Thwaites 3 3.5 4 tonne ton dumper workshop service manual

3 – 4.5 Tonne hydrostatic hydrostatic hydrostatic hydrostatic hydrostatic © Thwaites Limited Tier II: issue 1 service manual

3 – 4.5

3 – 4.5 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

3 – 4.5 Technical Data 1 Maintenance 2 Contents Section

3 – 4.5 1.0 Section 1 - Technical Data Contents Machine Identification 1.1 Location of Major Components 1.2 Torque Settings/Capacities 1.3 Page

3 – 4.5 1.1 Fig. 3 Fig. 4 Fig. 2 Fig. 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) Axle Serial Nº (Fig. 3) Front Rear Drive Motor Serial Nº (Fig. 4) Drive Pump Nº (Fig. 5) Machine Identification Section 1 - Technical Data Fig. 5

3 – 4.5 1.2 3 9 12 18 17 16 15 14 2 1 4 5 6 78 10 13 4 19 3 11 Location of Major Components 1. Skip/Bucket 2. Operator Manual Pocket 3. Wheel 4. Axle 5. Propshaft 6. Transfer Box 7. Chassis Locking Bar 8. Battery Box 9. Hydraulic Tank 10. Engine 11. Radiator/Oil Cooler 12. Fuel Tank 13. Hydrostatic Motor 14. Steering Ram 15. Kinglink 16. Slew Ram 17. Slew Ring 18. Skip Prop 19. Tipping Ram Section 1 - Technical Data

3 – 4.5 1.3 System Fluid Capacities Ltrs Engine oil 5.8 (with filter) Axle Front 6.0 Axle Rear 6.0 Cooling system 11.0 Hydraulic system 57.0 Brake reservoir 0.33 Fuel tank 45.0 Section 1 - Technical Data Torque Settings Nm Centre Pivot 486 Kinglink Bearing Pins Upper 330 Bearing mounting Plate Bolt 56 Wheel Nuts 270 Roll Bar Mounting Bolts 127 Slew Ring Bolts 169 Engine/Chassis Bolts 100 Engine Brackets/Engine Mounts 56 Diesel/Hydraulic Tank Drain Plugs 25 Axle Bolts 206

3 – 4.5 2.0 Section 2 - Maintenance Contents Lubrication and Maintenance Chart 2.1 Lubrication and Maintenance Schedule 2.2 Safe Working Practice 2.3 10 Hour Service - Cooling/Engine Oil 2.4 10 Hour Service - Hydraulic Filter/Air Filter 2.5 10 Hour Service - Axle 2.6 First 50 Hour Service - (Drive Belt) 2.7 First 50 Hour Service - (Engine) 2.8 First 50 Hour Service - (Hydraulic) 2.9 Page Page Note: The following service period recommendations are the maximum permissable and should never be exceeded. 50 Hour Service - Axle/Brake Oil 2.10 250 Hour Service - Engine Oil & Filter 2.11 250 Hour Service - Oil Sample 2.12 250 Hour Service - Fuel System 2.13 250 Hour Service - Fuel System 2.14 500 Hour Service - Park Brake 2.15 500 Hour Service - Hydraulic Oil Filter 2.16 1000 Hour Service - Axle Oil/Cooling Sys. 2.17 2000 Hour Service - Hydraulic Oil Replace 2.18 Recommended Lubricants 2.19

3 – 4.5 2.1 IMPORTANT NOTE After first 50 hours - Change engine oil - Change engine oil filter - Change hydraulic oil filter element- Adjust fan belt tension. Lubrication and Maintenence Chart Section 2 - Maintenance COOLANT 1 H²0 + 33% Antifreeze ENGINE OIL 2 BP Vanellus C5 Global HYDRAULIC OIL 3 BP Bartran HV46 OTHER SERVICES 4 Wheel Nut Tightness INDUCTION 5 Clean Filters BRAKES 6 Operation of Brakes FUEL 7 Diesel AXLE OIL/ 8 BP Terrac Super TRANSFER BOX Transmission S OTHER SERVICES 9 Tyre Pressure - Refer to Operators Manual GREASE 10 BP Energrease BRAKE SYSTEM 11 BP Energol HLP HM32 OTHER SERVICES 12 Fan/Drive Belts OTHER SERVICES 13 Hoses BATTERY 14 Battery Cable Connections OTHER SERVICES 15 Bolt tightness (Ref Page 1.3) LAP BELTS 16 Replace

Thwaites 3 3.5 4 tonne ton dumper workshop service manual

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