Terex TA3H Manual

Site Dumper
TA3H, TA3SH & TA3.5SH

Original Instructions
OPERATOR’S MANUAL
Issue Date: 1 May 2017
Language: English (EN)
Revision No: 2.0
Reference No: 1108
Mecalac Construction Equipment UK Ltd
Central Boulevard
Prologis Park
Coventry
CV6 4BX
United Kingdom
Tel: +44 (0)24 7633 9400

Fax: +44 (0)24 7633 9500
Email: [email protected]
Portal: Oneface.Mecalac.com
WWW.MECALAC.COM
Serial Number
Year of Construction
Date of Delivery
Dealer Stamp
Notice
Table of Contents
Table Of Contents
1 Introduction
1.1 Important Information ................................................................. 1.1
1.2 Safety Alert System .................................................................... 1.1
1.3 Intended Use .............................................................................. 1.1
1.4 Operations Manual ..................................................................... 1.1
1.5 Identification Plate ...................................................................... 1.2
1.6 Warranty Registration ................................................................. 1.4
1.7 Warranty and Maintenance ........................................................ 1.4
1.8 Service and Replacement Parts Enquiries ................................. 1.4
1.9 Official Documents European Community Only ......................... 1.4
1.10 California Proposition 65 ............................................................ 1.6
1.11 Bulletin Compliance .................................................................... 1.6
1.12 Contacting the Manufacturer ...................................................... 1.6
1.13 Transfer of Machine ownership .................................................. 1.7
2 Safety
2.1 Safety Alert System .................................................................... 2.1
2.2 ANSI Hazard Classification System ........................................... 2.1
2.3 Personal Protective Equipment (PPE) ........................................ 2.3
2.4 General Safety Information ......................................................... 2.4
2.5 Seat Belt ..................................................................................... 2.6
2.6 ROPS ......................................................................................... 2.6
2.7 Lockout and Tag Out .................................................................. 2.6
2.8 Hydraulic Fluid ............................................................................ 2.7
2.9 Fluid Levels ................................................................................ 2.7
2.10 Battery Electrolyte ...................................................................... 2.7
2.11 Fires ............................................................................................ 2.7
2.12 Water Cooled Engines ................................................................ 2.8
2.13 Lubricants ................................................................................... 2.8
2.14 Oil or Fuel Spillage ..................................................................... 2.8
2.15 Working on a Gradient ................................................................ 2.9
2.16 Responsibilities ......................................................................... 2.10
2.17 Overturning ............................................................................... 2.10
2.18 Safety Signs ............................................................................. 2.10
3 Technical Data
3.1 Dimensions ................................................................................. 3.1
3.2 Turning Circle ............................................................................. 3.3
3.3 Data ............................................................................................ 3.4
3.4 Noise Emissions ......................................................................... 3.5
3.5 Vibration Levels .......................................................................... 3.5
4 Description
4.1 TA3H Dumper - Forward Tip Skip .............................................. 4.1
4.2 TA3SH Dumper - Swing Skip ..................................................... 4.2
4.3 Description .................................................................................. 4.2
4.4 Skip ............................................................................................. 4.4
TA3H, TA3SH & TA3.5SH Table of Contents - 1

Table of Contents
4.5 Chassis .......................................................................................4.4

4.6 Hydraulic System ........................................................................4.5
4.7 Transmission System ..................................................................4.8
4.8 Battery Isolator ............................................................................4.9
4.9 Circuit Breakers & Audible Warning ..........................................4.10
4.10 Hour Meter ................................................................................4.11
4.11 Control Panel and Switch Functions .........................................4.12
4.12 Start Interlock ............................................................................4.15
4.13 Start/Stop Switch ......................................................................4.16
4.14 Direction Indicator Switch - When Fitted ...................................4.16
4.15 Machine Lighting .......................................................................4.17
4.16 Orange Flashing Beacon ..........................................................4.17
4.17 Parking Brake ...........................................................................4.19
4.18 Skip Control Lever ....................................................................4.20
4.18 Seat Belt ....................................................................................4.21
4.19 Tow Hitch ..................................................................................4.22
5 Transportation
5.1 Loading on to a Trailer or Lorry Using Ramps ............................5.1
5.2 Loading or Unloading using a Crane ..........................................5.1
5.3 Articulation Lock ..........................................................................5.2
5.4 Tie Down Points ..........................................................................5.3
5.5 Tie Down .....................................................................................5.4
6 Initial Setup & Adjustments
6.1 Delivery Checks ..........................................................................6.1
6.2 Setup ...........................................................................................6.1
6.3 Start Up and Adjustments ...........................................................6.2
7 Standard Operating Procedures
7.1 Pre Start Checks .........................................................................7.1
7.2 To Set the ROPS in the Work Position. ......................................7.1
7.3 To Lower the ROP’s for Transport ..............................................7.2
7.4 Seat .............................................................................................7.2
7.5 To Start the Engine .....................................................................7.5
7.6 To Stop the Engine .....................................................................7.6
7.7 To Move the Machine .................................................................7.6
7.8 Loading the Skip .........................................................................7.6
7.9 Skip Operation ............................................................................7.7
7.10 Parking the Machine After Use ...................................................7.9
8 Emergency Operating Procedures
8.1 Running Out of Fuel on a Slope ..................................................8.1
8.2 To Support or Lower the Skip with the Engine “Dead”.................8.1
8.2 “Jump Starting” the Machine .......................................................8.1
8.3 Towing the Machine ....................................................................8.2
9 Maintenance & Lubrication
9.1 General Information ....................................................................9.1
9.2 Maintenance Notes .....................................................................9.1
9.3 Cleaning The Machine ................................................................9.1
9.4 Battery Disposal ..........................................................................9.2
9.5 Hydraulic Oil Under Pressure .....................................................9.2
Table of Contents - 2 TA3H, TA3SH & TA3.5SH

Table of Contents
9.6 Skip Support ............................................................................... 9.2

9.7 Articulation Lock ......................................................................... 9.3
9.8 ROPS .......................................................................................... 9.4
9.9 Floor Plate Removal ................................................................... 9.4
9.10 Battery Removal ......................................................................... 9.5
9.11 Air Cleaner .................................................................................. 9.6
9.12 Engine Oil ................................................................................... 9.8
9.13 Engine Coolant ......................................................................... 9.10
9.14 Hydraulic System ...................................................................... 9.12
9.15 Hydraulic Tank .......................................................................... 9.13
9.16 Hydraulic Tank Removal .......................................................... 9.16
9.17 Transmission Pump .................................................................. 9.16
9.18 Hydraulic System Return Filter ................................................. 9.18
9.19 Hydraulic Hoses ........................................................................ 9.18
9.20 Fuel System .............................................................................. 9.19
9.21 Braking System ........................................................................ 9.21
9.22 Axle Breathers .......................................................................... 9.24
9.23 Front Axle ................................................................................. 9.24
9.24 Rear Axle/Transfer Box ............................................................ 9.25
9.25 Axle Bolts .................................................................................. 9.27
9.26 Centre Pivot .............................................................................. 9.27
9.27 Skip ........................................................................................... 9.29
9.28 Wheels and Tyres ..................................................................... 9.29
9.29 Maintenance Schedule ............................................................. 9.30
9.30 Lubrication Schedule Forward Tip ............................................ 9.31
9.31 Lubrication Schedule - Swing Skip ........................................... 9.33
10. Troubleshooting
10.1 General Troubleshooting .......................................................... 10.1
10.2 Electrical Troubleshooting ........................................................ 10.1
10.3 Hydraulic Troubleshooting ........................................................ 10.2
11. Recovery
11.1 Towing 1 .................................................................................... 11.1
11.1 Lifting with a Crane ................................................................... 11.1
12 Storage, Decommissioning & Disposal
12.1 Long Term Storage ................................................................... 12.1
12.2 Decommissioning ..................................................................... 12.1
12.3 Recommissioning ..................................................................... 12.1
12.4 Disposal .................................................................................... 12.2
12.5 Disposal of Used Batteries ....................................................... 12.2
13 Glossary of Terms
Appendix 1 - Electrical Diagrams
Appendix 2 - Hydraulic Diagrams
TA3H, TA3SH & TA3.5SH Table of Contents - 3

Table of Contents
Table of Contents - 4 TA3H, TA3SH & TA3.5SH

1. Introduction
1 Introduction
1.1 Important Information
Please read and follow this manual carefully. If you use the machine correctly:
• You will stay safe.
• Your machine will perform better and last longer.
We strongly recommend
• That your machine is properly maintained and regularly serviced, as specified in this manual.
• That you use original spare parts obtained from a Mecalac dealer.
We continually make improvements to these machines. We reserve the right to amend the
machine without changing these instructions.
Any modification to this machine which has not been approved by Mecalac in writing is prohibited
and immediately invalidates the manufacturer’s warranty.
The operator of this machine must be a competent person who has received thorough training
in the use of this type of machine. The operator must be supervised by a knowledgeable
supervisor.
For further information, please contact the Mecalac Service Department who will be happy to
help you.
1.2 Safety Alert System
The Safety Alert System identifies important safety messages in this manual. When you see this
symbol, adhere to all safety messages that follow to avoid possible injury or death.
1.3 Intended Use

