1. Manuals
  2. Brands
  3. Benford Manuals
  4. Utility Vehicle
  5. 2000
  6. Instructions manual

Benford 2000 Instructions Manual

4.w.d dumper straight & swing skip
Hide thumbs
Table of Contents

Advertisement

Quick Links

INSTRUCTION
2000 - 9000
(ITL)
Mechanical Drive Only
4.W.D Dumper Straight & Swing Skip
Publication No. B9507E-5 June 2004
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
Benford Ltd., Central Boulevard, ProLogis Park, Coventry CV6 4BX, England
Tel.: +44 (0)2476 339400 - Fax: +44 (0)2476 339500
www.terexce.com - Email : parts@benford.co.uk - sales@benford.co.uk

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 2000 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Summary of Contents for Benford 2000

  • Page 1 State of California to cause cancer, birth defects, and other reproductive harm Benford Ltd., Central Boulevard, ProLogis Park, Coventry CV6 4BX, England Tel.: +44 (0)2476 339400 - Fax: +44 (0)2476 339500 www.terexce.com - Email : parts@benford.co.uk - sales@benford.co.uk...
  • Page 2 General Safety Notes LEFT and RIGHT HAND All references in this manual to LEFT and RIGHT are as viewed from the Operating Position (Drivers Seat) Safety Notes...
  • Page 3 General Safety Notes This Manual is Designed as a Guide to the Machines Controls and Maintenance - IT IS NOT A TRAINING MANUAL This manual must not be removed from the machine and Modifications to this machine and/or changes to the should be kept in a useable condition.
  • Page 4 General Safety Notes WARNING Observe the Following Points for Your Safety and Protection Operators and maintenance personnel must always comply with the following safety precautions. These precautions are given here for your safety. Review them carefully before operating the machine and before performing general maintenance or repairs. Supervising personnel should develop additional precautions relating to the specific work area and local safety regulations.
  • Page 5 General Safety Notes Hydraulic Fluid Frozen Battery Electrolyte Fine jets of hydraulic fluid under pressure can penetrate the skin. Do not use your fingers to check for small leaks or expose uncovered areas of your body to leaks. Check for leaks using a piece of cardboard. Do Not Use a Machine with Frozen Battery Electrolyte Batteries with frozen electrolyte may explode if used or charged.
  • Page 6 Lubricants - Health and Safety Lubricants First Aid - Oil It is essential that anyone concerned with lubricants read and Swallowing understand the following text. If oil is swallowed, do not induce vomiting. Hygiene Get Medical Advice Lubricants are not a health risk when used correctly for their intended purposes.
  • Page 7 WARNING Observe the Following Points to Prevent Damage to the Machine Always replace hoses, couplers and other parts with parts supplied or recommended by Benford - NEVER USE SPARE PARTS OF INFERIOR SPECIFICATION. Never allow unqualified people to perform repairs on the machine.
  • Page 8 General Safety Notes Warning Transfers Used on the Dumper For safe use of machines on gradients, see instruction manual for skip uses Refer to Manual Sections: Gradients Always Use Seat Belt when Operating the Machine Refer to Manual Sections: Seat Operating Instructions Stay a safe distance away from the machine Refer to Manual Sections: General Safety Stay a safe distance from crushing zones...
  • Page 9 General Safety Notes Warning Transfers - continued Do not ride on machine except in supplied seat and Engage the articulation lock before lifting machine never expose body to high pressure fluid leaks Refer to Manual Sections: Transportation - Crane Refer to Manual Section: Working on the Hydraulic System, Maintenance Read the Instruction Manual before operating the machine and ALWAYS remove the start key before performing ANY maintenance...
  • Page 10 General Safety Notes Warning Transfers - continued Tyre Pressures Refer to Manual Section: Technical Specification, Tyre Specification/Capacity/Pressures/Wheel Torques Engine noise level Refer to Manual Section: Technical Specification, Noise Levels Safety Notes...
  • Page 11 General Safety Notes Roll Over Protective Structures - ROPS Fatigue and finite life problems associated with Maintenance welded products such as ROLL OVER PROTECTIVE Inspection - A scheduled, frequent visual check of mounting STRUCTURES (ROPS). hardware by operation or service personnel is recommended. As most ROPS are different and function in different service Operational experience of ROPS indicates that equipment environments, no specific inspection interval can be...
  • Page 12 Seat Belt Maintenance Guidelines WARNING Failure to properly inspect and maintain a seat belt can cause serious injury or loss of life in the event of an accident. It Is critical that any time the machine is involved in an accident, the entire seat belt system must be replaced. The seat belt should be considered to have a finite life and must be replaced as needed throughout the life of the machine.

  • Page 14: Table Of Contents

    Straight Skip Elevation ............................22 How the Hydraulics Function ........................... 23 Straight Skips ................................23 Swing Skips ................................25 ROPS - Rectangular Section 9000 Only ........................25 ROPS - Round Section 2000 to 9000 ........................26 2 to 9 Tonne Dumper Instruction Manual...

