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Table of Contents - 4

TA1EH

Table of Contents

(2)

Coolant .................................................................................9.10

9.12 Hydraulic System .......................................................................9.10

(1)

To Check the Hydraulic Oil Level .........................................9.11

(2)

To Add Hydraulic Oil ............................................................9.12

9.13 Fuel System ..............................................................................9.12

(1) To Add Fuel ..............................................................................9.12

9.14 Wheels and Tyres .....................................................................9.13

(1)

Recommended Pressures ....................................................9.13

9.15 Maintenance Schedule .............................................................9.14
9.16 Lubrication Diagram ..................................................................9.15
9.17 Lubrication Chart .......................................................................9.16
9.18 Fluids and Lubricants ................................................................9.16

(1)

Engine Oil .............................................................................9.16

(2)

Hydraulic System .................................................................9.17

(3)

Engine Coolant .....................................................................9.17

(4)

Fuel System .........................................................................9.17

(5)

Grease ..................................................................................9.17

9.19 Fluid Capacities ........................................................................9.17

10.

Troubleshooting

10.1 General Troubleshooting ..........................................................10.1

(1)

Engine will not start ..............................................................10.1

(2)

“Low” engine oil pressure light comes on .............................10.1

(3)

“High” coolant temperature light comes on ..........................10.1

(4)

Loss of coolant .....................................................................10.1

10.2 Electrical Troubleshooting .........................................................10.1

(1)

Circuit breaker keeps “tripping out”. .....................................10.1

(2)

System Dead ........................................................................10.1

(3)

Charge warning light remains On with engine running .........10.1

(4)

Lights and direction indicators do not work ..........................10.1

10.3 Hydraulic Troubleshooting ........................................................10.2

(1)

No Pressure .........................................................................10.2

(2)

Machine will not steer ...........................................................10.2

(3)

Skip will not raise or tip .........................................................10.2

11.

Recovery

11.1 Towing ......................................................................................11.1
11.2 Lifting with a Crane ...................................................................11.1

Storage, Decompressing & Disposal

12.1 Long Term Storage ...................................................................12.1
12.2 Decomissioning..........................................................................12.1
12.3 Recomissioning .........................................................................12.1

(1)

If stored for more than a period of 6 months: .......................12.2

12.4 Disposal ....................................................................................12.2
12.5 Disposal of Used Batteries ........................................................12.2

Glossary of Terms

Appendix 1 - Hydraulic Diagrams

Содержание TA1EH

Страница 1: ...Site Dumper TA1EH Stage 5 1 June 2021 English EN 2 5 1801 Original Instructions OPERATOR S MANUAL Issue Date Language Revision No Reference No ...

Страница 2: ...levard Prologis Park Coventry CV6 4BX United Kingdom Tel 44 0 24 7633 9400 Fax 44 0 24 7633 9500 Email constructionequipment mecalac com Portal Oneface Mecalac com WWW MECALAC COM Serial Number Date of Delivery Dealer Stamp Notice Year of Construction ...

Страница 3: ... 2 2 ANSI Hazard Classification System 2 1 2 3 Personal Protective Equipment PPE 2 2 2 4 General Safety Information 2 4 2 5 Seat Belt and Green Beacon 2 6 2 6 ROPS 2 6 2 7 Lockout and Tag Out 2 6 2 8 Hydraulic Fluid 2 7 2 9 Fluid Levels 2 7 2 10 Battery Electrolyte 2 7 1 Skin Exposure 2 7 2 Eye Contact 2 7 3 Battery Charging 2 7 4 Frozen Battery Electrolyte 2 7 2 11 Fires 2 7 2 12 Water Cooled Eng...

Страница 4: ...y Isolator 4 5 1 Operation 4 5 4 7 Circuit Breakers Audible Warning 4 6 4 8 Hour Meter 4 7 4 9 Control Panel and Switch Functions 4 8 4 10 Start Interlock 4 11 4 11 Start Stop Switch 4 11 4 12 Direction Indicator Switch When Fitted 4 12 4 13 Machine Lighting 4 12 1 Front Lighting 4 12 2 Rear Lighting 4 13 4 14 Orange Flashing Beacon 4 13 1 Storage 4 14 4 15 Forward Reverse Switch 4 14 4 16 Skip Co...

Страница 5: ...te the Skip 7 8 4 To Return to the Travelling Position 7 8 7 10 Parking the Machine After Use 7 8 8 Emergency Operating Procedures 8 1 Running Out of Fuel on a Slope 8 1 8 2 Jump Starting the Machine 8 1 8 3 Towing the Machine 8 2 8 4 Releasing the Brakes 8 3 9 Maintenance Lubrication 9 1 General Information 9 1 9 2 Maintenance Notes 9 1 9 3 Cleaning The Machine 9 1 1 Safety Signs 9 2 9 4 Battery ...

Страница 6: ... 1 2 Low engine oil pressure light comes on 10 1 3 High coolant temperature light comes on 10 1 4 Loss of coolant 10 1 10 2 Electrical Troubleshooting 10 1 1 Circuit breaker keeps tripping out 10 1 2 System Dead 10 1 3 Charge warning light remains On with engine running 10 1 4 Lights and direction indicators do not work 10 1 10 3 Hydraulic Troubleshooting 10 2 1 No Pressure 10 2 2 Machine will not...

