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1. N M 4 5 aunssaud TO JNIDNA TECHNICAL INFORMATION 3 7 AUDIBLE ALARM The following instructions should be carried out when fitting the Audible Alarm Timer Installation 1 Remove the existing connectors from the red and blue wires of the timer and audible alarm replace them with male crimp on bullet connectors The yellow wire of the alarm may be cut off 2 Position the timer on the radiator stay midway between the water temperature sender and radiator secure with the cable tie provided Connect the blue and red wires of the timer and alarm using female bullet connectors as illustrated below On the timer fit a 1 4 female lucar connector to the pink wire and fit male crimp on bullet connectors to both the brown and white 4 Connect the pink wire to the centre terminal on the water temperature sender Connect the brown wire to the green brown wire in the existing wiring loom Some machines are fitted with a diode in the green brown wire Connect white to the black earth wire in the existing wiring loom 5 Check that the start up alarm sounds off for approximately seven seconds when the starter switch is turned on Tape up all the wiring connectors Secure the wiring with nylon cable ties General Do not earth the blue or red wires connected to either t
2. Continued gt 7 1 454000 455000 456000 457000 Dumpers CONTROL VALVE forward tipping skip Item 32A 33 34 35 36 40 41 41A 42 43 44 45 46 47 90 51 52 55 56 57 V601155 Jan 04 Part no V600109 V600066 V600068 V600069 V602479 V602447 V602446 V602480 V602453 V600109 V600068 V602478 V600066 V602481 V602474 V602450 V602452 V600069 V602449 V602448 Serial no Description HANDLE assembly NUT HANDLE order assembly KNOB GAITER Oct 93 LEVER assembly SCREW WASHER LEVER amp CLEVIS assembly CLEVIS LEVER assembly KNOB LEVER NUT PIN LINK assembly PIN clevis CLIP spring LINK GAITER BRACKET PLATE seal N gt bh 45500085 Dumper with rotating skip JOYSTICK MONOBLOC CONTROL VALVE Item 10 11 12 13 14 15 16 V601155 Oct 04 Part no V2004580 V602693 V602689 V602690 V602691 V602692 V602773 V603617 V603618 57505 1 603619 V603620 V603621 V603622 Description KIT seals GAITER STEM ROD c w lock nut amp knob CUP c w screw STUB LEVER HOUSING pivot BRACKET SCREW grub SPOOL PIN roll PLATE FIXINGS for plate 7 2 Qty VALVE monobloc control JOYSTICK 1 AR Kit 1 7 B 2A 45500085 Dumper with rotating sk
3. 4015 401 1H9M30IS HIHVAH YOLVOICNI 3 9 TECHNICAL INFORMATION IFCUI electrical DNIHIM XOB3SN4 WOO S HOLO3NNOO HOLOW H3dIM HV3H NI d3HSVM HOLON H3HSVM INOH4 N 8 HOLON c HOLO3NNOO H3dIM INOHA r B m HOLIMS NOOV38 0L 6 7 99 HOLIMS HJLHVIS HOLIMS 3dIM HSVM INOUJ 016 7 9S 3 10 TECHNICAL INFORMATION HANDBRAKE PROTECTION CIRCUIT This circuit prevents the machine from being driven when the handbrake is applied x _ tal 62 u 59 590 FUSE BOX YELLOW BLACK E 3 8 RING BLACK y SA TO EARTH 5 OX BLUE WHITE REAR OF LAMP CLUSTER SOLENOID DUMP VALVE BLUE WHITE YELLOW BLACK 1 4 LUCAR INSULATED CONNECTORS YELLOW BLACK YELLOW BLACK YELLOW BLACK YELLOW BLACK PROTECTION SWITCH DUMP PEDAL HANDBRAKE CURRENT FLOW A DIODE ASSEMBLY O o x lt o gt LLI LL lt o TO SWITCHES 4mm RINGS TECHNICAL INFORMATION 3 11 DUMP PEDAL SAFETY START SWITCH For machines with electronic dump and mechanical gear change DUMP PE
4. 454000 455000 456000 457000 Dumpers TIPPING CIRCUIT forward tipping skip Item 13 14 15 20 21 23 22 50 51 52 53 54 55 V2002854 V2004760 8504 17505 7504 100506 119513 122506 119508 100504 122504 100504 154502 96509 100503 122503 V2002474 315040 26S03A 317S02B 317S02B 3650200 3650200 601155 issue 04 0198 Description VALVE control see page 7 B 1 valve handle stop BOLT WASHER spring NUT SEAL bonded ADAPTOR male ADAPTOR male ADAPTOR male SEAL bonded ADAPTOR male SEAL bonded FITTING tee m m f swivel FITTING elbow m f swivel SEAL bonded male 7 3 Qty 02 NO RAM tipping see page 7 R 2 2 CLIP P see page 7 4 SCREW set see page 7 A 4 NUT see page 7 A 4 WASHER spring see page 7 4 HOSE control valve return to tank HOSE pump to control valve HOSE control valve to rams extend HOSE control valve to rams retract HOSE ram to ram extend HOSE ram to ram retract bh 454000 455000 456000 457000 Dumpers 5 7 4 Item 10 11 12 13 14 15 17 V601155 issue 04 0198 Part no V2000325 V2003559 11504 267506 17505 7504
5. Serial Description Qty 1 V2004466 RAM tipping 2 2 64S02A HOSE ram to ram 2 3 321S02B HOSE front chassis 2 4 317S02B HOSE rear chassis 2 5 122S03 ADAPTOR 2 6 154S02 FITTING T piece 2 10 V2003253 TIE 6 15 V2004537 CLIP hose 2 16 11503C SCREW set 2 17 17S04 WASHER spring 2 18 267S05 WASHER flat 2 V601155 issue 04 0198 7 4 45500085 Dumper with rotating skip PAT SA 6 QIS Ta ROTATING HYDRAULIC CIRCUIT rotating skip 7 4 1 30287A03 2 25501 3 25501 4 154501 5 122502 6 3185010 601155 issue 04 0198 Serial Description rotating HOSE ram to ram HOSE front chassis FITTING piece m m f swivel ADAPTOR m m HOSE rear chassis Qty STEERING RAM with spherical bearings Item Part 1 V2002565 1 V2003542 2 72002566 30121A0109 4 30121A0112 5 57504 2 6 30121A0303 7 30121 0105 0 131501 11 5 204 V601155 Jan 04 Serial Description 2001 2041 RAM assembly CYLINDER ROD ram PISTON rear PISTON front SCREW grub RETAINER CAP end NIPPLE grease KIT seals 7 R 1A with bushes 7 R 1A Item 1A Part no Serial no Description Qty V602700 2042 RAM with BUSHES assembly 1 V2000952 RAM assembly without bushes 1 V2004197 CYLINDER 1 V2004198 ROD ram 1 30121 0109 PISTON rear 1 V2005014 RESTRICTOR as requi
6. mb FUEL PRE FILTER see page 3 18 ENGINE turbo DIPSTICK OIL FILTER FUEL FILTER element assembly FAN BELT FUEL PRE FILTER see page 3 18 Stage 1 emission compliant engines ENGINE naturally aspirated DIPSTICK OIL FILTER FUEL FILTER element assembly FAN BELT m FUEL PRE FILTER 3 18 ENGINE turbo DIPSTICK OIL FILTER FUEL FILTER element assembly FAN BELT gt mb FUEL PRE FILTER see page 3 18 For all other engine components see the Engine Parts Catalogue V601155 Sept 03 3 11 454000 455000 456000 457000 Dumpers HYDRAULIC DRIVE Item Y O 14 15 16 17 18 19 25 26 27 28 29 30 601155 issue 04 0198 V600540 V600540 V600942 V600583 V600943 V600944 V600945 9509 V600586 V600946 V600923 V600924 V600947 600587 V602242 V602253 V602252 V2004202 685050 68504 Serial k Description PLUG PLUG WASHER HOUSING adapter SEAL O ring GEAR NUT NUT WASHER SCREW STUD NUT PIN JOINT 3 A 11 Qty bh _b These items obsolete replace them it will be necessary to fit the complete kit V602242 as shown below DRIVE hydraulic pump assembly DRIVE unit SEAL O ri
7. N N N L COVER grease NUT Binx self locking SCREW set 1 NUT 2 WASHER spring 1 WIRE locking SEAL lead locking To lock fuel adjustment screws on pump 3 D 1A 454000 455000 456000 amp 457000 Dumpers ACCELERATOR PEDAL amp LINKAGE Item hh pa 12 13 14 15 16 20 21 22 23 26 V601155 issue Sept 03 V2003245 V2003246 V2004699 V2004699 7502 V2004756 43503 6505 10504 131502 425434000 11503 17504 7503 176501 87505 Serial 2356 2331 2356 2331 Description 4S4000 4S5000 4S6000 Dumpers 4S7000 Dumper CLEVIS CLIP spring ROD Not 4S7000 ROD 4S7000 Only NUT PEDAL assembly BUSH BOLT pivot WASHER flat NIPPLE grease SPRING SCREW set WASHER spring NUT COVER grease nipple NUT Binx self locking 3 D 1A Qty N PM 454000 455000 456000 457000 Dumpers PER 36 RADIATOR ASSEMBLY Item Part V2002312 V2003359 V600660 V2002286 V600661 178SPRO5E GA BB ar 6 7 28501 67501 8 10534 9 72003210 10 100502 11 2003267 Bb 2004762 602673 V600660 V602674 V600661 11502 267504 17503 6C 7502 7 11502 17503 8 267504 9 72003210 10 100502 11 2003267 6011
8. pump Loosen the vent screw T on the main ae V filter Operate the priming lever of the fuel Sar lift pump V until fuel free of air comes ET Ni from the banjo Tighten the screw Note l the drive cam of the fuel lift pump is at the point of maximum lift it will not be possible to operate the priming lever In this situation the crankshaft must be rotated one revolution WARNING Use a spanner to prevent movement of the fuelled starting aid W when the union nut X is loosened or tightened Loosen the union nut X at the fuelled starting aid and operate the priming lever of the fuel lift pump until fuel free of air SERVICE 2 19D comes from the connection Tighten the union nut at the starting aid Note For Lucas fuel injection pumps Loosen the union nut at the oullet connection of the low pressure fuel leak off pipe which is on top the governor housing of the fuel injection pump Operate the priming lever of the fuel lift pump until fuel free of air comes from the connection Tighten the union nut WARNING Do not tighten the union nuts of the high pressure pipes more than the recommended torque tension If there is a leakage from the union nut ensure that the pipe is correctly aligned with the atomiser inlet Do not tighten the atomiser union nut more as this can cause a restriction at the end of the pipe This can affect the fuel delivery Loosen the high pres
9. 1 602463 V602427 V602428 V602430 V601155 Jan 98 cab 8 0 3 Serial Description 2086 insulation cab complete complete kit is cut from the following materials FOAM PVC FACED 30mm thick sheet FOAM PVC FACED 15mm thick sheet SEALING STRIP 25 x 25mm x 1metre Qty 1 1 1 454000 455000 456000 457000 Dumpers INSULATION seat box 8 D 4 Partno Serial no Description Qty 1 V2004349 2086 KIT insulation seat box 1 2 11502 SCREW set 10 3 10S56 WASHER flat 10 4 61502 NUT binx self locking 10 V601155 Jan 98 454000 455000 456000 457000 Dumpers 1 V2004740 2 11503B 3 17504 4 267505 10 602416 32004742 11 178SPRO5E 12 602417 13 101507 16 V602420 32004741 17 11502 18 59514 20 602415 21 eO 25 26 26 101507 30 602432 31 V2004374 35 V602433 36 97505 40 602418 41 2003111 45 602421 46 2003253 V601155 Jan 98 Description HEATER SCREW set WASHER spring WASHER flat OUTLET rear demist BRACKET rear demist not illustrated SCREW self tapping DUCT rear demist RIVET OUTLET front demister front demist not illustrated SCREW self tapping OUTLET eyeball seat box KR A N SCREW self tapping 3 CONNECTOR duct seatbox 2 CONNECTOR duct
10. WHEN MACHINE UNATTENDED REMOVE STARTING HANDLE TO PREVENT UNAUTHORISED USE 17 N 55 at at DECALS amp PLATES Item 10 11 12 13 14 15 16 17 V601155 issue 04 0198 Part no V2003598 V2004223 V2004119 V2003665 V2004224 V2004225 V2004226 V2004227 V2004229 V2004245 V2004236 V2004282 V2004307 V2004384 V2004642 V2004288 V2004450 Serial no 9 A 3 Description DECAL British made DECAL DECAL Do not sling DECAL Sling point DECAL Chassis articulation lock DECAL ISO skip support DECAL Move seat forward DECAL Battery isolator DECAL Operators handbook DECAL No buckets No forks DECAL Towbar loadings DECAL Hot surfaces DECAL Electrical hazard DECAL Payload 7000Kg DECAL Rotating hazard DECAL Key Handle DECAL Gradiants Qty 9 4 454000 455000 456000 457000 Dumpers NOT LEAVE THIS MACHINE WITH THE SKIP RAISED BE AWARE THAT THE SKIP WILL LOWER QUICKLY TO THE CHASSIS IF THE TIPPING LEVER IS OPERATED WHEN THE ENGINE IS SWITCHED OFF THIS HANDBRAKE OPERATES ON THE TRANSMISSION AND MUST ONLY BE USED FOR PARKING OR EMERGENCY STOPS DAMAGE MAY BE CAUSED IF USED AS A SERVICE BRAKE TO AVOID INJURY DO NOT STAND BETWEEN THE SKIP AND MUDGUARDS AT ANY TIME UNLESS THE SKIP IS FULLY RAISED AND LOCKED iN POSITION ROPS FOPS STRUCTURE NOT 10 BE REPAIRED IF DAMAGED A REPLACEMENT TRUCTURE MUST BE
11. 72003675 2041 steer front 1 4 11504 SCREW set 1 4A 11504 20441 SCREW set 1 5 17505 WASHER spring 1 17505 2041 WASHER spring 1 6 267506 WASHER flat 1 6A 267506 2041 WASHER flat 1 8 V2003599 2041 SPACER front pin 1 9 V2003097 GUARD ram 1 10 V2003098 COVER steering ram 1 11 11503A SCREW set 2 12 17504 WASHER spring 2 13 267505 WASHER flat 2 14 11S03A SCREW set 2 15 17504 WASHER spring 2 16 176501 2 17 2003677 2041 RETAINER 1 18 59507 2041 NUT nylon insert 1 19 56508 NUT locking thin 1 If any of the items marked require replacing it will be necessary to discard ALL items and fit the components shown on page 8 5 When ram V2002565 item 1 is fitted the spacer V2003599 item 8 must always be used and not the spacers 10531 and 10520 items 20 amp 21 on page 8 5 V601155 July 95 454000 455000 456000 Dumpers PINS amp GUARDS For steering ram with bushes Part Serial no Description Qty 1 V2000952 2042 RAM steering see Hydraulic Section 1 2 2003514 2001 steer 1 V2004064 2042 PIN steer ram front 1 4 115048 2001 SCREW set 1 5 17505 2001 WASHER spring 1 6 267506 2001 WASHER flat 1 8 72004200 2042 BUSH 9 V2003097 2001 GUARD ram 10 V2003098 2001 COVER steering ram 11 11S03A 2001 SCREW set 12 17504 2001 WASHER spring 13
12. CHASSIS rear ltem 22 23 24 25 26 26 26A 27 27 27 28 V2002485 V2002128 V2004301 11506 17508 7506 V2002654 115130 17507 115130 17507 267508 V2002694 V2004751 V2002691 V2004750 8506 V2002148 V2001643 61506 11506H 11506E 267508 17508 8506 11506E 7506 601155 Jan 03 Serial 2001 dt H H H H H dt 2330 2331 2355 2356 8 2 Description CHASSIS rear GUARD bumper PIN drawbar SCREW set WASHER spring NUT BRACKET mounting transfer gearbox SCREW set WASHER spring SCREW set WASHER spring WASHER flat BRACKET engine mounting L H BRACKET engine mounting L H BRACKET engine mounting R H BRACKET engine mounting R H BOLT to frame WASHER special MOUNT rubber NUT self locking SCREW set bracket to engine SCREW set bracket to engine WASHER flat WASHER spring BOLT bracket to engine SCREW set bracket to engine NUT Turbo engines Naturally asperated engines Qty N M B N Continued gt 454000 455000 456000 457000 Dumpers Den CHASSIS rear 8 A 2 Part Serial Description Qty 30 V2001688 transmission mounting Compact Shuttle 2 30 V2004697 BRACKET transmission mounting Compact Plus 2
13. N DN NN 4 D 2A 454000 455000 456000 amp 457000 Dumpers CONTROL LEVER forward neutral reverse 4 D 2A Electronic operation Plus Transmission Part Serial no Description Qty 2408 4S4000 4S5000 4S6000 Dumpers 2404 4S7000 Dumper 1 V2004691 SWITCH forward neutral reverse 1 198S09K SCREW posidrive head special 4 3 267S03 WASHER flat 4 4 218515 NUT 4 V601155 Jan 04 454000 455000 456000 457000 Dumpers LEVER Item Part no Serial no 2001 2407 2001 2403 1 V2001679 2408 2404 1 V2004689 2 307120000 85050 4 7505 5 17506 6 230505 V601155 Jan 04 4 D 3 Description Qty 4S4000 4S5000 4S6000 Dumpers 4S7000 Dumper LEVER gear 1 Used with Shuttle transmission 4S4000 4S5000 4S6000 Dumpers 4S7000 Dumper LEVER gear 1 Used with Compact Plus transmission KNOB 1 BOLT 1 NUT 1 WASHER spring 1 NUT locking thin 1 454000 455000 456000 457000 Dumpers x 10A 15 078 32 PROPELLER SHAFTS Item 10 10 11 12 13 15 15A 15B 15C 15D 15E 16 17 601155 May 07 V2001612 V602487 V2004695 V600413 6S03A 87503 V2001640 V600413 131501 6S03GB 87S03 V2002313 V600413 131S01 6S03A 87S
14. 2407 454000 455000 456000 Dumpers 2408 2403 457000 Dumper 2404 31 8506 2 32 V2002148 WASHER special 4 33 V2001643 MOUNTING rubber 2 34 61S06 NUT 2 35 11505 SCREW set 8 36 17506 WASHER spring 8 37 267509 WASHER flat 12 40 V2002709 BRACKET radiator to chassis 1 41 115040 SCREW set 4 42 17505 WASHER spring 4 43 267506 WASHER flat 8 44 7504 4 V601155 Jan 04 3 454000 455000 456000 457000 Dumpers 1 V2001214 V2001238 V2003534 V2004440 V2003535 V2004441 V2003536 V2003537 CO CO CO CO CO D V2001226 5 11S05D 6 17S06 7 267S07 7 513211900 00 150515 9 59516 10 131501 11 131502 12 176501 V601155 Jan 98 Serial 2001 2065 2066 Description YOKE centre BUSH WASHER thrust 4mm WASHER thrust 4 5mm WASHER thrust 5mm WASHER thrust 5 5mm WASHER thrust WASHER thrust 7mm PIN pivot SCREW set WASHER spring WASHER flat WASHER tab WASHER flat NUT nylon insert NIPPLE grease straight NIPPLE grease 90 deg COVER grease nipple 8 3 Qty AR AR AR AR AR AR 454000 455000 456000 Dumpers PINS amp GUARDS 8 A 4 For steering ram with spherical bearings Part Serial no Description Qty 1 V2002565 2001 2041 RAM steering c w spherical bearings see Hydraulics Section 1 2 2003514 steer ram rear 1
15. UNIT steering Danfoss EM amp S KIT seals Danfoss KIT seals EM amp S IMPORTANT Be sure to quote the make of steering unit when ordering kits WASHER shakeproof REXROTH ZF steering unit KIT Steering unit amp fittings SCREW set WASHER spring SPACER UNIT steering Rexroth ZF KIT seals J J N lt WI Doo p A 454000 455000 456000 457000 Dumpers 2 W 1 WHEELS 5 Item Jo NO NO 24572 24573 V2000925 20512 23505 V600423 V600235 24578 24579 V2000925 20522 23505 V600423 V600235 24574 24575 V2001606 V2003335 23510 V2003358 V600423 V600235 24590 24591 V2004930 20525 23524 V2003358 V600423 V600235 V601155 issue 04 0198 Axle serial no Description 454000 WHEEL assembly L H WHEEL assembly R H RIM wheel TYRE 12 5 80 x 18 10 12 5 x 18 NOT USED NUT wheel WASHER spring 4S5000 not rotating skip WHEEL assembly L H WHEEL assembly R H wheel TYRE 12 5 80 x 18 12ply 12 5 x 18 NOT USED NUT wheel WASHER spring 455000 rotating skip 456000 457000 WHEEL assembly L H WHEEL assembly R H RIM wheel TYRE 16 70 x 20 WHERE USED VALVE WHERE USED NUT wheel WASHER spring Alternative 18 x
16. V2003215 11S02A 267504 17503 7502 V2003325 V2003531 267505 44501 2004464 2003563 2003109 267504 17503 7502 10537 02 10538 02 11501 267503 17502 7501 11501 V2004611 V2004530 11504D V601155 Jan 98 8 2 Description Qty COVER rear 4S4 5 6000 1 COVER 457000 1 SEAL for inside of document box illustrated 1m SEAL rubber 1 rubber 1 2 SCREW c sunk slotted 12 NUT locking 12 WASHER flat 12 HANDLE 3 SCREW set 6 WASHER flat 6 WASHER spring 6 NUT 6 STRUT gas 2 BUSH 4 WASHER flat 6 PIN split 6 KIT insulation FASTENER fir tree STOP rubber 2 WASHER flat 2 WASHER spring 2 NUT 2 CATCH toggle 2 PLATE catch 2 SCREW set 4 WASHER flat 12 WASHER spring 12 NUT 12 SCREW set 8 BRACKET 2 GUARD rear 1 SCREW set continued gt 454000 455000 456000 457000 Dumpers 8 2 GUARD COVER Item 52 53 54 55 56 5 58 59 60 61 62 63 Serial 17505 267506 7504 V2003225 11505F 267507 17506 7505 V2004533 11S03B 17S04 267505 601155 Jan 98 Description WASHER spring WASHER flat NUT SEAL order by metre SCREW set WASHER flat WASHER spring NUT GRILL guard SCREW set WASHER spring WASHER flat 8 B 2A Qty O 00 8 3 454000 455000 456000 457000 Dumpers CASING steering colu
17. 178mm AR 28 600371 SHIM 381mm AR 28 V600372 SHIM 508mm AR 29 600767 SPACER 1 30 600479 BEARING 4 31 V600768 SPACER 1 32 V600769 GEAR 1 33 V600770 SLEEVE 1 34 V600771 1 35 600401 BEARING 2 36 V600772 GEAR 1st 43T 1 37 600773 SYNCHRO 1st 2nd 1 38 V600398 SLEEVE 2 39 V600774 GEAR 2nd 35T 1 40 600775 output 1 41 600776 GEAR 3rd 271 1 42 600777 SYNCHRO 3rd 4th 1 43 600778 CIRCLIP 1 44 00779 GEAR 4th 207 1 45 600780 SHIM 051 45 V600781 SHIM 076mm AR 45 V600782 SHIM 178mm AR 45 V600783 SHIM 559mm AR V601155 issue 04 0198 continued gt 454000 455000 456000 457000 Dumpers 4 3 Shuttle Transmission 4 B 3 GEARS amp SHAFTS Serial Description 46 V600784 SPACER 2 47 600785 SEAL 1 48 V600786 YOKE 1 49 7600787 GEAR 5 drive 38T 1 50 V600 88 COUNTERSHAFT 1 Service Kits 600789 BEARING KIT main transmission AR Comprises items 2 10 14 30 33 amp 35 600865 THRUSTWASHER maintrans AR Comprises items 11 12 amp 16 above 600866 CLUTCH main transmission AR Comprises items 17 18 19 20 21 22 23 24 amp 25 above 600734 SEAL KIT main transmission AR Comprises items 38 40 42 amp 68 on page 4 B 2 plus items 13 24 amp 47 above 600867 RING main transmission AR Comprises items 17 21 amp
18. 20 21 22 Serial 2001 2407 2001 2403 V2004256 V2004257 V2004255 115050 267507 17506 7505 208561000 208561000 250166010 7501 17502 267503 8501 2001703 267507 2001704 44502B V2004260 V2004258 2003111 2003253 V601155 Jan 04 Description 4S4000 4S5000 4S6000 Dumpers 4S7000 Dumper VALVE transmission dump solenoid see also page 4 B 6 DIODE c w holder BRACKET SCREW set WASHER flat WASHER spring NUT SWITCH Operated by handbrake rod SWITCH Fitted behind dump pedal see also page 4 D 1A FITTING cable gland NUT WASHER spring WASHER flat BOLT BRACKET cable WASHER flat BRACKET fixed PIN split ROD connected to handbrake LOOM wiring STRAP nylon 200mm long STRAP nylon 380mm long Qty N n5 n5 N S Series Dumpers 454000 455000 amp Wheels AXLES amp MOUNTS AXLE HOUSING CROWN GEAR amp PINION DIFFERENTIAL WHEEL HUB BRAKES EPICYCLIC REDUCTION GEARS STEERING COLUMN WHEELS amp TYRES lt lt lt To beginning of Parts 2 A 1 2 A 2 2 A 3 2 A 4 2 5 2 6 2 7 2 5 1 2 W 1 2 1 454000 455000 456000 457000 Dumpers 2 2 2 5 2 4 N er page 2 A 7 page 2 A 6 13 2 3 AXLES amp MOUNTS Item 1 10 11 12 13 Part no Serial no
19. Compact Shuttle transmission Basic machine electrical circuit with Compact Plus transmission Audible alarm timer installation Road lights electrical circuit Cab electrical circuit Handbrake protection circuit Dump pedal safety start switch Handbrake safety start switch PARTS Page 2 14 2 17 2 21 2 23 2 26 2 27 2 29 2 34 2 36 2 38 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 3 10 3 11 3 12 INTRODUCTION HI The contents of this Handbook although correct at the time of publication may be subject to alteration by the Manufactures without notice Winget Limited operate a policy of continuous product development Therefore some illustrations or text within this publication may differ from your machine THE HANDBOOK WARNING The Operator must read all the Handbook and fully understand its contents before attempting to operate the machine THE HANDBOOK MUST NOT BE REMOVED FROM THE MACHINE The Handbook should be kept clean and in good condition Additional copies of the Handbook can be obtained from your Distributor The contents of this Operators Handbook are designed as a guide to the machine s controls operation working capacities and maintenance It is not a training manual Only trained operators should use this machine Consult your Distributor for details of authorised training courses In this Handbook are notes accompanied by a warning triangle WARNING These notes are used to ind