  • Page 15: And 3 Tonne Dumpers - Straight Skip

    Machine Data 2 and 3 Tonne Dumpers - Straight Skip Handbrake & Skip Control Steering Lever Wheel Seat Instruction Manual Holder Gear Lever Engine Seat Skip Canopy Support Centre Pivot Engine Stop Lister Only Bracket Propshaft Propshaft Front Axle Rear Axle Brake Fuel Tank Accelerator...

  • Page 16: 2, 3, 4, 5 And 6 Tonne Dumpers - Swing Skip

    Machine Data 2, 3, 4, 5 and 6 Tonne Dumpers - Swing Skip Handbrake & Skip Steering Control Lever Wheel Seat Gear Instruction Lever Manual Holder Skip Seat Engine Support Canopy Centre Pivot Engine Stop 2-3 Tonne Lister 5-6 Tonne Deutz Bracket Propshaft Propshaft...

  • Page 17: 4, 5, 6, 7 And 9 Tonne Dumpers - Straight Skip

    Machine Data 4, 5, 6, 7 and 9 Tonne Dumpers - Straight Skip Handbrake & Skip Steering Control Lever Wheel Dashboard Instruction Seat Manual Holder Gear Lever Skip Seat Engine Support Canopy Centre Pivot Engine Stop 2 & 3 Tonne Lister 5 &...

  • Page 18: Introduction

    Machine Data Introduction Chassis The chassis of the dumpers is of the two part articulating type The range of 2 to 9 tonne payload site dumpers have been having a centre pivot joint which articulates in both vertical, and designed to provide the greatest degree of component horizontal planes.

  • Page 19: Safety

    General Safety Safety Wash and Clean machine at end of working day - Keep water away from electrical components. Ensure drivers seat is correctly adjusted as described in the These machines are designed to carry out the function of Seat Operating section of this manual. transporting various free flowing materials.

  • Page 20: Safe Operation Decals

    General Safety Safe Operation Decals The machine has a number of special decals fitted which draw the users attention to various points of operation or safety. Before Using the Machine Read all the decals attached to the machine and fully understand their meaning.

  • Page 21: Delivery Checks

    Delivery Checks / Transportation Delivery Checks Transportation Loading Immediately on taking delivery of your new dumper, and before putting it into service: When loading the dumper onto a trailer or lorry, strong loading Read this handbook completely -- it could save a great deal ramps, a crane or similar lifting device should be used.

  • Page 22: Using Dumper As A Towing Vehicle

    Towing Towing - Torque Converters Models If using a crane or lifting device the rope, chain, strap etc. should be of sufficient strength to support the machine safely and be free from damage. See Technical Data section for machine weights. If towed, disconnect the top drive propshaft to prevent gearbox oil starvation.

  • Page 23: Driving Controls

    Driving Controls Driving Controls The range of dumpers have a common driving position and The driver is centrally positioned with the gear lever immediately controls for all models up to 3 tonne capacity. The 4, 5, 6, 7 and in front. The handbrake is located to drivers right, on seat support. 9 tonne capacity models have a shuttle torque converter Clutch, footbrake and accelerator pedals are located in standard transmission whereby an electric switch on the gearlever is used...

  • Page 24: Steering Column Control Variations

    Driving Controls Steering Column Control Variations Circuit Breaker Start Switch Start Switch Hourmeter Horn Charge Light Horn Oil Pressure Light No Lights Air Filter Light No Lights 2 Tonne Lister/Petter TS2 2 Tonne Hatz 2L31S 2 Tonne Swing Lister/Petter TS2 2 Tonne Swing Hatz 2L31S 3 Tonne Lister/Petter TS3...
  • Page 25 Driving Controls Dashboard Controls - Machines Fitted with Turner Gearbox Engine Heater Light - if fitted Indicator Battery Oil Pressure Water Temp or Warning Light Charge Light Light Fan Belt Light Circuit Breakers and Handbrake Light Audible Warning Forward / Reverse Indicator Selector Switch Switch...

  • Page 26: 2000-3000 Dumpers Only

    Driving Controls 2000-3000 Dumpers Only Audible Warnings Start Inhibitor - see Start Inhibitors - 2 and 3 Tonne On machines fitted with belt driven alternators, a continuous Machines tone audible warning will sound when start switch is in the RUN position, but the engine is not running.

  • Page 27: Seat Operating Instructions

    Seat Operating Instructions Seat Operating Instructions Angle Adjustment Weight Adjustment The seat backrest is adjustable for angle, this is achieved by The seat may be adjusted for drivers weight by sliding lever (3) lifting the lever (1) at the front of the seat cushion and sliding the downwards to the relevant weight position, as indicated by the seat cushion forwards/backwards.

  • Page 28: Starting The Engine

    Heat fitted with Lister or Hatz engines, have the start key switch Start positioned on the front of the dash. All later 2000 to 9000 machines have the start key switch positioned on the right Later hand side of the dashboard.

  • Page 29: Using Clutch And Gearbox

    Operating Instructions Using Clutch and Gearbox Changing Down Press clutch pedal down with left foot and at the same time Constant Mesh Gearbox 2 and 3 Tonne Models Only take the right foot off the accelerator. Move gear lever into neutral.