The machine has been designed and tested to carry out the function of transporting various free
flowing materials. If used correctly, it will provide an effective means of transportation and meet
the appropriate performance standards and regulations.
This machine is not suitable for under ground working or use in hazardous environments.
Use of this product in any other way is prohibited and contrary to its intended use
1.4 Operations Manual

This manual is a guide to the safe operation of the machine and the layout and position of all
controls. It also contains details of checks and procedures within the scope of the operator to
keep the machine in a safe and serviceable condition.
This manual is not a training manual. Contact Mecalac or your local dealer for details of suitable
training courses.
Any person who intends to use this equipment must read this operations manual carefully before
operating the machine.
Make sure this operations manual is kept with the machine at all times and is in good condition
- replace the manual immediately if it becomes dirty, damaged or has been lost. The manual
holder is located in the back of the seat (Figure 1.1) and is lockable
TA3H, TA3SH & TA3.5SH Page 1 - 1

1. Introduction
Replacement or additional copies of this publication can be ordered from your dealer.
COV00001
Figure 1.1 - Operations Manual Location
1.5 Identification Plate

The Vehicle Identification Number is recorded on a plate (Figure 1.2) located on the right hand
side of the rear chassis frame.
Figure 1.2 - Vehicle Identification Number Plate Location

You are advised to keep a record of your machines VIN number and the information recorded on
the plate in a safe place
Page 1 - 2 TA3H, TA3SH & TA3.5SH

1. Introduction
1. Company Address
2. Vehicle Identification Number
3. Machine Model
4. Designation
5. Operating Mass (Unladen)
6. Payload
7. Engine Power
8. Year Of Manufacture
9. Model Year
10. Bar Code
11. Works Order Number
Figure 1.3 - Vehicle Identification Plate Information - CE Machines
1. Company Address
3. Model
4. Designation
5. Operating Mass (Laden)
6. Maximum Front Axle Load
7. Maximum Rear Axle Load
8. Engine Power
9. Build Year
10. Model Year
11. Bar Code
Figure 1.4 - Vehicle identification Plate - German
1. Company Address
3. Machine Model
4. Designation
5. Operating Mass
6. Payload
7. Engine Power
8. Year Of Manufacture
9. Bar Code
Figure 1.5 - Vehicle Identification Plate Non CE

1. Introduction
1.6 Warranty Registration

Your dealer will have registered you as the owner with Mecalac at the time of sale. Should you
have any queries please consult your dealer in the first instance.
1.7 Warranty Terms and Conditions

Full terms and conditions of the machines warranty will be found on the warranty certificate
incorporated in or accompanying this manual.
1.8 Service and Replacement Parts Enquiries

Please state the vehicle type and the Vehicle Identification Number (VIN) when making enquiries
or orders and in all written correspondence.
1.9 Official Documents European Community Only

(1) CE mark
The Machinery Safety directive is intended to harmonise all the machinery safety regulations
throughout the community so that there will be no technical barriers to trade.
Compliance with the essential safety requirements of the EEC directives 2006/42/EC
(machinery), 2000/14/EC (Noise) and 2004/108/EC, permits companies to CE mark their
products.
The directive affects almost every equipment supplier and user in the community and in
particular, applies to this type of machine.
The regulations require that potential hazards from machinery are properly addressed and
guarded against.
The EC declaration of conformity is a requirement of CE marking. The declaration for this
machine (Figure 1.6) follows.

1. Introduction
Figure 1.6 - Copy of CE Certificate
Contents of the EC Declaration of Conformity

2006/42/EC Machinery Directive
Manufacturer: Mecalac Construction Equipment UK Limited

Central Boulevard
Prologis Park
Keresley End
Coventry
CV6 4BX
United Kingdom
Name of Person to Compile Technical File: Steve Price
Address of Person to Compile Technical File: Mecalac Construction Equipment

UK Ltd
Generic Denomination: Compact Dumper
Machine Function: Earth-moving machinery
Model / Type : TA3H

TA3SH
TA3.5SH
Serial/VIN number
Commercial Name: Same as Model /Type
Mecalac Construction Equipment UK Limited hereby declares that the above piece of machinery is in conformity with
the relevant provisions of the Machinery Directive 2006/42/ EC
Mecalac Construction Equipment UK Limited hereby declares that the above piece of machinery is in conformity with
the provisions of the following other EC-directives: Noise - Equipment Used Outdoors (2000/14/EC), Emissions - Non-
Road Engines (97/68/EC) and Electromagnetic Compatibility (2004/108/EC).
Mecalac Construction Equipment UK Limited hereby declares that the following European harmonised standards have
been used:
EN474-1 & EN474-6
Place of Issue: Coventry, United Kingdom
Date of Issue:
Empowered signatory
Gregg Horne
General Manager

1. Introduction
1.10 California Proposition 65

California (USA) state law stipulates that the manufacturers of machines operated within its
borders must provide a clear warning to customers regarding exposure to substances commonly
associated with the machine that are recognized by the state as harmful. Mecalac complies with
this requirement by providing the following information.
California
Proposition 65
Warning: This product contains and/or emits lead and

lead compounds, diesel engine exhaust, and used engine
oil, chemicals known to the state of California to cause
cancer
California
Proposition 65
Warning: This product contains and/or emits lead, lead

compounds and carbon monoxide chemicals known to
the state of California to cause birth defects or other
reproductive harm
1.11 Bulletin Compliance

• You must take action and comply with any safety bulletins transmitted to you by your dealer or
by Mecalac.
• Make sure the details of ownership of the machine are recorded by your dealer and the
information is accurate and up to date. Failure to do so may result in critical safety information
being withheld.
• Bulletins can only be issued to the recorded owner or keeper of the equipment. It is your
responsibility to make sure that your dealer or Mecalac has your correct details.
• If you are the new owner contact your local dealer with your details and quote the machines
VIN number to make sure you receive any future bulletins or updates.
1.12 Contacting the Manufacturer

At times it may be necessary to contact the manufacturer of this machine. You must supply the
Model and VIN Number of the machine together with your name and contact details.
You must contact Mecalac for:-
• For any product modifications to your machine.
• To report an accident involving Mecalac equipment.
• Product applications and safety.
• Standards and regulations compliance.
• To report change of ownership or ownership details (if not reported to a Mecalac dealer).

1. Introduction
1.13 Transfer of Machine ownership

If you sell or otherwise dispose of your machine you must tell your dealer or otherwise Mecalac.:-
• The name and address of the new owner
• The model and VIN number of the machine
• The date of transfer or disposal.

2. Safety
2 Safety
This manual is designed as a guide to the Machines Controls, Operation and Maintenance. IT IS
NOT A TRAINING MANUAL
2.1 Safety Alert System
The Safety Alert Symbol is used to alert you to potential personal injury hazards. Obey all safety
messages that follow this symbol to avoid possible injury or death
2.2 ANSI Hazard Classification System

(1) Only Applicable to ANSI Safety Signs)
ANSI safety signs are only fitted to machines used in the US, Canada, Australia and New
Zealand
A multi-tier hazard classification system is used to communicate potential personal injury
hazards.
The following signal words used with the safety alert symbol indicate a specific level of severity
of the potential hazard
All are used as attention getting devices on safety signs fixed to the machinery to assist in
potential hazard recognition and prevention
bDANGER
DANGER - (Always used with a safety alert symbol and white letters on a red background)
Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
bWARNING
WARNING - (Always used with a safety alert symbol and black letters on an orange background)
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
bCAUTION
CAUTION - (Always used with a safety alert symbol and black letters on a yellow background)
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

2. Safety
(2) Property Damage
NOTICE
NOTICE - (Used without a safety alert symbol and white italic letters on a blue background) Is
used to address practices not related to personal injury
(3) Procedure
PROCEDURE
PROCEDURE - (Used without a safety alert symbol and black letters on a green background).
This indicates a procedure that must be followed step by step for safe operation. Make sure all
safety notes have been considered before beginning the procedure.