20. clean with fresh oil and replace Run the engine until the transmission has reached normal operating temperature With the engine at idle speed check that the oil level is at the maximum level on the dipstick R Top up if necessary with clean oil of the correct grade For the correct type and grade of oil see Specifications WARNING Do not overfill the transmission Overfilling usually results in oil breakdown due to excessive heat and aeration from the churning action of the gears Early breakdown of the oil will result in heavy varnish and sludge deposits that plug up oil ports and build up on splines and bearings Overfilling will also result in oil leaks 2 26 SERVICE TRANSFER GEARBOX First 50 operating hours Change transfer gearbox oil See Every 1000 operating hours or Every 250 operating hours Check transfer gearbox oil level WARNING Clean the area surrounding plugs before removing Remove the level plug V and filler oreather plug U Top up via the filler oreather plug hole U until the oil is level with the level plug hole V Replace plugs For the correct type and grade of oil see Specifications Everv 1000 operating hours or Change transfer gearbox oil WARNING When removing drain plug 2 be sure to stand to one side to avoid oil which will spill from the hole Dispose of waste oil into waste oil storage tanks If sto
21. en 603548 un V603549 V603550 603551 D V603552 V603553 ed V603554 n V603555 B V603556 V601155 issue Sept 03 Serial no Description Qty Small Parts Kit comprising of items 3 95 96 plus items 3 17 18 105 106 110 111 on page 4 3 Bearing Kit comprising of items 12 33 35 51 53 60 61 85 plus item 59 on page 4 B 3 O Ring Kit comprising of items 77 79 90 plus items 19 40 88 107 on page 4 B 3 Seal Kit comprising of items 6 10 76 78 115 plus items 11 92A 93 112 on 4 B 3 Snap Ring Kit comprising of items 36 68 72 Shim Kit comprising of items 45 46 47 48 49 50 55 56 57 58 Thrust Washer Kit comprising of items 14 43 62 Basic Overhaul Kit comprising of kits V603542 V603545 603546 V603550 V603548 V603544 V603547 V603556 V603549 Pump Kit comprising of items 11 92 93 on page4 B 3 Direction Valve O Ring Kit Core Tube Kit for Direction Valve Valve O Ring Kit Gasket Kit 454000 455000 456000 amp 457000 Dumpers Shuttle Transmission CONTROL VALVE Mechanically operated Not used Compact Plus Transmission Item 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 32 V601155 Jan 04 Part no V600790 V600791 V600793 V600794 V600795 V600796 V600797 V600798 V600799 V600800
22. 10848 01 4602331 V2004235 V2003037 15S01A V2003593 V2003574 2003575 V601155 Jan 04 Serial Description Qty DECAL KIT 4S6000 4S5000 4S6000 4S7000 Each kit contains all decals needed for one dumper Discard those decals in the kit that are not relevant to a particular dumper DECAL Winget 5 DECAL stripe blue red order by metre DECAL 454000 2 The decal 2001 715 is printed to read 454000 The should be removed before fixing the decal to four tonne dumpers that have torque converter transmissions DECAL 455000 2 DECAL 456000 2 DECAL 457000 2 DECAL Keep clear obsolete use 4A 2 DECAL Keep clear of crush zone 2 DECAL Engine Housing Lid Closed 2 DECAL Brake reservoirs 1 DECAL Neg Earth obsolete use 7A 1 DECAL Negative Earth 1 PLATE Serial SCREW drive type not illustrated 4 DECAL Tyre pressures 2 DECAL Noise level 1 DECAL Noise level 1 9 2 454000 455000 456000 457000 Dumpers 2 11 DO WORK UNDER UNPROPPED SKIP DUMP RETURN SAFETY WARNING Before starting this machine the operator should be familiar with the operating instructions issued by the manufacturer The manufacturer s rated capacity must never be exceeded Before carrying out any maintenance servicing or greasing always ensure that the engine has been switched off Never work on a machine while it is runnin
23. 16 V2003636 LIGHT L H rear assembly 1 V2004358 LENSE 1 17 V2003130 BULB indicator 12V 21W 1 18 72003145 BULB brake rear sidelight 12V 21 5W 20 V2003635 COWL rear light 2 25 V2003638 LIGHT head 2 26 V2004220 WASHER Special 2 30 V2003652 LIGHTS front assembly 1 V2003637 LIGHTS L H front not illustrated 1 2004356 LENS 31 V2003137 BULB sidelight 12V 5W 1 32 V2003130 BULB indicator 12V 21W 1 35 V2003634 COWL head amp sidelights 2 36 11505 SCREW set 2 37 11S05E SCREW set 2 38 17506 WASHER spring 4 39 7505 6 40 2003168 SWITCH brake 1 41 10504 WASHER flat 2 42 95505 1 43 72003642 SWITCH indicator 1 44 V2003640 UNIT flasher 1 45 72003639 number plate 1 V601155 Jan 04 Continued gt 5 5 454000 455000 456000 457000 Dumpers OS AS JS E ROAD LIGHTS ltem 50 51 52 53 54 55 56 5 58 60 61 62 63 64 Serial 2003557 V2003252 V20035 3 V2004043 191906000 11501 267503 17502 7501 2004768 11503 267505 17504 7503 V601155 Jan 04 9 A 5 Description CLIP P type GROMMET GROMMET CONDUIT CONNECTOR 1 4 female Lucar SCREW set WASHER flat WASHER spring NUT BRACKET brake switch operation SCREW set WASHER flat WASHER spring NUT Qty AR n5 N L 6 454000 455000 456000 457000 Dumpers ELECTRICS 5 A
24. 33 35 36 37 38 39 40 45 46 47 48 49 50 55 56 5 58 59 Serial V2004473 V2004579 11S05F 267507 61505 54509 V2004493 V2004135 11505E 267507 61505 V2004234 7508 17511 V2004466 V2002619 11503 61503 30287 03 6507 10506 107518 V2004679 V2004677 V2004678 85040 267506 59503 8507 V2004004 61507 555020 V2003851 902502 V2004212 902502 V2004217 106209000 176501 601155 Jan 98 Description CHASSIS rotating skip RING bearing SCREW set WASHER flat NUT self locking PIN roll FRAME rotating BUSH skip pivot SCREW set WASHER flat NUT self locking SCREW skip stop NUT WASHER spring RAM skip tipping see 7 R 3 Pin ram base pivot SCREW set NUT self locking RAM skip rotating see page 7 4 BOLT rotating ram eye WASHER flat NUT self locking PIN rotating ram base BAR pin spacer BAR pin retainer BOLT WASHER flat NUT self locking BOLT LINK articulation lock NUT self locking PIN roll PIN PIN lynch SAFETY SUPPORT tip ram PIN lynch c w chain PIN SEAL strip 2 metres CAP grease nipple N DN NANN NNN O N NO D 454000 455000 456000 457000 Dumpers 2 TRAS N QA N po
25. EPICYLIC REDUCTION GEARS Item Part no V600103 V600104 V600105 4 V600106 10 11 12 13 14 15 17 18 19 V601155 issue 04 0198 V600107 V600864 V600234 V600418 V600108 V600233 V600197 V601162 V600236 V600237 Axle serial no 336 336 336 336 336 336 336 336 336 336 336 336 336 336 336 336 336 2 7 Description SHAFT CIRCLIP PINION WASHER thrust BEARING needle sets of 10 WASHER STUD STUD with collar WASHER see page 2 W 1 NUT see page 2 W 7 CARRIER assembly PIN lock SHAFT order assembly PLUG drain PLUG where used PIN SCREW Qty 16 16 Co A 454000 455000 456000 457000 Dumpers 2 5 1 STEERING COLUMN Item Part Axle serial no 2001 2051 2052 1 V601232 1 V2004153 2 V2002872 3 95506 4 267509 4A 17508 o V2003164 2051 o V2004152 2052 SA V600491 103504 695030 41505 9 CSE182 10 2003312 10 V2003362 10 7602682 N O 11 67504 602671 7 11504 8 17505 9 CSE182 10 2004696 10 V602670 601155 issue 04 0198 Description CAP wheel centre CAP wheel centre COLUMN steering assembly NUT WASHER flat WASHER spring WHEEL steer Obsolete use V2004152 with centre cap V2004153 WHEEL steering SPINNER knob DANFOSS EM amp S steering unit SCREW socket BOLT WASHER spring SPACER
26. V600732 V2003564 30113A0506 V2003565 11S05C 17S06 267507 V600733 V600734 V600735 V600736 V600737 Serial no Description Qty COVER 1 SCREW 8 PLUG 1 SCREW 15 GASKET 1 PIPE 1 SCREW 2 WASHER 4 SENDER temp See Electrics Sec 1 filler 1 SEAL O ring 1 DIPSTICK CAP 1 SCREW 2 WASHER spring 2 WASHER flat 2 Service Kits GASKET KIT main transmission Comprises items 23 44 55 69 amp 74 SEAL KIT main transmission Comprises items 38 40 42 68 above plus items 13 24 amp 47 on page 4 B 3 O RING KIT main transmission Comprises items 5 11 18 amp 25 above plus item 25 on page 4 B 3 SMALL PARTS KIT main transmission Comprises items 24 25 26 27 above BASIC OVERHAUL KIT main trans Comprises all above kits plus the kits on page 4 B 3 454000 455000 456000 457000 Dumpers Shuttle Transmission 4 B 3 GEARS amp SHAFTS Item CONDO 010100 OQ 11 12 13 14 15 16 17 18 17 18 19 20 601155 issue 05 0499 V600738 V600739 V600740 V600741 V600742 V600743 V600744 V600745 V600746 V600747 V600748 V600749 V600406 V600750 V600751 V600752 V600753 V600754 V600755 V600756 V600757 V602293 V602600 V602601 V600758 V600759 Serial no Description Qty 2001 2407 454000 455000 456000 Dumpers 2001 2403 457000 Dumper GEAR reverse idler 27T BEARING SPACER DIS
27. not articulated and with the parking brake applied When the skip is fully lowered the rear of the skip locates into a recess in the chassis This is to ensure that there is no rotary movement of the skip while the dumper is travelling To slew the skip Look at the rear of the skip where it is recessed into the chassis With the joystick lever gently tip the skip forward just sufficiently to raise the rear of the skip clear of the recess Allow the lever to self centre Move the lever in the direction that you wish to turn the skip Allow the lever to self centre Move the lever forwards to tip the skip Reverse the procedure to return the skip to the travelling position WARNING sure that the rear of the skip has fully seated in its recess in the chassis before travelling 1 8 OPERATION Towing the dumper WARNING dumper should only be towed if recovery is needed of a broken down unit WARNING Before attempting to tow the dumper Disconnect the transfer gearbox end X of the top propeller shaft Tie back the propeller shaft securely to the transmission unit DO NOT REMOVE THE TOP SHAFT FROM THE DUMPERH as this may permit the transmission output shaft Z to come out of the transmission casing If the output shaft were to come out of the transmission casing the transmission unit would lose Failure to observe this precaution may result in extensive inter
28. order assembly order assembly order assembly SCREW set SCREW set WASHER spring NUT SCREW slotted SCREW set WASHER spring NUT SPRING rubber BOLT CLAMP WASHER spring NUT PLATE seat mounting WASHER flat RETAINER male SCREW set WASHER spring NUT WASHER flat SUSPENSION UNIT 4 6 O AANA a A 00 D SUSPENSION UNIT with rubber shroud SCREW set PLATE clamping 454000 455000 456000 457000 Dumpers SEAT Grammer with suspension amp fittings 1 V2004218 1 2004624 11S03B 17S04 267S05 7503 V601155 Jan 98 Serial Description 2086 2172 SEAT GRAMMER MSG 20 2173 SEAT GRAMMER MSG 12 See page 8 C 3 for parts of seats SCREW set WASHER spring WASHER flat NUT From Jan 95 all machines including those built before Jan 95 being retro fitted with a ROPS FOPS frame or acab MUST also be fitted with a Grammer seat 8 C 2 Qty N A 8 3 454000 455000 456000 457000 Dumpers SEATS Grammer models MGS12 and MGS20 Item Part no Serial no V602577 2086 2 V602578 4 V602579 6 V602580 7 602581 8 7602582 8 NOT FITTED 9 V602583 9 NOT FITTED 10 V602584 ii x 12 V602585 19 15 16 V602586 16 NOT FITTED 17 V602587 s 18 603584 19 V602588 20 2 24 V602589
29. the tipping ram Insert the pins H and secure them with clip pins 9 Do not operate the hydraulic control lever with the ISO Skip Support place 2 1 2 2 SERVICE ARTICULATION LOCK The Articulation Lock is provided to lock the front and rear chassis together making the dumper a rigid unit The Articulation Lock MUST be in position before attempting to lift the dumper before commencing any maintenance work To install the Articulation Lock Turn the steering wheel until the front and rear chassis are in a straight line Remove clip pin L and extract pin M Swing the locking bracket N backward to the rear chassis and into clevis O It may be necessary to turn the steering wheel to align the bracket and clevis holes Fit pin M through the clevis O and bracket and secure with clip pin L SERVICE ACCESS TO SERVICE CHECKPOINTS The fuel tank filler cap X is situated on the left hand wing The hydraulic tank filler cap breather Y is situated on the right hand wing Ensure the area around the filler cap breather is free from dirt and debris Note On later dumpers the fuel and hydraulic tanks are fitted with a fluid level sight gauge These are situated adjacent to the rear wheels SERVICE 2 3 To open rear cover Release catches lift to open The cover is supported by two gas struts and will remain open until manually cl
30. 2 17506 WASHER spring 15 11S05K set 5 11S05M set 4 11S05H set 2 8S05P BOLT 1 Turbo engines 11S05F 2330 SCREW set Naturally asperated engines 11S05F 2355 SCREW set V600662 DOWEL Shuttle with SAE bell housing V603601 BELL HOUSING SAE 3 Turbo engines 17S06 WASHER spring 85040 2331 BOLT Naturally asperated engines 17S06 WASHER spring 85040 2356 BOLT V601155 Feb 04 12 12 12 12 454000 455000 456000 457000 Dumpers Shuttle Transmission CASING ltem 10 11 12 13 14 15 16 17 18 19 20 21 22 22 23 24 25 26 27 28 29 30 31 601155 issue 04 0198 V600663 V600664 V600665 V600666 V600667 V600668 V600669 V600670 V600671 V600672 V600673 V600674 V600675 V600676 V600677 V600678 V600679 V600680 V600681 V600381 V600682 V600683 V600684 V600685 V600686 V600687 V600688 V600674 V600689 V600344 V600690 V600691 V600692 V600693 Serial no 2001 2407 2001 2403 Description 454000 455000 456000 Dumpers 457000 Dumper CASE main CASE COVER WASHER SEAL O ring STRAINER WASHER sealing PLUG WASHER copper PLUG SCREW SEAL O ring NIPPLE bleed COVER BREATHER LEVER DOWEL SEATING SEAL O ring CLIP COVER CLIP cover SCREW SEATING SPACER GASKET SHIM PLUG SEAL O ring SPRING BAL
31. 25 02590 26 V602591 28 NOTI FITTED 36 NOT FITTED 3 V602592 38 V602593 39 7602594 40 V602595 V601155 Jan 04 Description CUSHION BACKREST FITTINGS PLATE backrest LEVER adjustment BASE seat MSG20 BASE seat MSG12 FITTINGS suspension cover MSG20 FITTINGS suspension cover MSG12 COVER suspension MSG20 COVER suspension MSG12 FITTINGS for seat frame FRAME seat FITTINGS for frame amp swinging arms BUMPERS ARM swinging inner ARM swinging outer SHOCK ABSORBER MSG20 SHOCK ABSORBER MSG12 SPRING tensioning MSG20 SPRING tensioning MSG12 LEVER weight adjustment HANDLE FITTINGS handle LEVER ARMREST L H ARMREST R H FITTINGS safety belt BELT safety self recoil type FITTINGS for switch SWITCH FITTINGS for switch SWITCH amp FITTINGS assembly BOX literature RAIL sliding with lever RAIL sliding BELT safety BELT amp FITTINGS assembly set 8 C 3 Qty hb mb e 8 D 1 454000 455000 456000 457000 Dumpers FRAME amp FITTINGS Part Serial no V2004280 1 V2004700 2 V2004727 V2004730 3 V600494 4 5 176501 10 V602410 11 2003234 12 V2003229 32003228 13 14504E 14 59514 15 V602412 16 V2004743 602411 17 11503 18 17504 19 267505 25 V60
32. 6 Part Serial no Description Qty 1 V2004745 2086 LOOM c w fusebox plugs amp switches 1 2 601177 FUSEBOX 1 3 601171 FUSE 5 light brown 1 3 V601172 FUSE 7 5 amp dark brown 1 V601173 FUSE 10 amp red 1 601174 FUSE 15 blue 1 3 V601175 FUSE 20 amp yellow 1 V601176 FUSE 25 amp white 1 5 WIPER front see page 5 A 7 1 6 WIPER rear see page 5 7 1 7 see 8 1 1 8 WASHER BOTTLE see page 5 A 7 1 9 V602401 LIGHT interior 1 10 V2004285 HOLDER 6 switches 1 10 72003643 HOLDER switches 1 10 2003348 INSERT blank replaces one switch 11 2003252 GROMMET open 17mm O D 1 12 72004364 GROMMET open 25mm O D 1 15 V2004350 SWITCH heater fan 1 16 2004354 INSERT heater fan 1 17 V2004351 SWITCH rear wiper 1 18 V2004352 INSERT rear wiper 1 19 V2004351 SWITCH front wiper 1 20 2004353 front 1 21 601800 BULB assemby 22 V602399 BULB AR 23 11S01A SCREW set 2 24 267503 WASHER flat 4 25 17502 WASHER spring 2 26 7501 2 30 72004355 CLIP self adhesive 2 191901100 TERMINAL NIPPLE not illustrated 3 V601155 issue 04 0198 454000 455000 456000 457000 Dumpers 5 AND WASHER Item W N 11 12 13 14 20 21 22 Part no V602337 V602334 V602331 V602330 V602333 V602332 V602426 1
33. 8 2 454000 455000 456000 Dumpers COVER engine Partno Serial no Description 1 V2002727 2001 2152 COVER rear 2 V2003225 SEAL 3 72002839 HINGE 4 145040 SCREW c sunk slotted 5 61502 NUT locking 6 267504 WASHER flat 10 V2003215 HANDLE 11 11502A SCREW set 12 267504 WASHER flat 13 17503 WASHER spring 14 7502 V602725 2001 2050 KIT catch 15 V2003293 2001 2050 CATCH 16 11501 2001 2017 set 16A 11501 2001 2017 SCREW set 168 101507 2018 2050 17 17502 2001 2017 WASHER spring 18 7501 2001 2017 19 72003294 2001 2050 PLATE catch 20 2003325 STRUT gas 21 2003531 BUSH 22 267S05 WASHER flat 23 44501 PIN split 25 V2003571 2001 2152 KIT insulation 26 V2003563 FASTENER fir tree 27 2003109 2051 STOP rubber 28 267504 2051 WASHER flat 29 17503 2051 WASHER spring 30 7502 2051 NUT V602724 2051 KIT catch toggle 35 10537 02 2051 toggle 36 V2003294 2051 PLATE catch 37 11S01A 2051 SCREW set 38 267503 2051 WASHER flat 39 17502 2051 WASHER spring 40 7501 2051 601155 Jan 04 454000 455000 456000 amp 457000 Dumpers 8 2 GUARD COVER Item 1 27 28 29 30 35 36 37 38 39 40 41 42 50 51 Serial V2004372 V2004372 2153 2122 106209000 V2003225 2003587 V2002839 145040 61502 267504
34. 8 7602692 c w screw 2 9 V602773 STUB LEVER 1 10 V603617 HOUSING pivot 1 11 603618 2 12 57505 1 grub 4 13 603619 SPOOL 2 14 V603620 PIN roll 2 15 V603621 PLATE 1 16 603622 FIXINGS for plate Kit 1 V601155 Oct 04 7 B 2C 4S5000RS Dumper with rotating skip de a gt gt ENT 2 JOYSTICK sectional control valve amp FITTINGS Part V2004761 2334 11504 267506 17505 7504 ONO Ol 20 2005023 21 8503 22 267505 23 17504 24 7503 30 100504 31 122504 32 128503 33 119513 35 119504 37 154502 38 120502 39 93510 Description BRACKET gate SCREW set WASHER flat WASHER spring NUT SPACER BOLT WASHER flat WASHER spring NUT SEAL bonded ADAPTOR m m FITTING elbow 90 deg m f ADAPTOR m m ADAPTOR m m FITTING Tee m m f swivel CAP blanking FITTING bulkhead m m NOTE Port designation V601155 Jan 04 32 FEED from pump Connected to hose number 51on page 7 3 33 RETURN to tank Connected to hose number 50 on page 7 A 3 35 upper Rotate skip to LEFT 35 lower Rotate skip to RIGHT 37 upper Skip tip UP 37 lower Skip tip DOWN 7 2 Qty 93 OQ N N 7 3 45500085 Dumper with rotating skip als gt 0 x dre TIPPING HYDRAULIC CIRCUIT rotating skip 7 3
35. 9 Series Dumpers OPERATORS HANDBOOK amp PARTS Manual V600869 May 2007 5 Section INTRODUCTION Contents Introduction to the handbook Machine identification Warranty terms amp conditions SAFE WORKING Machine modification Training Running in Driving Skip loading Gradients Hydraulics Servicing Decal identification OPERATION Controls layout Running in a new engine Pre start checks Driving the dumper Starting the engine Audible alarm Gear selection Steering Gradients Braking Stopping the dump truck Leaving the dump truck Skip operation Towing the dumper SERVICE Skip safety support Articulation Lock Access to service check points Service schedule chart Greasing Wheels amp Lyres Engine Page II 0 1 0 1 0 1 0 1 0 3 0 3 0 4 0 4 0 6 1 1 1 2 1 3 1 3 1 4 1 4 1 6 1 6 1 6 1 6 1 6 1 7 1 7 1 8 2 1 2 2 2 2 2 4 2 7 2 8 2 9 INTRODUCTION Section Cooling system Fuel system Air cleaner Transmission Transfer gearbox Axles Hydraulic system Braking system Battery Centre yoke installation TECHNICAL INFORMATION General specifications Road speeds Load capacities Lubricants amp fluids Capacities fluid Machine weights Adjustments Drawbar loads Pressures hydraulic Tyre pressures Vibration declaration Machine dimensions Basic machine electrical circuit with
36. Engine Service Manual for additional procedures SERVICE 2 7 GREASING Every 50 operating hours or weekly WARNING Always use lubricants of the grade specified Always lubricate and service BEFORE work commences and WITHIN the periods specified Always clean grease nipples filler caps etc BEFORE and AFTER lubrication Clean nipples before and after greasing Apply the grease gun until clean grease appears Location of grease points A Tipping rams B Skip pivots C Centre pivot D Front propeller shaft E Centre propeller shaft F Rear propeller shaft G Top propeller shaft H Dump pedal J Steel ram K Accelerator Clean and lubricate all linkages not fitted with a grease nipple Rotating skips additional greasing points Slew ring Slewing rams 2 8 SERVICE WHEELS amp TYRES Every 10 operating hours or daily Check wheel nuts Tighten these whenever necessary every ten hours or daily After a wheel change the nuts should be checked several times a day until they maintain their correct setting for wheel nut tightening torque see Specifications Check tyre pressures WARNING When adding air to a tyre ensure the area 15 clear of personnel Never over inflate a tyre beyond its specified pressure Check the pressure only when the tyres are cold for correct tyre pressures see Specifications Tyre condition Check the tyres for damage deterior
37. From Jan 95 all machines including those built before Jan 95 being retro fitted with a ROPS FOPS frame or a cab MUST also be fitted with a Grammer seat MOUNT front L H rear L H MOUNT front R H rear L Each mount is stamped with an indentification code followed by its part number See illustration BOLT 8 WASHER Special 8 WASHER flat 16 NUT self locking 8 BOLT 8 WASHER spring 8 CANOPY FOPS 1 WASHER flat 4 BOLT 2 NUT self locking 2 454000 455000 456000 Dumpers DCH 22 Item 1A 1B 18 19 20 21 22 23 24 30 31 32 33 Part no V2000954 V2003682 V2003597 V2003203 11503 11503 17504 7503 16508 115040 17505 7504 10519 01 8502 10364 02 17503 7502 V2002649 267509 V2000922 11502 17503 7502 267505 V2003654 V2004231 11S03C V2004206 V601155 Jan 98 Serial no 2001 2172 2001 2172 2001 2172 2001 2172 2001 2172 2012 2091 2001 2172 2001 2172 2001 2172 2001 2011 2001 2011 2001 2011 2001 2011 2001 2011 2001 2011 2001 2011 2001 2011 2001 2011 2001 2011 2001 2011 2001 2011 2001 2011 2001 2011 2012 2091 2092 2172 2092 2172 2012 2091 Description SEAT BELT seat BACKREST seat SLIDE RAIL assembly
38. GO lt lt lt To beginning of Book S Series Dumpers 4S4000 4S5000 Brakes BRAKING SYSTEM NOT 4S7000 BRAKING SYSTEM 4S7000 ONLY MASTER CYLINDER BRAKE PEDAL PARKING BRAKE transfer gearbox LEVER parking brake ELECTRIC DUMP SOLENOID lt lt lt lt To beginning of Parts 1 A 1 1 1 1 2 1 1 1 1 1 0 1 1 0 2 1 1 454000 455000 456000 Dumpers 5 5 1 1 Serial Description Qty 1 2001 MASTER CYL see page 1 A 2 2 2 32501 HOSE master cylinder to rear axle 1 3185010 HOSE master cylinder to front axle 1 4 121503 FITTING tee 1 5 25501B HOSE tee to hub 1 6 25501 HOSE tee hub 1 7 121503 FITTING tee 1 8 25501B HOSE tee to hub 1 9 25501 HOSE tee to hub 1 10 V2003515 male 4 11 298503 SEAL bonded 4 12 V2001630 BRAKE BLOCK 4 13 2003241 BOLT banjo 4 14 298502 SEAL bonded 8 15 2003030 RESERVIOR assembly 2 16 CLIP reservoir order assembly 1 17 11501 SCREW set 4 18 17502 WASHER spring 4 19 267503 WASHER flat 4 20 7501 4 21 72002991 HOSE reservoir to m cyl metres 2 22 129S01A NOZZLE 90 deg 1 23 135S01A FITTING reversable 45 deg 1 24 72003029 CLIP hose 4 25 V2003524 ADAPTOR male 4 26 V2003584 BRACKET brake fitting support L H 2 27 V2003585 BRACKET brake fitting support R H 2 32 V2003557 CLIP P 2 V601155 issue 04 0