Страница 7: ...e this symbol adhere to all safety messages that follow to avoid possible injury or death 1 3 Intended Use The machine has been designed and tested to carry out the function of transporting various free flowing materials If used correctly it will provide an effective means of transportation and meet the appropriate performance standards and regulations This machine is not suitable for under ground...

Страница 8: ...n 1 5 Identification Plate The Vehicle Identification Number VIN is recorded on a plate Figure 1 2 located on the right hand side of the rear chassis frame Figure 1 2 Vehicle Identification Number Plate Location 1 VIN Plate You are advised to keep a record of your machines VIN number and the information recorded on the plate in a safe place COV00001 1 ...

Страница 9: ... 7 Engine Power 8 Year Of Manufacture 9 Model Year 10 Bar Code 11 Works Order Number 1 Company Address 2 Vehicle Identification Number 3 Machine Model 4 Designation 5 Operating Mass Laden 6 Maximum Front Axle Load 7 Maximum Rear Axle Load 8 Engine Power 9 Build Year 10 Model Year 11 Bar Code 12 Works Order Number 1 Company Address 2 Vehicle Identification Number 3 Machine Model 4 Designation 5 Ope...

Страница 10: ...Community 1 CE mark The Machinery Safety directive is intended to harmonise all the machinery safety regulations throughout the community so that there will be no technical barriers to trade Compliance with the essential safety requirements of the EEC directives 2006 42 EC machinery 2000 14 EC Noise and 2004 108 EC permits companies to CE mark their products The directive affects almost every equi...

Страница 11: ...ON EQUIPMENT UK LIMITED hereby declares that the above piece of machinery is in conformity with the relevant provisions of the Machinery Directive 2006 42 EC MECALAC CONSTRUCTION EQUIPMENT UK LIMITED hereby declares that the above piece of machinery is in conformity with the provisions of the following other EC directives Non Road engine emissions EU 2016 1628 Noise Equipment Used Outdoors 2000 14...

Страница 12: ...ED hereby declares that the above piece of machinery is in conformity with the provisions of these regulations MECALAC CONSTRUCTION EQUIPMENT UK LIMITED hereby declares that the above piece of machinery is in conformity with the provisions of the following other enactments Noise Emission in the Environment by Equipment for use Outdoors Regulations 2001 and Electromagnetic Compatibility BS EN 13309...

Страница 13: ...N number to make sure you receive any future bulletins or updates 1 12 Contacting the Manufacturer At times it may be necessary to contact the manufacturer of this machine You must supply the Model and VIN Number of the machine together with your name and contact details You must contact Mecalac for For any product modifications to your machine To report an accident involving Mecalac equipment Pro...

Страница 14: ...Page 1 8 TA1EH 1 Introduction ...

Страница 15: ...wing signal words used with the safety alert symbol indicate a specific level of severity of the potential hazard All are used as attention getting devices on safety signs fixed to the machinery to assist in potential hazard recognition and prevention bDANGER DANGER Always used with a safety alert symbol and white letters on a red background Indicates a hazardous situation which if not avoided wil...

Страница 16: ...a blue background Is used to address practices not related to personal injury PROCEDURE PROCEDURE Used without a safety alert symbol and black letters on a green background This indicates a procedure that must be followed step by step for safe operation Make sure all safety notes have been considered before beginning the procedure ...

Страница 17: ...Visibility Clothing High visibility clothing must be worn at all times when operating this equipment Seat Belt The seat belt must be worn at all times when operating this equipment Protective Gloves Protective gloves must be worn when necessary to prevent injury from sharp objects Face Shield A face shield must be worn when conditions dictate to prevent eye or facial injury from flying objects Dus...

Страница 18: ... of alcohol or drugs etc Personal Protective Equipment must be used as specified on pages 2 2 and 2 3 Read this instruction manual carefully before operating the machine Make sure this instruction manual is kept with the machine at all times and is in good condition replace the manual immediately if it becomes dirty damaged or lost Read and understand all safety signs before operating the machine ...

Страница 19: ...hydraulic circuit hydraulic fluid leaking under pressure can penetrate the skin Do not operate the machine if it is damaged improperly adjusted or not completely and correctly assembled Keep footplates and steps free from dirt oil snow ice etc Do not remove the radiator cap when the engine is hot Do not add coolant to a hot engine Tyre changes and repairs to punctured tyres MUST only be carried ou...

Страница 20: ...ing the dumper skip Do not drive the machine on the public highway with the skip in the fully tipped position If anyone has any concerns with any safety aspect of the machine the problem must be reported and the machine must not be used until the safety concerns have been rectified or an authorised person has checked and satisfied the site personnel the machine is safe to use 2 5 Seat Belt and Gre...

Страница 21: ...hick paper to check for leaks Fluid injected into the skin must be surgically removed within a few hours by a doctor familiar with this type of injury or gangrene will result 2 9 Fluid Levels Make sure the machine is on firm level stable ground It must not be in a dangerous position or causing an obstruction Apply the parking brake Place gear lever is in neutral and the make sure engine is stopped...

Страница 22: ...trical fire Use a carbon dioxide dry chemical or foam extinguisher whilst waiting for the fire brigade Keep fire extinguisher seviceable and have it checked regularly Do Not Use Water to Extinguish a Machine Fire 2 12 Water Cooled Engines Water cooled systems operate under pressure to increase the boiling point of the coolant Therefore the coolant temperature may be greater than boiling water at s...

