Thwaites MACH 2264 Operator's Instruction Manual
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Thwaites MACH 2264 Operator's Instruction Manual

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5 - 9 Tonne
MACH 2257, 2263, 2264,
2265, 2266, 2290, 2297, 2298.
Operator's
Instruction
Manual

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Summary of Contents for Thwaites MACH 2264

  • Page 1 5 - 9 Tonne MACH 2257, 2263, 2264, 2265, 2266, 2290, 2297, 2298. Operator’s Instruction Manual...

  • Page 2: Safety Symbols

    Due to the varied nature of the operation of site dumpers and It is the policy of Thwaites Limited to promote safety in the the absence of an agreed test standard, any figures quoted by operation of its machines and to create a general awareness...

  • Page 3: Before Operating This Machine

    Before operating this machine Read operator’s instruction manual Distributor Contact your Thwaites representative in case of further questions Learn to operate this machine Ensure you are fit to operate Wear correct safety clothing and ensure that safety equipment is available...

  • Page 4: Safety Label Identification

    Safety label identification 20% max 25% max 25% max 16% max 25% max 20% max 16% max 20% max 25% max 25% max 20% max 25% max 20% max 20% max Complete checks in section before starting the engine...
  • Page 5 Safety label identification Safety labels The safety labels fitted to these machines are to warn the operator or bystanders of possible hazards. • Be sure you fully understand the content and position of the labels. • Ensure labels are clean and in good condition, do not clean labels with solvents. •...
  • Page 6 Before operating this machine Visually check the machine Are the chassis lock and the skip lock disengaged? Are the controls, crush zone or hydraulic rams Walk around the machine clean, and clear of any debris? Is the Roll-Over Protective frame (ROPS frame) secure, fully upright and undamaged? Is the seatbelt anchorage secure and serviceable? Are the covers and mudguards secure?
  • Page 7 Before operating this machine Mount the machine and check the controls Use the grabrails and foot steps provided to manoeuvre into seating position. Face the machine at all times when mounting and dismounting Is the engine cover secure and locked? Adjust the seat position for comfort and easy access to controls Fasten the seat belt.

  • Page 8: Layout Of Controls

    Layout of controls Control locations and functions Speedometer* Forward/Neutral/Reverse lever (Includes gear selection Powershift only) Steering wheel Camera monitor Display unit Hazard warning light switch* Blank Footbrake pedal Throttle pedal 10. Gear lever (Powershuttle only) 11. Handbrake lever 12. Battery isolator 13.
  • Page 9 Warning light location and functions Warning light location and function Battery charging Hand brake Seat belt Cold start pre-heat in operation Neutral Low fuel Lights Direction indicators Air filter blocked or water in fuel or low fuel pressure 10. Low brake oil level 11.
  • Page 10 Power distribution board layout Flasher unit F9 F10 F11 F12 F13 F14 F15 F16 F17 F18 F18 F20 F21 F22 F23 F24 F25 F26 Fuse TEST Complete checks in section before starting the engine...
  • Page 11 Power distribution board layout Fuse Table Relay Table Fuse No. Rating Function Relay No. Function Side lights LH Side lights RH Fuel pump Side lights Neutral start Hazard lights SPARE Fuel pump Motion inhibit - Drive (if fitted) Ignition switch Drive Display unit Seatbelt green beacon (if fitted)

  • Page 12: Seat Adjustment

    Control functions - in depth Seat adjustment A – Turn knob to set driver weight B – Lift to slide seat assembly forwards/backwards C – Lift handle to adjust backrest Seatbelt • Adjust length of belt when seated • Press buckle blade into buckle lock •...
  • Page 13 Control functions - in depth Forward/neutral/reverse lever (FNR lever) (powershuttle) • Push forwards to travel in a forward direction • Lever centred = neutral • Pull back to travel in a reverse direction If green beacon option is fitted seat belt must be buckled for lever to function Gear lever (powershift) •...
  • Page 14 Control functions - in depth Steering wheel - both hands • Turn the wheel clockwise to turn machine to right • Turn the wheel anti-clockwise to turn machine to left Ensure the non-steering hand is on the engine cover grabrail when using the spinner knob for low-speed single handed steering.
  • Page 15 Control functions - in depth Engine System Fault Monitoring The electronic control unit (ECU) protects the WARNING engine by monitoring for system faults. If a fault is detected, the error lamp located on the dash If secondary warning is ignored, the engine control unit will panel will either light continuously or flashes.
  • Page 16 Control functions - in depth Lowering and raising the ROPS frame • Remove linch pins and withdraw frame lock pins • Lower frame and insert lock pins and linch pins in new position • Reverse the procedure to raise the frame •...

  • Page 17: Indicator Switch

    Control functions - in depth Indicator switch • Push the switch to the left to indicate a left turn • Push the switch to the right to indicate a right turn • Place in central position to cancel Light switch •...

