change all specifications without prior notice www thwaitesdumpers co uk ...

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