Страница 23: ...olonged skin contact with used engine oils Dispose of used oil in accordance with local environmental regulations 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 nail br...

Страница 24: ...ient For different dumpers different maximum gradients apply Do not exceed the maximum gradient Poor ground conditions such as muddy slippy or uneven surfaces will reduce the maximum gradient The maximum gradient for TA1 machines is 20 or 14º or 1 in 5 3 Crossing a Slope Great care must be taken when crossing a slope to prevent the machine sliding sideways and out of control Different maximum late...

Страница 25: ... hold you in the seat until the machine comes to rest Do not try to jump clear of the machine when it is overturning you may be crushed by the machine The ROPS will provide protection in the event of a roll over 2 18 Safety Signs 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...

Страница 26: ...ate battery before maintaining the machine Fall Crush Do not carry passengers or allow people to ride on the machine Skin injection from high pressure fluid Use cardboard or wood to check for leaks Crush during roll over Only drive up and reverse down inclines of 11 19 1 in 5 or less Crush during roll over Do not drive across slopes exceeding 9 16 1 in 6 Crushing Insert skip cylinder safety lock s...

Страница 27: ... machine Machine Instability Read operators manual Crush during roll over Always wear a seat belt when operating the machine Crush Zone Stay clear of machine Crush Zone Turn the machine off and remove the key Fit articulation lock Lifting Fit articulation lock before lifting Use equipment rated for lifting the stated weight 000KG 000KG ...

Страница 28: ...cation ISO 14 1 2 3 4 5 6 7 12 13 15 16 17 17 15 18 19 20 21 22 23 24 8 9 10 11 COV00386 1 STARCO 255 75 15 3 8PR 2 3 Bar 33 5 PSI 2 27 Bar 33 0 PSI STARCO 255 75 15 3 8PR 1 37 Bar 20 0 PSI 1 51 Bar 22 0 PSI 16a 23a STARCO 7 00 12 AS DUMPER II 8PR STARCO 7 00 12 AS DUMPER II 8PR ...

Страница 29: ...eaker Reset 12 Information Operations Manual Location 13 Information Diesel Filling Point 14 Information Hydraulic Oil Filling Point 15 Safety Crush Hazard Front and Rear 16 Information Tyre Pressure Rear Starco Each Side 16a Information Tyre Pressure Rear Starco Narrow 17 Information Tie Down Points 18 Information Sound Level 19 Safety Crush Hazard Fit Articulation Lock Each Side 20 Safety Crush ...

Страница 30: ...Page 2 16 TA1EH 2 Safety 3 Safety Sign Location ANSI Figure 3 5 Safety Sign Location ANSI 1 7 25 6 5 4 3 2 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 18 16 24 COV00560 2 ...

Страница 31: ...ety Entanglement Hazard Stop Engine 12 Information Diesel Filling Point 13 Information Hydraulic Oil Filling Point 14 Information Dipstick Location 15 Safety Crush Hazard Front and Rear 16 Information Read Manual Before Towing 17 Information Tie Down Procedure 18 Information Tyre Pressure Rear Starco Each Side 19 Information Battery Isolator 20 Safety Crush Hazard Fit Articulation Lock Each Side 2...

Страница 32: ... 88 4 1621 3 63 8 725 8 28 5 2979 2 117 2 1167 4 45 9 1438 9 56 6 1744 3 68 6 952 0 37 5 2601 8 102 4 220 2 8 6 1117 4 43 9 TA1EH Narrow Tyres 2907 0 114 4 2458 0 96 7 2196 0 86 4 1571 0 61 8 725 8 28 5 2979 2 117 2 1117 0 43 9 1438 9 56 6 1694 0 66 7 952 0 37 5 2551 0 100 4 170 0 6 7 1057 0 41 6 A B C D E Front Axle Centre F G H I J K L M Maximum Heights with Skip Fully Elevated COV00355 ...

Страница 33: ...yre Data Table 3 3 Tyre Data Turning Circle A mm in TA1EH TA1 2EH 4590 8 180 7 Tyre Data Machine Tyre Make Size Pressure Front Pressure Rear TA1EH Starco 225 75 x 15 3 8PR AS Dumper 2 3 Bar 33 5 psi 1 37 bar 20 0 psi TA1EH Narrow Tyre Option Starco 700 x 12 8PR 2 27 bar 33 0 psi 1 57 bar 22 0 psi A COV00356 ...

Страница 34: ... Capacity 190cc 0 05 US Gal Wheels Wheel Nut Torque 120 Nm 88 ft lb Brakes Primary Within Wheel Motors Parking Within Wheel Motors Electrical System Voltage 12v Negative Earth Alternator Belt Driven Output 55 amp Battery 74Ah 12v Battery Cold Start Amps Type 072 DIN340A IEC 420A Hydraulic System Tank Capacity 25 3ltr 6 7 US Gal Fuel System Type Diesel Tank Capacity 32 5ltr 8 59 US Gal Skip Capacit...

Страница 35: ...nly Technical Data Machine Weights With Operator 75kg ISO6016 Unladen 1375kg Laden 1000kg 2375kg Without Operator Unladen 1300kg Laden 1000kg 2300kg Max front axle laden 1360kg Max rear axle laden 1015kg Model Declared Single Number Noise Emission Values to ISO 4871 A rated sound pressure level at operator station A rated sound power of machine LpAd LWAd TA1EH 83dB 101dB ...