2. Safety
2.3 Personal Protective Equipment (PPE)

You must wear the PPE shown in the tables below at all times when operating this equipment.
Do not wear rings, scarves or open jackets. Make sure that all loose clothing is tightly secured.
Long hair must be restrained.
Protective A protective helmet must Safety Safety boots must be worn

Helmet be worn at all times to Boots at all times when operating
prevent injury from falling this equipment
objects
Ear Ear protection must be Safety Safety glasses must be

Defenders worn at all times when Glasses worn at all times to prevent
operating or near this eye injury from flying
equipment objects
High High visibility clothing must Seat Belt The seat belt must be worn
Visibility be worn at all times when at all times when operating
Clothing operating this equipment. this equipment
You must wear the following PPE when site conditions dictate.
Protective Protective gloves must be Face A face shield must be worn

Gloves worn when necessary to Shield when conditions dictate to
prevent injury from sharp prevent eye or facial injury
objects. from flying objects
Dust Mask A dust mask must be worn Respirator A respirator must be worn
when site conditions dictate when site conditions dictate
Protective Protective clothing must be

Clothing worn when site conditions
dictate
You must wear the following PPE when performing maintenance on the machine.
Safety Safety glasses must be Safety Safety boots must be worn

Glasses worn at all times to prevent Boots at all times to prevent
eye injury from flying injury.
objects.
You must wear the following PPE when site conditions dictate when performing
maintenance on the machine.
Protective Protective clothing must be Protective Protective gloves must be

Clothing worn when conditions Gloves worn when conditions
dictate. dictate
Dust Mask A dust mask must be worn Face A face shield must be worn
when conditions dictate Shield when conditions dictate to
prevent eye or facial injury
from flying objects

2. Safety
2.4 General Safety Information

Consult your dealer or distributor for details of training courses.
All the time you are working on or with the machine you must consider any possible hazards and
how to avoid them.
Only authorised persons must be allowed to operate this machine.
Unauthorised use of this machine may invalidate your insurance.
Operators and maintenance staff must always comply with the following precautions. These
precautions are given here for your protection. Review them carefully before operating the
machine and before performing general maintenance or repairs. Supervising staff must develop
additional precautions relating to the specific work area and local safety regulations.
Warnings about the Operator

• Before operating the machine make sure you have had proper training and are fully
conversant with the machine and its operation - If in doubt ASK!
• Make sure you, and anyone else who uses the machine, have been trained to operate it
correctly and are physically and mentally fit.
• Do not operate the machine if you are unfit to do so because of alcohol or drugs etc.
• Personal Protective Equipment must be used as specified on pages 2 - 2 and 2 - 3.
• Read this instruction manual carefully before operating the machine. Make sure this
instruction manual is kept with the machine at all times and is in good condition - replace the
manual immediately if it becomes dirty, damaged or lost.
• Read and understand all safety signs before operating the machine.
• Check seat belts daily. YOU MUST ALWAYS WEAR A SEAT BELT WHEN OPERATING THE
MACHINE.
• If the machine is fitted with ROPS and the machine should roll over, the Operator must grip
the steering wheel firmly allowing the seat belt to restrain him/her in the seat until the machine
comes to rest.
Warning for the supervisor

• Establish a training programme for all operators to make sure they are fully familiar with its
operation.
Warnings about other people

• Make sure all bystanders are made fully aware of the safety instructions associated with this
machine and are kept well clear of the operating area.
• Do not carry passengers.
Warnings about the machine

• Make sure the ROPS is not damaged and has no unauthorised modifications.
• Always make sure there is adequate ventilation around the machine. Never run the engine in
an enclosed area without good ventilation or next to combustible materials.

2. Safety
• Stop the engine before refuelling, if there is a spillage mop it up and do not start the engine
until it has been done.
• The exhaust gets extremely hot. Do not place anything on top of it and keep all combustible
materials clear. Do not attempt any maintenance on a hot engine.
• Check your local laws and regulations, the engine may require a spark arrester etc.
• Before performing any maintenance on the machine, place a warning tag on the machine to
prevent accidental start-up and remove the start key and battery isolator. Put the locking bar
into position to prevent the front and rear chassis moving and creating a crushing zone.
• Do not inspect or clean the machine with the engine running.
• Make sure all guards or shields are in place before using the machine.
• Before carrying out maintenance on the hydraulic system make sure the hydraulic fluid is cool
and there is no residual pressure in the hydraulic circuit - hydraulic fluid leaking under
pressure can penetrate the skin.
• Do not operate the machine if it is damaged, improperly adjusted or not completely and
correctly assembled.
• Keep footplates and steps free from dirt, oil, snow, ice etc.
• Do not remove the radiator cap when the engine is hot. Do not add coolant to a hot engine.
• Tyre changes and repairs to punctured tyres MUST only be carried out by fully trained
operatives using the correct equipment. The manufacturer of this machine recommends a
competent firm is employed to carry out these tasks.
Warnings about the work environment

• Be familiar with all prohibited work areas such as excessive slopes and dangerous terrain
conditions.
• Do not drive on slopes or gradients that exceed the safe limits stated for this machine in this
manual.
• If the machine is to be used on the public highway or at night lighting in accordance with
national requirements of the country concerned must be fitted.
• Always use driveways approved by site management when driving around the site.
• In the event of an electrical/lightening storm park the machine in a safe place, dismount and
seek shelter
• Always park machine correctly on firm, level ground where it will not cause an obstruction or
danger - chock the wheels if necessary. DO NOT LEAVE THE ENGINE RUNNING or the start
key in the start switch.
• Before taking the machine on public roads make sure that the machine complies with all road
traffic regulations and obey all driving laws.Warnings about using the Skip
• Do not work under a raised skip unless the props/supports are fitted and locked in position.
• Only fill skip with free flowing loads.

2. Safety
• When manoeuvring or driving the machine with the skip raised take extreme care as forward
visibility will be restricted.
• Do not drive around the site with the skip raised.
• The operator must get off machine when loading the dumper skip.
• Do not drive the machine on the public highway with the skip in the fully tipped position.
If anyone has any concerns with any safety aspect of the machine the problem must be
reported and the machine must not be used until the safety concerns have been rectified
or an authorised person has checked and satisfied the site personnel the machine is safe
to use.
2.5 Seat Belt

A seat belt is provided for operator safety. It is important that the seat belt is inspected and
checked regularly See Maintenance Section.
Failure to properly inspect and maintain a seat belt can result in death or serious injury.
The seat belt MUST be worn at all times when operating this equipment.
An optional green beacon is available. The green beacon shows from a distance that teh dumper
driver is wearing his seatbelt. The beacon is mounted on the ROPS frame and flashes when in
operation. Do not use the green beacon on a public highway.
2.6 ROPS
A ROPS (Roll Over Protective Structure) is provided for operator safety.
Although ROPS appear to be relatively maintenance-free, regular periodic inspections to make
sure ROPS are damage free and thus capable of functioning in a roll over cannot be over
emphasized.
Through periodic inspections, cracks, loose bolts, damage, and other normal wear and tear
related problems can be eliminated before they become serious.
Proper inspection and maintenance procedures can make sure that ROPS will perform the life
saving function they are designed for and expected to do.
Details on the inspection and maintenance of the ROPS will be found in the Maintenance
Section.
A damaged ROPS must be replaced by a genuine part from the original manufacturer of the
machine and fitted by an authorised dealer.
Do NOT modify or attach items to the ROPS without the manufacturers approval.
Do NOT use the ROPS as an attachment point for towing or pulling equipment.
2.7 Lockout and Tag Out

To prevent unauthorised starting of the machine, before any maintenance you must always:-
• Apply parking brake.
• Place transmission in Neutral
• Remove start key.
• Turn battery isolator to OFF and remove key
• Place warning notice in a prominent position warning others not to attempt to start or drive the
machine.

2. Safety
2.8 Hydraulic Fluid

Fine jets of hydraulic fluid under pressure can penetrate the skin.
Relieve all pressure before dismantling any hydraulic system.
Do not use your fingers to check for small leaks or expose uncovered areas of your body to leaks.
Use a piece of cardboard or thick paper to check for leaks.
Fluid injected into the skin must be surgically removed within a few hours by a doctor familiar with
this type of injury or gangrene will result
2.9 Fluid Levels

Make sure the machine is on firm, level stable ground. It must not be in a dangerous position or
causing an obstruction. Apply the parking brake. Place gear lever is in neutral and the make sure
engine is stopped before checking ALL fluid levels.
2.10 Battery Electrolyte

Contact with battery acid can cause serious burns, blindness or even death. Protective clothing,
gloves and a face shield must be worn at all times when handling or working on a battery.
(1) Skin Exposure
If the skin is exposed to battery electrolyte, the affected skin must be washed immediately with
running water.
If burning is severe seek immediate medical attention.
(2) Eye Contact
If eyes are exposed to battery electrolyte, wash eyes with running water and obtain immediate
professional medical attention.
(3) Battery Charging
When charging the battery hydrogen gas is produced.
Make sure the area is well ventilated to prevent the risk of explosion from a build up of hydrogen.
(4) Frozen Battery Electrolyte
Batteries with frozen electrolyte may explode if used or charged.
Never 'jump start' a machine with a frozen battery.
To help prevent freezing, keep the battery fully charged.
Do Not Use a Machine with Frozen Battery Electrolyte
2.11 Fires
Using water to extinguish an oil fire could spread the fire or give you a shock from an electrical
fire.
Use a carbon dioxide, dry chemical or foam extinguisher whilst waiting for the fire brigade.
Keep fire extinguisher seviceable and have it checked regularly
Do Not Use Water to Extinguish a Machine Fire