39. INSTALLED ANY UNAUTHORISED MODIFICATION WILL VOID CERTIFICATION AND RESULT IN INJURY DISCHARGE BATTERY ISOLATOR ISOLATING THE BATTERY WITH THE ENGINE RUNNING EXCEPT IN CASES OF EMERGENCY WILL LEAD TO DAMAGE TO THE VEHICLE ELECTRICAL SYSTEM LEFT m RIGHT ENSURE HEAPED LOAD DOES NOT RESTRICT FORWARD TO AVOID DAMAGE TO VISIBILITY THE TRANSMISSION DO NOT USE THE DUMP PEDAL AS A FOOTREST TO AVOID DAMAGE TO THE TRANSMISSION AND DRIVE TRAIN BRING MACHINE TO A STANDSTILL BEFORE CHANGING FORWARD OR REVERSE DIRECTION TIGHTEN SLEW RING BOLTS EVERY WEEK DECALS amp PLATES ltem 10 11 12 Part no DM106 V2004281 V2004754 V2004643 V2004645 V2004748 V2004680 V2004798 V2004799 V2004744 V2004227 V2005126 V601155 Jan 04 Serial no 9 4 Description DECAL Handbrake DECAL Hands clear DECAL Damage DECAL Dump slew return DECAL Transmission dump pedal DECAL Transmission damage DECAL Slew ring bolts DECAL Skip raised DECAL To avoid injury DECAL Eye protection DECAL Battery Isolator DECAL Heaped load Qty 454000 455000 456000 457000 Dumpers SPECIAL TOOLS Item Part no Serial no 1 V2003674 2001 5 32004212 2082 6 902502 7 V2004217 8 106209000 601155 issue 04 0198 Description ALIGNMENT GUIDE pivot pins ISO SAFETY SUPPORT skip tip ram PIN lynch cw chain BOLT special SEAL strip 2
40. LIGHTS used with Item 11 12 13 14 15 16 17 18 19 20 21 22 25 26 27 28 V601155 Part no V2003111 V2003233 V2003252 V2003253 V2003583 V2003638 V2003892 V2004043 V2004355 V2005003 144 39001 144779001 191901700 191907000 208143001 208143002 267507 59504 85055 8505T V2003577 V601800 V602399 V2004219 issue 05 0499 Description TIE nylon cable TERMINAL Lucar female GROMMET open TIE nylon cable TERMINAL Lucar male LIGHT working WASHER Special CONDUIT order by metre CLIP self adhesive BRACKET working light WIRE blue red order by metre WIRE black order by metre TERMINAL ring TERMINAL Lucar female SLEEVE 100mm long SLEEVE 400mm long WASHER flat NUT Nyloc self locking BOLT BOLT SWITCH on off assembly RETAINER amp BULB assembly BULB INSERT working light 5 4 Qty 10 10 5 5 454000 455000 456000 457000 Dumpers 2 5 57 8 eo ROAD LIGHTS 5 A 5 Part Serial no Description Qty 1 V2003645 LOOM assembly 1 2 P FUSEBOX 1 3 FUSE 4 2003641 SWITCH hazard lights 1 5 V2003647 INSERT hazard lights 1 6 V2003644 SWITCH head lights 1 7 2003646 1 10 2003643 PANEL three switch 1 11 V2004285 PANEL six switch 1 12 V2003348 BLANK switch panel 6 15 V2003651 LIGHT R H rear assembly 1
41. SEAL O ring 1 47 W600330 SWITCH safety start 1 48 600674 SEAL O ring 1 49 V600832 PIN 1 50 V600833 CIRCLIP 1 51 V600834 GASKET 1 52 V600835 SCREW 1 53 V600836 WASHER 1 54 V602572 GASKET 1 55 V600838 SCREW 2 56 V600839 FITTING adaptor 1 60 V602566 SPOOL 1 61 V602565 SPRING 1 64 V602570 PLUG 1 65 V600810 WASHER copper 1 66 V602571 SPOOL 1 70 602563 SOLENOID 1 71 02562 SEAL O ring 1 208561000 SWITCH dump 2 Positioned under inch dump pedal and handbrake V601155 Jan 04 454000 455000 456000 457000 Dumpers INCH DUMP PEDAL Used with Compact Shuttle Transmission ltem 1A 1B 10 11 12 13 14 Part no Serial no 2001 2355 2001 2330 V2003509 10650A14 445026 7503 V2003503 V2003092 43503 6505 10504 425434000 131501 11503 17504 7503 87505 176501 V601155 Jan 04 Description 4S4000 4S5000 4S6000 Dumpers 4S7000 Dumper CLEVIS PIN clevis PIN split NUT ROD PEDAL assembly BUSH BOLT WASHER flat SPRING NIPPLE grease SCREW set WASHER spring NUT NUT self locking COVER grease nipple 4 D 1A 454000 455000 456000 amp 457000 Dumpers INCH DUMP PEDAL Used with Compact Plus Transmission ltem 10 11 12 13 14 15 16 17 18 19 20 Part no 2356 2331 V2003092 43503 6505 10504 425434000 131501 11503 17504 7503 87505 176501 20561000 250166010 8501 267503
42. V2002305 2001 Page 2 A 2 Page 2 A 3 Page 2 A 4 Page 2 A 5 Page 2 A 6 Page 2 A 7 V2003332 26 910 61507 8507Z V601155 issue 03 0198 Description AXLE assembly HOUSING axle CROWN WHEEL amp PINION DIFFERENTIAL WHEEL HUB BRAKES amp DRIVESHAFTS EPICYCLIC REDUCTION GEARS PLATE lower WASHER flat NUT Binx self locking BOLT 32 16 16 454000 455000 456000 457000 Dumpers AXLE HOUSING 2 A 2 Part Axle serial no Description Qty 1 V601129 336 HOUSING axle 1 2 V600196 336 BREATHER 1 600461 336 ADAPTOR breather 1 6 V601157 336 SUPPORT differential assembly 1 V600162 336 BOLT with collar 4 9 V600076 336 BUSH 4 10 V600077 336 PIN 2 11 V600078 336 PLUG drain 2 13 V601128 336 BOLT with collar 10 14 V601158 336 PLUG 1 601156 336 PLATE axle serial number 1 601130 336 RIVET for serial plate 4 601155 issue 04 0198 2 A 3 454000 455000 456000 457000 Dumpers Item N N N NN mo Co 10 10 11 12 13 V601155 issue 04 0198 Part no V601159 V602639 V602640 V602641 V602642 V602643 V602644 V602645 V602646 V602647 V602648 V600215 V601131 V601132 V600216 V600217 V600201 V600218 V600219 17503 11502 V601133 V600220 V600221 Axle serial no 336 336 336 336 336 336 336 336 336 336 336 336 336
43. V600801 V600802 V600803 V600804 V600805 V600806 V600807 V600808 V600809 V600810 V600673 V600681 1 V600812 V600813 V600814 V600816 V600817 V600818 V600819 V600820 Serial no 2001 2407 2001 2403 Description Qty 454000 455000 456000 Dumpers 457000 Dumper CONTROL VALVE assembly 1 BODY 1 LEVER see page 4 D 2 1 1 1 SEAL O ring 1 VALVE 1 1 RING 1 VALVE 1 SPRING 1 GASKET 1 BODY 1 SCREW 4 SEAL 2 BALL 1 SPRING 1 WASHER 1 PLUG 1 PLUG 1 WASHER copper 1 SCREW 1 PLUG SCREW 4 SPOOL 1 SPRING inner 1 SPRING 1 VALVE pressure 1 SPRING inner 1 SPRING outer 1 PISTON soft shift 1 continued gt 454000 455000 456000 457000 Dumpers Shuttle Transmission CONTROL VALVE Mechanically operated Not used Compact Plus Transmission Item 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 601155 Jan 04 V600821 V600822 V600823 V600824 V600825 V600826 V600827 V600674 V600688 V600828 V600829 V600830 30097A0199 V600674 V600330 V600674 V600832 V600833 V600834 V600835 V600836 V600837 V600838 V600839 Description GASKET BODY GASKET SPRING BALL COVER SCREW SEAL O ring PLUG VALVE low dividing GUIDE SPRING BALL SEAL O ring SWITCH safety start SEAL O ring PIN CIRCLIP GASKET
44. WORKING ALWAYS aware local national regulations the use the machine NEVER commence work with the machine until the Daily or every ten hours service checks have been made See Service Section for details ALWAYS check wheel nut tightness daily NEVER carry passengers Ensure that the seat is securely fixed to the machine Where seat belt restraints are fitted as part of Rops Fops protection they must be worn Check that the seat belt is in good condition free from cuts and frayed edges ALWAYS remain in the driving seat whenever the engine is running Never attempt to operate any controls unless seated ALWAYS apply the parking brake before leaving the driver s seat NEVER dismount with the engine running and never leave the machine unattended with the key in the starter switch When Battery Isolators are fitted they must be activated only when the engine is turned off except in cases of emergency Activating a Battery Isolator when the engine is running can result in damage to the electrical components and circuits NEVER fill the fuel or hydraulic tanks with the engine running ALWAYS drive only on surfaces that are known to be stable ALWAYS keep the floor plates and walkways clean NEVER drive the machine close to the edge of any excavation Always use effective wheel stops to prevent the machine running close to the edge Make sure that the stops are in proportion to the si
45. by Winget Limited are used The equipment must be serviced in accordance with the service schedules laid down by Winget Limited Evidence that these have been complied with may be required before Warranty Claims are reimbursed The Manufacturer s policy is one of continuous improvement Winget Limited reserve the right to change specifications without notice No responsibility will be accepted for discrepancies which may occur between specification of machines and the descriptions contained in publications WORKING 0 1 Safety is the responsibility all persons working with this articulated dump truck Think safety at alltimes Read and remember the contents of this handbook The safe working recommendations for specific tasks are found with the instructions for the relevant operation in this Handbook MACHINE MODIFICATION WARNING Any modifications to the machine will affect its working parameters and safety factors Refer to the Manufacturers before fitting any non standard equipment or parts The Manufacturers accept no responsibility for any modifications made after the machine has left the factory unless previously agreed by the Manufacturers in writing the Manufacturers will accept no liability for damage to property personnel or the machine if failure is brought about due to such modifications or fitment of spurious parts TRAINING WARNING Only trained operators should use this machine Opera
46. cc O LL l lt 2 I O WIRING of basic dumper without cab or road lig Compact Shuttle transm 2 9 lt Ta O LL lt 2 I O WIRING LAYOUT basic dumper without cab or road lights Compact Plus transm with electronic F N R ission N Pac 7 OIA dwe oz MOTI3A O 1 H M vr 1HVISOWH3HL i d GION310S UN 91 om 4016 aNiona 1 dues 1 wenns nuon aid dwe 01 L 3uVdS NOISSINSNVHL HOLIMS WYV1V 3SH3A3U HOLIMS s GION3 1OS QION71OS QHVMHOd MOTI3A 4 t LHD 14716 34VS JHALVHIAW3L didind d Mn NOISSINSNVHL JONVHO O NMOHS N 9 N 4 NI 53003 4101020 ONIAIM 5 NOISSINSNVHL MNIT HOLIMS 1 5 LYVLS 5 L 1 31 9 39Vd 335 WHVIV 3SY3A3H 94 18 1 INVIOOD 3unssaud 3NIDN3 AN
47. distance J Max skip height at discharge K Front lip to ground L Height with ROPS FOPS canopy M Height with cab N Turning circle Side discharge distance Width of skip discharge lip 2 13 1 67 0 38 2 29 0 33 0 71 2 32 1 54 2 88 2 93 9 62 2 13 1 67 0 38 2 29 0 33 0 71 2 32 1 54 2 88 2 93 9 88 2 1 1 78 1 14 2 29 0 37 0 57 3 32 1 68 2 91 2 97 9 50 2 17 1 74 1 31 2 29 0 37 0 49 2 35 1 59 2 91 2 97 10 00 2 17 1 81 0 34 2 29 0 3 0 57 2 37 1 63 2 91 2 97 10 33 oz MOTI3A 9 hts I y GION31OS 1 16 LUVLS 1 YOLVNYSL O N dues z SANS Ki 2 5 NOISSINSNVHL HOLIMS N Y 3SH3A3H 35Vd 33S WHVIV 3SH3A3U dfi LHV1S ission 2 NOOV3H ania i 3unssatid JDHVHO NOISSINSNVHL INVIOQO 3NION3 JONVHO m Z O n gt Z gt N M 53000 10109 5 5 uaqNas JHNLVHIAW3L JUNLVHIAWAL NOISSINSNVHL 1 3NI9N3 2 9 lt
48. flat 4 NUT Binx self locking 4 BRACKET radiator support 1 SCREW set 1 WASHER flat 2 WASHER spring 2 NUT 2 HOSE top 1 HOSE bottom 1 CLIP hose 2 CLIP hose 2 SEAL rubber strip AR Item RECIRCULATION GUARDS Part no Serial no 3 R 3 Description 12 13 14 15 16 V2003580 V2003581 V2003582 V2003579 V2004454 V2003587 7502 17503 267504 11502 178SPRO5E 11S02A V2004763 267504 17503 11S02A 2214 2215 2215 2215 2215 2215 GUARD L H upper GUARD L H lower GUARD R H lower GUARD upper Not 457000 GUARD R H upper 4S7000 only STRIP seal order by metre NUT WASHER spring WASHER flat SCREW SCREW self tapping SCREW set RADIATOR BRACKET guard mounting WASHER flat WASHER spring SCREW set Qty 2M 17 17 26 Oo O O N 601155 issue 04 0198 S Series Dumpers Transmission TORQUE CONVERTER amp TRANSMISSION BELL HOUSING Compact Shuttle to engine CASING Shuttle GEARS SHAFTS Shuttle CASING Compact Plus GEARS amp SHAFTS Compact Plus CONTROL VALVE Mechanically operated Compact Shuttle CONTROL VALVE Solenoid operated Compact Shuttle INCH DUMP PEDAL Compact Shuttle INCH DUMP PEDAL Compact Plus CONTROL LEVER Forward Neutral Reverse Compact Shuttle CONTROL LEVER Forwar
49. increased oil consumption OPERATION Pre start checks WARNING Never commence work with the dumper until the checks detailed in Every 10 operating hours or daily have been carried out see Service Schedule Check that all controls are clean and not slippery and that they all function correctly Check that the areas around pivot points rams and linkages are all free from mud ice and debris Check that all grab handles steps and platforms are clean and dry Check the dumper for any obvious damage or faults Check that all decals an be clearly read Driving the dumper WARNING Never operate controls unless you are seated on the dumper and ALWAYS remain in the driving seat whenever the engine is running Ether type fuels must not be used If the battery charge or engine oil pressure warning lights fail to cancel stop the engine If the engine coolant or transmission oil temperature warning lights illuminate stop the engine Detect the fault before continuing DO NOT PROCEED IFA FAULT IS EVIDENT Never attempt to start the dumper by pushing or towing This would result in extensive internal damage to the transmission 1 4 Starting engine Ensure the parking brake 5 is in the raised ON position Ensure that the forward reverse control lever 14 is in neutral this is the central safety gate position Note The forward reverse lever m
50. metres CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer birth defects and other reproductive harm
51. of the correct grade to the new filter Allow time for the oil to pass through the filter element For correct grade of engine oll see Specifications Lubricate the top of the filter seal with clean engine lubrication oil Fit the new filter and tighten it bv hand oniv Do not use a strap wrench Gheck that the level of oil in the sump is to the MAX mark on the dipstick S Top up if necessarv with clean oil of the correct grade Operate the engine and check for leakage from the filter SERVICE SERVICE Stop the engine When the engine has cooled check that the level of oil the sump is to the MAX mark on the dipstick Top up if necessary with clean oil of the correct grade WARNING The filter contains anti drain valve to ensure that lubrication oil does not drain from the filter Therefore ensure only genuine parts are used Every 1000 operating hours or yearly Valve clearances tappets Have the valve clearances tappets checked by your Distributor 2 14 SERVICE COOLING SYSTEM WARNING Never start the engine without liquid in the cooling system Antifreeze is toxic and must never be taken internally If swallowed accidentally medical advice should be sought immediately Antifreeze is corrosive to the skin If it is spilled onto the skin accidentally it should be washed off immediately It is advisable to wear protective clothing and eye protection when ha
52. repairs The Company accepts no liability for any consequential loss damage or injury resulting directly or indirectly from any defect in the goods Items not covered by Warranty and considered to be the customer s responsibility include normal maintenance services replacement of service items and consumables replacement required due to abuse accident misuse or improper operaton replacement of wearable items e g pins bushes brake linings clutch linings etc The Warranty will not apply where the equipment is modified converted or used for purposes other than those for which it was designed unless clearance for the modifications etc have been granted by the Manufacturer in writing The Pre Delivery Inspection and Warranty Registration Document must be completed correctly and returned to the Manufacturer within 7 days of sale date Failure to do so may result in the claim being subsequently rejected Tyres and tubes are not covered by Warranty but are covered by the tyre manufacturers own warranty system which provides against defects in material or workmanship Engines are covered separately by the engine manufacturers and engine warranty repairs must be handled by the relevant engine manufacturers distrubutors No claim will be considered if other than genuine Winget Limited parts which must be obtained from Winget Limited via an authorised Distributor are used to effect a repair or if lubricants other than those recommended
53. seatbox 1 SCREW self tapping 2 RIVET 2 heater 2 ADAPTER reducer male female 1 HOSE 5 8 O D order by metre CLIP hose 4 DUCTING 38mm O D order by metre TIE nylon 16 DUCTING 55mm O D order by metre TIE nylon 8 S Series Dumpers 4S4000 4S5000 Miscellaneous DECALS amp PLATES SPECIAL TOOLS lt lt lt To beginning of Parts 9 1 454000 455000 456000 457000 Dumpers WINGET LIMITED PO Box 89 5 Lane Bonon Lancs BL 4 OWW el 101204 665165 101204 665206 Serial No Engine No Capacity Mass kg of ka Seddon Group Company 454000 455000 456000 2457000 CLEAR 11 5 Lo A ENGINE IS RUNNING a 3299939 3 105 145 1 75 25 P s 455000 BE 3 75bar 55 1 7 25 P s 456000 16 0 70 20 G open 16 0 70 20 3 45bar 50 1 7 25 P s 457000 L s V2003574 dB DANGER 12 KEEP ENGINE HOUSING Lwa LID CLOSED WHEN ENGINE 15 RUNNING 2005575 dB Top up with Hvdraulic Oil ONLY DO NOT use Brake Fluid 7 NEGATIVE EARTH DECALS amp PLATES Item 3A 3B 3C 3D 4A 10 11 12 Part no V602214 V2003039 V2003038 V2001715 V2001716 V2001717 V2004357 DM198 V2004191 504600900
54. the guide 15 onto the pivot pin 4 and insert upwards through the chassis thrust washers and yoke 15 Secure the pin in the same manner as the horizontal pivot pin 3 SERVICE TECHNICAL INFORMATION 3 1 SPECIFICATIONS Engine Naturally aspirated Direct injection In line 4 cylinder diesel Power output 59 4 kW 79 bhp 2200 rev min Engine Turbo Direct injection In line 4 cylinder diesel Power output 79 4 kW 106 bhp 2200 rev min Engine Naturally aspirated Stage 1 emission compliant Direct injection In line 4 cylinder diesel Power output 59 4 kW 79 bhp 2200 rev min Engine Turbo Stage 1 emission compliant Direct injection In line 4 cylinder diesel Power output 79 4 kW 106 bhp 2200 rev min Cooling Liquid 50 water with 50 antifreeze Axles Double reduction by bevel set and planetary hub reduction gears Oil Immersed inboard hydraulic disc brakes Brakes service Oil immersed inboard hydraulic disc on all hubs Parking operated ratchet type actuating a disc brake mounted on the transfer gearbox Transmission Compact Shuttle with manual F N R selection earlier dumpers Compact Plus with electronic F N R selection later dumpers 4 speed powershuttle reverser with integral torque converter giving instant forward reverse selection Hydraulics Gear type pump 57 litre min c w priority valve for steering system Skip operating control valve with pressure relief valve T
55. 0 Dumpers TRANSFER GEARBOX assembly Part Serial no Description 1 V2000938 2001 V601155 issue 04 0198 TRANSFER GEARBOX assembly BRAKE parking see Brakes Section 4 2 454000 455000 456000 457000 Dumpers INPUT amp IDLER SHAFT transfer gearbox Item 10 11 12 13 14 15 16 V601155 issue 04 0198 Part no V600422 V600840 V600433 V600434 V600841 V600437 V600442 V600443 V600444 V600445 V600456 V600458 V600842 V600458 V600844 30156A0180 Serial no 2001 Description CIRCLIP CIRCLIP SEAL oil SEAL oil BEARING SEAL SHIM 0 3mm SHIM 0 1mm SHIM 0 05mm WASHER thrust SHAFT idler GEAR SLEEVE GEAR SHAFT input BEARING 4 F 2 Qty AR AR AR 454000 455000 456000 457000 Dumpers OUTPUT SHAFT transfer gearbox Item Part no Serial no 1 V600016 2001 2 V600434 3 30156A0180 4 600845 V600015 6 V600014 7 600458 8 V600432 9 V600449 10 V600438 11 V600436 12 V600431 V601155 issue 04 0198 Description FLANGE SEAL oil BEARING BEARING SPACER SHAFT output GEAR oil RING centralising SEAL O ring SEAL O ring RING locking 4 F 3 Qty 4 4 454000 455000 456000 8 457000 Dumpers HOUSING transfer gearbox Item O 11 12 13 14 15 16 17 18 18 19 601155 issue 04 0198 V600868 V60
56. 0078 V600452 V600453 V600454 V600439 V600013 17S05 11S04D V600420 V600440 V600847 V600457 V600848 V600450 V600849 11S03A V600850 V600455 11S03C 11S03Y 17504 Serial 2001 98 98 April 98 98 Description HOUSING transfer gearbox PLUG drain SHIM 0 10 SHIM 0 19mm SHIM 0 35mm SEAL O ring COVER WASHER spring SCREW COVER PLUG breather WASHER ADAPTOR breather WASHER flat PLATE serial number RIVET SCREW set WASHER flat COVER SCREW M8x25 use with washer 17S04 SCREW 8 22 use without washer WASHER spring use with screw 11503 4 F 4 Qty AR AR AR QI 4 S Series Dumpers 4S4000 Electrics MAIN ELECTRICS 5 A 1 REVERSE ALARM amp TIMER 5 A 2 BEACON 5 3 WORKING LIGHTS used with 5 canopy 5 4 WORKING LIGHTS used with ROPS 5 4 ROAD LIGHTS 5 5 ELECTRICS 5 6 SCREEN WIPERS amp WASHERS 5 7 lt lt lt beginning Parts 5 1 454000 455000 456000 457000 Dumpers MAIN ELECTRICS 5 A 1 Part Serial no Description Qty 1 V2003561 2001 START SWITCH 1 2 V601179 KEY 1 3 V2003540 RING key 1 Used with Shuttle Iransmission 4 V2002875 2001 2407 LOOM Not 4S7000 1 4 V2002875 2001 2403 LOOM 457000 Only 1 Used with P
57. 03 V2002314 V601530 V2004180 V600413 V602787 V602788 87503 Serial 2001 2407 2001 2403 2408 2404 2051 Description 4S4000 4S5000 4S6000 Dumpers 4S7000 Dumper PROPELLER SHAFT fixed length Compact Shuttle transmission to transfer gearbox FLANGE prop shaft fixed length 454000 455000 456000 Dumpers 457000 Dumper PROPELLER SHAFT sliding joint Compact Plus transmission to transfer gearbox FLANGE prop shaft variable length BOLT NUT self locking PROPELLER SHAFT transfer gearbox to rear axle YOKE FLANGE NIPPLE grease straight BOLT BOLT NUT self locking PROPELLER SHAFT transfer gearbox to front axle YOKE FLANGE NIPPLE grease straight BOLT NUT self locking PROPELLER SHAFT from short shaft to front axle CARRIER bearing GUARD bearing carrier YOKE FLANGE END YOKE NUT BOLT NUT self locking Continued gt 454000 455000 456000 457000 Dumpers 10A 15 DTR 32 PROPELLER 5 5 Item 18 19 20 21 22 23 25 26 Part no 11505E 267507 61505 V2003333 V2003333 V2003334 10307 01 176501 V601155 Jan 04 Serial Description SCREW set bearing carrier WASHER flat NUT self locking STRAP bearing STRAP bearing BOLT bearing strap KIT U J repair COVER grease nipple N 1 454000 455000 456000 8 45700