Страница 36: ...e only Actual work site operation and operator characteristics will have a large influence on actual values for specific circumstances Operation Value Uncertainty Hand Arm Vibration as defined in EN474 1 All operations 2 5m s2 N A Whole body vibration values as defined in ISO TR 25398 Work Cycle 0 529 rms 0 264m s2 ...

Страница 37: ...Page 3 6 TA1EH 3 Technical Data ...

Страница 38: ...e ahead of the driver and is designed to carry free flowing materials It is raised and lowered hydraulically The machine discharges its load to the front of the machine If necessary the skip can be raised 1m before tipping to provide an higher discharge point This feature is particularly useful when tipping loads into builders skips trucks etc bWARNING The skip must only be used to carry free flow...

Страница 39: ...c failure the steering will still operate but under these circumstances steering wheel loads are high and the dumper must only be driven at slow speeds 5 Transmission Power is transmitted to the wheels by means of an hydraulic pump and hydraulic motors Refer to 4 5 Hydraulic System A switch selects forward or reverse travel Because the machine has hydrostatic drive and will not free wheel as with ...

Страница 40: ... controlled by joystick operated control valve Twin hydraulic cylinders mounted between the front chassis and the lift arm carriage assembly permit the skip to be elevated by 1m for high discharge purposes The joystick control for skip operations is positioned to the right of the drivers seat 1 Raised Skip As a safety aid when working on the machine a stop is provided that fits over the skip ram r...

Страница 41: ...the dumper to be towed in an emergency there is provision release the hydraulically applied brakes on the wheel motors A second engine driven hydraulic pump provides power for steering and skip operation Both pumps draw oil from a tank located inside the chassis The tank is fitted with a suction strainer a level gauge and a filler breather cap bCAUTION A crush hazard is created when the machine is...

Страница 42: ...e lifting lowering and tipping of the dumper skip The skip can be raised and tipped at varying speeds dependent on engine speed and it can be stopped at any intermediate point if required 4 6 Battery Isolator The battery isolator Figure 4 5 is both a maintenance aid and an anti theft and vandalism device It has a removable key 1 When carrying out any maintenance on the machine the battery isolator...

Страница 43: ...position Should this occur the reason for the overload should be investigated and the components at fault replaced or repaired Once the repair has been completed the circuit breaker should be reset by pressing the button until it locks in position thus restoring the electrical supply The audible warning is fitted to warn the operator that the engine is overheating If the alarm sounds the machine m...

Страница 44: ...description 4 8 Hour Meter The hour meter Figure 4 7 records the amount of time the engine has been running This is useful for determining service intervals maintenance etc Figure 4 7 Hour Meter 1 Hour Meter COV00228 1 ...

Страница 45: ...Inhibitors 5 Instruction Direction Indicators When Fitted 6 Hazard Lights Switch When Fitted 7 Instruction Engine Start Switch 8 Switch Lighting When Fitted 9 Warning Light Direction Indicators When Fitted 10 Warning Light Engine Cold Start 11 Warning Light Engine Oil Pressure LOW 12 Horn Button 13 Instruction Forward Reverse Control 14 15A Circuit Breaker Engine Electrical System 1 2 3 4 5 7 8 9 ...

Страница 46: ...ngine is not running When the engine starts and full RPM is selected the charge warning light goes off The warning light should stay off while the engine is running If the light fails to go off when the engine is running STOP THE ENGINE IMMEDIATELY Do not use the machine until the fault has been rectified Warning Light Engine Coolant Temperature The water temperature warning light should only come...

Страница 47: ...ighting When fitted This switch will turn the headlights and front rear side lights on and off Instruction Engine Start Key Switch This instruction shows the start key position to use when the engine cold start aid is required Switch Name Description Hazard Light Switch Pressing the button will cause all four direction indicator lights to begin flashing and will continue to do so until the button ...

Страница 48: ... symbol 1 on the dashboard decal Figure 4 9 indicates the Operator must be seated to deactivate the start inhibitor before starting the machine Figure 4 9 Start Interlock Function 4 11 Start Stop Switch The Start Stop Switch Figure 4 10 is operated by a removable key The switch has a protective cover that must be fitted when the key is removed to prevent the ingress of damp and moisture Figure 4 1...

Страница 49: ...eft or Right Moving indicator lever forwards A will turn on the left hand indicator lights Moving the lever backwards B will turn on the right hand indicator lights Figure 4 11 Direction Indicator Switch 1 Direction Indicator Switch 4 13 Machine Lighting 1 Front Lighting Each front light cluster Figure 4 12 contains a headlight 1 side light 2 and a direction indicator light 3 Figure 4 12 Front lig...

Страница 50: ...gistration plate Light The registration plate light although mounted independently will come on when the rear lights are switched on 4 14 Orange Flashing Beacon The orange Flashing Beacon Figure 4 14 is provided to warn people of the dumpers presence The beacon is fitted to the machines ROPS The orange Flashing Beacon is easily removed to prevent theft or vandalism by slackening the nut and liftin...

Страница 51: ...blic highway using a lorry or trailer There is a storage position inside the engine chamber 4 15 Forward Reverse Switch The forward reverse switch selects the direction of travel for the machine Figure 4 16 refers With the switch in central Neutral position there is no drive to the hydraulic motors and the brakes are applied When Forward or Reverse is selected the brakes are automatically released...