2. Safety
2.12 Water Cooled Engines

Water cooled systems operate under pressure to increase the boiling point of the coolant.
Therefore, the coolant temperature may be greater than boiling water at standard atmospheric
pressure (100ºC).
Never Maintain Cooling System when the Engine is HOT.
2.13 Lubricants
Lubricants should be handled in accordance to the lubrication manufacturers recommended
practices.
Whenever handling oil products, maintain good standards of care plus personal and plant
hygiene.
For details of these precautions we advise you to read the relevant publications issued by your
local health authority.
• Avoid contact with lubricants. Wear oil resistant gloves when performing maintenance.
• ALWAYS keep lubricants out of reach of children.
• NEVER store lubricants in open or unlabelled containers.
(a) New Oil
There are no special precautions needed for the handling or use of new oil other than the normal
care and hygiene practices.
(b) Old Oil
Used engine crankcase lubricants contain harmful contaminants. In laboratory tests it was shown
used engine oils can cause skin cancer and reproductive harm. Avoid inhalation of vapours,
ingestion and prolonged skin contact with used engine oils. Dispose of used oil in accordance
with local environmental regulations.
Observe the following precautions.
• Avoid prolonged, excessive or repeated skin contact with used engine oil.
• Apply a barrier cream to the skin before handling used engine oil.
• Note the following when removing engine oil from the skin.
• Wash skin thoroughly with soap and water. Using a nail brush will help.
• Use special hand cleansers to help clean dirty hands.
• Never use petrol, diesel fuel or kerosene.
• Avoid skin contact with oil soaked clothing.
• Do not keep oily rags in pockets.
• Wash dirty clothing before reuse.
• Throw away oil soaked shoes.
(C) First Aid - Oil
(1) Swallowing Oil
If oil is swallowed, do not induce vomiting.
Get Medical Advice.
(2) Skin Contact
In the case of excessive skin contact, wash with soap and water.
(3) Eye Contact
In the case of eye contact, flush with water for 15 minutes. If the irritation persists, get medical
attention.
2.14 Oil or Fuel Spillage
Absorb with sand or a locally approved brand of absorbent granules. Scrape up and dispose of
in a chemical disposal area.

2. Safety
2.15 Working on a Gradient

(1) Always face the top of a slope.
When ascending or descending a gradient with a dumper the skip MUST ALWAYS face the top
of the slope. Always drive up and reverse down slopes (Figure 2.1). Do not attempt to drive
down a slope as there is a serious risk of overturning.
R x
Figure 2.1 - Ascending or Descending Gradients
(2) Maximum Gradient

The maximum gradient for this machine is 25% (or 14º, or 1 in 4) See X in Figure 2.2. Do not
exceed the maximum gradient.
Poor ground conditions such as muddy, slippy or uneven surfaces will reduce the maximum
gradient.
25% max
Figure 2.2 - Maximum Gradient
(3) Crossing a Slope

Greater care must be taken when crossing a slope to prevent the machine sliding sideways and
out of control.
The maximum slope is 25% (14º, 1 in 4) See Y in Figure 3.3. Do not attempt to exceed this figure.
max 25%
Figure 3.3 - Crossing a Slope

2. Safety
2.16 Responsibilities
Site management must identify possible dangers and make arrangements to eliminate them.
Site management are responsible for planning driveways around the site which will prevent the
machine from experiencing excessive slopes, soft ground or having to drive over edges
especially at an angle etc. The driveways must also avoid any other possible dangers e.g.
overhead cables, work areas etc.
The operator must make sure the machine is driven correctly at all times especially with regards
to speed, overloading, only using the machine for the intended task, not driving dumpers with a
lift-skip in the raised position etc.
2.17 Overturning
If the machine begins to overturn you must grip the steering wheel firmly allowing the seat belt
to hold you in the seat until the machine comes to rest. Do not try to jump clear of the machine
when it is overturning -the machine may crush you. The ROPS will provide protection in the event
of a roll over.
2.18 Safety Signs

Safety signs are fitted to the machine to warn of possible dangers and MUST be replaced
immediately if they become unreadable or lost.
If the machine is repaired and parts have been replaced on which safety signs were fixed new
safety signs must be fitted before the machine is put into service. Use mild soap and water to
clean safety signs - DO NOT use solvent based cleaners as they will damage safety sign
material.
ALL safety signs listed must be present on the machine and must be legible.

2. Safety
(a) Safety Sign Symbols

Table 2.1 - Description of Safety Symbols
HAZARD AVOIDANCE
Read and understand operator’s
manual before using the
Attention - for your safety! equipment
Remove start key and isolate

battery before maintaining the
Attention - for your safety! machine
Do not carry passengers or

allow people to ride on the
Fall/Crush machine
Use cardboard or wood to check

Skin injection from high for leaks.
pressure fluid
Only drive up and reverse down

Crush during roll over inclines of 14° or less.
19.5%
11˚
1:5
Do not drive across slopes

Crush during roll over exceeding 14°
Insert skip cylinder safety lock/

Crushing support
Keep clear of hot surfaces

Burn

2. Safety
Keep away from fan and

Entanglement belt.Turn off engine and remove
key before servicing.
Stay clear of machine

Crushing
Read operators manual

Machine Instability
Always wear a seat belt when

Crush during roll over operating the machine
Stay clear of machine

Crush Zone
Turn the machine off and

Crush Zone remove the key.
Fit articulation lock
Fit articulation lock before lifting

Lifting ?000KG Use equipment rated for lifting
?000KG
the stated weight.

2. Safety
(b) Safety Sign Location - ISO

Figure 3-4 - Safety Sign Location - ISO
12
13
14
T121979
T119903
11
10
9
15
3517 702M1
8
16
7
17
6
18
5
4
3
19
2
20
1
T119903
3517 702M1
21
14
15

2. Safety
Table 2.2 - Safety Signs - ISO
1. Safety - Read Instruction Book

2. Safety - Fall Hazard - No Passengers
3. Safety - High Pressure Oil Leaks
4. Safety - Energised Equipment Hazard
5. Safety - Tip Over Hazard
7. Information - Push to Reset Circuit Breaker
8. Information - Noise LWA
9. Information - Disconnect or Isolate Battery
10. Safety - Crush Hazard - Use Seat Belt
11. Safety - Entanglement Hazard Each Side
12. Safety - Burn Hazard
13. Safety - Towing Hazard
14. Safety - Crush Hazard Front and Rear
15. Information - Tie Down 4 Points
16. Information - Diesel Filling Point
17. Safety - Crush Hazard Each Side
19. Information - Lifting
20. Information - Lift Point
21. Safety - Crush Hazard

2. Safety
(c) Safety Decal Location - ANSI

Figure 3.5 - Safety Sign Location - ANSI
11
13
12
10
9
3517 702M1
14
8
15
16
7
6
17
5
4
18
3
19
2
1
3517 702M1
20
13
14

2. Safety
Table 2.3 - Safety Signs - ANSI
1. Safety - Read Instruction Book

2. Safety - Fall Hazard - No Passengers
3. Safety - High Pressure Oil Leaks
4. Safety - Energised Equipment Hazard
7. Information - Push to Reset Circuit Breaker
8. Information - Disconnect or Isolate Battery
9. Safety - Crush Hazard - Use Seat Belt
10. Safety - Entanglement Hazard Each Side
11. Safety - Burn Hazard
12. Safety - Towing Hazard
13. Safety - Crush Hazard Front and Rear
14. Information - Tie Down 4 Points
15. Information - Diesel Filling Point
18. Information - Lifting
19. Information - Lift Point
20. Safety - Crush Hazard

3. Technical Data
3 Technical Data
3.1 Dimensions
(a) TA3H
F
A
B
E
C
D
COV00005
Figure 3.1 - Dimensions

Table 3.1 - Dimensions
Dimensions mm (in)
Model A B C D E F G H I
ROPS Across Across Mass
Beacon Skip Tyres
TA3H 1401 239 1939 3725 213 1891 2689 2920 1957 1846 2395 Kg*
(55.15) (9.4) (76.3) (146.6) (8.3) (74.4) (105.8) (114.9) (77.0) (72.6) (5289lb)
2320 Kg**
(5114lb)
* With Operator (75kg)