  • Page 18: How To Start And Stop The Engine

    How to START and STOP the engine To start the engine • Insert key into switch - Position 0 = Power Off. • Turn the key clockwise - Position 1 = Power On. Cold weather start pre-heating begins automatically as required.

  • Page 19: Preliminary Checks

    Preliminary checks Function checks - engine ON Brakes • Does the foot brake feel firm? • If the hand brake is on, and a gear is selected, a buzzer will sound and the drive may be disconnected. Steering • Rotate steering wheel clockwise and anti-clockwise. Electrics •...
  • Page 20 Driving procedure and safe parking Moving from rest and stopping • Depress dump valve pedal. • Select first gear. • Release dump valve pedal. • Select forward or reverse. • Release hand brake fully (machine may move). • Slowly depress throttle pedal and move away. •...
  • Page 21 How to operate DPF regeneration Standstill Regeneration When the regeneration lamp flashes: • Run the machine under load or; • Standstill Regeneration. Note: Standstill Regeneration with reduce soot levels on DPF filter. WARNING Failure to respond to DPF regeneration lamp will cause the engine control unit to automatically reduce available power and / or automatically shutdown the engine and bring the machine to a halt.
  • Page 22 DANGER IMMEDIATE HAZARDS WHICH WILL RESULT IN SEVERE PERSONAL DANGER IMMEDIATE HAZARDS WHICH WILL RESULT IN SEVERE PERSONAL INJURY OR DEATH INJURY OR DEATH WORKING ON GRADIENTS Swivel Skip DO NOT exceed maximum stated gradients DO NOT turn across gradients DO NOT brake suddenly in wet, muddy, icy conditions or when operating on loose surfaces DO NOT run downhill with controls in neutral...

  • Page 23: Camera Monitor

    DANGER IMMEDIATE HAZARDS WHICH WILL RESULT IN SEVERE PERSONAL DANGER IMMEDIATE HAZARDS WHICH WILL RESULT IN SEVERE PERSONAL INJURY OR DEATH INJURY OR DEATH CRUSH ZONE Stay clear of articulation area when the engine is running Never operate the machine’s controls when standing on either side of machine WORKING UNDER A RAISED SKIP Lock both skip safety props during maintenance...
  • Page 24 DANGER IMMEDIATE HAZARDS WHICH WILL RESULT IN SEVERE PERSONAL DANGER IMMEDIATE HAZARDS WHICH WILL RESULT IN SEVERE PERSONAL INJURY OR DEATH INJURY OR DEATH VISIBILITY 5T Powerswivel The visibility maps show machines in standard build and travel configuration. The maps provide an approximate indication of what can be seen by the operator and any blind spots when seated in the driving position wearing a seatbelt.
  • Page 25 DANGER IMMEDIATE HAZARDS WHICH WILL RESULT IN SEVERE PERSONAL DANGER IMMEDIATE HAZARDS WHICH WILL RESULT IN SEVERE PERSONAL INJURY OR DEATH INJURY OR DEATH 6T Powerswivel 6T Forward Tip 1.2m 1.2m 1.3m 1.3m Camera Camera Operators field of vision Operators field of vision Blind spots Blind spots Attention! Section...
  • Page 26 DANGER IMMEDIATE HAZARDS WHICH WILL RESULT IN SEVERE PERSONAL DANGER IMMEDIATE HAZARDS WHICH WILL RESULT IN SEVERE PERSONAL INJURY OR DEATH INJURY OR DEATH 9T Forward Tip 9T Powerswivel 1.2m 1.2m 1.8m 1.8m Camera Camera Operators field of vision Operators field of vision Blind spots Blind spots Attention! Section...

  • Page 27: Unloading The Machine

    WARNING HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN SEVERE WARNING HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH PERSONAL INJURY OR DEATH LOADING THE MACHINE Apply hand brake, set transmission to NEUTRAL, turn engine OFF, disembark the machine and STAND CLEAR DO NOT exceed the machine’s rated capacity...
  • Page 28 WARNING HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN SEVERE WARNING HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH PERSONAL INJURY OR DEATH DRIVING NEVER dismount from a moving machine DO NOT drive with the bucket tipped (bulldozing) Avoid confined work areas - exhaust fumes...

  • Page 29: Towing A Trailer

    DO NOT exceed maximum tow bar pull or vertical load Towing must not be carried out on sloping ground Always use a Thwaites approved towing pin TRANSPORTATION Reverse machine slowly onto a suitable trailer DO NOT drive the machine forward when loading...