  • Page 30: Torque Converter & Shuttle Gearbox

    Operating Instructions Torque Converter & Shuttle Gearbox The dumpers are either fitted with a Spicer Compact Plus Forward Powershift Reversing Shuttle or an ITL PowerShuttle gearbox with integral 4 speed synchronised transmission and a Borg Warner Torque Converter. The procedure for driving the vehicle is as follows:- Direction Select Forward / Reverse using the Direction Switch.

  • Page 31: Steering

    Operating Instructions Steering The dumpers have a chassis which incorporates a design known The steering referred to above (i.e. a hydraulic ram connecting as centre pivot articulated steering. The chassis is in two parts, the frames) is controlled through the steering wheel acting on an a front and a rear section which are joined together in the middle 'Orbitrol' hydrostatic steering unit.

  • Page 32: Stopping The Dumper

    Operating Instructions Stopping the Dumper Parking Brake Manual Gearbox Models 2 to 3 Tonne Remove foot from the accelerator pedal. These dumpers have a parking brake system which is integral with the front axle and is operated by an over centre handbrake, Depress the clutch pedal and apply the footbrake.

  • Page 33: Gradients

    Operating Instructions Gradients Maximum Gradient ALWAYS Reverse Down Steep Inclines When ascending or descending a gradient, especially when the (2 to 7000) X = 25% (14º, 1 in 4) skip is loaded, the skip MUST ALWAYS face the top of the incline.

  • Page 34: Skip Uses

    Operating Instructions Skip Uses The skip in the lowered or loading position is located such that Never Elevate Dumper Skips Unless the driver has a good view ahead, therefore when loading the skip the Dumper Is On Level Ground get off the machine and do not allow the load to be heaped in such a fashion as to impair the drivers view.

  • Page 35: Swing Skip Elevation And Slewing

    Operating Instructions Swing Skip Elevation and Slewing Raise Lower Elevation of the skip is by means of a single double acting ram. The slewing action is controlled by a dual axis control valve - move the lever forwards and backwards to lower or raise Left the skip, and sideways to slew skip left or right.

  • Page 36: How The Hydraulics Function

    Hydraulic System How the Hydraulics Function The hydraulic system provides power to operate the vehicle The pump generates a maximum pressure of 150 bar (2200psi) steering and to power the skip elevation. on the standard skip dumpers and 170 bar (2500psi) on the turntable skip dumpers.

  • Page 37: Swing Skips

    Hydraulic System 5, 6, 7 and 9 Tonne Straight Hydraulic Circuit Control Valve Skip Ram From Pump Orbitrol Skip Ram Pump Hydraulic Tank Steering Ram Hydraulic Oil Cooler - if fitted Swing Skips The control valve, operated by a lever adjacent to the drivers seat, speed, and it can be stopped at any intermediate point for controls the lifting, lowering and slewing of the dumper skip.

  • Page 38: Rops - Rectangular Section 9000 Only

    9000 ROP's and FOP's ROPS - Rectangular Section 9000 Only Travelling Position The ROP's on the 9000 dumper is pivoted at seat level to allow the ROP's to be lowered to reduce the transportation height - not the working height. Remove the four 'R' clips from the locking pins, two either side, and remove the pins.

  • Page 39: Rops - Round Section 2000 To 9000

    The ROP's on the 9000 dumper is pivoted at seat level to allow the ROP's to be lowered to reduce the transportation height - not the working height. This is also an option on the 2000 to 7000 Remove the two 'R' clips from the locking pins, one either dumpers.
  • Page 40 Blank Page 1-27 2 to 9 Tonne Dumper Instruction Manual...
  • Page 42 2000 9000 Four Wheel Drive Dumpers Mechanical Drive Only Including 2000, 3000, 4000, 5000 and 6000 Swing Maintenance Section 2 to 9 Tonne Dumper Instruction Manual...
  • Page 43 2 to 9 Tonne Dumper Instruction Manual...
  • Page 44 Contents Skip Prop Instructions ..........................6 Lubrication Notes ............................7 Cleaning ..............................7 Working on the Hydraulic System ......................7 Battery ................................ 8 Gel Batteries - 9000 Dumper Only ......................9 Battery Maintenance ..........................9 Care and Maintenance ..........................10 Checking Coolant Level - Perkins Only ....................
  • Page 45 Machine Documents Instruction Manual Holder IMPORTANT This Instruction Manual and machine documents MUST be kept in the manual holder provided to allow the Operators to have immediate access to the information contained in the manual. Brake Fluid Under NO circumstances allow conventional BRAKE FLUID to be added to the system and also NEVER purge the system and refill with brake fluid, otherwise damage will occur to all the rubber sealing components in the brake system When Checking Liquid Levels, Machine MUST be Positioned on a Firm, Well Ventilated Level...
  • Page 46 Never smoke or leave the engine running when refuelling Always use Genuine Benford Spare Parts Always test the machine thoroughly before putting it back to work Observing these points will not make the repair of the machine safe but combined...

  • Page 47: Skip Prop Instructions

    Maintenance Skip Prop Instructions Swing Skip Elevate the skip fully and lift the skip prop into its upright position Lower the skip until the skip prop supports the skip Skip Prop 2, 3 and 4 Tonne Straight Skip Elevate the skip fully and remove the grip clip from the pin securing the prop in its storage position Remove the pin and lower the prop until the hole in the prop and chassis are aligned...