Страница 52: ...er 3 Lever Lock Certain Markets Moving the lever forward towards the skip will cause the skip to tip Moving the lever towards the rear of the machine will cause the skip to lower Upon releasing the lever it will automatically return to the centre Neutral position By moving the lever to right will cause the lift arm to raise giving the high discharge facility Moving the lever to the left the skip w...

Страница 53: ...matically applied With the forward reverse switch in the Neutral position the accelerator pedal is used to increase engine speed to enable the skip to be raised tipped and lowered more rapidly Figure 4 18 Accelerator Pedal 4 18 Wheel Chock A wheel chock Figure 4 19 refers is supplied for certain markets to prevent machine movement When needed it should be removed from its storage position under th...

Страница 54: ...Belt with Green Beacon Optional This type of belt retracts automatically when the release button is pressed and the tongue is released Figure 4 23 refers When the tongue of the belt is inserted in the buckle and clicks into place a green beacon Figure 4 24 located on the ROPS frame will flash indicating to site management and others that the driver of the machine is correctly wearing their seat be...

Страница 55: ...Page 4 18 TA1EH 4 Description Figure 4 24 Green Beacon Seat Belt Warning ...

Страница 56: ...ry see Tie Down Release the articulation lock before unloading The beacon must be removed and the ROP s lowered when transporting the machine by rail or on the public highway using a lorry or trailer 5 2 Loading or Unloading using a Crane Refer to Figure 5 1 A lifting point 1 is provided each side of the steering column for lifting the machine Using these points and a 2 legged chain will give a sa...

Страница 57: ... or maintenance Figure 5 2 Articulation Lock 1 Lock Bar 2 Pin PROCEDURE 1 To fit the lock bar remove the grip clip and pin from the lock bar 2 Pivot the lock bar around until the hole in the bar aligns with the hole in the rear chassis 3 It may be necessary to move the steering wheels slightly to align the holes 4 Refit the pin and secure with the grip clip 2 1 COV00358 ...

Страница 58: ...ers Figure 5 3 Tie Down Points 5 6 Tie Down When the machine has been put in an acceptable position on the lorry or trailer it must be secured in place to prevent movement It is preferred to use the tie down points illustrated in Figure 5 3 however figure 5 4 illustrates an alternative tie down method Which ever method is used the machine must be secure Figure 5 4 Alternative Tie Down Method COV00...

Страница 59: ...con and store safely 4 Lower ROPS to transport position 5 Nail blocks chocks at the front rear and outside of each wheel 6 Tie down using tie down points provided with suitable chains straps or ropes Alternatively ropes may also be placed over wheels as shown in Figure 5 4 7 Loose ends of chains straps or ropes must be secured to the lorry trailer bed ...

Страница 60: ...ght metal parts Check for damage and missing parts Check all fluid levels Check tyres are inflated to correct pressures 6 2 Setup Place the ROPS in the work position Figure 6 1 refers Figure 6 1 ROPS Set Up 1 Linch Pin 2 Locking Pin bDANGER The machine must not be used until the ROPS has been raised and secured in the work position It is prohibited to use a machine without the ROPS installed in th...

Страница 61: ...gns of overheating Re start the engine drive the machine a short distance to check operation of transmission brakes and steering Check if the skip tips raises and lowers Park up and stop the engine Report and have rectified any faults before placing machine into service PROCEDURE 1 Remove the linch pins from the locking pins either side of the ROPS 2 Remove the locking pins 3 Push the top half of ...

Страница 62: ...ion PROCEDURE 1 Check general condition of machine missing parts loose fasteners fuel lines for damage hydraulic hose end fittings for leakage hose outer covers for ballooning etc 2 Check that the operators platform steps etc are clean and free from mud or ice 3 Check the engine and hydraulic oil levels make sure the engine and hydraulic tank are filled using clean oil and a clean container 4 Chec...

Страница 63: ... of the operator Figure 7 2 Operators Seat 1 Fore and aft movement 2 Backrest Angle Adjustment 3 Weight Adjustment PROCEDURE 1 Remove the linch pins from the locking pins 2 Remove the locking pins 3 Push the top section of the ROP s upwards to its working position 4 Refit the locking pins and secure with the linch pins 5 Fit the beacon PROCEDURE 1 Remove the beacon 2 Remove the linch pins from the...

Страница 64: ... knob clockwise adjusts the seat for the larger person and anticlockwise for the smaller person When the knob is turned the pointer 4 moves to allow the operator to select the correct weight from the scale 3 If the seat weight adjustment is not set the Operator may experience discomfort or personal injury The engine will not start unless the seat is adjusted correctly for the operators weight and ...

Страница 65: ...eat place the seat belt across the hips and insert the latch 3 into the buckle 1 until it locks into position Adjust by pulling the belt through the buckle until it is a firm comfortable fit across the hips To remove the seat belt press the button 2 and lift the latch 3 out of the buckle 1 Figure 7 5 Seat Belt COV00092 1 COV00633 1 2 3 ...

Страница 66: ...reverse switch is in the Neutral position 2 Turn the start key to position 1 Run Pre heat 3 Wait for the Pre heat warning light to go out 4 Turn the key against spring pressure to the start position to crank the engine 5 Release the key as soon as the engine starts It will return to the Run position by spring pressure NOTICE Do Not use starting sprays to assist engine starting Do Not crank engines...