  • Page 30: Engine Maintenance

    WARNING HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN SEVERE WARNING HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH PERSONAL INJURY OR DEATH EXHAUST GAS REGENERATION Park machine outside in a safe, clear area away from people, building and flammable materials.
  • Page 31 CAUTION HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN MINOR PERSONAL INJURY OR PRODUCT OR PROPERTY DAMAGE USING A CRANE TO LIFT THE MACHINE Tip skip fully forward (except 9 Tonne) Engage skip safety prop Engage chassis locking bar Lift using centre eye provided HINGED ROPS Use grab handles, tread grips and steps when standing on the machine to lower the ROPS frame.

  • Page 32: Machine Recovery

    CAUTION HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN MINOR PERSONAL INJURY OR PRODUCT OR PROPERTY DAMAGE HAND BRAKE DO NOT apply hand brake if machine is moving (except in an emergency) MACHINE RECOVERY Towing procedure Ensure towing straps or chains are suitable for the machine to be towed.
  • Page 33 CAUTION HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN MINOR PERSONAL INJURY OR PRODUCT OR PROPERTY DAMAGE HANDBRAKE EMERGENCY RELEASE Fig. 1 Fig. 2 DANGER Wheels must be chocked before carrying out this procedure Loosen the four lock nuts (Fig 1 A) on the release screws (Fig 1 B) then back off the nuts by approximately 8 mm.

  • Page 34: Troubleshooting

    Troubleshooting Instrument panel warning lights Symbol Designation (Error Code) Reason for illumination Required action Battery charging Alternator not charging Check belt tension Hand brake Hand brake ON Cancel as required Seat belt Seat belt has NOT been fastened Fasten seat belt Cold start pre-heat Cold start pre-heat in process None...
  • Page 35 Check oil cooler clean if required. Transmission oil pressure Oil pressure too high or too low Check oil level Ash charging Indicates diesel particle filter has become Contact Distributor/Thwaites Ltd. permanently clogged, can no longer regenerate. Selective Catalytic Reduction Not applicable to these machines None...
  • Page 36 Data Chart – Powerswivel Dimensions (mm) Weight (kg) Noise A. Length ................4815 ..4815 ..5047 Unladen Airborne (10 m) B. Width .................2135 ..2280 ..2435 Front axle ............1730..1800..2160 C. Height (ROPS frame & Beacon)........3380 ..3430 ..3610 Rear axle ............2640..2660..3460 55.4 kW D.
  • Page 37 Data Chart – Front tip Noise Dimensions (mm) Dimensions (mm) Weight (kg) Weight (kg) Noise Airborne (10 m) A. Length ..............4475 .... 4670 ...4686 A. Length ..................4475 ...4670 Unladen Unladen Airborne (10 m) B. Width ..............2354 .... 2485 ...2485 B.

  • Page 38: Maintenance Tasks

    Maintenance Tasks Safe Working Practice: Recommended maintenance tasks: Before lubrication and maintenance tasks: • Turn ignition switch ‘ON’ without starting engine, and wait • Machine must be on firm level ground. 2 seconds for all warning lamps to turn off. •...
  • Page 39 Daily (10 Hour) maintenance checks Diesel fuel tank volumes Engine oil level • Check fuel level, indictor flashes when 2 bars remaining (Fig 1). • Pull out lubricating oil dipstick and wipe clean (Fig 3) • Insert lubricating oil dipstick as far as it will go. •...
  • Page 40 Daily (10 Hour) maintenance checks Engine coolant level Transmission oil level • View level of coolant in expansion bottle • Pull out lubricating oil dipstick and wipe clean (Fig 2) • Insert lubricating oil dipstick as far as it will go (Fig 2). •...
  • Page 41 Daily (10 Hour) maintenance checks Check brake functions Note: Refer to section1 of this manual for control layout. Hand Brake No regular maintenance is required. Check hoses for leaks. If leaks or damage is found do not operate the machine until the fault has been corrected.
  • Page 42 Weekly (50 Hour) maintenance checks Hydraulic oil level Check wheels and tyres Check tyre pressures (Refer to data chart in section 4) and • With oil cold, ensure rams are in correct position by lowered ensure wheel nuts are in position and tight (330Nm) bucket, turning steering to full left lock and if power swivel, turn bucket into the straight ahead position.
  • Page 43 Weekly (50 Hour) maintenance checks Lubricate all grease points: Apply grease to the following points provided around the machine to improve operation of moving parts: Steering cylinder Tipping cylinder(s) Kinglink assembly Skip pivot pins Propshafts Engine cover hinges Folding ROPS frame pins Slew cylinders (Powerswivel Only) Slew Ring (Powerswivel Only) 10.
  • Page 44 Normal service intervals: 10hrs, 50hrs, (first 100hrs), 250hrs, 500hrs, 1000hrs, 2000hrs Please refer to the Thwaites service manual for further maintenance information. We reserve the right to change all specifications without prior notice. www.thwaitesdumpers.co.uk...

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