  • Page 48: Lubrication Notes

    Maintenance Lubrication Notes Working on the Hydraulic System Never Attempt to Tighten or Loosen Hydraulic Fittings when Engine is Running. Hydraulic Oil Leaks at High Pressure Can Easily Penetrate the Skin - If the Skin is Penetrated with Hydraulic Oil Seek Expert Medical Attention Immediately Beware of Scalding from Hot Oil Check Oil Temperature BEFORE Draining Never Attempt to Tighten or Loosen Hydraulic Fittings...

  • Page 49: Battery

    Maintenance Battery Nearside Bonnet Door Before Attempting Any Major Maintenance Disconnect Battery Battery Isolator Battery Isolator Battery Isolator must always be used when carrying out service/ maintenance work which would be dangerous if the engine was to be 2, 3 & 4 Tonne started or the machine electric system were to be activated.

  • Page 50: Gel Batteries - 9000 Dumper Only

    Maintenance Gel Batteries - 9000 Dumper Only BATTERY The Special Battery Supplied with a 9000 Dumper Must NEVER be Replaced with a Conventional Lead / Acid Battery for Safety Reasons Battery Maintenance Safety The design of the battery, with its electrolyte absorbed in The machine is fitted with a special battery which should microporous glass, makes it an extremely safe battery.

  • Page 51: Care And Maintenance

    Maintenance Care and Maintenance If In Doubt - Check Air Cleaner Frequently Before carrying out any service or maintenance work ensure that all safety precautions have been taken, for example: Cleaning Air Filter The Engine On the underside of the air cleaner casing is the dust ejector vent nozzle.
  • Page 52 Maintenance Air Filter Location Depending on Engine Option 5 and 6 Tonne 5, 6, 7 and 9 Deutz Tonne Perkins 2 Tonne Hatz Remote 2 and 3 Tonne 4 Tonne Perkins Mounted Lister and Deutz Air Filter Location Options 2-11 2 to 9 Tonne Dumper Instruction Manual...

  • Page 53: Checking Coolant Level - Perkins Only

    Maintenance Checking Coolant Level - Perkins Only Cleaning To Prevent Scalding Do NOT Remove Radiator Filler Cap when Engine is Hot! Avoid Spraying Electrical Equipment with Pressure Washers When the engine is cold open the radiator filler cap cover and undo the radiator cap. Clean the dumper thoroughly, this will make it easier to find If the coolant level is more than 20 to 25mm from the bottom oil leaks and loose fittings etc.

  • Page 54: Draining And Refilling Engine Oil

    Maintenance Draining and Refilling Engine Oil Ensure Engine Oil is Warm but NOT HOT! Ensure engine oil is warm but not hot. This will allow the old oil to drain quicker and more thoroughly. Place a suitable receptacle under the engine drain plug. See diagrams for drain plug location.

  • Page 55: Hydraulics

    Maintenance Hydraulics Filters A description of the hydraulics, and circuit diagrams are contained During ANY hydraulic maintenance extreme care should be in this manual under the section headed Hydraulic System. The taken to ensure the cleanliness of the hydraulic circuit. By system components are maintenance free other than the suction observing strict hydraulic cleanliness the machine will benefit strainer and return line filter.

  • Page 56: Hydraulic System Maintenance - Metal Tanks

    Maintenance Hydraulic System Maintenance - Metal Tanks Filter Body Return Line Filter Servicing Drain the hydraulic system Rubber Ring Unscrew the filter bowl from the filter body Clean the contact face of the filter body Filter Smear rubber sealing ring on new filter with clean oil or Cartridge grease and screw the new filter to the filter body.
  • Page 57 Maintenance Hydraulic System Maintenance - Plastic Tanks Dipstick & Breather Spring Seal Always Position Machine On Firm, Level Ground When Checking Fluid Levels Filter Housing Hydraulic Tank Checking Hydraulic Oil Level Return Filter To check the hydraulic oil level, stop the engine and unscrew the dipstick / breather and remove from the tank.
  • Page 58 Maintenance Suction Strainer When changing this filter it is recommended the tank is removed and cleaned. Hose Thoroughly clean the tank and surrounding area. Suction Drain the hydraulic oil. Undo the hose clip on the suction Hose Strainer strainer hose and pull the hose from the suction strainer. Clip Unscrew the suction strainer from the tank.

  • Page 59: Diesel System Maintenance - Plastic Tanks

    Maintenance Diesel System Maintenance - Plastic Tanks Fuel Filter Servicing is limited to changing the filter. Diesel Fuel Level Read the engine manufacturers manual for detailed filter replacement instructions. Dispose of the filter canister in an environmentally safe way. When Refuelling Stop the Engine and Beware of Naked Flames, Grinding Sparks etc.
  • Page 60 Maintenance Removing Diesel Fuel Tank and Cleaning Before refitting the tank, thoroughly clean the inside and outside of the tank and its mounting area. To refit the tank reverse the above procedure, ensure the spacers are in position before tightening the fixing nuts and bolts.