58. 1 V2004504 2 72004565 11503 4 61503 7 V2002621 11503 9 61503 15 131501 16 176501 601155 issue 04 0198 Description SKIP rotating PIN skip pivot SCREW set self locking ram pivot SCREW set NUT self locking NIPPLE grease CAP grease nipple 6 A 2 Qty S Series Dumpers 4S4000 Hydraulics HYDRAULIC PUMP FILTER amp TANK STEERING CIRCUIT TIPPING CIRCUIT forward tipping skip BRACKETS amp HOSE PROTECTOR CONTROL VALVE forward tipping skip JOYSTICK MONOBLOC CONTROL VALVE rotating skip JOVSTICK monobloc control valve amp FITTINGS JOYSTICK SECTIONAL CONTROL VALVE rotating skip JOYSTICK sectional control valve amp FITTINGS TIPPING CIRCUIT rotating skip ROTATING CIRCUIT rotating skip STEERING RAM with spherical bearings STEERING RAM with bushes NOT 4S7000 STEERING RAM with bushes 457000 ONLY TIPPING RAM forward tipping skip TIPPING RAM rotating skip SWIVEL RAM rotating skip lt lt lt To beginning of Parts 7 A 1 7 2 7 3 7 4 7 1 7 2 7 2 7 B 2B 7 B 2C 7 B 3 7 B 4 T R 1 7 R 1A 7 R 1B 7 R 2 7 R 3 7 R 4 454000 455000 456000 457000 Dumpers HYDRAULIC FILTER V2002695 V601178 V2002703 V600948 V2004203 V603609 68S05E 17S05 N 100506 119515 136506F 129506F V2003232 V20032
59. 1501 267503 17502 7501 V602467 V2003252 V2003266 V601155 issue 04 0198 Serial no 2086 Description MOTOR front wiper ARM front wiper BLADE front wiper NOZZLE front washer MOTOR rear wiper COVER motor ARM rear wiper BLADE rear wiper NOZZLE rear washer BOTTLE screen washers c w motors amp pumps Fixings not illustrated for Washer Bottle SCREW set WASHER flat WASHER spring NUT HOSE 6 metres GROMMET open VALVE non return not illustrated for rear screen washers 5 7 Qty N N A S Series Dumpers 4S4000 4S5000 Skips FORWARD TIPPING SKIP 6 A 1 ROTATING SKIP 6 2 lt lt lt beginning Parts 6 1 454000 455000 456000 457000 Dumpers SKIP forward tipping Item N O1 10 11 12 13 14 20 21 Part no V2000966 V2000965 V2000964 V2004299 V2002619 11S03M V2002621 11S03M 61S03 V2003056 11S03G 17S04 7503 V2003500 V2004004 902502 V601155 Jan 04 Serial no 2001 2023 2023 Description 454000 455000 456000 457000 skip SCREW set PIN ram pivot SCREW set NUT self locking RETAINER mudflap SCREW set WASHER spring NUT MUDFLAP SUPPORT PIN lynch OO OD 2 45500085 Rotating Skip Dumper SKIP rotating Part Serial
60. 17502 7501 V601155 Jan 04 Serial Description 4 D 1A Qty 4S4000 4S5000 4S6000 Dumpers 4S7000 Dumper PEDAL assembly BUSH BOLT WASHER flat SPRING NIPPLE grease SCREW set WASHER spring NUT NUT self locking COVER grease nipple SWITCH dump GLAND cable Also used with the optional Solenoid Operated Control Valve fitted to Compact Shuttle Transmission see page 1 D 2 BOLT WASHER flat WASHER spring NUT 454000 455000 456000 457000 Dumpers CONTROL LEVER forward neutral reverse operation Shuttle Transmission Item O Part no Serial no 2001 2407 2001 2403 307120000 203S05 V2003501 V2003519 61S02 267S04 V2003518 178SPS03D 14S04E 555512300 267S07 44S03D V2003250 10582A01 V2003522 V2003527 7503 17504 7503 V2003504 267505 445030 V2003539 7502 61502 V2003538 V2003676 V2003586 11502 7502 V601155 Jan 04 Description 4S4000 4S5000 4S6000 Dumpers 4S7000 Dumper KNOB NUT locking HANDLE lever BLOCK self locking WASHER PLATE selector SCREW SCREW counter sunk head SPRING WASHER flat PIN split BUSH pivot NUT locking LEVER BALL JOINT NUT WASHER spring NUT ROD WASHER flat PIN split BRACKET NUT NUT self locking BRACKET handle support BRACKET retaining BRACKET SCREW set NUT 4 D 2
61. 19 5 WHEEL assembly L H WHEEL assembly R H RIM wheel TYRE 18 x 19 5 WHERE USED VALVE WHERE USED NUT wheel WASHER spring N 32 32 N 32 32 N N N CO N N N S Series Dumpers 4S4000 HYDRAULIC DRIVE FUEL TANK amp LOW PRESSURE FUEL SYSTEM EXHAUST AIR CLEANER From serial number 2001 to 2223 AIR CLEANER NOT 457000 From serial number 2224 AIR CLEANER 4S7000 ONLY From serial number 2122 ACCELERATOR PEDAL amp LINKAGE ACCELERATOR PEDAL amp LINKAGE RADIATOR RADIATOR HOSES amp FITTINGS AIR RECIRCULATION GUARDS lt lt lt To beginning of Parts 3 A 1 3 A 11 3 A 18 3 C 1 3 C 4 3 D 1 3 D 1A 3 R 1 3 R 2 3 R 3 454000 455000 456000 457000 Dumpers __ by So Serial Description Perkins 4 Cylinder 1000 Series Quote engine serial number before ordering parts V2002308 V600971 V600600 V601044 V600941 oo Y O O V2004290 V602694 V602637 V601044 V600941 oo NO O 1 V2005032 6 V600600 7 V602695 1 V2004670 5 V602697 6 V602637 7 V602695 8 V602698 2355 2330 2356 2331 NOT emission compliant engines ENGINE naturally aspirated DIPSTICK OIL FILTER FUEL FILTER element assembly FAN BELT
62. 198 1 A 1A 4S7000 Dumper BRAKE SYSTEM with Pressure Regulating Valve Item 22 23 24 25 26 27 28 29 30 31 31A 32 33 34 V601155 issue 04 0198 Part no 325016 318501D 121503 25501B 25501A 121503 25501B 25501A V2003515 298503 V2001630 V2003241 298502 V2003030 11501 17502 267503 7501 V2002991 129501A 135501A V2003029 V2003524 V2003584 V2003585 298503 V2003515 V2004564 11S03C 17S04 2003557 267505 25501 Description MASTER CYL see page 1 A 2 HOSE master cylinder to rear axle HOSE master cylinder to front axle FITTING tee HOSE tee to hub HOSE tee to hub FITTING tee HOSE tee to hub HOSE tee to hub ADAPTOR male SEAL bonded BRAKE BLOCK BOLT banjo SEAL bonded RESERVIOR assembly CLIP reservoir order assembly SCREW set WASHER spring WASHER flat NUT HOSE reservoir to master cyl metres NOZZLE 90 deg FITTING reversable 45 deg CLIP hose ADAPTOR male BRACKET brake fitting support L H BRACKET brake fitting support R H SEAL bonded FITTING m m VALVE pressure regulating SCREW set WASHER spring CLIP P WASHER flat HOSE valve to adaptor T NN 1 A 1A Qty 2 gt N T BND 92 4 454000 455000 456000 457000 Dumpers MASTER CYLINDER 1 A 2 Item Part 1 V20009 7 1 V2003672
63. 1B V600117 1B V601698 N 61S04 3 267S06 4 11S04E 5 298S04 Serial no Description Qty Dumpers are fitted with either GIRLING FRENOS IRUNA Master Cylinders Be sure to quote the name marked on the Master Cylinder before ordering parts MASTER CYLINDER GIRLING 2 MASTER CYLINDER FRENOS IRUNA KIT repair GIRLING 1 KIT repair FRENOS IRUNA 1 self locking 4 WASHER flat 4 BOLT 4 SEAL bonded 4 V601155 issue 04 0198 B 4S4000 4S5000 4S6000 amp 4S7000 Dumpers 9 g lt 1 JA Rat BRAKE PEDAL Item Part 1 V2002384 1 V2004292 2 V2002595 3 V2003307 4 267510 5 445030 6 V2002385 7 10650 18 8 10514 9 445026 10 20117A06 11 10650419 12 267506 13 44502 14 42002386 15 7504 16 333601010 17 176501 601155 issue 04 0198 Serial 2001 2086 Description PEDAL brake Dumpers without cabs PEDAL brake Dumpers with cabs BUSH SPRING WASHER flat PIN split BAR link PIN pivot WASHER flat PIN split LEVER compensating PIN pivot WASHER flat PIN split CLEVIS NUT NIPPLE grease 135 deg CAP grease nipple ON 1 1 454000 455000 456000 457000 Dumpers PARKING BRAKE transfer gearbox Item Part Serial Description The Parking Brake is sold as components only The Parking Brake assembly is part of the Transfer Gearbox see Transmission Section 1 11S05D 2 1
64. 1S05F 3 V600508 4 17S06 5 V600509 6 V600510 7 V600511 8 V600512 9 V600513 10 V600467 11 600515 12 600516 13 V600517 14 V600518 15 V600519 16 V600520 17 600521 18 600522 V601155 issue 04 0198 2001 SCREW SCREW NUT WASHER spring WASHER locking PLUG SPRING LINK BALL COVER dust COVER SCREW special ROD brake actuating PIN HOUSING BRAKE assembly DISC brake BRAKE MECHANISM 454000 455000 456000 457000 Dumpers parking brake Item 1 1A 11 12 13 14 15 16 17 18 19 20 21 22 23 24 V601155 issue 04 0198 Part no 20208A01 20208 0101 V2003305 445030 V2003190 V2003219 95502 11503 17504 7503 003220 56504 267505 V2001703 267507 V2001704 V2001705 V2003508 11504 17505 445026 267507 525040 267506 Serial 2001 Description LEVER parking brake assembly KNOB lever cable lever PIN split CABLE NUT domed NUT locking SCREW set WASHER spring NUT NUT domed NUT locking WASHER flat cable WASHER flat BRACKET fixed LEVER fulcrum PIN SCREW set WASHER spring PIN split WASHER flat SCREW c sunk WASHER flat 454000 455000 456000 457000 Dumpers Shuttle Transmission ELECTRICAL DUMP SOLENOID option Item Co OO NO 10 11 13 14 15 16 14 15 16 17 18
65. 2004173 Serial Description Qty BRACKET 1 Bracket is fixed behind existing screw on the transmission CLIP P type 1 SCREW set 1 WASHER flat 1 WASHER spring 1 NUT 1 HOSE PROTECTOR 1 7 1 454000 455000 456000 457000 Dumpers CONTROL VALVE forward tipping skip Item TS ORNE N 00 N OD 9 10 11 12 13 14 16 17 18 20 21 22 24 25 26 27 28 29 30 31 32 V2002854 V601188 9503 41505 10503 6503 V601184 V600178 V601183 V601186 V601185 V2003117 V2003114 V600179 V2003115 V600190 V600026 V2003124 V600023 V600022 V600057 V600062 V2003122 V600059 V600060 V600061 V600063 V600065 V600064 V601155 Jan 04 Serial no 2001 Description VALVE control assembly KIT stud assembly NUT order assembly WASHER spring order assy SIUD order assembly wW WASHER shakeproof order assy Alternative fittings 2001 Oct 93 NUT WASHER spring WASHER flat BOLT COVER outlet KIT seals inter section HOUSING amp SPOOL order assy VALVE check KIT seals Spool RETAINER seals SEAT spring SPRING SPACER SCREW shoulder CAP end SCREW c w washer COVER inlet KIT seals relief valve VALVE relief LEVER assembly SCREW c w washer SEAL wiper BRACKET handle PIN roll LINK CLEVIS PIN clip PIN WO CO CO CO N N N
66. 2405 26 V602406 2003200 30 V6002403 31 V6002404 32 11502 33 115020 34 267504 35 17503 36 7502 40 V2002506 41 11503B 42 267505 43 17504 44 7503 50 V602425 55 V602429 V602430 V601155 Jan 04 2086 Description CAB c w CLADDING amp GLASS CAB frame only DOOR L H frame only illustrated DOOR frame only not illustrated WASHER flat brass NIPPLE grease CAP grease nipple HANDLE door pull HANDLE exterior LATCH interior L H illustrated LATCH interior not illustrated SCREW counter sunk head self locking PIN amp BLOCK assembly latch striker BLOCK latch striker pin GUARD latch pin not illustrated SCREW set WASHER spring WASHER flat SEAL door side amp bottom SEAL door aperture RETAINER door assembly RETAINER male RETAINER female SCREW set SCREW set WASHER flat WASHER spring NUT BRACKET door retainer SCREW set WASHER flat WASHER spring NUT MAT floor N OOQ O gt gt DD NNN NNN AA T O NN n5 n5 SEAL foam 20x30mm order by metre SEAL foam 25x25mm order by metre continued gt 8 0 1 454000 455000 456000 457000 Dumpers FRAME amp FITTINGS ltem 56 5 58 60 61 65 66 6 68 69 70 75 76 77 78 79 80 81 90 91 92 Serial V2003199 V602424 V2003199 V601392 V2004668 178SPRO
67. 267505 2001 WASHER flat 14 11S03A 2001 SCREW set 15 17504 2001 WASHER spring 2 16 176501 2001 COVER grease 17 545041 2042 roll 1 18 V2004210 2042 NUT special cw locking tabs 1 19 56S08 2001 NUT locking thin 1 Welded to under side of lower steering arm on centre pivot casting 20 10531 2042 SPACER front pin 1 21 10520 2042 1 22 333113000 2042 NIPPLE grease 1 30 72004194 2042 to thicken centre 1 When fitting pin V2004064 item 3 to machines manufactured before serial number 2042 it is necessary to order thickening plate V2004194 item 30 which must be welded to the top surface of the upper lug of the centre pivot X V601155 July 95 8 6 457000 Dumper O 111213 18 17 PINS GUARDS steering ram Item 11 12 13 14 15 15A 16 17 18 19 20 21 22 Part no V2004266 V2003514 V2004064 11504 17505 267506 V2004200 V2004286 V2003098 11S03A 17504 267505 115030 17504 267505 176501 545041 V2004210 96508 10531 10520 333113000 601155 Jan 98 Serial 8 6 Description RAM steering see Hydraulics Section PIN steer ram rear PIN steer ram front SCREW set WASHER spring WASHER flat BUSH GUARD piston rod COVER steer ram SCREW set WASHER spring WASHER flat SCREW set WASHER spring WASHER flat COVER grease nippl
68. 32 119516 100509 E gt 11 V2000238 12 10363 02 13 11503 14 17504 15 V2002274 16 2003562 16 10565A01 16 72004291 17 11501 17 101507 17 101507 18 17502 V601155 Oct 04 Serial no 2001 2001 Oct 93 Oct 93 Jan 95 Jan 95 2001 Oct 93 Oct 93 Jan 95 Jan 95 2001 Oct 93 Description PUMP with tapered shaft KIT pump repair KIT pump adaptor not illustrated SCREW D OBSOLETE use the pump screws and washers below PUMP with splined shaft KIT pump repair SCREW WASHERS N 5 See page 3 A 11 for pump drive assy SEAL bonded ADAPTOR male FITTING elbow reversable ELBOW 90 deg swept CLAMP hose CLAMP hose ADAPTOR male SEAL bonded FILTER assembly CARTRIDGE SCREW set WASHER spring TANK HYDRAULIC MUDWING N N N FILLER CAP with dipstick obsolete Use V2004291 with rivets 101S07F 1 FILLER CAP without dipstick obsolete Use V2004291 with rivets 101S07F 1 FILLER anti splash set WASHER spring 6 Continued gt 454000 455000 456000 457000 Dumpers HYDRAULIC PUMP FILTER TANK Item 19 20 21 25 70 71 72 73 100504 127504 V2004929 V2003051 3 503BE V2001605 V2003253 V6011
69. 336 336 336 336 336 336 336 336 336 336 2 A 3 Description Qty CROWN GEAR amp PINION matched pair SHIM 2 50mm SHIM 2 60mm SHIM 2 70mm SHIM 2 80mm SHIM 2 90mm SHIM 3 00mm SHIM 3 10mm SHIM 3 20mm SHIM 3 30mm SHIM 3 40mm BEARING SPACER collapsible WASHER WASHER NUT ring SEAL oil COVER BOLT M6x20 Used with spring washer 17S03 WASHER spring BOLT M6x16 Used without spring washer BOLT NUT nylon insert FLANGE AR AR AR AR AR AR AR AR AR AR 2 4 454000 455000 456000 457000 Dumpers 127 AT 2 2 4 Vi O Ly y SW DIFFERENTIAL 2 A 4 Partno Axle serial no Description Qty 1 V601160 336 HOUSING matched pair assembly 1 2 V600083 336 BOLT 12 4 V600408 336 WASHER thrust 2 V602684 336 KIT differential 1 Kit consists of items 4 6 7 13 amp 14 7 V600086 336 PLATE 2 9 V600222 336 BOLT M6x12 2 used with spring washer 17S03 17503 336 WASHER spring 2 9 V602707 BOLT M6x10 2 used without spring washer 17S03 10 V600223 336 PLATE locking 2 11 V600224 336 NUT ring 2 12 V600225 336 BEARING 2 13 V600087 336 PIN dowel 1 14 V600088 336 ROD pinion 2 V601155 issue 04 0198 2 5 454000 455000 456000 457000 Dumpers WHEEL Item 10 11 13 16 17 19 19 20 21 22 V601155 Jan 04 Par
70. 4 Serial 2001 H H H H H Description BEACON assembiv BULB beacon CONNECTOR Bullet female CONNECTOR Bullet male TIE nylon CONNECTOR Lucar male CONNECTOR ring SWITCH off on assembly RETAINER amp BULB assembly BULB INSERT beacon switch Beacon with ROPS WIRE orange WIRE black CONDUIT GROMMET Beacon without ROPS WIRE orange WIRE black SUPPORT beacon SUPPORT beacon GROMMET open SCREW set WASHER spring NUT WASHER flat SCREW set WASHER spring NUT Up to and from serial numbers 2152 2153 2121 2122 V601155 issue 05 0499 454 5 6000 457000 9 A 3 Qty 3 metres 1 metres 1 1 5 metres 1 1 5 1 WWW 454000 455000 456000 457000 Dumpers WORKING LIGHTS used with 5 canopy 1 V2003638 2 72004220 72003233 4 72003252 o 52003577 V601800 5B 602399 6 V2004219 7 V2004043 8 144779003 8 144772000 10 V2004355 V601155 issue 05 0499 Serial 5 4 Description Qty LIGHT working 3 WASHER Special as required female Lucar 6 GROMMET 3 SWITCH on off assembly 1 RETAINER BULB assembly 1 BULB 1 INSERT working light 1 CONDUIT order by metre AR WIRE black 9 metres WIRE red yellow 5 metres CLIP self adhesive 2 WORKING
71. 4 Ib 455000 3575 kg 7879 Ib 45500085 3985kg 8783 Ib 456000 3825 kg 8430 Ib 457000 3985 kg 8783 lb These weights nominal vary depending on the model and specification of the dumper ADJUSTMENTS Wheel nut 220 Ibf ft 300 Nm DRAWBAR LOAD Weight drawbar 2500 N 250 kg Drawbar pull 10000N 1000 kg VIBRATION DECLARATION PRESSURES hydraulic working 454000 110 bar 1600 Ib in 455000 131 bar 1900 Ib in 455000 RS 127 1850 456000 162 bar 2350 Ib in 457000 162 bar 2350 Ib in TYRE PRESSURES 12 5 80 18 12 5 80 18 1 75 25 455000 RS rotating skip 16 0 70 20 16 0 70 20 3 45bar 50 1 75 25 1 4 56000 16 0 70 20 16 0 70 20 1 75 25 p 457000 Whole body vibration level aw m s 0 7 0 8 typical Note The absence of a harmonised test code together with the variable conditions under which this equipment may be used allows only representative figures to be quoted Hand arm vibration level ana m s Less than 2 5 3 4 TECHNICAL INFORMATION MACHINE DIMENSIONS Dimensions in meters 4S4000 455000 45500085 456000 457000 Overall length 4 43 4 43 4 64 4 60 4 60 B Overall width 2 06 2 30 2 14 2 37 2 47 Height to top of steering wheel D Loading height E Discharge height F Wheelbase G Ground clearance H Forward discharge
72. 43 above 600735 O RING KIT main transmission AR Comprises items 5 11 18 amp 25 on page 4 B 2 plus item 25 above 600737 BASIC OVERHAUL maintrans Comprises all above kits plus the kits on page 4 2 601155 issue 04 0198 454000 455000 456000 457000 Dumpers Plus Transmission CASING ltem 38 38A 40 59 80 81 82 84 84A 86 88 92 92 93 94 102 103 104 105 106 V601155 Jan 04 Part no V603015 V603491 V603492 V600674 V603493 V603495 V603479 V603480 V603483 V603484 V603485 V603078 V603086 V600705 V600710 V603019 V603020 V601234 V603022 V603026 V603047 V603048 V603049 85040 17505 V600732 V603052 V603056 V600704 V600700 V600674 V603062 V603063 V603064 V600679 V600682 Serial no 2408 2404 4 B 4 Description 454000 455000 456000 Dumpers 457000 Dumper CASING front assembly CASING rear assembly PLUG 8 O RING assembly O RING HOUSING cold start spring BOLT BOLT WASHER copper BALL SPRING cold start RING HOUSING oil filter WASHER plain GASKET filter housing BOLT PLUG expansion VALVE directional assembly PLUG cable connector O RING SUPPORT RING coarse filter PLUG breather CAPSCREW socked head BREATHER SCREW set WASHER spring SENDER temperature O RING drain plug PUMP SEAL oil RING sealing RING sealing LE
73. 4S5000RS Dumper with rotating skip TIPPING for rotating skip Item Part 20 21 601155 issue 04 0198 V2004466 V2004470 V2004471 V2003184 V2003374 V2002476 5750 2 V2000328 V2002620 131501 176501 Description tipping for rotating skip CYLINDER ram ROD ram CAP RETAINER PISTON SCREW grub KIT seals SEAL piston 0 RING 0 RING BACKING RING SEAL SEAL wiper BUSH NIPPLE grease CAP grease nipple 7 3 Qty swivel skip rotation Item 14 20 21 Part no Serial no 30287A03 30287A0304 30287A0305 V2004681 30121A0402 30121A0401 57S04D2 54S04N CSE204 V2004682 131S01 176S01 V601155 Jan 04 7 R 4 Description RAM skip rotation assembly CYLINDER ram ROD ram EYE replaceable welded item CAP PISTON SCREW grub or ROLL PIN KIT seals SEAL piston 0 RING SEAL wiper SEAL BACKING RING 0 RING BUSH NIPPLE grease CAP grease nipple Qty 5 Series Dumpers 4S4000 Chassis amp CHASSIS FRONT forward tipping skip CHASSIS FRONT rotating skip CHASSIS REAR CENTRE YOKE PINS amp GUARDS NOT 4S7000 for steering ram with spherical bearings PINS amp GUARDS NOT 457000 for steering ram with bushes PINS amp GUARDS for steering ram 4S7000 ONLY PANELS ENGINE COVER NOT 457000 From serial number 2001 to 2152 REAR GUA
74. 55 Jan 04 Date Apr 00 Description SEAL bonded PLUG drain Gauge oil level BRACKET hoses HOSE filter to pump HOSE filter to tank BRACKET 4S7000 only TIE cable nylon 4S7000 only 454000 455000 456000 457000 Dumpers 7 2 7 2 7 2 7 3 7 3 1 1 STEERING HYDRAULIC CIRCUIT Item 11 11 11 12 13 14 15 20 21 22 23 60 61 61 62 63 64 Co Serial met 2001 122502 100502 122503 100503 119508 100504 V2002565 2001 2041 V2000952 2042 V2004266 V2003560 267507 11S05F 17S06 7505 V2003533 11S03H 17504 7503 535010 63502 635020 27502 64502 64502 2032 2033 601155 issue 04 0198 7 2 Description STEER UNIT See page 2 S 1 male SEAL bonded ADAPTOR male SEAL bonded ADAPTOR male SEAL bonded STEER RAM NOT 457000 See page 7 1 STEER RAM NOT 4S7000 see page 7 R STEER RAM 457000 only see 7 R 18 CLIP P fitted to transfer gearbox WASHER not illustrated SCREW set WASHER spring NUT CLAMP hoses set WASHER spring NUT HOSE pump to steer unit priority flow HOSE steer unit to tank HOSE steer unit to tank HOSE pump to steer unit HOSE steer unit to ram extend HOSE steer unit to ram retract Qty
75. 55 issue 04 0198 Serial 2001 2214 2001 2214 2001 2214 2001 2214 2001 2214 2001 2214 2001 2214 2001 2214 2001 2214 2001 2214 2001 2214 2001 2214 2001 2214 2001 2214 2001 2214 2215 2215 2215 2215 2215 2215 2215 2215 2215 2215 2215 2215 2215 2215 2215 Description RADIATOR assy Covrad RADIATOR CAP COWL COOLER oil SCREW self tapping USED USED USED SCREW set WASHER shake proof WASHER flat PLUG drain SEAL bonded HOSE order by metre RADIATOR assy Becool RADIATOR CAP COWL COOLER SCREW set WASHER flat WASHER spring NUT SCREW set WASHER spring WASHER flat PLUG drain SEAL bonded HOSE order by metre a Qo OO AR a0 000000 gt 2 454000 455000 456000 457000 Dumpers RADIATOR HOSES amp FITTINGS Item 10 11 13 14 15 16 17 18 19 20 21 22 23 V601155 issue 04 0198 Part no V2003328 26 506 61504 V2003354 V2003354 V2003560 V2003353 V2002455 11502 267504 61502 V2003033 11S03C 267505 17504 7503 V2001698 V2001697 97511 97513 106209000 Serial 2001 3 R 2 Description Qty RADIATOR assy see page R 1 1 INSULATOR 2 WASHER flat 2 NUT self locking 2 HOSE 1 HOSE 1 CLIP hose AR ADAPTOR male 2 GUARD fan 2 SCREW set 4 WASHER
76. 5E V2003568 106209000 555253800 11502V 17503 7502 101507 V2004361 V2004362 11501 267503 17502 7501 V2003225 V601155 Jan 98 HH Description TRIM edging strip SEAL TRIM edging strip MIRROR 8 D 1 Qty order by metre order by metre order by metre 1 PLATE foam retaining not illustrated 1 SCREW self tapping CASE document 2 1 SEAL foam within Document Case AR BRACKET document case mounting SCREW set WASHER spring NUT RIVET PLATE rear sides infill PLATE rear top infill SCREW set WASHER flat WASHER spring NUT SEAL SCREW set WASHER Special WASHER flat NUT self locking N ABD CO OO order by metre See FRAME ROPS amp FOPS page 8 B 4 8 0 2 454000 455000 456000 457000 Dumpers GLAZING cab Item 10 11 15 16 Part no V2004734 V2004735 V2004736 V2004737 V2004738 V2004739 V602431 V2000772 V2003235 V601155 Jan 98 Serial no 2086 8 D 2 Description Qty WINDOW complete unit for door 1 WINDOW complete unit for L H door 1 GLASS rear screen 1 GLASS front screen 1 GLASS rear quarter 2 GLASS front quarter 2 SUPPORT glass gutter order by metre SCREW self tapping AR ADHESIVE clear Tube AR ADHESIVE black Tube AR 454000 455000 456000 457000 Dumpers 8 0 3 H41 HI INSULATION