** Without Operator

3. Technical Data
(b) TA3SH & TA3.5SH
F
A
C
D
COV00006
Figure 3.2 - Dimensions

Table 3.2 - Dimensions
Dimensions mm (in)
Model A B C D E F G H I Mass
ROPS Across Across
Beacon Skip Tyres
TA3SH 1467 792 1939 3952 213 1892 2689 2919 1690 1846 2455 Kg*
(57.7) (31.2) (76.3) (155.5) (8.3) (74.4) (105.8) (114.9) (66.5) (72.6) (5412lb)
2340 Kg**
(5159lb)
TA3.5SH 1467 792 1939 3952 213 1892 2689 2919 1690 1846 2455 Kg*
(57.7) (31.2) (76.3) (155.5) (8.3) (74.4) (105.8) (114.9) (66.5) (72.6) (5412lb)
2340 Kg**
(5159lb)
* With Operator (75kg)

** Without Operator

3. Technical Data
3.2 Turning Circle
COV00007
Figure 3.3 - Turning Circle

Table 3.3 - Turning Circle
Turning Circle A mm (in)

TA3H TA3SH TA3.5SH
Ø 9421 (370.0) Ø 9105 (358.4) Ø 9105 (358.4)

3. Technical Data
3.3 Data
Table 3.4 - Data
Engine TA3H TA3SH TA3.5SH
Manufacturer/Model Kubota V2203-M
Power 32.4kW (43.5hp) @ 2,600 r.p.m.
Oil Capacity 9.5ltr (2.5US Gal)
Cooling System Capacity 9.0ltr (2.37 US Gal)
Transmission
Type Hydrostatic
Drive 4 Wheel Drive - High & Low Range - Forward & Reverse
Transfer Box/Rear Axle
Manufacturer/Model Dana
Oil Capacity (Axle) 4.7ltr (1.24 US Gal)
Oil Capacity (Transfer Box) 0.35ltr (0.092 US Gal)
Front Axle
Manufacturer/Model Dana
Oil Capacity 4.7ltr (1.24 US Gal)
Tyres & Wheels
Mitas
Size 11.5/80 x 15.3 x 10ply 11.5/80 x 15.3 x 10ply 11.5/80 x 15.3 x 14ply
Pressure - Front 3.0 bar (43.5 psi) 3.0 bar (43.5 psi) 4.4 bar (64 psi)
Pressure - Rear 2.0 bar (29 psi) 2.0 bar (29 psi) 2.0 bar (29 psi)
Starco
Size 295/80 x15.3 x 10ply
Pressure - Front 3.9 bar (56.5 psi) 3.9 bar (56.5 psi) 3.9 bar (56.5 psi)
Pressure - Rear 2.0 bar (29 psi) 2.0 bar (29 psi) 2.0 bar (29 psi)
Wheel Nut Torque 450 Nm (335 ft-lb)
Brakes
Primary Hydraulic Multi Plate In Board Wet Disc - Front Axle Only
Parking Mechanical - Front Only
Electrical System
Voltage 12v Negative Earth
Alternator Belt Driven
Output 55 amp
Battery 74Ah 12v
Battery Cold Start Amps Type 072 DIN340A - IEC 420A
Hydraulic System
Tank Capacity 37ltr (9.8 US Gal)
Fuel System
Type Diesel
Tank Capacity 37ltr (9.8 US Gal)

3. Technical Data
Table 3.4 Data (continued

TA3H TA3SH TA3.5SH
Machine Weights
Unladen- Kg (tons) 2320 (2.55) 2380 (2.62) 2380 (2.62)
Operating Mass - Kg (Tons) 2395 (2.64) 2455 (2.70) 2455 (2.70)
Laden - Kg (Tons) 5395 (5.94) 5455 (6.01) 5955 (6.56)
Front Axle Laden - Kg (Tons) 3073 (3.38) 3651 (4.02) 4124 (4.54)
Rear Axle Laden - Kg (Tons) 2322 (2.55) 1804 (1.98) 1831 (2.01)
Skip Capacity
Maximum Safe Payload 3000kg (6600lb) 3000kg (6600lb) 3500kg (7716lb
Heaped Capacity 1.95 cu M (2.5 cu yds) 1.87 cu M (2.4 cu yds) 1.87 cu M (2.4 cu yds)
Water Capacity 1.25 cu M (1.6 cu yds) 1.00 cu M (1.3 cu yds) 1.00 cu M (1.3 cu yds)
Struck Capacity 1.60 cu M (2.0 cu yds) 1.50 cu M (1.9 cu yds) 1.50 cu M (1.9 cu yds)
This machine can operate in ambient temperatures of between -15°C and +46°C without special
Operating Environment
preparation. Refer to fluids and lubricants
3.4 Noise Emmissions

Table 3.5 - Noise Emissions
Declared Single-Number Noise Emission

Values to ISO 4871
Model
A- rated sound pressure level at
A - rated sound power of machine
operator station
LpAd LWAd
TA3H 84dB 101dB
TA3SH 84dB 101dB
TA3.5SH 84dB 101dB
Note: The noise figures are only applicable for European CE Markets only.
3.5 Vibration Levels

Table 3.6 - Hand/Arm Vibration
Operation Value Uncertainty

Hand Arm Vibration
as All operations <2.5m/s2 N/A
defined in EN474-1
Whole body vibration
values as defined in Work Cycle 0.529 rms 0.264m/s2
ISO/TR 25398
Note: these values are for guidance only. Actual work site, operation and operator characteristics
will have a large influence on actual values for specific circumstances.

4. Description
4 Description
4.1 TA3H Dumper - Forward Tip Skip
Figure 4.1 - TA3H Forward Tip Skip

4. Description
4.2 TA3SH Dumper - Swing Skip
Fig 4.2 - TA3SH Swing Skip
4.3 Description
This range of 3 and 3.5 tonne payload, 4 wheel drive site dumpers have been designed to
provide the greatest degree of component standardisation possible, thus providing the user with
simplified servicing requirements.
There are 3 models in the range: the TA3H with a conventional forward tipping skip and the
TA3SH and TA3.5SH which have a rotatable skips.
(1) Skip
All models in the range have a load carrying skip located over the front axle, ahead of the driver.
The TA3H discharges its load to the front of the machine; the TA3SH and TA3.5SH have a swing
skip which rotates through 180° enabling the load to also be discharged on either side of the
machine.
(2) Engine
A Kubota naturally aspirated 4 cylinder cylinder diesel engine is fitted. The engine is positioned
at the rear of the machine behind the driver.
All machines are fitted with electric starting; a separate key operated switch is provided and is
located adjacent to the steering wheel.

4. Description
(3) Chassis
The chassis is of the two part articulating type having a centre pivot which articulates in both
vertical and horizontal planes. Front and rear axles are bolted directly to the chassis.
(4) Steering
Steering of the dumper is by an ‘Orbitrol’ hydrostatic steering unit, that powers a single ram
connecting the front and rear chassis units.The steering unit is operated by a conventional
steering wheel.
The steering wheel is fitted with a “spinner” knob to aid low speed manoeuvring on the worksite.
Under no circumstances must the knob be used to control the machine when it is used on the
public highway. If possible the knob should be removed from the steering wheel before highway
travel.
bWARNING
Use of a steering wheel knob when travelling on the public highway is illegal and strictly
prohibited. Its use at travelling speeds may cause accidents leading to serious injury or even
death.
In the event of hydraulic failure the steering will still operate but under these circumstances
steering wheel loads are high and the dumper must only be driven at slow speeds.
(5) Transmission
Power is transmitted to the wheels by means of an hydrostatic drive to a conventional mechanical
transfer box and axles.
Because the machine has hydrostatic drive and will not “free wheel” as with a conventional
gearbox the transmission pumps free wheel facility must be engaged before the machine is
towed. Failure to do this will cause serious damage to the machine
NOTICE
Place Hydrostatic Drive In “Freewheel” Before Towing Dumper. Failure To Do So Will Cause
Serious Damage
(6) Brakes
The vehicle braking is provided by means of totally enclosed oil immersed brakes located within
the front axle
These brakes are self adjusting sintered multi-plate discs which are hydraulically operated. A
separate mechanically operated parking brake is fitted.
(7) Electrical System

A 12 volt negative earth electrical system is fitted. All models use a belt driven alternator to
charge the battery. Machines are available with full lighting when specified to comply with current
road traffic regulations.
(8) ROPS
Machines are fitted with a ROPS (Roll Over Protective Structure) to protect the operator in the
event the machine overturns.