  • Page 61: Brakes

    Maintenance Brakes Brake Bleeding Ensure only mineral hydraulic oil is used to bleed braking system Arrangements Procedure Models 2 - 4 tonne have NEWAGE axles with oil immersed totally enclosed multi-plate brakes (4 plate front and 2 plate rear). Remove master cylinder floor plate cover, 2 to 4 tonne, and Some models have braking on front axle only, see Technical Data the reservoir cap.
  • Page 62 Maintenance Parking Brake - 2 and 3 Tonne (Including Swing Models) To March 2001 The parking brake facility is incorporated into the brakes of the Adjuster front axle and is self compensating. Nuts Lever The parking brake lever fitted, is of the over centre type, and if incorrectly adjusted can place excessive load on brake cable Grub Screw...
  • Page 63 Maintenance Transmission Parking Brake Transmission Parking Brake - Upto March 2001 - From March 2001 4, 5, 6, 7 and 9 Tonne 5 to 9 Tonne The parking brake is mounted on the transmission between the The parking brake is mounted on the transmission between the gearbox and the transfer box, and can be accessed from the gearbox and the transfer box, and can be accessed from the underside of the dumper.

  • Page 64: Front And Rear Axles

    Maintenance Front and Rear Axles Changing Axle Oil Ensure axle oil is warm - Not Hot, to facilitate draining. Totally enclosed sealed multi-plate brake axles are fitted, which Position the machine on level ground. have automatic compensation for wear of the friction discs. Normal servicing is limited to lubrication as detailed in the Clean dirt from around drain plug and oil level / filler plug.
  • Page 65 Maintenance Remove the handbrake cable from the axle. Loosen the eight nuts and bolts fixing the axle to the front Pre March/April 2001 frame and remove the two front wheels. Fixing Bolts, Undo the eight nuts and bolts fixing the axle to the front Washers, Nuts frame and lower the axle on the trolley jack.

  • Page 66: Wheels And Tyres

    Maintenance Wheels and Tyres Rear Axle Removal Check the tyres regularly for damage by cuts and embedded particles, i.e. nails, steel, glass etc. and check / adjust the Ensure the machine is positioned on firm, level ground pressures weekly. See Technical Data section for tyre pressures. and the handbrake is ON and the front wheels are chocked.

  • Page 67: Gearbox

    Maintenance Gearbox Undo and remove the two nuts and bolts, joining the two gearbox side brackets, located on the top of the gearbox. Undo the nuts fixing the gearbox side brackets to the gearbox. Due to the complexity of the Shuttle Gearbox only routine servicing tasks are described for this gearbox Remove the return line filter, complete with bracket, and in this manual.
  • Page 68 Maintenance Refitting Gearbox Loosely refit the anti-vibration crossmember complete with the right hand gearbox bracket. Fit the left hand gearbox mount and return line filter bracket. refit the two nuts and bolts holding the gearbox side brackets together at the top of Before Refitting Gearbox Ensure ALL Worn and the gearbox.

  • Page 69: Gearbox And Transfer Box

    Maintenance Gearbox and Transfer Box Newage Transfer Boxes Ensure transfer box oil is warm - Not Hot!, to facilitate Three types of gearbox are used on the range of machines plus draining. Position the machine on level ground. a transfer box which has 2 varying ratios. The appropriate combination for each is as below.
  • Page 70 Maintenance Turner Shuttle Gearbox If Towed, Disconnect Top Drive Propshaft to Prevent Gearbox Oil Starvation Failure to Observe this Instruction May Cause Extensive Gearbox Damage The only routine maintenance required is weekly checking of gearbox oil level using the screw in dipstick (A) accessed through the removable cover plate to left of gearlever, and changing oil at the specified intervals, as detailed in the 0202-061...
  • Page 71 Maintenance Oil Changes Turner Shuttle Gearbox Lubrication An initial oil change and flush is recommended after the To ensure proper lubrication and operating temperatures it is transmission is placed in actual service. This change should be most important that appropriate lubricants are used and that the made at any time following 50 hours in service , but should not correct oil level is maintained.
  • Page 72 Maintenance ITL PowerShift Gearbox The only routine maintenance required is weekly checking of gearbox oil level using the dipstick (A) accessed through the right hand engine cover, and changing oil and filter (B) at the specified intervals, as detailed in the Maintenance section. Checking Oil Level Drive the machine for approximately one minute.

  • Page 73: The Clutch

    Maintenance The Clutch Models 2 and 3 Tonne Straight and correctly and the clutch is not abused by slipping. Routine Adjustment Swing Skips Adjustment stops 1 and 2 are preset and normally require no Models 2 and 3 Tonne Straight and Swing Skips adjustment.
  • Page 74 Maintenance Clutch Replacment - Models 2 and 3 Tonne Straight and Swing Skips Clutch plate Before carrying out the following procedure it is advisable to thoroughly clean the machine. Remove the gearbox, see Gearbox Section. Clutch Cover Slacken the six setscrews around the clutch cover. Once the setscrews have been loosened undo them in a diagonally Release opposite sequence, two turns at a time until the clutch cover...

  • Page 75: Chassis

    Maintenance Chassis The two part chassis is of the centre pivot articulating type and This arrangement is illustrated in the diagram below and shows is of a design which enables both front and rear axles to be full movement of the chassis in both horizontal and vertical attached directly to the chassis members.