77. 7 78 79 93 84 85 8 89 90 91 95 9 98 99 100 101 115 V601155 issue Sept 03 Part no V603034 V603035 V603036 V603037 V603038 V603039 V603040 V603041 V603042 V603043 V603044 V603045 V603046 V603050 17S05 V600753 V603051 V603053 V603054 V603055 V603057 V603058 V603059 V603060 V603061 V600693 V600785 V603542 V603543 Serial no SERVICE KITS 4 B 4A Description GEAR 27 reverse primary RING retaining clutch pack PLATE retaining clutch pack PLATE clutch steel 6 per pack PLATE clutch friction 6 per pack CIRCLIP RETAINER spring SPRING piston return PISTON clutch RING sealing O RING piston outer RING sealing piston outer O RING piston inner SPACER needle bearings WASHER spring BEARING needle primary gears WASHER output flange SCHEW O RING YOKE 1410 series BALL FORK shift 1st 2nd FORK shift 3rd 4th RAIL shift 1st 2nd RAIL shift 3rd 4th SCREW shift fork SEAL oil Clutch Pack Kit comprising of items 68 69 70 72 73 74 75 76 77 78 79 Input Shaft Assembly Kit comprising of items 65 and kit V603542 Qty A ho n5 no Continued gt 4 B 4A 454000 455000 456000 amp 457000 Dumpers Plus Transmission 4 B 4A GEARS amp SHAFTS Item Part no E V603544 o V603545 V603546 e V603547
78. 7S05 WASHER flat 4 5 V2004457 PIPE steel horizontal 1 6 72004458 1 11502 SCREW set 2 6B 267504 WASHER flat 4 6C 17503 WASHER spring 2 6D 7502 NUT 2 7 V2004183 HOSE rubber elbow reducer upper 1 8 72004459 steel small 1 9 V2004595 HOSE rubber elbow lower 1 10 97S13 CLIP 17 97515 CLIP hose 6 19 V2004455 PIPE steel 1 20 2003356 HOSE rubber 135 deg elbow 1 27 V2003188 HOSE rubber 90 deg elbow 2 V601155 issue 04 0198 454000 455000 456000 457000 Dumpers 12 20 22 16 21 4 30 26 49 00 12 ACCELERATOR PEDAL amp LINKAGE 3 D 1 ltem AA N N 12A 13 14 15 16 17 20 21 22 23 26 30 31 32 224410000 V2003532 V2003094 V2004769 7503 V2003096 11504 17505 267506 445030 267505 V2003091 43503 6505 10504 131501 425434000 V2003548 11S03M 17504 7503 176501 87505 11503 7503 17504 V2003592 V2003591 V601155 Jan 04 Serial no 2001 2355 2001 2330 2001 2355 2001 2330 Description Qty 454000 455000 456000 Dumpers 457000 Dumper CLEVIS 1 CLIP spring 1 ROD Not 457000 1 ROD 457000 Only 1 NUT 1 SCREW WASHER spring WASHER flat PIN split WASHER flat PEDAL assembly BUSH BOLT WASHER flat NIPPLE grease SPRING LEVER SCREW set WASHER spring NUT
79. DAL RELEASED With the dump pedal released Te the switch depressed the Safety Start Switch engine will not start Dump Pedal 12V TO E HANDBRAKE SWITCH 12V FROM FUSE e WHITE RED WHITE RED urple RED with p sleeve 0000 Switch with internal link removed DUMP PEDAL DEPRESSED To start the engine the dump pedal must be depressed i e this will release the switch lt 12V START 12V FROM SOLENDID 79 E Fuse 4 596 LCLOSED WHITE RED WHITE RED RED with purple sleeve Switch with internal link removed 3 12 TECHNICAL INFORMATION HANDBRAKE SAFETY START SWITCH For machines with electronic dump and mechanical gear change HANDBRAKE RELEASED Handbrake With the handbrake released i e the switch depressed the engine will not start Safety Start Switch 12V FROM DUMP PEDAL SAFETY START SWITCH lt lt 12VTO FINRSWITCH gt X Switch with internal link Zu BLUE WHITE HANDBRAKE APPLIED To start the engine the handbrake must be applied i e this will release the safety start switch 12V TO 12V FROM DUMP PEDAL WARNING LAMP l SAFETY START SWITCH lt WHITE LINK Switch with internal link fitted 5 Brakes Axles amp steering Engine Transmission Electrics Skip Hydraulics Chassis amp panels Miscellaneous OO O QI 5
80. EAL order by metre MARORA MND 0 CO continued gt 8 1 454000 455000 456000 457000 Dumpers PANELS ltem 16A 16B 16C 16D 17 18 19 20 21 22 23 26 27 28 29 31 31A 32 32A 33 34 35 36 37 38 39 40 41 V601155 issue Sept 03 11S05F 267507 17506 7505 V2002274 V2002275 7504 17505 267506 115040 V2003505 7504 17505 115040 267506 V2003523 V2004121 V2002679 V2004120 7502 17503 V2003595 11504 17505 7504 V2003183 V2003045 V2003046 V2004296 11506D 17508 267509 Serial 2041 2042 2041 2042 Description SCREW set WASHER flat WASHER spring NUT WING HYDRAULIC TANK See 7 1 WING L H FUEL TANK See page 3 18 NUT WASHER spring WASHER flat SCREW set WASHER spring SCREW set WASHER flat CLAMP battery CLAMP battery ROD clamp ROD clamp NUT WASHER spring COVER battery SCREW set WASHER spring NUT ANTI SLIP MATERIAL Machines WITHOUT cabs GRABRAIL L H GRABRAIL R H Machines WITH cabs 2001 2152 GRABRAIL SCREW set WASHER spring WASHER flat COVER engine 4S4 5 6000 only COVER engine Not used on 4S7000 sheets 10 10 10 10 OD NN 2 2 2 6 2 4 6 4 6 4 6 1 1
81. HER spring 3 30 7S03 NUT 2 32 V2003511 BATTERY 1 32A 2004204 2071 COVER battery terminal 1 QUO Bes ALARM reversing see page 5 2 1 37 11502 SCREW set 4 38 V2003530 ADAPTOR male 1 39 100502 SEAL bonded 1 40 7502 4 41 7502 4 42 267504 WASHER flat 4 43 17503 WASHER spring 4 45 V2003123 2052 GAUGE hour meter 1 50 2004794 SWITCH isolator 1 51 V602757 KEY isolator switch 1 52 10989A01 CABLE positive 1200mm long 1 53 513359400 CABLE positive 1000mm long 1 Note When fitting Isolator switch 50 cables 52 amp 53 are used in place of cable 22 54 11S01B SCREW set 2 55 59S13 Nyloc self locking 2 56 267S03 WASHER flat 2 454000 455000 456000 457000 Dumpers REVERSE ALARM AND 1 V2003748 2 V2003111 3 191901800 4 191901100 5 191906000 6 72003528 V601155 issue Sept 03 Serial 2001 5 2 Description TIMER TIE BULLET male CONNECTOR sleeve CONNECTOR lucar 1 4 7 insulated ALARM reverse Qty 5 3 454000 455000 456000 457000 Dumpers 15 21 20 20 21 22 23 24 25 26 27 28 V2003576 V600430 191901100 191901800 V2003111 V2003583 191901700 V2003577 V602399 V601800 V2003578 144776002 144779002 V2004043 V2003252 144776001 144779001 V2003567 V2004999 V2003573 11504D 17505 7504 17505 11504D 17505 750
82. ITHOUT power assistance 15 slow strenuous for the driver It should only used emergencies Tipping control valve The control valve 7 receives oil from the pump 4 and delivers it to the skip tipping rams 8 The rate of oil flow to the rams is proportional to the distance that the control valve lever is moved If the control valve lever is held either fully backwards or forwards after the rams have reached their full stroke a relief valve opens allowing the oil to return to the tank 2 30 Dumpers with rotating skips The tank filter pump and steering circuit operate in the same manner as for the conventional forward tipping skip See the previous page Rotating skip operation The skip is operated by a four way joystick control valve Joystick control valve The control valve 7 receives oil from the pump and delivers it to either the tipping rams 8 or the swivel rams 9 The rate of oil flow to the rams is proportional to the distance that the control valve lever is moved If the lever is held in one of its most extreme positions either left right or forwards backwards after any of the rams have reached their full stroke a relief valve opens allowing the oil to return to the tank Because the joystick is fitted with a gate it is not possible to move the lever diagonally therefore it is not possible to tip and swivel simultaneously SERVICE DISCHARGE LEFT E RIGHT
83. Joystick gate SERVICE Dumping hydraulic pressure WARNING Always dump all hydraulic pressure from the system before servicing any hydraulic component To dump pressure Ensure that the skip is fully lowered Stop the engine Move the skip control lever several times in each direction Safe working WARNING Do not allow oils to come into regular contact with skin This can lead to serious skin diseases Medical evidence suggests they may include skin cancer Always wear protective gloves when handling oils for topping up draining or refilling Always practise the greatest cleanliness when servicing hydraulic components Always clean the areas surround filler points filters before and after servicing Dispose of waste oil into waste oil storage tanks if storage tanks are not available consult your Distributor or local authority for addresses of local designated disposal points It is illegal to dispose of waste oil into drains or water courses or to bury When working on the hydraulic system allow the hydraulic oil to cool before disconnecting any components or draining down the system 2 31 Hydraulic system checks If the hydraulic system fails to operate completely or does so extremely slowly carry out the following checks Check that the hydraulic tank is full of oil See Every 10 hour or daily servicing procedures for checking hydraulic oil level Check that the
84. L shift 3rd 4th FORK shift 1st 2nd FORK shift 3rd 4th SCREW 9 C2 N N no continued gt 454000 455000 456000 457000 Dumpers Shuttle Transmission CASING Item 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 50 51 52 53 54 55 63 64 65 66 6 68 69 V601155 Feb 04 Part no V600694 V600695 V600696 V600697 V600699 V600700 V600701 V600702 V600703 V600704 V600688 V600705 V600706 V600707 V600708 V600709 V600710 V600711 V600712 V600713 V600714 V600715 V600716 V600717 V600718 V600719 V600720 V600721 V600696 V600722 V600723 Serial no Description LUG shift The two lugs must be ordered as a matched pair Never replace one without the other PLATE SCREW ROD shift 1st 2nd BELL HOUSING see page 4 2 SCREW SEAL ring PUMP amp OIL SEAL assembly SEAL washer SCREW SEAL PLUG GASKET HOUSING ADAPTOR FILTER WASHER SCREW PLUG assembly RING COVER SCREW NUT SCREW GASKET DOWEL PLUG PIPE COVER SCREW PLUG GASKET continued gt 454000 455000 456000 amp 457000 Dumpers Shuttle Transmission 4 B 2 CASING Item 70 71 72 73 74 75 76 77 78 80 80A 81 82 83 84 V601155 issue 04 0198 Part no V600724 V600725 V600726 V600727 V600728 V600729 V600730 V600731
85. Loosen the union nut T at the thermostart plug and operate the lift pump until fuel free from air flows from the connection Tighten the union nut T Loosen the union nuts of the high pressure pipes S at two of the fuel injectors Operate the starter motor until fuel free from air flows from the pipe connections Tighten the high pressure pipe connections S The engine is now ready to start If the engine runs correctly for a short time and then stops or runs roughly check for air the fuel system If there is air in the system there is probable a leak in the low pressure fuel system 2 19 SERVICE Bleeding the fuel system later type fuel filter WARNING your skin comes into contact with high pressure fuel obtain medical assistance immediately If air enters the fuel system it must be removed before the engine can be started e fuel tank is drained during normal operation e low pressure fuel pipes disconnected of the low pressure fuel system leaks during engine operation In order to eliminate air from the fuel system proceed as follows Vent screws are not fitted to the fuel injection pump Air will usually be removed from the fuel pump automatically WARNING f the fuel system is empty or If the canister of the fuel filter as been renewed it will be necessary to eliminate air from the fuel system especially the fuel injection
86. RD ENGINE COVER From serial number 2122 4S7000 ONLY From serial number 2153 4S4 5 6000 CASING steering column FRAME ROPS amp CANOPY FOPS SEAT amp suspension units SEAT GRAMMER with fittings SEAT GRAMMER parts CAB FRAME 8 FITTINGS GLAZING cab INSULATION cab INSULATION seatbox HEATER cab lt lt lt To beginning of Parts gt CO O 8 1 454000 455000 456000 457000 Dumpers CHASSIS front forward tipping Item 15 16 17 18 19 20 25 26 27 28 V2002577 V2004135 V2002474 11503 V2002621 61503 208143000 176501 131501 8507 V2004004 61507 555020 V2003851 902502 V2004234 7508 267512 17511 601155 Jan 98 Serial 2001 2042 2042 2042 2042 2042 2042 2042 2042 2042 2042 Description CHASSIS front BUSH skip pivot RAM tipping see Hydraulics Section SCREW set PIN self locking SLEEVE pvc COVER grease nipple NIPPLE grease straight BOLT SUPPORT articulation lock NUT self locking PIN roll PIN PIN lynch SCREW skip stop NUT WASHER flat WASHER spring N 8 A 1A 4S5000 Dumper with rotating skip CHASSIS front rotating skip Item Q 10 10 11 12 13 15 16 17 20 21 22 23 30 31 32
87. RES DAILY CHANGE HYDRAULIC OIL FILTER ELEMENT AFTER FIRST 100 HOURS AND THEREAFTER EVERY 306 HOURS THE HANDBRAKE OF THIS VEHICLE OPERATES ON THE TRANSMISSION AND MUST ONLY BE USED FOR PARKING OR EMERGENCY STOPS DAMAGE MAY BE CAUSED IF USED AS SERVICE BRAKE WARNING TIGHTEN WHEEL 5 DAILY y pd D e gt gt 2003594 2003518 2 DECALS amp PLATES Item 4A 4B 4C cO 11 12 13 15 16 157 504694600 10541 27 10541 38 10541 39 10536 02 V2003142 V2003516 311503B V2004758 311503B V2003518 1785 5030 V2004759 10284A01 V2003100 20132A02 V2003101 V2003594 V601155 Jan 04 Serial no 9 A 2 Description DECAL Do not work under unpropped skip DECAL Dumper safety DECAL MAX PAYLOAD 4000 kgs DECAL MAX PAYLOAD 5000 kgs DECAL MAX PAYLOAD 6000 kgs DECAL Non free running loads DECAL Tighten wheel nuts daily PLATE Gear positions manual F N R SCREW not illustrated PLATE Gear positions electrical F N R SCREW not illustrated PLATE F N R manual selection SCREW not illustrated DECAL F N R electrical selection DECAL Dump Return DECAL Hydraulic oil year 1993 PLATE dumper safety obsolete DO NOT USE DECAL Diesel fuel DECAL Access points 9 A 3 454000 455000 456000 amp 457000 Dumpers 16
88. S04 267S05 V2002452 V2004461 V2002466 V2003240 V601168 V601169 V601170 11502 61502 Serial 2001 Description SILENCER Not 4S7000 SILENCER 4S7000 only BAND mounting SCREW set WASHER spring WASHER flat PIPE exhaust Not 457000 PIPE exhaust 4S7000 only PIPE exhaust flexible CLAMP band STUD NUT JOINT SCREW set NUT self locking 454000 455000 456000 457000 Dumpers AIR CLEANER amp FITTINGS ltem NO OF 00 10 11 11A 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 33 34 35 601155 155 04 0198 V2003355 V600485 V600486 V600487 V600484 V600658 V600659 V2003596 97515 V2003188 97515 V2003271 7503 17504 267505 11503 97515 V2003298 V2002939 V2003356 11S02A 267504 17503 7502 V2003297 V2003296 V2003188 V2003299 7503 17504 11503 Serial 2001 2223 2223 2223 2223 2223 2223 2223 2223 2152 2152 2153 2223 2153 2223 2223 2223 2223 2223 2223 2223 2223 2223 2223 2223 2223 2223 2223 2223 2223 2223 2223 2223 2223 2223 3 2 Description AIR CLEANER assembly COVER COLLECTOR dust NUT wing ELEMENT outer NUT ELEMENT inner BODY order assembly CAP stack assembly CLIP HOSE rubber 90 deg elbow CLIP hose CLAMP band NUT
89. SCREW WASHER GASKET SCHEW FITTING adaptor 454000 455000 456000 457000 Dumpers Shuttle Transmission with electric dump 4 B 6 CONTROL VALVE Optional Not used on Compact Plus Transmission Part Serial no Description Qty 2001 2407 454000 455000 456000 Dumpers 2001 2403 457000 Dumper V2004256 CONTROL VALVE assembly 1 1 V602567 BODY 1 2 LEVER see page 4 D 2 1 V600793 1 4 7600794 1 5 V600795 SEAL O 1 6 V600796 VALVE 1 7 7600797 1 15 V600805 BALL 1 16 V602564 SPRING 1 17 7600807 WASHER 1 18 V600808 PLUG 1 19 V600809 PLUG 20 V600810 WASHER copper 21 V600673 SCREW 22 V600811 PLUG 3 23 V600812 SCREW 4 28 V600816 SPRING 1 29 7602568 VALVE pressure 1 30 V600818 SPRING inner 1 31 V600819 SPRING outer 1 32 V602569 PISTON 1 33 V600821 GASKET 1 34 V600822 BODY 1 35 V600823 GASKET 1 36 V600824 SPRING 1 3 V600825 BALL 1 38 7600826 1 39 7600827 SCREW 3 40 600674 SEAL O ring 1 41 600688 PLUG 1 V601155 Jan 04 continued gt 4 6 454000 455000 456000 457000 Dumpers 23 17 18 07 as E D 29 22 30 Shuttle Transmission with electric dump 4 B 6 CONTROL VALVE Optional Not used on Compact Plus Transmission Part Serial no Description Qty 43 V600829 GUIDE 1 44 V600830 SPRING 1 45 30097A0199 BALL 1 46 V600674
90. TANCE PIECE SHIM 051mm AR SHIM 076mm AR SHIM 178mm AR SHIM 559mm AR GEAR reverse idler 251 1 WASHER 1 NUT self locking 1 DOWEL BEARING WASHER thrust outer WASHER thrust RING sealing BEARING GEAR forward primary WASHER thrust inner RING snap RETAINER stamped no 66196 Rings V600756 amp Retainers V600757 were only fitted when FOURTEEN plain clutch discs were fitted in the transmission lt N N AAN KIT ring amp retainer 2 RING snap RETAINER stamped no 69729 1 Rings V602600 amp Retainers V602601 are used when SIXTEEN plain clutch discs are fitted in the transmission DISC friction lined 14 DISC clutch plain 14 16 O A 90 NOTE During overhaul of the transmisson discard all old friction and clutch discs and the retainers then fit SIXTEEN new plain clutch discs and fourteen new lined fricton discs with two new Hings V602600 and Retainers V602601 continued 454000 455000 456000 457000 Dumpers 4 3 Shuttle Transmission GEARS amp SHAFTS Part Serial no Description Qty 21 V600760 RING 2 22 V600761 RETAINER 2 23 V600762 PISTON 2 24 600763 SEAL 2 25 V600764 SEAL O ring 2 26 V600765 SHAFT input 1 27 7600766 reverse primary 1 28 600367 SHIM 051mm AR 28 V600368 SHIM 076mm AR 28 V600369 SHIM 127mm AR 28 V600370 SHIM
91. VER stub gear BOLT SEATING gear lever assemly PIN anti rotation COVER dust N wo N Continued gt 454000 455000 456000 457000 Dumpers Plus Transmission CASING Item 107 108 109 110 111 112 113 114 116 117 118 120 121 130 131 132 133 134 V601155 Jan 04 Part no V603065 V600668 V603066 V603067 V603132 V603133 V603535 V600684 V603536 V600707 V600711 V600335 V603537 V2003565 V2003564 30113A0506 11S05C 17S06 267507 V603538 V603539 V603540 V603541 Serial no Description O RING suction strainer STRAINER suction VALVE cartridge pressure regulator CLIP Oetiker CLIP Oetiker PLUG VALVE relief converter SETSCREW strainer cover FILTER oil ADAPTOR filter PLUG drain DOWEL case PLATE cover strainer DIPSTICK CAP TUBE filler SEAL O ring SCREW WASHER spring WASHER flat Items below not illustrated CAPSCREW PLUG sealing GUIDE spring GASKET MN 4 B 4A 454000 455000 456000 amp 457000 Dumpers Plus Transmission GEARS amp SHAFTS Item 12 14 28 29 30 31 32 33 34 35 36 43 44 45 46 47 48 49 90 51 52 53 54 55 56 5 58 60 61 62 63 64 65 66 V601155 issu
92. WASHER spring WASHER flat SCREW set CLIP hose ADAPTOR PIPE steel HOSE rubber 135 deg elbow SCREW set WASHER flat WASHER spring NUT INDICATOR restrictor ADAPTOR HOSE rubber 90 deg elbow TUBE nylon order by metre NUT WASHER spring SCREW set Qty N AR 454000 455000 456000 Dumpers FER JA AIR CLEANER amp FITTINGS 3 C 3 Item Partno Serial no Description Qty 1 V2004764 2224 AIR CLEANER assembly 1 2 V602663 2224 ELEMENT outer 1 7602687 2224 NUT wing 1 4 7602664 2224 ELEMENT inner 1 5 V602688 2224 COLLECTOR dust 1 6 2224 BODY order assembly 1 7 V602665 2224 INDICATOR restrictor 1 10 11503 2224 set 11 17504 2224 WASHER spring 4 12 267505 2224 WASHER flat 4 17 97515 2224 CLIP hose 5 7 18 V2005103 2356 steel 310 long 19 72002939 2224 2355 steel 620 long 1 19 72005102 2356 steel 545 long 1 20 V2003356 2224 rubber 135 deg elbow 1 21 V2005104 2356 HOSE rubber straight 1 27 V2003188 2224 HOSE rubber 90 deg elbow 2 V601155 issue 04 0198 457000 Dumper AIR CLEANER amp FITTINGS 3 4 Serial Description Qty 1 V2003355 2122 2227 AIR CLEANER assembly 1 See page 3 C 2 for elements 1 V2004764 2228 AIR CLEANER assembly 1 See page 3 C 3 for elements 2 11503 SCREW set 4 3 17S04 WASHER spring 4 4 26
93. age at this point will allow air into the fuel system Eliminate the air from the fuel system See Bleeding the fuel system Bleeding the fuel system If air enters the fuel system it must be eliminated before the engine can be started Air can enter the system if e The fuel tank is drained during normal operation e The low pressure fuel pipes are disconnected e A part of the low pressure fuel system leaks during engine operation see following pages to bleed system SERVICE 2 19B To bleed the fuel system earlier type fuel filter WARNING your skin comes into contact with high pressure fuel obtain medical assistance immediately Loosen the banjo connection bolt fitted on the top of the fuel filter Operate the priming lever N on the fuel pump until fuel free from air flows from the filter vent point Note li the drive cam of the fuel lift pump is at the point of maximum lift it will not be possible to operate the priming lever In this situation the crankshaft must be turned revolution Tighten the banjo connection bolt M Turn the start key to position Loosen the vent screw P situated in the lock screw of the hydraulic head and the vent screw R situated on the governor cover of the fuel injection pump Operate the priming lever N of the fuel lift pump until fuel free from air flows from the vent screws Tighten the vent screws
94. anks are not available consult your distributor or local authority for addresses of local designated disposal points It is illegal to dispose of waste oil into drains or water courses or to bury it Equipment which includes friction materials will sometimes contain asbestos When removing friction material dust from components such as when servicing brakes or clutches do not blow out with an airline it could be harmful to inhale the dust Remove the dust with a vacuum cleaner or wipe clean with a damp rag Waste should be placed in a sealed container marked and disposed of in accordance with local or national regulations The accumulated dust found in clutch housings may contain lead antimony No food should be eaten at a work place contaminated by this dust Hands must be washed before eating Do not blow out dust with an airline NEVER work under an unpropped skip always fit the special Skip Support that has been supplied with the dumper ALWAYS fit the articulation lock when servicing or working on the machine 0 6 WORKING DECALS Attached to the dumper are several pictorial warning decals For detailed information on how to safely use the items described by the decals see the Safe working Operation Servicing sections of this Handbook Descriptions of the decals are as follows Fuel tank filling point Before lifting the engine cover ensure the seat has been moved fully forward Hydr