Страница 67: ...ise to OFF position 0 PROCEDURE 1 Make sure the forward reverse switch in Neutral 2 Start the engine 3 Select Forward or Reverse Note the machine may automatically creep in the forward or reverse directions without depressing the accelerator pedal 4 Depress the accelerator pedal gently and the machine will begin to move 5 Control the speed of the machine with the accelerator as required 6 If trave...

Страница 68: ...skip 3 To raise the lift arm 4 To lower the lift arm bWARNING It is important to get off and stand clear of the machine when loading the dumper with a backhoe loader digger loader shovel or similar to prevent injury from falling objects PROCEDURE 1 Position the machine where the load is to be discharged 2 Make sure the area is clear of bystanders 3 Make sure the lever lock is off 4 Push the contro...

Страница 69: ... 3 The skip will lower PROCEDURE 1 Position the machine where required 2 Make sure the area is clear of bystanders 3 Push the control lever to the right away from the operator the lift arm and skip will raise up PROCEDURE 1 Move the control lever to the left towards the operator 2 The lift arm and skip will lower bWARNING Never attempt to move the machine with the lift arm and skip in the elevated...

Страница 70: ...ll lit area to park the machine where it will not cause an obstruction or danger to others 2 Fit the lock to the skip control lever 3 Set the forward reverse switch to the Neutral position 4 Stop the engine and remove the start key 5 Open the bonnet set the battery isolator to OFF and remove the isolator key 6 Close the engine cover lock and remove the key 7 Employ the wheel chock if necessary ...

Страница 71: ...Page 7 10 TA1EH 7 Standard Operating Procedures ...

Страница 72: ...attery on the machine Refer to figure 8 1 When doing so you must wear the correct protective clothing gloves and a face shield see Safety Section in this manual Observe the following points The discharged battery must not be frozen The slave battery must be of the same nominal voltage as the discharged battery The jumper cables are of sufficient capacity to carry the starting current It is necessa...

Страница 73: ...h for a maximum distance of 50m PROCEDURE 1 Connect the positive jump lead from the positive terminal on the slave battery to the positive terminal on the machine battery 2 Connect the negative cable from the negative terminal on the slave battery to a suitable point on the machine chassis 3 Start the engine using the machines start key 4 Allow engine speed to fall to idle 5 Carefully remove the n...

Страница 74: ...eir storage positions 3 Remove the rubber cap from the wheel motor 4 Place the plate over the end of the motor 5 Fit the bolt through the hole and screw into the motor 6 Tighten the bolt to release the brakes 7 Once repairs have been completed unscrew the bolts to re apply the brakes 8 Re fit the plates in their storage position 9 Re fit the rubber cap to the motor 10 Start the engine the brakes w...

Страница 75: ...Page 8 4 TA1EH 8 Emergency Operating Procedures ...

Страница 76: ...a support before working under a raised skip Always fit the articulation lock when working in the area of the centre pivot Refer to and adhere to the Lubricating and Service Schedules detailed in this manual When checking fluid levels park the machine on a firm level surface in a well ventilated position away from naked flames grinding sparks etc Make sure the work area is clean and tidy before st...

Страница 77: ...ssure in the hydraulic circuit before carrying out repairs to the hydraulic system or components 9 6 Skip Support A skip support is provided to support the skip in the raised position when maintenance is being carried out The support is stored on the underside of the skip when not in use secured in position by a pin and R clip Figure 9 1 refers bWARNING Fine jets of hydraulic fluid under pressure ...

Страница 78: ...d of the skip ram to prevent the rod retracting Refer to Figure 9 2 Figure 9 2 Skip Support In Position 1 Skip Support PROCEDURE 1 Fully raise the skip 2 Remove the support 1 from its storage position and place over the piston rod of the ram 3 Fit the pin to the support and secure with the R clip 4 Carefully lower the skip until the weight is resting on the support COV00364 2 1 3 COV00365 1 ...

Страница 79: ...a of the centre pivot failure to fit the lock could cause a pinch point or trap that will result in death or serious injury PROCEDURE 1 To fit the lock remove the grip clip and pin from the locking bar 2 Pivot the locking bar around until the holes in the bar are aligned with the hole in the rear chassis bracket 3 Re fit the pin and secure with the grip clip bDANGER Battery Acid Contact with batte...

Страница 80: ...the air cleaner requires servicing Check system for leaks PROCEDURE 1 Remove the protective covers from the battery terminals 2 Disconnect the negative ve cable from the battery 3 Disconnect the positive ve cable from the battery 4 Undo the nuts and washers and remove the battery clamp 5 Lift the battery clear of the machine NOTICE Maximum protection against dust is only possible if the air cleane...

Страница 81: ...rating the major air cleaner components Figure 9 6 Air Cleaner 1 Sediment Cup 2 Main Element 3 Secondary Element 4 Body 5 Blockage Indicator 6 Dust Ejector 7 Clamp 2 Dismantling the Air Cleaner It is recommended that the air cleaner is dismantled and reassembled by a competent person to ensure there are no air leaks that would permit dust and dirt to enter the engine COV00388 1 2 5 1 6 4 3 COV0038...