  • Page 76: Overhauling Centre Pivot

    Maintenance Overhauling Centre Pivot Before commencing work it is advisable to clean / wash Pay particular attention to the hydraulic and brake down the dumper especially where parts are to be line connections which should be thoroughly cleaned removed and reused. to stop dirt from entering the systems.
  • Page 77 Maintenance Dismantling Centre Pivot 1 - Remove Dust Cap Remove the two plastic dust caps from top and bottom of the centre pivot pin. 2 - Remove Nut Remove the 1.7/8" A/F nut from top of the centre pivot. & Washer Note : This nut has been torqued to 1,090 Nm.
  • Page 78 Maintenance Refitting Skip Remove skip pivot pins, one at a time, and fit the large washers in their correct positions. Refit new pivot pin and retain with washer and split pin supplied. Align the hole in With suitable lifting gear position skip on dumper and fit the head of the pin with the tapped hole in skip.

  • Page 79: Straight Skip Adjustment

    Maintenance Finally Grease all pivot pins, bearings and grease points. Remove any blocks and jacks from around dumper. Re-connect battery. Start engine and run at idle, check for any hydraulic leaks. Centre Pivot Pin Lock Screws Centre Pivot Pin Lock The skip may act unpredictably while air exists in the Screws hydraulic circuit Before operating skip ensure area...

  • Page 80: Preservation And Storage

    Maintenance Preservation and Storage If machine is to be stored for a long period of time the following Check the hydraulic oil level and top up as required procedures should be applied : Store the machine on solid level ground which is not liable Thoroughly wash down the exterior of the machine and to flooding, standing water or airborne contamination.
  • Page 82 2000 9000 Four Wheel Drive Dumpers Mechanical Drive Only Including 2000, 3000, 4000, 5000 and 6000 Swing Lubrication Section 2 to 9 Tonne Dumper Instruction Manual...
  • Page 83 2 to 9 Tonne Dumper Instruction Manual...
  • Page 84 Contents Skip Prop Instructions ............................... 6 Lubrication Notes ..............................7 Cleaning ..................................7 Working on the Hydraulic System ..........................7 Service Schedule ..............................8 Lubrication Points and Lubricants 2, 3 and 4 Tonne Straight ................... 9 Lubrication Points and Lubricants 2, 3, 4, 5 and 6 Tonne Swing ................10 Lubrication Points and Lubricants 5, 6, 7 and 9 Tonne Straight ................
  • Page 85 Lubrication Machine Documents Instruction Manual Holder IMPORTANT This Instruction Manual and machine documents MUST be kept in the manual holder provided to allow the Operators to have immediate access to the information contained in the manual Brake Fluid Under NO circumstances allow conventional BRAKE FLUID to be added to the system and also NEVER purge the system and refill with brake fluid, otherwise damage will occur to all the rubber sealing components in the brake system When Checking Liquid Levels, Machine MUST be Positioned on a Firm, Well Ventilated Level...
  • Page 86 Never smoke or leave the engine running when refuelling Always use Genuine Benford Spare Parts Always test the machine thoroughly before putting it back to work Observing these points will not make the repair of the machine safe but combined...

  • Page 87: Skip Prop Instructions

    Skip Prop Instructions Linch Pin Skip Prop Stored Skip Prop Skip Prop in Prop Position Swing Skip Early 5, 6, 7 and 9 Tonne Straight Skip Elevate the skip fully and lift the skip prop into its upright Elevate skip fully, remove linch pins securing props in their position.

  • Page 88: Lubrication Notes

    Lubrication Lubrication Notes Working on the Hydraulic System Never Attempt to Tighten or Loosen Hydraulic Fittings when Engine is Running. Hydraulic Oil Leaks at High Pressure Can Easily Penetrate the Skin - If the Skin is Penetrated with Hydraulic Oil Seek Expert Medical Attention Immediately Beware of Scalding from Hot Oil Check Oil Temperature BEFORE Draining Never Attempt to Tighten or Loosen Hydraulic Fittings...

  • Page 89: Service Schedule

    Lubrication Service Schedule . y l y l l o i t . c t s t l . y l . t l r i a . r o t l i f . s t o l l .

  • Page 90: Lubrication Points And Lubricants 2, 3 And 4 Tonne Straight

    Lubrication Lubrication Points and Lubricants 2, 3 and 4 Tonne Straight Skip Pivots Skip Ram Pivots Front Axle Centre Pivot 1 Drive Shaft Couplings Steer 2 Transfer Box Pivots Handbrake Cable Clutch, Brake and Accelerator Linkage 5 Brake Reservoir Clutch Withdrawal Shaft 2 &...

  • Page 91: Lubrication Points And Lubricants 2, 3, 4, 5 And 6 Tonne Swing

    Lubrication Lubrication Points and Lubricants 2, 3, 4, 5 and 6 Tonne Swing Skip Pivots Skip Ram Pivots Slew Ram Pivots Front Axle 5 Slew Ring Centre Pivot 1 Drive Shaft Couplings Steer 2 Transfer Box Pivots Handbrake Cable Brake, Clutch Accelerator Linkage 5 Brake Reservoir...