95. ation SERVICE ENGINE Every 10 operating hours or daily Check engine lubrication oil level WARNING Lubrication oil cleanliness 15 vital for the successlul operation of your engine The oil should be stored under the cleanest possible conditions When changing or topping up oil use only clean receptacles Do not allow the oil to come into contact with the rubber hoses on the engine Do not check oil level until the engine has been stopped for 2 minutes Remove and clean dipstick M then check that the oil is at the full mark If level is low top up through the filler N to the full mark with clean oil of the correct grade DO NOT OVERFILL For correct grade of engine oil see Specifications First 50 operating hours or weekly When your new engine has run for 50 operating hours the following service procedures should be carried out Change engine lubrication oil See Every 250 operating hours Change engine lubrication oil filter See Every 250 operating hours Check engine idle speed WARNING Any alteration to the engine idle soeed MUST be carried out by your Distributor because incorrect adjustment could cause damage to the engine or transmission 2 10 SERVICE Every 50 operating hours or weekly Check fan drive belt tension WARNING ff the fan drive belt shows any signs of wear damage or stretching it should be replaced To ensure maximum life it is rec
96. aulic oil filling point The Battery Isolator is situated close to this decal BATTERY ISOLATOR ISOLATING THE BATTERY WITH THE ENGINE RUNNING EXCEPT IN CASES OF EMERGENCY WILL LEAD TO DAMAGE TO THE VEHICLE ELECTRICAL SYSTEM Do not attach lifting hooks to this part of Read Operators Handbook or the dumper Operators Handbook storage place Attach lifting hooks to this eye The battery negative terminal is connected to earth WORKING Articulation Lock when used prevents the front and rear chassis from articulating This decal indicates the maximum loads that the dumper towbar can carry and pull 2500 250kg Forks and buckets are not to be used to push or lift the dumper Only mount the dumper from the rear using the steps and handles Keep clear of this Crush area between the front and rear articulating chassis of the dumper 0 7 ISO Skip Support when used is pinned around the tipping ram rod to prevent the ram from closing These surfaces may be hot ru electrical hazards maximum permitted skip load 7000 E Kg reverse down gradients when Always loaded 0 8 WORKING Keep hands away from moving parts Always wear eye protection 1 1 CONTROLS LAYOUT 1 Steering wheel 8 Gear lever 15 Warning lights panel 2 Foot brake 9 Key start sw
97. c pressures See Check that the hvdraulic pressures are correct 2 34 SERVICE BRAKING SYSTEM Every 10 operating hours or daily Brake oil reservoirs Check the oil level in the reservoirs H Never allow the oil to fall more than 10mm below top level marks Braking System The braking system is designed to require the minimum of maintenance and no defects should normally occur If air is present the system it will be indicated by sluggish response by spongy action of the brake pedal A Bleed screw rear axle R H B Bleed screw rear axle L H C Bleed screw front axle L H D Bleed screw front axle E Master cylinder rear axle F Master cylinder front axle G Balance bar linkage H Brake oil reservoirs To bleed the braking system Check that all connections are tight and the bleed screws are closed Check that there is sufficient oil in the brake reservoirs WARNING Clean the areas surrounding bleed screws and brake reservoirs before servicing SERVICE WARNING Do not allow the reservoirs to empty during the bleeding procedure Dispose of waste oil into waste oil storage tanks If storage tanks are not available consult your Distributor or local authority for addresses of local designated disposal points lt is illegal to dispose of waste oil into drains or water courses or to bury it Attach bleeder tube V to the first bleed screw A and immerse the o
98. cap especially if the engine is hot Before opening any drain plugs ensure a suitable container is placed on the ground to catch spilt coolant When opening plugs remember to stand to one side to avoid coolant which will spill from the drain plug Ensure the machine is parked on firm level ground Apply the parking brake Stop the engine 2 16 SERVICE Remove the drain plug U at the bottom of the radiator to drain the radiator Remove the drain plug T from the side of the cylinder block to drain the engine Ensure that the drain plug hole is not restricted Remove the filler cap Flush the system with clean water Refit the drain plugs and refill the system at the radiator filler cap R using the correct mixture of coolant It is preferable to use a coolant mixture of 50 antifreeze and 50 water as this will give greater protection against freezing and engine corrosion WARNING Always use antifreeze of the correct type and grade For type and grade see Specifications Check hoses During the renewal of coolant carefully examine the radiator hoses for cracks cuts or damage SERVICE 2 17 FUEL SYSTEM Every 10 operating hours or daily Check fuel tank level Note Later dumpers are fitted with a fuel level sight gauge his is situated on the fuel tank adjacent to the rear wheel Fill the fuel tank at the end of each day to reduce overnight condensation within t
99. ch gives priority flow to the steering In preference to skip tipping Main components forward tipping skip Tank Filler oreather strainer Filter Pump Steer unit Steer ram Tipping control valve Tipping rams CON O GND Tank The tank 1 has a filler oreather which Incorporates a dipstick The assembly 2 also Includes a strainer Filter Oil is drawn from the tank via the filter 3 the suction line The filter is fitted with a spin off cartridge element Pump From the pump 4 there are two delivery hoses One hose supplies the Steering unit 5 while the other supplies the skip tip control valve 7 A valve within the pump 4 gives priority flow to the steering unit 5 This priority valve is activated by a pressure sensing hose from the steering unit Steering unit The steering unit 5 consists of a distributor valve and a rotary meter When the steering wheel is turned the distributor valve directs oil from the pump via the rotary meter to one or other of the steering ram ports 6 depending on the direction in which the steering wheel is turned The rotary meter ensures that the oil volume supplied to the ram 6 Is proportional to the distance that the steering wheel is turned If the oil flow from the pump 4 fails the steering unit can function as a hand pump this will allow the machine to be steered but without power assistance WARNING Steering W
100. d DO NOT RUN THE ENGINE WITH THE INDICATOR SHOWING RED THIS WILL CAUSE TO THE ENGINE Regular preventive servicing of the air cleaner as previously described will prevent this occurring WARNING Always obey the Air cleaner blocked indicator IMMEDIATELY To reset the indicator press IN the rubber N SERVICE SERVICE 2 23 TRANSMISSION First 50 operating hours Change transmission oil and filter See Every 750 operating hours Every 50 operating hours or weekly Check transmission oil level Check the transmission oil level when the machine has stood for 2 minutes with the engine at idle speed WARNING ALWAYS check and top up the transmission oil with the engine running at idle speed Clean the area surrounding lt y dipstick before removing Check the oil level at the dipstick filler cap R Unscrew the dipstick from the filler tube Clean the dipstick blade and re insert into the filler tube Do not screw down the cap The oil level is correct when it reaches the maximum mark on the dipstick with the engine at idle speed and the transmission at normal operating temperature Too up if necessary through the dipstick filler tube T with clean oil of the correct grade is most important not to overfill Re insert the dipstick R and screw the cap down securely For the correct type and grade of oil see Specifications 2 24 SERVICE Ev
101. d Neutral Reverse Compact Plus GEAR LEVER PROPELLER SHAFTS TRANSFER GEARBOX assembly INPUT amp IDLER SHAFT transfer gearbox OUTPUT SHAFT transfer gearbox HOUSING transfer gearbox lt lt lt To beginning of Parts 454000 455000 456000 457000 Dumpers we CT lt kA Y A Serial 1 V2003351 2001 2 72003258 2001 Description TORQUE CONVERTER DRIVE PLATE assembly SCGREW set order assembly WASHER flat order assembly DRIVE PLATE order assembly SUPPORT plate order assembly SCREW set order assembly TORQUE CONVERTER amp Compact TRANSMISSION 4 A 1 Qty 8 72003352 Compact Shuttle TRANSMISSION 454000 455000 456000 Dumpers 457000 Dumper CASING see page 4 2 GEARS amp SHAFTS see page 4 B 3 CONTROL VALVE mechanically operated see page 4 B 5 CONTROL VALVE solenoid operated see page 4 B 6 2001 2407 2001 2403 8 V2004669 Compact Plus TRANSMISSION 454000 455000 456000 Dumpers 457000 Dumper CASING see page 4 B 4 GEARS amp SHAFTS see page 4 B 4A 2408 2404 V601155 Jan 04 BELL HOUSING Compact Shuttle transmission Item 10 11 12 11 12 Part no Serial no Description 4 2 Qty Shuttle with stressed block bell housing V600698 2001 BELL HOUSING stressed block 1 8S05G BOLT 1 7505
102. e PIN roll NUT special c w locking tabs NUT locking thin Welded to under side of lower steering arm on centre pivot casting SPACER front pin SPACER rear pin NIPPLE grease 8 1 454000 455000 456000 457000 Dumpers PANELS Item 6B 6C 6D 7 8 10 11 12 12 12 12C 13 13 14 15 15A 15B 16 V601155 Sept 03 Part no V2003093 V2004755 V2004369 V2005036 145040 11504 267506 17505 7504 V2001815 V2004368 11502B 17503 7502 11S04F 267506 61504 V2003019 V2001689 11S02A 17S03 267504 V2002745 V2002745 115040 17505 267506 7504 V2003225 Serial no Description Machines WITHOUT cabs 2001 1t PLATE floor PLATE floor Machines WITH cabs 2001 H 2330 2331 2355 2356 PLATE floor c w access plate SCREW c sunk for access plate Turbo engines Naturally asperated engines SCREW set WASHER flat WASHER spring NUT Machines WITHOUT cabs SEATBOX c w cover item 12 Machines WITH cabs 2001 2152 SEATBOX c w cover item 12 SCREW set WASHER spring NUT SCREW set WASHER flat NUT nylon insert SPACER Not ROPS frame or cab COVER part of item 6 SCREW set WASHER spring WASHER flat GUARD rear 4S4 5 6000 only GUARD rear Not used on 4S7000 SCREW set WASHER spring WASHER flat NUT S
103. e Sept 03 V603492 V600674 V600722 V603398 V600773 V603481 V603482 V603016 V603017 V603018 V600772 V603558 V600401 V600771 V600770 V600776 V603023 V600767 V600367 V600368 V600369 V600370 V600371 V600372 V600406 V603024 V603025 V600784 V600780 V600781 V600782 V600783 V600479 V603027 V603028 V602029 V603030 V603031 V603033 Serial no 2408 2404 4 B 4A Description Qty 454000 455000 456000 Dumpers 457000 Dumper PLUG 8 O RING assembly 12 O RING 12 GAP sealing 1 SLEEVE reverse shift hub 2 SYNCHRONISER assembly 2 BEARING thrust 2 WASHER thrust 2 output 4th gear 1 SHAFT output 3rd gear 1 SHAFT output 2nd gear 1 output 1st gear 1 SPACER 1 BEARING 2 SPACER 1st gear bearing 1 SLEEVE 1st gear bearing 1 CIRCLIP 1 thrust 4th gear 1 SPACER bearing 2 SHIM 0 002 A R SHIM 0 003 A R SHIM 0 005 A R SHIM 0 007 A R SHIM 0 015 A R SHIM 0 020 A R BEARING reverse idler amp input shaft 4 SHAFT output 1 BEARING 2 SPACER bearing 2 SHIM A R SHIM A R SHIM A R SHIM A R BEARING countershaft front 1 BEARING 1 WASHER thrust 2 COUNTERSHAFT 1 GEAR reverse idler 1 SHAFT input 1 GEAR forward primary 1 Continued gt 4 4 454000 455000 456000 457000 Dumpers 6 Z Y Plus Transmission GEARS amp SHAFTS Item 67 68 69 70 71 72 73 74 75 76 7
104. e thrust washers proceed as follows Push the yoke backwards until it touches the rear member of the chassis R Measure the distance between the front of the yoke and the chassis S Halve this dimension to the nearest millimetre The resulting figure is to be the thickness of the rear thrust washer 10 3 Using grease to hold it in place position thrust washer 10 onto the chassis 4 Insert thrust washer 11 in front of the yoke IMPORTANT Thrust washer 11 must be of sufficient thickness to eliminate all horizontal float from the yoke 5 Screw the guide 15 onto the pin 3 6 From the rear of the chassis insert the guide pin through the chassis thrust washers and yoke 7 Secure the pin with screws 5 and washers 6 7 8 Unscrew the guide from the pin and fit washer 8 nut 9 SERVICE 2 39 Installing vertical pivot pin 10 Bring the front and rear chassis together so that the yoke sits on the U pivot mount T of the rear chassis 11 Measure the distance between the A Top of the yoke and the upper pivot Z T mount U Halve this dimension to the nearest millimetre The resulting figure is to be the thickness of the lower thrust washer 12 12 Insert thrust washer 12 beneath the yoke 13 Insert thrust washer 13 above the yoke IMPORTANT Thrust washer 13 must be of sufficient thickness to eliminate all vertical float from the yoke 14 Screw
105. eering Never hold the steering on full lock for more than a few seconds because the excessive use of the relief valve will cause overheating of the components Gradients WARNING When driving on gradients remember the following Slippery or loose surface conditions can adversely affect safe dumper operation particularly on gradients Choose routes that avoid steep slippery or loose gradients Never park the dumper on a gradient Never attempt to turn on or drive across a gradient Always drive forwards up gradients when loaded Always reverse down gradients when loaded Never tow up or down gradients Never operate High Discharge or Rotating skip on a gradient OPERATION Electronic control Mechanical control Braking The brake pedal operates the brakes in the conventional manner WARNING Never make unnecessary crash stops when travelling at speed especially in forward direction Stopping the dumper Release the accelerator and brake to a halt progressively select neutral gear Ensure the forward reverse control 14 is in the neutral safety gate position Apply the parking brake when stationary Turn the key start switch to the OFF position and remove the key OPERATION Leaving the dumper WARNING At the end of the working day turn the wheels from lock to lock when parking to clear mud and water from the steering ram rod This will reduce the risk o
106. ery 250 operating hours Note adjacent illustrations show the Shuttle transmission Change transmission oil filter Remove the external oil filter W and replace with a new filter Run the engine until the transmission has reached the normal operating temperature Check that the oil level is at the maximum level on the dipstick with the engine running at idle speed up necessary with clean oil of the correct grade For the correct type and grade of oil see Specifications Everv 750 operating hours Change transmission oil and filter WARNING Disposal of waste oil Dispose of waste oil into waste oil storage tanks If storage tanks are not available consult your Distributor or local authority for addresses of local designated disposal points lt is illegal to dispose of waste oil into drains or water courses or to bury it Clean the area surrounding plugs before removing When removing drain plug X be sure to stand to one side to avoid oil which will spill from the hole To change transmission oil and filter Run the engine to warm the oil Stop the engine Place a suitable container beneath the drain plug X Y Remove the drain plug X BEFORE removing the filler cap dipstick R SERVICE Flush through with clean oil Replace drain plug Remove the external oil filter W and replace with a new filter Remove the suction strainer Y
107. ery hot ALWAYS work out of doors or in a well ventilated area NEVER run an engine in an enclosed space Exhaust fumes in enclosed areas can kill ALWAYS disconnect battery cables and remove battery before using an external charger carrying out welding repairs or to prevent unauthorised usage when unattended or during a repair NEVER allow unqualified personnel to attempt to repair remove or replace any part of the machine or anyone to remove large or heavy components without adequate lifting tackle WORKING 0 5 NEVER attempt to modify or repair the ROPS frames FOPS canopies by welding drilling or any other means Attempts to do so will invalidate ROPS FOPS Certification ALWAYS obtain advice before mixing oils some are incompatible If in doubt drain and refill NEVER allow oils and fuels to come into regular contact with skin This can lead to serious skin diseases including medical evidence suggests skin cancer ALWAYS wear protective gloves when handling oils and fuels whether topping up draining or refilling ALWAYS wash hands if oils or fuels come into contact with the skin Many liquids used in this machine are harmful if taken internally or splashed into the eyes In the event of accidentally swallowing oils fuels anti freeze battery acid etc DO NOT encourage vomiting seek qualified medical assistance immediately ALWAYS dispose of waste oils and fuels into waste oil storage tanks If storage t
108. f wear and damage from dirt and ice Ensure the dumper is parked on firm level ground Do not park on a gradient Check that the parking brake is applied Check that the forward reverse control 14 is in the neutral safety gate position Ensure that the skip is fully lowered With the engine stopped operate the hydraulic lever fully in each direction several times to dump hydraulic pressure from the system Remove the starter key from the switch If unattended for some time remove the earth cable from the battery or activate the Battery Isolator where fitted Skip tipping The skip tipping rams are dual acting They have to be Powered up and Powered down However If the skip is raised and the engine is switched off DO NOT operate the control valve as the skip will rapidly lower to the chassis WARNING Never venture under raised skip unless it is fitted with an ISO Skip Support See Service Safetv Section 2 1 7 Rotating skip operation The skip is operated bv a jovstick control valve the lever of which is moved through a gate DISCHARGE LEFT lt m 4 RICHT LOWER Because of the gate it is not possible to move the lever diagonally therefore it is not possible to tip and slew the skip simultaneously Slewing the skip WARNING Before attempting to slew the skip The dumper must be stationary on level ground with the front and rear chassis in line
109. g W504694600 WINGET DUMPER SAFETY BEFORE OPERATING THIS MACHINE THE DRIVER SHOULD BE FAMILIAR WITH THE OPERATING INSTRUCTIONS ISSUED BY THE MANUFACTURER THE MANUFACTURER S RATED PAYLOAD MUST NEVER BE THE WEIGHT ALL LOADS ABOVE SKIP WATER LEVEL MUST BE CHECKED 3 PASSENGERS MUST NOT BE CARRIED AT ANY TIME USE EXTREME CARE WHEN DESCENDING STEEP GRADIENTS AND KEEP SPEED TO A MINIMUM DO NOT APPLY BRAKES VIOLENTLY WHEN TRAVELLING DOWN STEEP GRADIENTS 4A maximum payload 4000 kgs 6 DO NOT TOW DOWN GRADIENTS OTHERWISE JACK KNIFING MAY OCCUR BUMPERS ARE NOT DESIGNED AS TOWING VEHICLES BUT LOADS INCLUDING WEIGHT OF TRAILER NOT EXCEEDING THE RATED PAYLOAD OF THE DUMPER MAY BE TOWED ON LEVEL GROUND IN FIRST GEAR PROVIDING THE DUMPER SKIP 15 LOADED WITH HALF THE RATED PAYLOAD TO ENSURE TYRE ADHESION WHEN BRAKING NEVER DRIVE THE MACHINE TOO CLOSE TO THE EDGE OF ANY EXCAVATION ESPECIALLY IF THE GROUND 15 LOOSE OR WET NEVER MAKE ANY ADJUSTMENTS TO THE MACHINE WHILST 15 IN MOTION NEVER FILL THE FUEL TANK WITH THE ENGINE RUNNING EXERCISE CAUTION WHEN THE ENGINE 1 HOT ALWAYS KEEP THE FLOOR PLATES CLEAN NEVER DISMOUNT WHILE MACHINE IS IN MOTION maximum payload soookgs 4C maximum payload 6000kgs ALWAYS APPLY HANDBRAKE BEFORE LEAVING THE DRIVERS SEAT TAKE EXTRA CARE WHEN TIPPING NON FREE RUNNING LOADS OPERATORS INSTRUCTIONS CHECK CONDITION AND PRESSURE OF TY
110. he tank WARNING Never mix gasoline or any other fuel mixes to diesel fuel because of increased fire or explosion risks To fill the tank WARNING Never smoke when refilling the tank Always keep control of the filler pump nozzle Stop the engine Apply the parking brake Clean the area around the filler cap 5 Remove the cap Fill the tank with diesel fuel WARNING Do not fill the tank to capacity Allow room for expansion and wipe up spilt fuel immediately otherwise paintwork will be damaged Replace the filer cap S Check fuel pre filter for water If there is sediment in the glass bowl E drain as follows Loosen the drain F at the bottom of the filter and allow the water fuel to drain into a suitable container Retighten the drain F when uncontaminated fuel begins to flow 2 18 First 50 operating hours When your new engine has run for 50 operating hours the following service procedures should be carried out Clean pre filter See Every 250 operating hours Clean fuel lift pump strainer See Every 250 operating hours Change fuel filter See Every 250 operating hours Every 250 operating hours Clean pre filter WARNING Clean the area surrounding the pre filter before removing Loosen the drain F and drain all the contents of the filter into a suitable container Hold the base of the filter G while unscrewing the retaining bolt Remove the fil
111. he timer or alarm doing so will damage the internal circuits of the timer rendering it unservicable The timer has two live feeds a A live feed from the water temperature sender operates the alarm in the start up mode b A live feed from the transmission mounted pressure switch operates the alarm in the reverse mode Selecting reverse while the engine is running and the start up alarm sounding will automatically override the start up alarm and allow the reverse alarm to sound as it would normally whilst reversing TIMER for audible alarm U U R R Bullet connectors AUDIBLE ALARM 1 4 Female Lucar 7 ape WATER tates SD SENDER WIRING COLOUR CODES Black Green Brown Orange Purple Red Blue White Yellow Pink B G N O P R U K G N Bullet connectors TU From mounted transmission reverse solenoid transmission TECHNICAL INFORMATION 3 8 ROAD LIGHTS electrical circuit YOLVOICNI LNOHH 5 LNOti3 LNOtid H 1 1NOY3 5 H T LNOWS H 11NOH3 dueot 2 due 9 7 L HOLIAS 015 HOLIMS HOLVOIONI HOLIMS LHOMOVSH 2 DNINYY LHOMOVSH HOLIMS NOILINDI L YOLVOICNI 9 4 9 HOLVOIONI