4. Description
4.4 Skip
The dumper vehicle is basically a load carrier and the skip can be used for a multitude of building/
contracting site functions, but essentially it is used for carrying free flowing materials from
excavations or demolitions and general site building activities.
On forward tip machines the skip is raised and lowered by a double acting hydraulic cylinder
mounted between the front chassis and the underside of the skip and controlled by joystick
operated control valve.
On swing skip machines the ram is mounted between the top of the turntable and the underside
of the skip.
The swing skip is mounted on a ball bearing slew ring and is rotated by twin hydraulic rams.The
swing skip must be mechanically locked in the straight ahead position to prevent movement
when travelling.
The joystick control for skip operations is positioned to the right of the drivers seat.
(1) Raised Skip

As a safety aid when working on the machine a stop is provided that fits over the skip ram when
the skip is raised. This prevents the skip lowering accidentally and causing injury. You must not
reach or work under a raised skip without the ram stop fitted.
(2) Swing Stop

On swing skip machines a locking device is used to locate the skip in the straight ahead position
when the skip is fully lowered.Before slewing to the left or right, it is necessary to raise the skip
slightly to clear the stop.
4.5 Chassis
The two part chassis is of the centre pivot articulating type and is of a design which enables both
front and rear axles to be attached directly to the chassis members.
The front and rear frames are connected in the middle by a vertical pivot in spherical bearings
and a horizontal link, which connects between the spherical bearing of the vertical pivot and an
additional spherical bearing located in the rear frame.
This arrangement is illustrated in Figure 4.3 and shows full movement of the chassis in both
horizontal and vertical planes, thus ensuring maximum wheel adhesion at all times
.
10.5˚
30˚
COV00031
Figure 4.3 - Chassis Articulation

4. Description
4.6 Hydraulic System

The hydraulic system Figures 4.4 & 4.5 provides power to move the machine, through the
hydrostatic drive, operate the vehicle steering and to power the skip elevation. It also provides
power for skip rotation on swing skip models.
An engine driven hydraulic pump powers the hydraulic motor mounted on the transfer box which
transmits power to both axles. A second engine driven hydraulic pump provides power for
steering and skip operation. The pumps draw oil from a tank located inside the chassis. The tank
is fitted with a suction strainer, an oil level gauge, and a filler/breather cap.
The pump providing power for steering and skip operations generates a maximum pressure of
170bar (2500 psi) for forward tip machines and 210 bar (3045 psi) swing skip machines. The
system is protected by a relief valve in the control valve that is set at the same pressure.
A return line filter is fitted to the circuit and is of the replaceable cartridge type.
An oil cooler is fitted to cool the hydraulic oil.
Steering of the dumper is by means of a single hydraulic ram connecting the front and rear
frames, the oil supply to the ram is controlled by an “Orbitrol” hydrostatic steering unit.
The unit receives oil via a carry over port in the 3 way control valve and constantly meters oil to
the steering ram as the steering wheel is turned.
The control valve, operated by a lever next to the drivers seat, controls the lifting, lowering and
(on swing skip models) slewing of the dumper skip.
The skip can be elevated at varying speeds dependent on engine speed, and it can be stopped
at any intermediate point for discharging of partial loads.

4. Description
3
11
10 4
5
7 6
8
COV00025
Figure 4.4 - Hydraulic System - Forward Tip

1. Ram - Skip Tip
2. Skip Control Valve
3. Hydraulic Pump - Steering and Skip Functions
4. Oil Cooler
5. Engine
6. Hydraulic Pump - Transmission
7. Hydraulic Motor - Transmission
8. Hydraulic Tank
9. Return Filter
10. Ram - Steering
11. “Orbitrol” Steering Unit

4. Description
12
3
10 11
5 4
7 6
8
COV00026
Figure 4.5 - Hydraulic System - Swing Skip

1. Ram - Skip Tip
2. Skip Control Valve
3. Hydraulic Pump - Steering and Skip Functions
4. Oil Cooler
5. Engine
6. Hydraulic Pump - Transmission
7. Hydraulic Motor - Transmission
8. Hydraulic Tank
9. Return Filter
10. Ram - Steering
11. “Orbitrol” Steering Unit
12. Slew Rams

4. Description
4.7 Transmission System
2 3
COV00024
Figure 4.6 - Transmission System

1. Drive Shaft
2. Hydraulic Motor
3. Rear Axle
4. Transfer Box
5. Front Axle
A hydrostatic drive transmission system fitted. A piston type hydraulic pump attached to; and
driven by the engine drives an hydraulic motor mounted to the transfer box. The transfer box is
integral with the rear axle and transmits drive to both axles; the front axle is driven by a driveshaft
connecting the axle to the transfer box. The machine is in permanent 4 wheel drive.
To enable the dumper to be towed in an emergency there is provision to disconnect the relief
valves on the pump to permit oil to flow freely through the system.

4. Description
4.8 Battery Isolator

The battery isolator; Figure 4.7, is both a maintenance aid and an anti-theft and vandalism
device. It has a removable key 1.
When carrying out any maintenance on the machine, the battery isolator key must be removed
to prevent the engine from being started or the electric circuit being activated.
When parking or leaving the machine, remove the battery isolator key to prevent unauthorised
people from using or stealing the machine.
COV00011
Figure 4.7 - Battery Isolator
(1) Operation
When the key is in the horizontal position the battery is supplying power to the machine and the
machine may be used normally.
Turning the key anti-clockwise to the vertical position - 2; Figure 4.8, disconnects the power
supply to the machine and allows the key to be removed from the isolator switch.
COV00010
Figure 4.8 - Battery Isolator - OFF Position

4. Description
4.9 Circuit Breakers & Audible Warning

Refer to Figure 4.9. Circuit breakers are located on the left hand side of the dashboard. A 15 amp
circuit breaker is fitted protecting the engine starting system. On machines with highway lighting
a second 30 amp circuit breaker is fitted.
In the event of a fault occurring the circuit breaker will trip out, this being indicated by the button
protruding out beyond its normal position.
Should this occur the reason for the overload should be investigated and the components at fault
replaced or repaired.
When the repair has been completed the circuit breaker should be reset by pressing the button
until it locks in position thus restoring the electrical supply.
The audible warning is fitted to warn the operator that the engine is overheating. If the alarm
sounds the machine must be parked safely and the engine stopped until the cause of the
overheating is determined.
COV00227
Figure 4.8 - Circuit Breakers & Audible Warning

1. Audible Warning
2. Circuit Breakers

4. Description
4.10 Hour Meter

The hour meter, Figure 4.9. records the amount of time the engine has been running. This is
useful for determining service intervals, maintenance etc.
COV00228
Figure 4.9. - Hour Meter

1. Hour Meter

4. Description
4.11 Control Panel and Switch Functions
1 2 3 4 5 6
30A
7
15A
17
16
15 14 13 12 11 10 9
COV00034
Figure 4.9 - Control Panel

1. 30A Circuit Breaker - Lighting (When Fitted)
2. Warning Light - Direction Indicators (When Fitted)
3. Warning Light - Battery Charge
4. Warning Light - Brake Fluid Level LOW
5. Warning Light - Engine Cold Start
6. Instruction - Start Inhibitors
7. Instruction - Direction Indicators (When Fitted)
8. Instruction - Engine Start Switch
9. Switch - Lighting -(When Fitted)
10. Warning Light - Engine Coolant Temperature HIGH
11. Warning Light - High Speed Selected
12. Warning Light - Engine Oil Pressure LOW
13. Warning Light - Parking Brake ON
14. Horn Button
15. Instruction - Forward/Reverse and Low/High Speed
16. Switch - Hazard Warning Lights
17 15A Circuit Breaker - Engine Electrical System

4. Description
Table 4.1 - Dashboard Symbol Description
Symbol Name Description

30A Circuit breaker - A - 15A Engine Starter System
Electric Circuit B - 30A Lights (if fitted)
15A
Circuit breakers protect the machines electrical
system.
Horn Button The horn is used to warn others and must only
be used for this purpose. Excessive use may
cause others to ignore a genuine warning.
Warning Light - This warning light will come on when the start
Engine Oil Pressure switch is turned to the RUN position.
When the engine starts, the light should go off.
If the light fails to go off or come on when the
engine is running -
STOP THE ENGINE IMMEDIATELY
Do not use the machine until the fault has been
rectified.
Warning Light - The battery charge warning light should only
- +
Battery Charge come on when the start switch is ON and the
engine is not running. When the engine starts
and full RPM is selected the charge warning
light goes off. The warning light should stay off
while the engine is running.
If the light fails to go off when the engine is
running -
rectified.
Warning Light - The water temperature warning light should
Engine Coolant only come on when the start switch is in the
Temperature RUN position and should go out when the
engine is cranked.
If the warning light comes on when the engine
is running the water temperature is too high, a
warning buzzer will also sound.
If engine temperature warning light comes on
when engine is running -
rectified
Warning Light - When fitted, this light will flash when the
Direction Indicator indicator switch is moved into the left or right
turn position.
If the light fails to perform this function, do not
use the machine until the cause has been
rectified.