  • Page 92: Lubrication Points And Lubricants 5, 6, 7 And 9 Tonne Straight

    Lubrication Lubrication Points and Lubricants 5, 6, 7 and 9 Tonne Straight Skip Pivots Skip Ram Pivots Front Axle Centre Pivot Drive Shaft Couplings Steer Ram 2 Transfer Box Pivots Handbrake Cable Brake, Clutch Accelerator Linkage 5 Brake Reservoir Drive Shaft Couplings Radiator Coolant Gearbox...
  • Page 94 2000 to 9000 Four Wheel Drive Dumpers Mechanical Drive Only Including 2000, 3000, 4000, 5000 and 6000 Swing Technical Specification 2 to 9 Tonne Dumper Instruction Manual...
  • Page 95 Vibration Declaration Whole Body Vibration Level a (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.
  • Page 96 Contents Vibration Declaration ..............................2 Dimensions and Weights - 2 to 9 Tonne Straight Skip Dumpers ................. 4 Dimensions & Weights - 2 to 6 Tonne Swing Dumpers ....................5 Engine Rating ................................6 Skip Capacities ................................6 Dumper Speeds ................................. 7 Noise Levels ................................

  • Page 97: Dimensions And Weights - 2 To 9 Tonne Straight Skip Dumpers

    General Specification Dimensions and Weights - 2 to 9 Tonne Straight Skip Dumpers B = Overall Width G = Overall Height with ROP's 2 to 9 Tonne Dumper Instruction Manual...

  • Page 98: Dimensions & Weights - 2 To 6 Tonne Swing Dumpers

    General Specification Dimensions & Weights - 2 to 6 Tonne Swing Dumpers B = Overall Width G = Overall Height with ROP's 2 to 9 Tonne Dumper Instruction Manual...

  • Page 99: Engine Rating

    General Specification Engine Rating . P . t s i t s i t s i t s i & & & Skip Capacities - 1 litre = 0.001 Cubic Metre t i l t i l t i l 2 to 9 Tonne Dumper Instruction Manual...

  • Page 100: Dumper Speeds

    General Specification Dumper Speeds t s i t s i t s i t s i Noise Levels & & & & & 2 to 9 Tonne Dumper Instruction Manual...

  • Page 101: Brake Arrangements

    General Specification Brake Arrangements & & & & & & Gear and Transfer Boxes & & & & & Tyre Specification / Capacity / Pressures / Wheel Torques & & & & 2 to 9 Tonne Dumper Instruction Manual...

  • Page 102: Anti-Freeze Concentrations

    General Specification Anti-Freeze Concentrations º º º 6 º 0 º 7 º 1 º 8 º 0 Lubricant Capacities - (Litres) & & * Total oil capacity of the Gearbox, Torque Converter and Oil Cooler Replacement of oils is best carried out when the engine and transmission is warm allowing the oil to flow freely, carrying away any contamination at the same time 2 to 9 Tonne Dumper Instruction Manual...

  • Page 103: Engine Fuel, Lubrication And Coolant

    General Specification Engine Fuel, Lubrication and Coolant t i l t s i t s i t s i t s i & & & * - SAE 10W/30 Engine Oil ** - SAE 15W/40 Engine Oil 4-10 2 to 9 Tonne Dumper Instruction Manual...

  • Page 104: Alternators And Batteries

    General Specification Alternators and Batteries t s i t s i t s i t s i & & & 4-11 2 to 9 Tonne Dumper Instruction Manual...

  • Page 105: Electric Circuit - 2 And 3 Tonne Hatz

    Electric Circuit - 2 and 3 Tonne Hatz Electric Circuit - 2 and 3 Tonne Hatz Hour Meter Blocked Air Filter Switch Oil Pressure Switch Alternator Fuel Valve Starter Battery 12v Start Key Switch Circuit Breaker 10A 10 - Charge Light 11 - Oil Light e t i...
  • Page 106 Electric Circuit - 2 and 3 Tonne Hatz 4-13 2 to 9 Tonne Dumper Instruction Manual...

  • Page 107: Electrical Circuit - 2 And 3 Tonne Lister No Lights

    Electric Circuit - 2 and 3 Tonne Lister No Lights Electrical Circuit - 2 and 3 Tonne Lister No Lights Battery 12v Starter Starter Solenoid Ignition Switch Key Position Terminal Number Relay Connections Ignition Switch Ignition Audible Warning 10 - Hour Meter 11 - Circuit Breaker...
  • Page 108 Electric Circuit - 2 and 3 Tonne Lister No Lights 4-15 2 to 9 Tonne Dumper Instruction Manual...

  • Page 109: Electrical Circuit - 2 And 3 Tonne Lister With Lights

    Electric Circuit - 2 and 3 Tonne Lister With Lights Electrical Circuit - 2 and 3 Tonne Lister With Lights Battery 12v Battery Isolator Starter Alternator Hour Meter Flashing Beacon / Auxillary Socket Horn Button Horn Clutch Switch 10 - Engine Temperature Warning Light - if fitted 11 -...
  • Page 110 Electric Circuit - 2 and 3 Tonne Lister With Lights 4-17 2 to 9 Tonne Dumper Instruction Manual...
  • Page 111 Electric Circuit - 2 and 3 Tonne Lister With Lights Marker Light Front Left Marker Light Front Right Marker Light Rear Left Marker Light Rear Right Number Plate Lights Brake Lights Front Head Lights Front Indicator Lights Rear Indicator Lights 10 - Hazard Light Switch 11 -...
  • Page 112 Electric Circuit - 2 and 3 Tonne Lister With Lights 4-19 2 to 9 Tonne Dumper Instruction Manual...