112. icate that the procedure being described in the Handbook must be followed to avoid serious injury or death to yourself or others or damage to the machine The warnings are also used to protect the machine from unsafe servicing practices Pay particular attention to the warnings given in the Handbook If you have any doubts about any aspect of the machines capability or servicing procedures you must consult the manufacturer MACHINE IDENTIFICATION Please record the model and serial numbers of your machine in the spaces provided and quote them when ordering parts Model Year Dumper serial no Key start Transmission Transfer gearbox steering tipping L H tipping Tyre amp size INTRODUCTION WARRANTY TERMS CONDITIONS The Manufacturer assures you that if any part of the machine becomes defective due to faulty manufacture or materials within 12 months from the date of purchase the part will be repaired or replaced under warranty free of charge by any authorised Winget Distributor Warranty repairs must be carried out by Winget Distributors This Warranty is given to the first owner and may be transferred to subsequent owners for the balance of the Warranty period The Manufacturers liability only extends to the costs of repair or replacement of the faulty parts and necessary labour charges involved in the
113. ient NEVER tow up down or across a gradient NEVER operate high discharge or rotary skips on gradients HYDRAULICS WARNING ALWAYS Dump pressure from the system before carrying out any maintenance or adjustments see Service Hydraulic system ALWAYS purge hydraulic rams before commencing work With the engine running operate the hydraulic control to fully extend and retract the rams NEVER leave the machine unattended with pressure in the system ALWAYS practise the greatest cleanliness in maintaining hydraulic components SERVICING WARNING ALWAYS report any defect at once before an accident or consequential damage can occur ALWAYS conform to service schedules except where 1 Warning lights or warning indicators call for immediate attention 2 Adverse conditions necessitate more frequent servicing ALWAYS wear correctly fitting protective clothing Loose or baggy clothing can be extremely dangerous when working on running engines or machinery ALWAYS where possible work on or close to engines or machinery only when they are stopped If this is not practical remember to keep tools test equipment and all parts of your body well away from the moving parts ALWAYS Dump pressure from the hydraulic system before carrying out any kind of maintenance or adjustment see Service Hydraulic system ALWAYS avoid contact with exhaust pipes exhaust manifolds and silencers when the engine is running these can be v
114. ip Gog SN 416 BO x1 S M SLDS Q 30 30 47 ER JOYSTICK monobloc control valve amp FITTINGS V2004761 11504 267506 17505 7504 ONO Ol 20 2004616 21 85021 22 267504 23 17503 24 7502 30 100504 31 122504 32 128503 33 119513 34 128505 35 119504 36 119508 37 154502 38 120502 39 93510 601155 issue 04 0198 Serial 2001 2333 Description BRACKET gate SCREW set WASHER flat WASHER spring NUT SPACER BOLT WASHER flat WASHER spring NUT SEAL bonded ADAPTOR m m FITTING elbow 90 deg m f ADAPTOR m m FITTING elbow 90 deg m f ADAPTOR m m ADAPTOR m m FITTING Tee m m f swivel CAP blanking FITTING bulkhead NOTE Port designation 32 FEED from pump Connected to hose number 510n page 7 A 3 34 RETURN to tank Connected to hose number 50 on page 7 A 3 35 upper Rotate skip to LEFT 35 lower Rotate skip to RIGHT 36 39 Skip tip DOWN Skip tip UP 7 B 2A Qty N AD CO NN JN O 45500085 Dumper with rotating skip 7 B 2B JOYSTICK SECTIONAL CONTROL VALVE 7 B 2B Parno Description 1 2005021 2334 VALVE sectional control JOYSTICK 1 2 V602693 KIT seals AR 5 V602689 GAITER 1 6 V602690 1 7 V602691 ROD lock nut amp knob 1
115. itch A Battery charging 3 Accelerator pedal 10 Horn B Engine oil pressure 4 Dump pedal 11 Fuel tank C Engine coolant temp 5 Parking brake 12 Hydraulic tank D Transmission oil temp 6 Seat 13 Indicator air cleaner E Parking brake 7 Skip control tip return under engine cover F Beacon optional plus swivel on rotating on later machines G Lighting kit optional skips 14 Forward reverse control H Indicator optional 1 2 OPERATION DRIVING THE DUMPER Safety Warnings WARNING Always wear correctly fitting protective clothing Loose or baggy clothing can be extremely dangerous when operating or servicing machinery Always mount the dumper using the steps and handles at the rear NEVER attempt to mount the dumper from any other position Only skilled personnel are permitted to work with this dumper Always be aware of local and national regulations governing the use of the dumper Running in a new engine A gradual running in of a new engine is not necessary Prolonged operation at light loads during the early life of the engine is recommended Maximum load can be applied to a new engine as soon as the engine is put into service and the coolant temperature has reached a minimum of 60 deg C 140 deg F WARNING Do not operate the engine at high speeds without a load Do not overload the engine Do not allow the engine to run at idle speed for long periods this may cause bore glazing and
116. ls plus the following Transmission oil and filters change Transmission 2 26 2 9 2 27 2 36 2 21 2 17 2 23 2 29 2 23 2 6 SERVICE Service Operation Reference Page Every 1000 operating hours or yearly Carry out the procedures for the previous service intervals plus the following Hydraulic oil tank and filter Hydraulic system 2 29 Hydraulic pressures Hydraulic system 2 29 Transfer gearbox oil change Transfer gearbox 2 26 Valve clearances tappets Engine 2 9 Front and rear axle oil change Axles 2 2 First 2000 operating hours or every 2 years Carry out the procedures for the previous service intervals plus the following Change engine coolant Cooling system 2 14 Check coolant hoses Cooling system 2 14 Brake system overhaul Braking system 2 34 Fuel injectors Fuel system 2 17 Alternator and starter motor Have the alternator an starter motor checked by your Distributor Extra services Dirty working conditions Increase the frequency of all services during extremes of dirt vegetable waste heat and cold especially those relating to clean air cooling efficiency lubrication and machine cleanliness Laying up When a machine is to remain idle remove the battery to the workshop Seal all openings e g air intake exhaust breathers Grease bright parts and protect rubber components from direct sunlight Fill fuel tank check the tyre pressures and exhaust any pressure from the hydraulic system see also the
117. lus Transmission 4 V2005205 2408 LOOM 457000 4 V2005205 2404 LOOM 4S7000 Only NOTE Loom 2005205 be used place of loom V2002875 4A V2004257 DIODE part of loom V2005205 1 5 601177 FUSEBOX assembly 1 6 V601171 FUSE 5 amp light brown 1 6 V601172 FUSE 7 5 amp dark brown 1 6 601173 FUSE 10 amp red 1 6 601174 FUSE 15 amp blue 1 6 601175 FUSE 20 yellow 1 6 601176 FUSE 25 amp white 1 7 11S01A SCREW set 2 8 267503 WASHER flat 2 17502 WASHER spring 2 7501 2 9 72002661 PANEL warning lights assembly 1 10 BULB AR 11 311S03B SCREW c sunk head 2 13 V2003570 BUTTON horn 1 15 V2003144 HORN 1 16 11S03A SCREW set 1 17 MOTOR starter see Engine Parts Book 18 V2003510 CABLE earth starter motor 1 19 V600588 SENDER coolant 1 20 V600601 SENDER oil pressure 1 21 ALTERNATOR see Engine Parts Book 22 10989A01 CABLE battery to starter motor 1 23 V600732 SENDER transmission oil temperature 1 V601155 Jan 04 Continued gt 5 1 454000 455000 456000 457000 Dumpers MAIN ELECTRICS V601155 Jan 04 Part Serial Description Qty 24 V600330 SWITCH safe start 1 25 V2003529 SWITCH reversing alarm 1 26 V2003510 CABLE earth transmission 1 27 10990A08 2001 2070 CABLE earth battery 1 27 2004216 2071 CABLE earth battery 1 27 V2004214 2071 ISOLATOR battery earth 1 28 11503 SCREW set 2 29 17S04 WAS
118. materials to level or backfill material into excavations NEVER leave the machine with the skip raised or rotated TOWING WARNING NEVER attempt to tow a dumper before first reading Towing the dumper see Contents page NEVER attempt to start the engine of a dumper by towing or pushing Dump trucks are not designed as towing vehicles however trailers may be towed providing that 1 The combined weight of the trailer and its load does not exceed the specified maximum drawbar pull and drawbar load of the dumper see specifications 2 Trailers may be towed in first gear on level dry ground provided purpose made towing pin is used 3 The dumper skip must be loaded with half the rated payload to ensure tyre adhesion when braking NEVER tow loads up down or across gradients GRADIENTS WARNING NEVER operate on any gradients which exceed 25 1 in 4 or across gradients which exceed 16 1 in 6 ALWAYS remember that slippery or loose surface conditions can adversely affect safe machine operation including braking particularly on gradients ALWAYS choose routes that avoid steep slippery or loose gradients NEVER coast down gradients Always negotiate gradients in first gear ALWAYS drive forwards up gradients when loaded ALWAYS reverse down gradients when loaded ALWAYS keep the load facing uphill 0 4 WORKING NEVER park gradient If this is unavoidable ALWAYS chock the wheels NEVER attempt to turn on a grad
119. mn Item 2A Part no V2003085 V2003086 V2004757 V2003087 V2004174 V2004305 V2004306 11502V 11504B 17505 267504 V2003348 2003673 153505 11503 267505 17504 7503 V2004308 V601155 Jan 04 Serial no 2001 2001 2407 2001 2403 2408 2404 2001 2051 2052 2086 8 B 3 Description CASING steering column PANEL instruments mechanical F N R H 454000 455000 456000 Dumpers H 457000 Dumper PANEL instruments electrical F N R 454000 455000 456000 Dumpers 457000 Dumper PLATE cover without hole for gauge PLATE cover with hole for gauge PLATE cover holes for six switches PLATE cover holes for nine switches set set WASHER spring WASHER flat PLATE plastic blank BRACKET column U BOLT c w clamp and nuts SCREW set WASHER flat WASHER spring NUT GROMMET blank Qty CO N Ct HIG B 4 454000 455000 456000 amp 457000 Dumpers y LHRV2003728 RHRV2003729 FRAME 5 amp CANOPY FOPS Item 1 amp W 10 11 11A 12 13 14 20 21 22 23 V2003724 V2003726 V2003728 V2003727 V2003729 8509H V2003892 267508 59515 85090 17507 V2003725 267512 8508W 59507 601155 Jan 98 Serial 2001 8 4 Description Qty FRAME ROPS 1 5
120. n engine without air cleaners fitted Every 50 operating hours or weekly Check air cleaner With the engine stopped remove the outer element R Check the element for contamination and damage Check the inside of the filter housing for heavy build up of dust If the element contamination or dust build up is excessive service the air cleaner as described in Every 250 operating hours below Check that the rubber dust collector T is not obstructed by debris Every 250 operating hours Service air cleaner With the engine stopped remove both the outer element R and inner element S Clean the inside of the air cleaner casing using a damp lint free cloth paying particular attention to the element seats If there is an excessive build up of dust renew the outer element R 2 22 Check the condition of both outer and inner elements Discard elements if they are excessively contaminated distorted or the bonded gaskets are loose Hold each element up to the light to check for damage or worn areas of paper Refit new or existing elements as required WARNING Never attempt to clean and re use an element Note Under normal operating conditions a new inner element S MUST be fitted at every third change of an outer element R Air cleaner blockage indicator The air cleaner blockage indicator will show RED through the clear panel M if the air supply to the engine is severely restricte
121. nal damage to the transmission Ensure that the gear lever and forward reverse lever are ALWAYS in neutral while the top propeller shaft is disconnected WARNING Never attempt to start the dumper by pushing or towing This would result in extensive internal damage to the transmission When towing the dumper always ensure that the speed is kept to an absolute minimum as the lack of power assistance makes manual steering very slow and strenuous SERVICE SAFETY WARNING Read the safety notes in the Safe Working section of this book Also note the following SKIP SUPPORT BRACKET The Skip Support MUST ONLY be used when tipping ram s are to removed To install the Skip support bracket Raise the skip using the hydraulic control lever Remove clip pin A from pin D Swing down the bracket and locate it on pin C It may be necessary to adjust the height of the skip before the hole will align with the pin Re install clip pin on Do not operate the hydraulic control lever with the Skip Support Bracket in place ISO SKIP SUPPORT The ISO Skip Support MUST be used whenever working under a raised skip To install the ISO Skip Support Release the Support K from its storage position at the front of the chassis Ralse the skip fully using the hydraulic control lever Place the Support K around the rod of
122. ndling antifreeze Keep antifreeze out of the reach of children Keep radiator fins and air intakes clean Buckled fins and intakes reduce the efficiency of the cooling system and may lead to overheating Every 10 operating hours or daily Check coolant level WARNING If the machine is working continuously in hot weather check the level several times a day Never check the coolant level with the engine running The cooling system 15 pressurised and care sure be taken when removing the radiator cap especially the engine is hot Never fill up a hot system with cold coolant mixture damage may be caused to the engine SERVICE Check and if necessary top up the cooling system Remove the filler cap R SLOWLY If there is liquid in the header tank the system may be refilled with safety If allow the engine to cool completely before topping up up with coolant to between 13 25mm 0 5 1 in below the filler neck with the correct mixture If the cooling system has leaked due to hose failure or similar it is extremely Important that any lost coolant is replaced following repairs by a pre mixed solution of antifreeze and water DO NOT use anti leak additives Every 2000 operating hours or 2 years Change engine coolant WARNING Never remove the radiator cap R with the engine running The cooling system is pressurised and care sure be taken when removing the radiator
123. ng GASKET SCREW socket head cap SCREW socket head cap 454000 455000 456000 457000 Dumpers 3 18 FUEL TANK amp LOW PRESSURE FUEL SYSTEM Item 10 11 12 13 14 15 16 17 18 20 21 22 23 24 24 29 30 31 32 35 V2002275 100504 127504 V2003209 V2003295 V602660 V2003357 V2003327 V2003339 V2003029 V2002991 V2002991 V2002991 11503 17504 267505 7503 V601004 V600605 V600604 V600613 V600614 V2004928 V601155 Jan 04 Serial no 2001 Apr 00 Description FUEL TANK MUDWING SEAL bonded PLUG drain FITTING nylon eloow filler assembly GASKET filler cap PIPE fuel 90 deg PIPE fuel straight PIPE fuel 90 deg CLIP hose HOSE fuel line order by metre HOSE fuel line order by metre HOSE fuel line order by metre FILTER fuel see page 3 1 3 A 18 Qty AR AR AR LIFT PUMP tuel see Engine Parts Cat SCREW set WASHER spring WASHER flat NUT PRE FILTER assembly PRE FILTER bowl Quote Engine Serial Number before ordering engine parts WASHER PLUG NUT FITTING ferrule GAUGE fuel level N n5 n5 MON 454000 455000 456000 457000 Dumpers 2 1 EXHAUST Item N O 10 11 12 13 601155 issue 04 0198 Part no V2002451 V2004453 V2003336 11S03A 17
124. ng the engine with a slave battery Always disconnect battery leads or activate battery isolator where fitted before carrying out any maintenance to the electrical system Every 250 operating hours Check battery electrolyte level The battery is situated on the left hand side of the machine Ensure that the electrical connections are clean and tight and coat the terminals with petroleum jelly to protect them from corrosion SERVICE Remove battery filler plugs and check that the electrolyte level is between 6 9mm 0 25 0 37 in above the tops of the separators If necessary top up with distilled water Replace battery filler plugs Battery removal WARNING the battery is to be removed from the dumper ensure the following procedure is used Switch off the engine Remove the starter key from the dumper Ensure all electrical circuits are switched off Activate the Battery Isolator where fitted Remove the battery cover and clamp Disconnect the earth lead from the battery before removing the positive lead Lift the battery from the dumper WARNING When installing the battery the positive lead MUST be connected first 2 38 SERVICE CENTRE YOKE INSTALLATION pivot pins guide tool Installing horizontal pivot pin 1 Position the yoke 1 within the front chassis 2 Thrust washers 10 amp 11 are to be fitted at each end of the yoke To calculate the thickness of th
125. ommended that a belt tensioner gauge is used to check the belt tension Fit the gauge at the centre of the longest free length S and check the tension If a Burroughs gauge is used the correct tension is 355N 80151 36kgf If the tension is 220 50101 22kgf below adjust to the correct tension lf a gauge is not available press down the belt with the thumb at the centre of the longest free length S and check the deflection With moderate thumb pressure of approximately 45N 10lbf 4 5kgf the correct deflection of the belt is 10mm 3 8 adjust fan drive belt tension Loosen the pivot fasteners P of the alternator and adjustment link fasteners Change the position of the alternator to give the correct belt tension Tighten the pivot fasteners P and the adjustment link fasteners Check the tension again to ensure that it Is still correct If a new belt has been fitted the tension should always be checked again after the first 20 hours of operation SERVICE 2 11 Every 250 operating hours Change engine lubrication oil amp filter WARNING Disposal of waste oil Dispose of waste oil into waste storage tanks If storage tanks are not available consult your Distributor or local authority for addresses of local designated disposal points It is illegal to dispose of waste oil into drains or water courses or to bury it Lubrication oil cleanliness is vital fo
126. osed and fastened This will give access to r Locking catches F Fuel filter L Document case B Gas struts G Coolant filler M Fan belt C Engine oil filler H Air cleaner N Fuel pre filter D Engine oil dipstick J Air intake E Engine oil filler K Brake fluid reservoirs 2 4 SERVICE SERVICE SCHEDULE Service Operation Reference Page Warning lights and indicators require IMMEDIATE action Warning indicates RED Air cleaner Air cleaner 2 21 Every 10 operating hours or daily Engine lubricating oil level Engine 2 9 Radiator coolant level Cooling system 2 14 Fueltank level Fuel system 2 17 Air cleaner dust collector Air cleaner 2 21 Fuel pre filter water trap Fuel system 217 Hydraulic oil level Hydraulic system 2 29 Tyre condition and pressure Wheels and tyres 2 8 Wheel nut tightness Wheels and tyres 2 8 Axle joints Axles 2 27 Brake oil reservoirs Braking system 2 34 General Check for oil leaks damage or faults and report as necessary First 50 operating hours Carry out the procedures for Every 10 operating hours or daily plus the following Engine lubricating oil and filter change Engine 2 9 Fan belt tension Engine 2 9 Engine idle speed Engine 2 9 Fuel filter change Fuel system 2 17 Fuel lift pump strainer Fuel system 2 17 Transmission oil change Transmission 2 23 Transfer gearbox oil change Transfer gearbox 2 26 Hydraulic pressures check Hydraulic system 2 29 Hydraulic filter change Hydra
127. r assembly Loosen the drain device 1 at the bottom of the canister and allow the water fuel to drain into a suitable container Note If the filter does not have a drain device fitted release the cap J on top of the filter head Remove the nylon insert to lower the level of the fuel in the filter canister This will prevent fuel spill when the clamp ring K is released Support the filter canister L and rotate the clamp ring to the left M and remove the clamp ring Hemove the canister from the filter head by a direct pull downwards N and discard the old canister Ensure the filter head is clean Push the new canister fully into the filter head Support the canister fit the clamp ring and rotate it to the right to fasten the canister to the head If the nylon insert was removed to lower the fuel level in the filter ensure that it is fitted correctly and fit the cap Eliminate the air from the fuel filter see Bleeding the fuel system later type filter 2 19 SERVICE Fuel lift pump Clean sediment chamber and strainer as follows Remove the cover and joint W from the top of the fuel lift pump X and remove the gauze strainer Y Inspect the joint and renew if necessary Carefully wash all the sediment from the lift pump body Clean the gauze strainer joint and cover Assemble the lift pump Ensure that the lift pump body and the cover are fitted together correctly because leak
128. r the successful operation of your engine The oil should be stored under the cleanest possible conditions When changing or topping up oil use only clean receptacles Do not allow the oil to come into contact with the rubber hoses or the engine To change the oil Operate the engine until it is warm Park the machine on firm level ground Apply the parking brake Stop the engine Clean the area surrounding the drain plug R before removing Place a suitable container beneath the plug to catch the draining oil When opening the drain plug remember to stand to one side to avoid oil which will spill from the plug hole Remove the sump drain plug R and its O ring and allow the oil to drain from the sump Check that the O ring is not damaged if necessary renew the O ring Replace the O ring and drain plug and tighten to 34Nm 25 Ibf ft 3 5 2 12 Remove the filler U fill the sump with clean engine lubrication oil of the correct grade to the MAX mark on the dipstick 5 DO NOT OVERFILL For correct grade of engine oll see Specifications To change engine lubrication oil filter Place a suitable container beneath the filter W to catch spilt oil Remove the filter W with a strap wrench or similar tool Ensure that the adaptor X is secure in the filter head Discard the filter Clean the filter head Add clean engine lubrication oil