4. Description
Table 4.1 - Dashboard Symbol Description (continued)
Symbol Name Description

Instruction - Start This instruction informs the operator that they
Inhibitor must sit on the seat before the engine will start.
A start inhibitor is fitted which prevents the
engine being started unless the operated is
seated.
Switch Instruction - When fitted, this instruction informs the
Direction Indicator Operator in which direction to move the switch
in order to operate the LEFT and RIGHT
direction indicators
Switch - Hazard When fitted, the hazard warning light switch will
Warning Lights cause all four indicator lights to flash and is
used to warn others the machine is
experiencing problems and should be given
special attention.
Switch - Lighting - This switch will turn the headlights and front,
When fitted rear side lights on and off.
III Instruction - Engine This instruction shows the start key position to
Start Key Switch use when the engine cold start aid is required.

4. Description
Table 4.2 - Switch Operation
Switch Name Description

Hazard Light Switch Pressing the button will cause all four direction
indicator lights to begin flashing and will
continue to do so until the button is pressed
again
Horn Button When pressed, this button will cause the horn
to sound.
Light Switch Turning the switch clockwise from the OFF

position (A) to position (B) will cause the front
and rear side (marker) lights and the
registration plate lights to come on. Turning the
switch to the next position (C) will cause the
A main headlights to come on.
C
B
4.12 Start Interlock

A interlock is fitted for safety purposes and prevents the engine from starting unless the operator
is sitting on the seat. This interlock comprises an inhibitor switch within the seat that is operated
when the operator is seated on the machine. If you attempt to start the machine without sitting
on the seat the engine will not start.
The symbol (1), on the dashboard decal - Figure 4.10, indicates the Operator must be seated to
deactivate the start inhibitor before starting the machine.
.
COV00035
Figure 4.10 - Start Interlock Function

4. Description
4.13 Start/Stop Switch

The Start/Stop Switch - Figure 4.11, is operated by a removable key. The switch has a protective
cover that must be fitted when the key is removed to prevent the ingress of damp and moisture.
.
0 1
2
COV00064
Figure 4.11 - Start/Stop Switch

1. Star/Stop Switch
The switch has 3 positions-
- 0 - Off
- 1 - Run
- 2 - Start
Once the engine has started the switch should return to the run position.
4.14 Direction Indicator Switch - When Fitted

This switch; Figure 4.12, is used to turn on the LEFT or RIGHT, front and rear indicator lights to
inform others of the operators intention to turn the machine to the Left or Right.
Moving indicator lever forwards, A will turn on the left hand indicator lights. Moving the lever
backwards, B will turn on the right hand indicator lights.
B
1
COV00065
Figure 4.12 - Direction Indicator Switch

1. Direction Indicator Switch

4. Description
4.15 Machine Lighting

Each front light cluster, Figure 4.13, contains a headlight (2), side light (3) and a direction
indicator light (1).
1 2
COV00041
Figure 4.13 - Front light cluster

Each rear light cluster, Figure 4.14, contains a rear light (4), brake light (3), direction indicator
light (1) and reflector (2). The registration plate light is fitted separately.
Figure 4.14 - Rear light cluster

The brake lights come on when the brake pedal is pushed down and go out when the pedal is
released. They operate independently of the main lighting. The registration plate lights are
mounted independently but operate in conjunction with the rear lights.
4.16 Orange Flashing Beacon

The Flashing Beacon, Figure 4.16, is provided to warn people of the dumpers presence. The
beacon is fitted to the machines ROPS and is controlled by switch (1) located on the ROPS.
The Flashing Beacon is easily removed to prevent theft or vandalism by slackening nut (2) and
lifting the beacon off its mounting stem.

4. Description
Figure 4.16 - Flashing Beacon

1. Switch
2. Securing Nut
When the beacon has been removed, the top of the mounting stem is covered by pulling the
rubber stem cap (1) over the mounting stem, Figure 4.17.
COV00013
Figure 4.17 - Beacon Mounting Stem

1. Rubber Cover
(1) Storage
To help prevent damage, theft and vandalism the flashing beacon can be removed from its
working position on the ROPS and stored inside the lockable engine compartment when not
required. A dedicated mounting point, Figure 4.16, is provided. It is held in position by tightening
the nut (1).

4. Description
COV00087
Figure 4.16 - Beacon Storage Position

1. Beacon Storage Mounting
4.17 Parking Brake

The parking brake lever - Figure 4.17, is located to the right of the drivers seat. With the lever (1)
vertical the brake is applied. A catch prevents the brake from being released accidentally. Before
the brake can be released it is necessary to lift the catch (2) to enable the lever to be moved to
the horizontal (released) position.
COV00080
Figure 4.17. - Parking Brake

1. Parking Brake Lever
2. Release Catch

4. Description
bWARNING
The parking brake may not hold on gradients steeper than 8.5° (15%). If possible always park
on flat level ground. If it is necessary to park on a slope it must not exceed the figures stated
above and the machine must be parked across the slope and the wheels chocked to prevent
movement.
4.18 Skip Control Lever

The skip control lever - Figure 4.18, is located to the right of the drivers seat. Moving the lever
forward towards the skip will cause the skip to tip. Moving the lever towards the rear of the
machine will cause the skip to lower. Upon releasing the lever it will automatically return to the
centre (Neutral) position.
COV00066
Figure 4.18. - Skip Control

1. Skip Control Lever
On swing skip machine by moving the lever to right the skip will rotate to the right and by moving
the lever to the left the skip will rotate to the left. The skip must be raised by 75mm to clear the
skip lock - Figure 4.19 before it can be rotated to the left or right.
COV00068
Figure 4.19. Skip Lock (Swing Skip Machines Only)

1. Skip Lock

4. Description
4.19 Seat Belt

A seat belt is provided for the safety of the operator and must be worn at all times when operating
this equipment. It is prohibited to alter or modify a seat belt. Avoid twisting the webbing.
(1) Standard Seat Belt

This is a normal lap type seat belt Figure 4.22 refers.
1 2
3
COV00633
Figure 4.22 - Standard Seat Belt

1. Buckle
2. Button
3. Tongue
(2) Retracting Seat Belt with Green Beacon (Optional)

This type of belt retracts automatically when the release button is pressed and the tongue is
released. Figure 4.23 refers. When the tongue of the belt is inserted in the buckle and clicks into
place, a green beacon, Figure 4.24 located on the ROPS frame will flash indicating to site
management and others that the driver of the machine is correctly wearing their seat belt. The
engine will not start unless the operator is wearing the seat belt correctly.
1
Figure 4.23 - Automatically Retracting Seat Belt

1. Release Button
2. Tongue
3. Retractor Unit

4. Description
Figure 4.24 - Green Beacon - Seat Belt Warning
4.20 Tow Hitch

A tow hitch Figure 4.20 is provided primarily for recovery purposes. The machine has not been
designed for, and we do not recommend its use as a towing vehicle, but if so used always make
sure that the weight of the trailer and its load does not exceed half the rated payload of the
dumper.
Figure 4.20 - Tow Hitch

1. Pin
2. Grip Clip
It is important that if the machine is used for towing:
• The skip is loaded with half the rated payload to provide adhesion when braking.
• The machine must NEVER be driven down a gradient as “jackknifing” may occur.
• Only “low” speed is selected and the machine is never driven on or across gradients.
The grip clip (2) must be fitted to the pin (1) once the trailer etc. has been coupled up.
bWARNING
The dumper must not be used as a towing vehicle on the public highway

5. Transportation
5 Transportation
5.1 Loading on to a Trailer or Lorry Using Ramps
bDANGER
Keep all bystanders well clear when loading or unloading a dumper.
When loading dumper onto a trailer or lorry, strong loading ramps must be used. Ramps must be
strong enough to take the weight of the machine.
The angle of the loading ramps must not exceed the grade ability (1 in 4 - 25%) of the dumper.
In wet, muddy or icy conditions this angle will be reduced considerably.
Make sure the trailer or lorry will not move during loading by applying its brakes and also
chocking its wheels if necessary.
The skip must be empty when transporting the machine.
When the machine has been loaded and is positioned correctly fit the articulation lock.
Secure the machine to the Trailer or Lorry - see Securing the Machine for Transport.
Release the articulation lock before unloading.
5.2 Loading or Unloading using a Crane

Refer to Figure 5.1. A single lifting point (1) is provided for lifting the machine. Using this point
will give a safe stable lift. Other methods of lifting are not recommended.
The crane must have adequate capacity to lift the machine.
Any chains, ropes and straps used must be of sufficient strength to support the machine safely.
Before lifting the machine must be in the straight ahead position with the front and rear chassis
in line.
Fit and secure the articulation lock before lifting.
COV00044
Figure 5.1 - Lifting Point

1. Lift Point

5. Transportation
5.3 Articulation Lock

The articulation lock, Figure 5.2 prevents chassis movement when lifting the machine with a
crane or during transport or maintenance.
2
1
3
COV00043
Figure 5.2 - Articulation Lock

1. Lock Bar
2. Pin
3. R Clip
PROCEDURE
1 To fit the lock bar remove the grip clip and pin from the lock bar.
2 Pivot the lock bar around until the hole in the bar aligns with the hole in the rear chassis.
3 It may be necessary to move the steering wheels slightly to align the holes.
4 Refit the pin and secure with the grip clip.

