Thwaites 5 6 7 8 9 tonne ton dumper workshop service manual

T0479 © Thwaites Limited April 2006 Mach 490, Mach 550, Mach 560, Mach 566, Mach 555, Mach 564, Mach 568, Mach 557, Mach 565, Mach 569 Service manual 5-9 tonne Mach 566 – 6 Tonne Powerswivel Mach 568 – 7 Tonne Front Tip

5-9 tonne D C A B C E F 1 Park dumper on firm level surface and apply parkbrake. 2 Chock wheels 3 Push seat fully to rear of slide adjusters. 4 Open engine cover. 5 Disconnect air cleaner tube (jubilee clip). 6 Unbolt and remove towing jaw & pin (Fig. 1(B)) 7 Remove towing support bracket nuts and bolts (Fig. 1(A)) 8 Attach suitable crane straps to top of ROPS frame (See component weights). 9 Remove rear grill panel (4 Bolts). 10 Loosen the bottom nuts and bolts both sides (Fig. 3(D)) DO NOT REMOVE. 11 Remove top two nuts and bolts on both sides (Fig. 2(C)). 12 Using suitable crane and slings pull back and lower rear panel and engine cover assembly onto safety straps (2 off). Re-assembly • Ensure that the air cleaner tube (Fig. 4, F) is fitted to the inlet pipe (Fig. 4, E) when re-assembling • Using the crane return rear panel to upright position. Note - Ensure oil cooler pipe routings are unobstructed. • Ensure all nuts and bolts are torqued correctly. WARNING • Keep hands/fingers away from hinged area of back panel • Heavy Components - Use suitable lifting equipment. WARNING Weight of rear cover assembly will vary depending on type of protective frame fitted to your machine. If your machine is fitted with a ROPS/FOPS canopy, this must be removed prior to hinging back or removing the rear panel. HOW TO HINGE BACK REAR COVER Fig. 1 Fig. 2 Fig. 3 Fig. 4

5-9 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

5-9 tonne Technical Specification ................................................... 1 Maintenance .................................................................... 2 CONTENTS

5-9 tonne 1.0 CONTENTS Machine Identification .................................................. 1.1 Location of Major Components ................................... 1.2 Torque Settings/Capacities .......................................... 1.3

5-9 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 Serial Nº (Fig 5.) MACHINE IDENTIFICATION Fig. 1 Fig. 2 Fig. 3 Fig. 4 Fig. 5

5-9 tonne 1.2 LOCATION OF MAJOR COMPONENTS 1 Skip 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 Slew Ram 19 Slew Ring 20 Skip Prop 21 Tipping Ram

5-9 tonne 1.3 System Fluid Capacities Ltrs Engine oil (with filter) ............................................................. 08.5 Transmission .......................................................................... 18.5 Axle Front/Rear (5-7t) ............................................................ 11.5 Axle Front/Rear (9t) ............................................................... 15.0 Transfer case ............................................................................ 0.6 Cooling system ...................................................................... 23.0 Hydraulic system ................................................................... 74.0 Brake reservoir ......................................................................... 0.3 Fuel tank ................................................................................. 68.0 Recommended Lubricants – see page 2.23 Torque Settings Nm Axle Bolts ................................................................................ 650 Bearing mounting plate bolts .................................................... 80 Centre pivot ............................................................................. 550 Diesel/ hyd tank drain plugs ..................................................... 25 Engine/Gearbox .............................................. (+ Loctite 243) 55 Eng Brkt/rubber mounts .......................................................... 250 Eng/Brkt/engine ...................................................................... 190 Kinglink bearing pins upper .................................................... 480 Prop bolts straps ........................................................................ 75 Prop bolts G/box ..................................................................... 120 Ram Pin Nuts (continue around to next split-pin hole) .......... 450 ROPS Frame ............................................................................ 250 Slew Ring Bolts ....................................................................... 170 Transfer Box ............................................................................ 250 Wheel nuts .............................................................................. 330 Weight of Components kg Rigid ROPS ............................................................................ 70kg Hinged ROPS ......................................................................... 90kg ROPS/FOPS ......................................................................... 240kg Rear Cover ........................................................................ 143.5kg Engine Cover c/w Seat ....................................................... 67.5kg Rear Grill Panel ................................................................... 16.5kg Towing jaw & pin ................................................................... 4.0kg Torque Setting Nm Rear Cover/Chassis ................................................................. 250 ROPS frames/Cover ................................................................ 250 Towing Bracket .......................................................................... 55 Support Bracket ......................................................................... 55 SECTION 1 - TECHNICAL DATA

5-9 tonne 2.0 Note: The following service period recommendations are the maximum permissable and should never be exceeded. Lubrication And Maintenance Chart ........................... 2.1 Lubrication And Maintenance Schedule ..................... 2.2 Safe Working Practice .................................................. 2.3 Every 10 Hours - Cooling ............................................. 2.5 Every 10 Hours - Transmission/Engine oil .................. 2.6 Every 10 Hours - Fuel system/Air filter ........................ 2.7 Every 10 Hours - brake test .......................................... 2.8 Every 50 Hours - Hydraulic Oil ..................................... 2.9 Every 50 Hours - Brake Oil ......................................... 2.10 Every 50 Hours - Drivebelt ......................................... 2.11 Every 50 Hours - Park brake & caliper adjustment .... 2.12 Brake pad replacement .............................................. 2.13 First 100 Hours - Hydraulic oil filter ............................ 2.14 First 100 Hours - Transmission oil filter ..................... 2.15 First 100 Hours - Engine oil/filter ................................ 2.16 Every 250 Hours - Engine Oil & Filter ......................... 2.17 Every 250 Hours - Axles and Transfer Case .............. 2.18 500 Hour Service - Transmission ............................... 2.19 500 Hour Service - Fuel Filter/Air Filter ...................... 2.20 500 Hour Service - Hydraulic Oil Filter ...................... 2.21 1000 Hour Service - Transmission ............................. 2.22 1000 Hour Service - Axle and transfer box oil .......... 2.23 2000 Hour Service - Cooling system ......................... 2.24 2000 Hour Service - Hydraulic oil .............................. 2.25 Recommended Lubricants ......................................... 2.26 SECTION 2 - MAINTENANCE

5-9 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 - Check idle speed. LUBRICATION AND MAINTENANCE CHART COOLANT 1 H²0 + 50% Antifreeze ENGINE OIL 2 BP Vanellus C5 Global 15W 40 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 (including hubs) 8 TRACTELF SF3 HYDRAULIC OIL 9 BP Energol HLP HM32 TRANSFER BOX 10 BP Energear Hypo 80W-90 11 Tyre Pressure GREASE 12/13 BP Energrease L21M BRAKE SYSTEM 14 BP Bartran HV32 OTHER SERVICES 15 Drive Belts OTHER SERVICES 16 Hoses OTHER SERVICES 17 Bolt tighness (Ref Page 1.3) BATTERY 18 Battery Cable Connections LAP BELTS 19 Replace WIRING/LIGHTS 20 Inspect ROPS 21 Inspect

Thwaites 5 6 7 8 9 tonne ton dumper workshop service manual

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