129. rage tanks are not available consult your Distributor or local authority for addresses of local designated disposal points lt is illegal to dispose of waste oil into drains or water courses or to bury it Place a suitable container beneath the drain plug 2 Drain oil by removing the plug Z at the bottom of the casing Replace drain plug Fill with oil at filler plug U to the level plug V Replace plugs For the correct type and grade of oil see Specifications SERVICE 2 27 AXLES Every 10 operating hours or daily Check for leaks Check for oil leaks around joints seals First 50 operating hours Change front and rear axle oil Change the lubrication oils in both the front and rear axle WARNING Dispose of waste oil into waste oil storage tanks If storage tanks are not available consult your Distributor or local authority for addresses of local designated disposal points It is illegal to dispose of waste oil into drains or water courses or to bury it Clean the area surrounding plugs before removing Place a suitable container beneath drain plugs before removing When removing drain plugs be sure to stand to one side to avoid oil which will spill from the hole Remove drain plug M and drain oil from the differential casing Replace drain plug Refill at the level filler plug P with clean oil of the correct grade Replace filler plug Service each hub in
130. red 1 30121 0112 PISTON front 1 57504 2 SCREW grub 1 30121A0303 RETAINER 1 30121A0105 CAP end 1 131501 2 CSE204 KIT seals 1 V2004200 BUSH 2 4 All new rams must be fitted with bushes and then drilled with grease holes before being supplied to the customer V601155 issue 05 0499 7 R 1B STEERING RAM with bushes 10 15 601155 issue 05 0499 V602701 V2004266 V2004262 V2004265 V2003184 V2003374 V2005015 V2002476 57503 2 131 01 131502 V2000328 V2004200 7 R 1B Description RAM with BUSHES assembly assembly without bushes CYLINDER ROD ram CAP end RETAINER RESTRICTOR as required PISTON SCREW grub NIPPLE grease straight NIPPLE grease 90 deg KIT seals BUSH All new rams must be fitted with bushes and then drilled with grease holes before being supplied to the customer Qty 7 2 454000 455000 456000 457000 Dumpers TIPPING forward tipping skip 7 2 Serial Description Qty 1 2002474 RAM tipping assembly 2 1 V2002477 CYLINDER ram 1 2 72002620 BUSH 4 3 57S03AB2 grub 1 4 V2002476 PISTON 1 5 V2003374 RETAINER 1 6 V2003184 CAP end 1 7 2000330 ROD ram 1 8 72000328 seals 1 9 0 RING 10 SEAL 1 11 SEAL 1 12 SEAL 1 13 0 RING 14 RING 1 15 131501 NIPPLE grease straight 2 V601155 issue 04 0198 R 3
131. s the engine starts Always ensure that the engine and starter motor are stationary before the starter motor is engaged again Check that the warning lights have gone Out Starting a cold engine Turn the starter key to B The start up alarm will sound for seven seconds Ensure that the battery charging and engine oil pressure warning lights have illuminated Note Dumpers with electronic F N H Press the dump pedal down fully and hold Then turn the kev to C and keep it there for 15 seconds Press the accelerator down fully hold Turn the key to D to engage the starter motor Allow the key to return to position as soon as the engine starts If the engine does not start 15 seconds turn the start key to position and hold it there for 15 seconds Then engage the starter motor again Check that the warning lights have gone out If the engine still does not start consult your Distributor 1 6 Engaging gears IMPORTANT When changing gear always depress the dump pedal 4 before moving the gear lever 8 from one gear to another To change from forward to reverse Brake to a halt progressively Move the forward reverse control 14 backward into the reverse position The reverse alarm will begin to sound It will continue to sound until the control is returned to the neutral position To change from reverse to forward Reverse the above procedure St
132. suction filter element has been regularly changed in accordance with the service schedule If not change the filter element Check that the suction pipe is not blocked Check that no leaks are apparent on suction side of pump as this could cause the pump to cavitate Periodically check the hoses between the pump and the tank to ensure they are deformed Any deformation in the hoses may result in a restricted flow of fluid and damage to the pump If none of these procedures correct the fault contact your Distributor Check the hydraulic pressures Tip Circuit Fit a 200 Bar 3000 psi gauge into the hydraulic system at the base of the tipping rams or where fitted to the test point on the control valve With the engine running at full operate the tipping control lever until the rams are fully extended and relief valve is blowing With the relief valve blowing read the pressure shown on the gauge it should read as follows 4S4000 110 Bar 1600 psi 4S5000 131 Bar 1900 psi standard skip 45500085 127 Bar 1850 psi rotating skip 456000 162 Bar 2350 psi 457000 162 Bar 2350 psi 2 32 SERVICE Steering Circuit Fit a 200 bar 3000 psi gauge into the hydraulic system at the base of the steering ram With the engine running at full rom turn steering wheel to full lock and check that the reading on the gauge is showing 175 Bar 2500 psi If the gauge does no
133. sure connections at two of the atomisers WARNING Damage to the fuel injection pump battery and starter motor can occur if the starter motor is used excessively to eliminate air from the fuel system Use the starter key to operate the starter motor until fuel free from air comes from the pipe connections Tighten the high pressure pipe connections to 2 Nm 20lbf ft 2 8kgf m Return the key to the OFF position The engine is now ready to start WARNING Operate the engine at low idle speed for a minimum of two minutes immediately after air has been removed from the fuel system This will ensure that the pump free of air and prevent any damage to the pumps internal parts by metal to metal contact 2 20 SERVICE If the engine runs correctly for a short time and then stops or runs roughly check for air in the fuel system If there is air the system there is probably leakage the low pressure system Every 2000 operating hours or 2 years Fuel injectors Have the fuel injectors checked by your Distributor SERVICE 2 21 AIR CLEANER WARNING The service intervals specified below refer to machines working under normal service conditions If the machine is working in extremes of dust dirt or other air contaminants the air cleaner elements should be checked more frequently and renewed as required Never remove air cleaner elements whilst the engine is running and never run a
134. t no V600502 V600503 V600229 V601134 V601135 V600504 V600232 V600417 V600501 V6001 12 V6001 13 V600114 V600075 V602626 V600202 V600115 V600116 Axle serial no 336 336 336 336 336 336 336 336 336 336 336 336 422 336 422 423 336 336 336 2 5 Description Qty CROWN 2 RING locking 2 BOLT 12 BUSH centring 20mm diameter 10 BUSH centring 24mm diameter 2 CARRIER wheel 2 BEARING 4 HUB wheel 2 SEAL c w wear ring 2 SHAFT hub PLUG 4 STUD 20 NUT used with stud V600114 item 19 BOLT M14x75 BUSH PIN BLEED NIPPLE 20 454000 455000 456000 457000 Dumpers SE BRAKES Item 8A 10 11 12 13 14 14 15 16 17 18 V601155 issue 04 0198 Part no V600462 V600089 V600464 V602599 V600483 V600498 V600499 V600496 V600496 V600497 V600499 V600095 V600096 V600097 V600098 V600098 V600099 V600100 V600101 V600102 Axle serial no 336 336 336 423 336 336 336 336 336 336 336 336 336 336 336 422 423 336 336 336 336 Description RING PISTON PIN Not used KIT brake self adusting BUSH WASHER SCREW BUSH BUSH SPRING SCREW RING DISC Brake PLATE PIN split PIN split SLEEVE CIRCLIP DRIVESHAFT SEAL 2 A 6 Qty h 2 7 454000 455000 456000 457000 Dumpers
135. t read as shown above contact your Distributor as there may be a fault in the relief valve Relief valves The relief valves are pre set by the manufacture and should NOT be adjusted Every 10 operating hours or daily Check hydraulic oil level Do not check oil level before closing the tipping rams and the engine has been stopped for two minutes Clean the area surrounding the filler cap before removal There are two types of oil level indicator incorporated within the filler they 1 The cap is fitted with a dipstick B The oil level is correct when between the maximum minimum D marks on the dipstick 2 The strainer has a cone F at its base The cap has no dipstick The oil level is correct when the top of the cone is just visible On later dumpers an oil level sight gauge is fitted to the side of the hydraulic tank Do not overfill it will cause leakage from the breather SERVICE First 50 operating hours Change hydraulic oil filter element WARNING Before changing the filter element stop the engine and dump hydraulic pressure Remove and discard filter cartridge S Clean joint area wipe with hydraulic oil and fit new cartridge Do not over tighten Run the engine to circulate the oil Operate the hydraulic control lever to purge any air stop the engine and top up the tank as required with clean hydraulic oil of the correct type and grade For correct
136. ter base and the glass bowl E Take care to collect all of the seals Using clean diesel fuel and a lint free cloth clean the inside of the glass bowl E the base and the inside of the filter head Check the condition of the seals Renew if necessary Reassemble the filter Eliminate air from the filter and fuel svstem See Bleeding the fuel svstem Change fuel filter earlier tvpe WARNING 115 important that correct parts are used when replacing the fuel filter The use of an incorrect filter could damage the fuel injection pump and injectors Clean the area surrounding the fuel filter before removing SERVICE Loosen the drain U at the bottom of the filter and allow the water fuel to drain into a suitable container Use a strap wrench or similar tool to loosen the filter canister and remove the canister Ensure that the threaded adaptor V is secure the filter head and that the inside of the head is clean SERVICE 2 19 Lightly lubricate the top seals of the canister with clean diesel fuel Fit the new Canister to the filter head and tighten by hand Eliminate the air from the filter See Bleeding the fuel system earlier type filter Change fuel filter later type WARNING Discard the used fuel filter and any spilt fuel in a safe place and in accordance with local regulations Henew a canister as follows Thoroughly clean the outside surfaces of the fuel filte
137. ther end of the tube in a small quantity of hydraulic oil contained in a glass jar W Slacken the bleed screw and depress the pedal to its full extent Release pedal and repeat the process until oil pumped into the jar contains no air bubbles Remove bleeder tube and release pedal Lock the bleed screw Repeat the procedure for bleed screws B C and D Top up brake reservoirs H Apply normal working load on brake pedal for two or three minutes and examine the entire system for leaks NOTE Always ensure that free play of 1 to 2mm exists between the master cylinder push rods and the pistons when the brake pedal is released Unless the pistons in both master cylinders are allowed to fully return brake pressure will build up and the brakes will remain on 2 36 SERVICE BATTERY Safe handling of batteries WARNING The battery contains a sulphuric acid electrolyte which can cause severe burns and produce explosive gases Wear protective clothing gloves and goggles when servicing the battery Avoid contact with the skin eyes or clothing If spilled onto the skin flush immediately with cold water If splashed into the eyes flush immediately with cold water for 15 minutes and get prompt medical attention Do not take internally If accidentally swallowed call a doctor immediately Do not use a naked flame or smoke near the battery Do not produce sparks with cable clamps when charging the battery or starti
138. tors should hold an appropriate full motor vehicle driving licence and undergo both a safety awareness course and a driver training course for articulated dump trucks run by the or equivalent body leading to the award of a C T A or equivalent It is strongly recommended that operators read the H S E publication Safe Working with Small Dumpers which is available from government bookshops HMSO or from other bookshops quoting the following number ISBN 011 8836935 Another useful publication is British Standard number BS 6264 Procedure for Operator Training For Earth Moving Machinery available from the British Standard Institution RUNNING IN WARNING DRIVING WARNING While a gradual running in of a new engine is not necessary it is extremely important that the instructions given in Section 1 Operation on Running in a new engine should be followed very closely during the first fifty hours of operation NEVER use the machine for purposes other than those for which it was designed This machine was designed to carry loads such as soil clay sand wet concrete stone or other similar materials It was not designed to carry loads which may move around in the skip uncontrollably or to carry any loads or materials which overhang the skip any way If in any doubt as to the Suitability of this machine for a particular task contact your nearest Distributor or the Manufacturer for advice 0 2
139. turn Revolve the hub until the drain level filler plug N is at the bottom Remove plug N and drain oil 2 28 SERVICE Revolve the hub until the plug hole is at the 3 or 9 o clock position R Refill with clean oil of the correct grade Intil the oil is level with the hole Replace plug For the correct type and grade oil see Specifications Everv 250 operating hours Check front and rear axle oil levels Park the machine on firm level ground Apply the parking brake Stop the engine Do not check the oil level until the machine has stood for 2 minutes WARNING Clean the area surrounding plugs before removing The differential case oil levels are correct when they reach the level plug holes P lf the oil level is low top up with clean oil of the correct grade Check each hub oil level individually Revolve the hub until the filler level plug is at the 3 or 9 o clock position The hub oil levels are correct when they reach the filler level plug holes If the oil level is low top up with clean oil of the correct grade For the correct type and grade of oil see Specifications Everv 1000 operating hours Change front and rear axle oil Use the procedure described in First 50 operating hours above SERVICE HYDRAULIC SYSTEM Dumpers with forward tipping skips The hydraulic system provides power for both steering and skip tipping It Is a split system whi
140. type and grade of oil see Specifications Gheck hvdraulic pressures see Check that the hvdraulic pressures are correct Everv 500 operating hours Change hvdraulic oil filter element Ghange the hvdraulic oil filter element using the procedure described in First 50 operating hours 2 33 Everv 1000 operating hours Change hvdraulic oil and filter element Run the engine and operate the hvdraulics to warm the oil Fullv close the tipping rams Stop the engine and dump hydraulic pressure Disconnect the battery earth cable WARNING Clean the area surrounding the drain plug and filler cap Place a suitable container large enough to catch all the oil on the ground below the drain plug When the drain plug is removed be sure to stand to the side to avoid the oil which will spill from the hole Remove the drain plug and drain the oil from the tank Flush out the tank with clean hydraulic oil taking extreme care to remove all dirt and foreign matter Refit drain plug Clean the filler cap breather Refill the tank with clean oil of the correct type and grade For correct type and grade of see Specifications Run the engine to circulate the oil and operate the hvdraulic control to purge anv air Stop the engine and top up the tank as required Change the hvdraulic oil filter element using the procedure described in First 50 operating hours Gheck hvdrauli
141. ulic system 2 29 Front and rear axle oil change Axles 2 27 Plus the procedures listed on the following page for every 50 operating hours weekly SERVICE Service Operation Reference Every 50 operating hours or weekly 2 5 Page Carry out the procedures for Every 10 operating hours or daily plus the following Greasing points Greasing points Transmission oil level Transmission Air cleaner element Air cleaner Fan belt Engine 2 7 2 23 2 21 2 9 pedal travel Check the action of the brake pedal It should have a short travel and firm action If travel is excessive or the action spongy have the brakes serviced by your Distributor Slew ring Tighten fixing bolts General Check for loose fixings nuts and bolts etc First 250 operating hours Carry out the procedures for the previous service intervals plus the following Transfer gearbox oil level Transfer gearbox Engine lubricating oil and filter change Engine Front and rear axle oil levels Axles Battery electrolyte level Battery Air cleaner element Air cleaner Fuel filter change Fuel system Transmission oil filter Transmission Parking brake Check function of the parking brake and adjust if necessary First 500 operating hours Carry out the procedures for the previous service intervals plus the following Hydraulic filter change Hydraulic system First 750 operating hours Carry out the procedures for the previous service interva
142. ust be lifted through a safety gate X which prevents accidental engagement of the lever Audible alarm The dumper is fitted with an audible alarm This has two modes of operation 1 Start up alarm As soon as the key is turned from the off position the alarm sounds for seven seconds as a warning of imminent Start up 2 Reverse alarm When the engine is running and the forward reverse control is moved into the reverse position the alarm will sound It will continue to sound until the control is returned to the neutral position The bleeping of the start up alarm is faster than that of the reverse alarm this is to avoid confusing the two With the engine running and the start up alarm sounding selecting reverse will automatically override the start up alarm and allow the reverse alarm to sound in its normal manner Starter key positions A Off B Warning lights C Heater thermostart D Starter Electronic control Mechanical control OPERATION Starting a warm engine Turn the starter key to B The start up alarm will sound for seven seconds Ensure that the battery charging and engine oil pressure warning lights have illuminated Note Dumpers with electronic F N H Press the dump pedal down fully and hold Push down the accelerator to a quarter of its travel and hold Turn the starter key to D to engage the starter motor Allow the key to return to position as soon a
143. yres 454000 12 5 80 18 455000 12 5 80 18 455000 RS 16 0 70 x 20 4S6000 16 0 70 x 20 4S7000 16 0 70 x 20 Noise levels All models except 457000 83LpA 105LwA 4S7000 only 85LpA 104LwA 3 2 ROAD SPEEDS approximately 1 Gear km h mph 4S4000 4S5000 4S5000 RS 4S6000 4S7000 TECHNICAL INFORMATION 274 Gear km h mph 34 Gear km h mph 16 5 10 3 16 5 10 3 18 5 11 5 18 5 11 5 18 5 11 5 4 Gear km h mph 23 5 14 7 23 5 14 7 25 0 16 0 25 0 16 0 25 0 16 0 All speeds forward or reverse LOAD CAPACITIES Heaped ft litres Max safe load Liquid kg Ib litres 454000 4000 8818 455000 5000 11023 455000 RS 5000 11023 456000 6000 13228 457000 7000 15432 3700 131 0 Struck litres LUBRICANTS AND FLUIDS Capacities Approximately 9 4 litres Approximately 13 0 litres 14 0 litres with cooler 2 3 litres 7 0 litres 1 0 litre per hub 55 0 litres tank capacity 0 60 litre As required Total oils factory fill Rubia XT 15W 40 Transmission MP Engine oil Transmission Transfer gearbox Transmission MP Axles main casing amp differential Transmission MP Hubs Transmission MP Hydraulic system Azzola ZS46 Braking system Azzola ZS22 General grease Multis EP2 CAPACITIES fluids Fuel oil tank capacity Cooling system radiator capacity 57 litres 12 5 gall 18 5 litres 4 1 gall TECHNICAL INFORMATION 3 3 MACHINE WEIGHT unladen 454000 3550 kg 782
144. ze of the wheels and are set sufficiently far enough back from the edge of any excavation to prevent the weight of the load causing a collapse NEVER adjust the tyre pressures in an attempt to improve traction on soft ground or obtain a softer ride on hard ground Incorrectly adjusted tyres can affect the steering and handling characteristics NEVER attempt to free a machine which is bogged down by pushing with the bucket of a backhoe loader tracked excavator or other similar machine NEVER attempt to lift the machine unless the articulation lock is engaged When working within the articulation point crush zone always fit the articulation lock NEVER work under an unpropped skip Always use the skip support provided NEVER make unnecessary crash stops when travelling at soeed especially in forward direction WORKING 0 3 SKIPS AND LOADING WARNING NEVER exceed the rated payload The weights of all loads above skip water level must be checked NEVER remain on the machine when loading the skip with excavators or loaders Stop the engine apply the parking brake dismount and stand well clear ALWAYS ensure that the load is evenly distributed in the skip NEVER carry loads or heap materials in such a manner as to affect the forward vision ALWAYS take extra care when tipping non free running loads particularly with Rotary Skips and High Discharge machines NEVER use the skip in a tipped position to bulldoze heaped

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