Страница 82: ...Figure 9 7 Dipstick Location 1 Dipstick The oil level should be between the MAX and MIN marks on the dipstick Figure 9 8 PROCEDURE 1 Clean the area around the air cleaner 2 Loosen clamps holding the sediment cup to the air cleaner body and pull cup clear 3 Remove the elements from the body 4 Clean the main element by tapping gently on a firm object or by blowing gently with compressed air from ins...

Страница 83: ...ne compartment Refer to the Lubrication Tables for the correct grade and quantity of oil Figure 9 9 Engine Oil Filler Cap 1 Filler Cap PROCEDURE 1 Open the engine cover 2 Allow oil to settle for a few minutes 3 Clean the area around the dipstick 4 Remove the dipstick wipe clean with paper check level and replace the dipstick 5 If the oil level is below the MIN level oil must be added COV00033 1 2 ...

Страница 84: ... fresh oil of the correct grade to the engine 3 While adding oil check the level frequently to make sure it does not go over the MAX level 4 When the oil is up to the required level replace the filler cap 5 Wipe up any spilt oil NOTICE Do not overfill the engine Too much engine oil may cause damage to the engine bWARNING NEVER perform checks or maintenance on the cooling system when it is hot NEVE...

Страница 85: ...ays thoroughly clean machine before any hydraulic maintenance Use paper roll not rag to wipe parts Always use fresh clean hydraulic oil from a sealed container Never use dirty containers for oil storage Never use dirty containers or funnels for filling hydraulic system A filler cap incorporating a dipstick is fitted to the top of the hydraulic tank Figure 9 11 refers An indicator on the filter whe...

Страница 86: ...rk PROCEDURE 1 Stop the engine and unscrew the dipstick breather and remove from the tank 2 Wipe all traces of oil from the dipstick with clean paper and refit the dipstick 3 Remove the dipstick again and check the level of the oil 4 Never allow the oil level to go below the minimum mark Min 2 or above the maximum mark Max 1 5 Add the correct grade of oil as required 6 Check the level and replace ...

Страница 87: ... half full or Full Figure 9 13 Fuel Tank 1 Level Gauge 2 Filler Cap PROCEDURE 1 Unscrew the dipstick breather 2 Add oil as required 3 Use the dipstick breather to check the level 4 Continue adding oil until it reaches the upper mark on the dipstick 5 Replace the dipstick breather 6 Wipe up any spilt oil bDANGER Avoid sparks naked flames etc when filling or maintaining the fuel system Do not smoke ...

Страница 88: ...he tyres The pressures should be checked and adjusted if necessary weekly using valve 1 Figure 9 14 Tyre Inflation Valve 1 Tyre Inflation Valve 1 Recommended Pressures PROCEDURE 1 Remove the filler cap 2 Add fuel until the gauge reaches the full mark 3 Refit the filler cap 4 Clean up any spilt fuel TA1EH TA1EH Narrow Tyres Front 2 3 Bar 33 5 psi Front 2 27 Bar 33 0 psi Rear 1 37 Bar 20 0 psi Rear ...

Страница 89: ...and functional Check articulation lock is present and functional Visually check machine for fluid leaks damage missing parts unreadable safety signs etc 50 Hours As for 10 hours and including Lubricate the centre pivot Lubricate all other grease nipples see lubrication chart Oil all control pivots e g throttle etc Check wheel nut torque Check clean and protect battery connections Check for air lea...

Страница 90: ...TA1EH Page 9 15 9 Maintenance Lubrication 9 16 Lubrication Diagram Figure 9 15 Lubrication Diagram A D B B A D E E D D C C L K H F F G J COV00454 ...

Страница 91: ...Hydraulic Oil Tank Mecalac Premium Hydraulic 46 or Shell Tellus S2 V46 High VI Hydraulic Oil HV ISO 46 10 400 H Cooling System BASF Glysantin G48 Water Mixture 50 Extended Life Antifreeze 10 Autumn J Engine Sump Mecalac Low Ash Engine Oil 15W 40 or Shell Rimula RT4L 15W 40 API CH 4 CG 4 CF 4 CF ACEA ES E3 SAE 15W 40 10 400 K Fuel Tank Diesel DERV to EN590 10 400 L Centre Pivot Starplex All Purpose...

Страница 92: ...vot Starplex All Purpose Grease EP2 Lithium Complex Grease Gr Lic NLGI 2 Other Grease Points Multi Purpose Grease EP2 Lithium Grease Gr Li NLGI 2 9 19 Fluid Capacities Table 9 5 Fluid Capacities 800 21745 MECALAC PREMIUM HYDRAULIC 46 1 X 5 LITRE TIN 800 21746 MECALAC PREMIUM HYDRAULIC 46 20 LITRE 800 21747 MECALAC PREMIUM HYDRAULIC 46 209 LITRE Concentration Ratio Protection ºC Protection ºF 20 1 ...

Страница 93: ...Page 9 18 TA1EH 9 Maintenance Lubrication ...

Страница 94: ...nk Do NOT add coolant until system is cold 4 Loss of coolant Loose hose clips Split coolant hose Radiator leaking 10 2 Electrical Troubleshooting 1 Circuit breaker keeps tripping out Check wiring for damage and short circuits Check beacon socket if the rubber cover is split or fitted incorrectly water can enter 2 System Dead Check battery isolator is set to ON Check battery connections Check circu...

