Thwaites 9 390 tonne ton dumper workshop service manual

T0469 © Thwaites Limited Tier II: Issue 1 Service manual 9 tonne 390 – 9 Tonne Front Tip

9 tonne

9 tonne This manual has been written to provide maintenance and service information necessary to keep the Thwaites machine operating safely and efficiently throughout its service life. Prior to Commencing Maintenance Work You Must : • Read and fully understand the enclosed working instructions. • Ensure that any required safety precautions have been taken. • Adhere to safety notices contained within this manual. • Fully understand the risks involved and be competent to perform the work. • Use only genuine spare parts as replacement items. • Ensure that prior to the machine being used, after maintenance work has been completed, all safety checks and tests have been completed. Any problems please contact your local distributor In compiling this document we have endeavoured to provide the most up-to-date and accurate information. Due to Thwaites continual product development we reserve the right to amend information contained within this manual without prior notice. INTRODUCTION

9 tonne Technical Specification ................................................... 1 Maintenance .................................................................... 2 CONTENTS

9 tonne Machine Identification .................................................. 1.1 Location of Major Components ................................... 1.2 Torque Settings/Capacities .......................................... 1.3 SECTION 1 - TECHNICAL DATA

9 tonne 1.1 Serial Numbers Note machine serial numbers. Always quote them in communication with Thwaites dealer or Head Office. Model Type (Fig 1.) Vin Nº (Fig 1.) Engine Serial Nº (Fig 2.) Gearbox Serial Nº (Fig 3.) Axle Serial Nº (Fig 4.) Transfer Box/Drive Motor Serial Nº (Fig 5.) MACHINE IDENTIFICATION Fig. 1 Fig. 2 Fig. 3 Fig. 4 Fig. 5

9 tonne 1.2 LOCATION OF MAJOR COMPONENTS 1. Skip/Bucket 2. Operator Manual Pocket 3. Wheel 4. Axle 5. Propshaft Lower Rear 6. Propshaft Top Rear 7. Tranfer Box 8. Propshaft Front 9. Chassis Locking Bar 10. Battery Box 11. Fuel Tank 12. Engine 13. Radiator/Oil Cooler 14. Hydraulic Tank 15. Gearbox 16. Steering Ram 17. Kinglink 18. Skip Prop 19. Tipping Ram

9 tonne 1.3 System Fluid Capacities Ltrs Engine oil (with filter) ............................................................. 12.0 Transmission .......................................................................... 18.5 Axle Front ............................................................................... 25.0 Axle Rear ................................................................................ 25.0 Transfer case ............................................................................ 0.6 Cooling system ...................................................................... 23.0 Hydraulic system ................................................................... 74.0 Brake reservoir ......................................................................... 0.3 Fuel tank ................................................................................. 68.0 Torque Settings Nm Axle Bolts ................................................................................ 607 Bearing mounting plate bolt .................................................... 56 Centre pivot ............................................................................. 554 Diesel/ hyd tank drain plugs ..................................................... 25 Engine/Gearbox ....................................................................... 56 Eng Brkt/chassis mtg ............................................................... 250 Eng/Brkt/eng mtg ...................................................................... 77 Kinglink bearing pins upper .................................................... 486 Prop bolts straps ........................................................................ 77 Prop bolts G/box ..................................................................... 118 Ram Pin Nuts ........................................................................ 250+ ROPS Frame ............................................................................ 250 Rear Cover ............................................................................... 250 Transfer Box ............................................................................ 250 Wheel nuts .............................................................................. 680 Weight of components Kg Rigid ROPS ................................................................................ 70 Hinged ROPS ............................................................................. 90 ROPS/FOPS ............................................................................. 240 Rear cover ............................................................................... 170 Engine cover s/w seat ............................................................... 67 Rear grill panel ........................................................................ 16.5 Towing jaw and pin .................................................................. 4.0 Torque settings Nm Rear cover/chassis .................................................................. 250 ROPS frames/cover ................................................................. 250 Towing bracket .......................................................................... 56 Support bracket ......................................................................... 56 TORQUE SETTINGS AND CAPACITIES

9 tonne Lubrication And Maintenance Chart ........................... 2.1 Lubrication And Maintenance Schedule ..................... 2.2 Safe Working Practice .................................................. 2.3 First 100 Hour Service - (Engine) ................................. 2.5 First 100 Hour Service - (Hydraulic) ............................. 2.6 First 100 Hour Service - Transmission ......................... 2.7 First 100 Hour Service - Axle oil ................................... 2.8 10 Hour Service - Cooling system ............................... 2.9 10 Hour Service - Engine oil/fuel system .................. 2.10 10 Hour Service - Transmission/Air Filter .................. 2.11 10 Hour Service - Brake test ....................................... 2.12 10 Hour Service - Brake Oil ........................................ 2.13 50 Hour Service - Hydraulic Oil ................................. 2.14 50 Hour Service - Drivebelt ........................................ 2.15 250 Hour Service - Brake adjustment ........................ 2.16 Note: The following service period recommendations are the maximum permissable and should never be exceeded. 250 Hour Service - Engine Oil & Filter ....................... 2.18 500 Hour Service - Axle ............................................. 2.19 500 Hour Service - Axle/Transmission ...................... 2.20 500 Hour Service - Fuel Filter/Air filter ....................... 2.21 500 Hour Service - Hydraulic Oil Filter ...................... 2.22 1000 Hour Service - Transmission/Transfer box ....... 2.23 2000 Hour Service - Cooling system ......................... 2.24 2000 Hour Service - Hydraulic oil .............................. 2.25 Recommended Lubricants ......................................... 2.26 SECTION 2 - MAINTENANCE

9 tonne 2.1 IMPORTANT NOTE After first 100 hours: Change engine oil; Change engine oil filter; Change hydraulic oil filter element; Change transmission oil filter; Change Axle oil (including hubs); Check idle speed. LUBRICATION AND MAINTENANCE CHART COOLANT 1 H²0 + 33% Antifreeze ENGINE OIL 2 BP Vanellus C5 Global TRANSMISSION OIL 3 BP Autran MBX OTHER SERVICES 4 Wheel Nut Tightness INDUCTION 5 Clean Filters BRAKES 6 Operation of Brakes FUEL 7 Diesel AXLE OIL 8 BP Tractran 9 HYDRAULIC OIL 9 Energol HLP HM32 TRANSFER BOX 10 BP Energear Hypoid Gear + Transmission 80W-90 11 Tyre Pressure GREASE 12/13 BP Energrease BRAKE SYSTEM 14 BP Energol HLP HM32 OTHER SERVICES 15 Drive Belts OTHER SERVICES 16 Hoses OTHER SERVICES 17 Bolt tightness (Ref Page 1.3) BATTERY 18 Battery Cable Connections LAP BELTS 19 Replace

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Thwaites 9 390 tonne ton dumper workshop service manual

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