  • Page 113: Electrical Circuit - 4, 5, 6, 7 & 9 Tonne Perkins

    Electric Circuit - 4, 5, 6, 7, & 9 Tonne Perkins Electrical Circuit - 4, 5, 6, 7 & 9 Tonne Perkins Battery 12v Battery Isolator Starter Alternator Engine Oil Pressure Switch Engine Fuel Solenoid Hourmeter Engine Start Heater Water Temperature Switch 10 - Hand Brake Switch 11 -...
  • Page 114 Electric Circuit - 4, 5, 6, 7, & 9 Tonne Perkins 4-21 2 to 9 Tonne Dumper Instruction Manual...
  • Page 115 Electrical Circuit - 4, 5, 6, 7 & 9 Tonne Perkins Forward Drive Solenoid Reverse Drive Solenoid Reverse Bleeper Horn Button Horn Gear Stick Button Seat Switch Forward Neutral 10 - Reverse e t i 11 - Direction Switch o l l 4-22 2 to 9 Tonne Dumper Instruction Manual...
  • Page 116 Electrical Circuit - 4, 5, 6, 7 & 9 Tonne Perkins 4-23 2 to 9 Tonne Dumper Instruction Manual...
  • Page 117 Electrical Circuit - 4, 5, 6, 7 & 9 Tonne Perkins Marker Light Front Left Marker Light Front Right Marker Light Rear Left Marker Light Rear Right Number Plate Lights Brake Lights Front Head Lights Front Indicator Lights Rear Indicator Lights 10 - Indicator Switch 11 -...
  • Page 118 Electrical Circuit - 4, 5, 6, 7 & 9 Tonne Perkins 14 15 4-25 2 to 9 Tonne Dumper Instruction Manual...

  • Page 119: Electrical Circuit - 5 And 6 Tonne Deutz

    Electrical Circuit - 5 and 6 Tonne Deutz Electrical Circuit - 5 and 6 Tonne Deutz Battery 12v Battery Isolator Starter Alternator Engine Oil Pressure Switch Audible Warning - Start Key Left ON Hourmeter Switch - Cooling Fan Belt Broken Hand Brake Switch 10 - Warning Light - Engine Overheating...
  • Page 120 Electrical Circuit - 5 and 6 Tonne Deutz 4-27 2 to 9 Tonne Dumper Instruction Manual...
  • Page 121 Electrical Circuit - 5 and 6 Tonne Deutz Forward Drive Solenoid Reverse Drive Solenoid Reverse Bleeper Horn Button Flashing Beacon / Auxillary Socket Horn Gear Stick Button Seat Switch 10 - Forward 11 - Neutral e t i 12 - Reverse o l l 13 -...
  • Page 122 Electrical Circuit - 5 and 6 Tonne Deutz 4-29 2 to 9 Tonne Dumper Instruction Manual...
  • Page 123 Electrical Circuit - 5 and 6 Tonne Deutz Marker Light Front Left Marker Light Front Right Marker Light Rear Left Marker Light Rear Right Number Plate Lights Brake Lights Front Head Lights Front Indicator Lights Rear Indicator Lights 10 - Indicator Switch 11 - Hazard Lights Switch...
  • Page 124 Electrical Circuit - 5 and 6 Tonne Deutz 14 15 4-31 2 to 9 Tonne Dumper Instruction Manual...
  • Page 125 Electrical Circuit - 9 Tonne Perkins Tier 2 c t i c t i c t i c t i c t i c t i c t i 4-32 2 to 9 Tonne Dumper Instruction Manual...
  • Page 126 Electrical Circuit - 9 Tonne Perkins Tier 2 4-33 2 to 9 Tonne Dumper Instruction Manual...
  • Page 127 Electrical Circuit - 9 Tonne Perkins Tier 2 - Site Light Option g i l c t i c t i c t i 4-34 2 to 9 Tonne Dumper Instruction Manual...
  • Page 128 Electrical Circuit - 9 Tonne Perkins Tier 2 - Site Light Option 4-35 2 to 9 Tonne Dumper Instruction Manual...
  • Page 129 Electrical Circuit - 9 Tonne Perkins Tier 2 - RTA Light Option c t i c t i c t i c t i 4-36 2 to 9 Tonne Dumper Instruction Manual...
  • Page 130 Electrical Circuit - 9 Tonne Perkins Tier 2 - RTA Light Option 4-37 2 to 9 Tonne Dumper Instruction Manual...

  • Page 131: Torque Figures

    Torque Figures 4-38 2 to 9 Tonne Dumper Instruction Manual...

  • Page 132: Conversion Factor Example

    Torque Figures Conversion Factor Example The tightening torques given on the previous pages are for unplated nuts and bolts. As finish and lubrication materially affect tightening torque by increasing or reducing friction, it is necessary to apply correction factors to achieve the required bolt loading when one or both of the components is plated.

This manual is also suitable for:

30004000500060009000

Table of Contents

Save PDF