Страница 95: ...hooting 10 3 Hydraulic Troubleshooting 1 No Pressure Check if sufficient oil in tank 2 Machine will not steer Check steering lock is NOT fitted Check steering ram hoses for leaks 3 Skip will not raise or tip Check hoses for leaks ...

Страница 96: ...s fitted before lifting operations commence CAUTION With the engine dead the hydraulic system will not function the steering will still operate but under these circumstances steering wheel loads are high and the dumper must only be towed at very slow speeds NOTICE The machine may be towed at a maximum speed of 2km h 1 2 mph for a maximum distance of 50m Exceeding this speed or distance may damage ...

Страница 97: ...Page 11 2 TA1EH 11 Recovery ...

Страница 98: ...ke sure that the cooling system is adjusted for full protection for the climatic conditions expected at the storage location Adjust if necessary Parking After thoroughly cleaning the entire machine park it on a hard dry level surface that is free from grease and oil Lower the bowl body bucket blade and attachments Apply the parking brake Note If machine is delivered from the Mecalac facility with ...

Страница 99: ... or grease to brake discs Hinges Apply oil Seat Slide Adjusters Coat with grease Seats Armrests and Cushions When machine is not equipped with a cab cover these items with plastic or waterproof barrier paper and secure with adhesive tape Provide an opening in the underside of the protective materials to prevent condensation build up Cabs All windows doors and vents must be closed Hoods Hoodsides C...

Страница 100: ...the seals from drying out Check fuel tank is full of diesel 12 4 Decomissioning Before placing the machine into storage 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 the engine manufac...

Страница 101: ... Air Intakes Remove temporary storage covers from the air intake openings Hydraulic Cylinders Remove protective coating from piston rod surface Vents and Breathers Remove seals and plugs from all breather openings then install all breathers and vents Belts Adjust tension on all belts Engines Consult the relevant maintenance manual dealer for instructions on removing an engine from storage Transmis...

Страница 102: ...them Fire extinguishers must be readily available if cutting welding equipment is so used Fluids must be drained off into suitable containers and if possible recycled or otherwise disposed of in an environmentally friendly way in accordance with local regulations Where possible recyclable materials must be separated out and processed in accordance with local regulations using an authorised agent I...

Страница 103: ... pump and hydraulic motors to drive the wheels ISO International Standards Organisation Linch Pin Pin with spring loaded retaining clip Orbitrol Hydrostatic steering unit a valve controlled by the machines steering wheel that meters oil to the steering ram to turn the machine to the left or right Parking Brake Mechanical device to prevent machine moving when not in use R Clip A spring steel clip i...

Страница 104: ...Page 13 2 TA1 0EH 13 Glossary of Terms ...

Страница 105: ...TA1EH Appendices 1 Appendices Appendix 1 Hydraulic Diagrams ...

Страница 106: ...12 micron 0 5 Bar 3 8 BSP B B B 0 5 Bar 3 8 BSP 1 L R R A1 A2 1 X A2 R A1 1 X 1 L R 2 3 1 22 bar Rs2 370 bar 370 bar M4 M3 Rs1 M1 M2 C R G2 G1 BH A B S T2 T1 L R T P M 4 150bar A1 P L T B1 A1 B2 A2 B B B B B B COV00378 1 4 2 3 5 6 8 7 13 14 11 12 15 20 19 18 17 16 9 10 B ...

Страница 107: ... Orbitrol 6 Hydraulic Cylinder Steering 7 Wheel Motor MS E02 Rear Right 8 Wheel Motor MS E02 Rear Left 9 Check Valve 10 Check Valve 11 Wheel Motor MS02 Front Left 12 Wheel Motor MS02 Front Right 13 Main Hydraulic Pump Poclain PM25 14 Engine Kubota D1005 15 One WayRestrictor Arrows on body show free flow direction 16 Brake Valve 17 Hydraulic Tank 18 Filter 12 Micron 1 7 Bar 19 Oil Cooler 20 Hydraul...

Страница 108: ...Appendices 4 TA1EH Appendices ...

Страница 109: ...ail of the warranty the user undertakes to have the periodic maintenance defined in the the Manual of use and maintenance or Operator Manual or any other Supplier document relative to the maintenancecarried out by the specialised staff of an authorised SUPPLIER Distributor or workshop with SUPPLIER genuine filters and lubricants If requested by Supplier Buyer must return the defective equipment to...

Страница 110: ... Supplier INCIDENTAL OR CONSEQUENTIAL DAMAGE LIMITATIONS ON LIABILITY NOTWITHSTANDING ANYTHING TO THE CONTRARY CONTAINED IN THIS WARRANTY SUPPLIER SHALL NOT BE LIABLE FOR ANY AND SPECIFICALLY DISCLAIMS ALL INDIRECT CONSEQUENTIAL INCIDENTAL AND OTHER DAMAGES OR LOSSES OF ANY KIND INCLUDING BUT NOT LIMITED TO LOST PROFITS LOSS OF PRODUCTION LOSS OF USE DOWNTIME OR HIRE CHARGES INCREASED OVERHEAD LOS...

Страница 111: ......

Страница 112: ...MECALAC Construction Equipment UK Ltd Central Boulevard ProLogis Park Coventry CV6 4BX UK Tel 44 0 2476 339 400 www mecalac com Mecalac Mecalac mecalac ...

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