5. Transportation
5.5 Tie Down Points

Tie down points are provided at the front and rear of the machine. The chains, straps, ropes etc.
must be attached to the machine’s front tie down points (1) forward tip skip, Figure 5.3. or (2)
swing skip, Figure 5.4. and rear tie down points, Figure 5.5 (each side of machine).
COV00084
Figure 5.3. - Front Tie Down - Forward Tip Skip
Figure 5.4. - Front Tie Down - Swing Skip

5. Transportation
Figure 5.5. - Rear Tie Down Point (3)
5.6 Tie Down

When the machine has been put in an acceptable position on the lorry or trailer it must be
secured in place.
COV00050
Figure 5.6 - Alternative Tie Down Method
PROCEDURE
1 Place the machine in a suitable position.
2 Apply the parking brake.
3 Fit the articulation lock.
4 Lower ROPS to transport position.
5 Nail blocks/chocks at the front, rear and outside of each wheel.
6 Tie down using tie down points provided with suitable chains straps or ropes. Ropes may
also be placed over wheels as shown in Figure 5.6.
7 Loose ends of chains, straps or ropes must be secured to the lorry/trailer bed.

6. Initial Setup & Adjustments
6 Initial Setup & Adjustments

6.1 Delivery Checks
On delivery of the machine:-
• Remove any packaging and shipping supports.
• Release any transport locks.
• Clean any protective coating from bright metal parts.
• Check for damage and missing parts.
• Check all fluid levels.
• Check tyres are inflated to correct pressures.
6.2 Setup
Place the ROPS in the work position, Figure 6.1. refers.
bDANGER
The machine must not be used until the ROPS has been raised and secured in the work
position. It is prohibited to use a machine without the ROPS installed in the work position.
1
2
COV00029
Figure 6.1 - ROPS Set Up

1 Linch Pin
2 Locking Pin

6. Initial Setup & Adjustments
PROCEDURE
1. Remove the linch pins from the locking pins either side of the ROPS.
2. Remove the locking pins.
3. Push the top half of the ROPS upwards to the working position.
4. Refit the locking pins.
5. Secure the locking pins in position with the linch pins.
6. Remove the rubber cover and fit the beacon to the stem on top of the ROPS.
7. Switch on the beacon and check it is working correctly.
6.3 Start Up and Adjustments

When all delivery checks have been made and the ROPS has been placed and secured in the
work position:-
• Start the engine and allow to run for a few minutes to warm up.
• Check all instruments and warning lights are functioning correctly.
• Check lighting and indicators operate (if fitted).
• Stop the engine and check for any fluid leaks or signs of overheating.
• Re-start the engine, drive the machine a short distance to check operation of transmission,
brakes and steering.
• Check if the skip tips, lowers and (swing skip models only) rotates in either direction.
• Park up and stop the engine.
• Report and have rectified any faults before placing machine into service.

7. Standard Operating Procedures
7 Standard Operating Procedures

Before using this equipment the operator must read and fully understand this Instruction Manual
and pay particular attention to Section 2 - Safety and Section 4 - Description which describes the
major components of the machine and the layout and function of all the controls.
NOTICE
ALL Operators of this machine must be authorised, mentally and physically capable of operating
this machine and fully trained in its operation.
7.1 Pre Start Checks

Make sure the machine has been cleaned to enable leaks etc. to be noticed easily during the pre-
start check and during normal operation.
PROCEDURE
1. Check general condition of machine - missing parts, loose fasteners, fuel lines for
damage, hydraulic hose end fittings for leakage, hose outer covers for ballooning, etc.
2. Check engine and hydraulic oil levels - make sure the engine and hydraulic tank are filled
using clean oil and a clean container.
3. Check fuel tank is full - make sure the tank is filled when the engine is cold and the
machine is in a well ventilated area, with the engine stopped using clean fuel and
container. It is advisable to fill the tank at the end of a working session to prevent
condensation forming in the tank during long periods of inactivity, e.g. overnight.
4. Check battery and battery cable condition.
5. Check for adequate ventilation if the machine is to be started or run in a building etc.
6. Make sure the ROPS is in the “work” position.
7.2 To Set the ROPS in the Work Position.

Refer to figure 7.1
1
2
COV00029
Figure 7.1. - ROPS pins

1 Lynch Pin

2 Locking Pin
PROCEDURE
1. Remove the linch pins from the locking pins.
3. Push the top section of the ROPS upwards to its working position.
4. Refit the locking pins and secure with the linch pins.
5. Fit the beacon.
7.3 To Lower the ROPS for Transport
PROCEDURE
1. Remove the beacon.
2. Remove the linch pins from the locking pins.
4. Lower the top section of the ROPS downwards.
5. Refit the locking pins and secure with the linch pins.
7.4 Seat
The seat is adjustable for operator comfort. The adjustments allow the seat to be moved forwards
and backwards, the back of the seat may be tipped forwards and backwards and the seat
suspension may be adjusted to the weight of the operator.
Figure 7.2. - Operators Seat

1. Fore and aft movement
2. Backrest Angle Adjustment
3. Weight Adjustment

4 3
+
1
COV00091
Figure 7.3. - Seat Adjustment

1. Fore and aft adjustment
2. Weight adjustment knob
3. Scale
4. Pointer
(1) Seat Adjustment

Refer to Figure 7.3. Lifting the lever (1) allows the seat to move forwards or backwards to suit the
leg length of the operator. When the lever is released the seat is locked in position.
(2) Weight Adjustment

The weight adjustment knob (2) is used to adjust the seat characteristics to suit the weight of the
operator.
Turning knob clockwise adjusts the seat for the larger person and anticlockwise for the smaller
person.
When the knob is turned, the pointer (4) moves to allow the operator to select the correct weight
from the scale (3).
If the seat weight adjustment is not set, the Operator may experience discomfort or personal
injury.
The engine will not start unless the seat is adjusted correctly for the operators weight and the
operator is seated.
(3) Backrest Angle Adjustment

Refer to Figure 7.4. Lifting the lever (1) allows the back of the seat to be pushed forwards or
backwards to suit the preference of the operator. When the lever is released the seat is locked
in the selected position.

COV00092
Figure 7.4. - Backrest Angle

1. Adjustment Lever
(4) Seat belt

Refer to Figure 7.5. Sit on the seat, place the seat belt across the hips and insert the latch (3)
into the buckle (1) until it locks into position.
Adjust by pulling the belt through buckle (B) until it is a firm, comfortable fit across the hips.
To remove the seat belt, press the button (2) and lift the latch (3) out of the buckle (1).
1 2
3
COV00633
Figure 7.5. - Seat Belt

1. Buckle
2. Button
3. Latch

7.5 To Start the Engine

Before starting the engine check to see that there are no obvious faults with the machine. Refer
to Figure 7.6 which shows the start key positions.
0 1
2
COV00225
Figure 7.6. - Key Switch Positions

0. Off
1. Run/Pre Heat
2. Start
PROCEDURE
1. Sit on the seat.
2. Check that the parking brake is applied and the forward/reverse switch is in Neutral.
3. Turn the start key to position 1 (Run) an audible warning will sound indicating the parking
brake is applied.
4. Wait for the heater warning light to go out.
5. Further turn the switch to position 2 (START) and crank the engine.
6. Release the key immediately the engine starts and allow the to return to position 1.
NOTICE
Do Not use starting sprays to assist engine starting.
Do Not crank engines for more than 10 seconds - allow 30 seconds before between starting
attempts.
Never engage the starter motor when the engine is running.

7.6 To Stop the Engine
PROCEDURE
1. Stop the machine in a safe position on firm level ground.
2. Apply parking brake and place the forward/reverse switch in Neutral.
3. Turn start key anticlockwise to OFF - position 0.
7.7 To Move the Machine

Refer to Figure 7.7
A
B
C
1
D
E 2
COV00226
Figure 7.7. - Forward/Reverse and Fast Slow Switches

1. Forward Reverse Switch - A, Forward - B, Neutral - C, Reverse
2. Speed Switch - D, Fast - E, Slow
PROCEDURE
1. Make sure the parking brake is ON.
2. Make sure the forward/reverse switch in Neutral.
3. Start the engine.
4. Select Fast or Slow on the speed switch.
5. Select Forward or Reverse.
6. Release the parking brake.
7. Depress the accelerator pedal gently and the machine will begin to move.
8. Control the speed of the machine with the accelerator or brakes as required.
7.8 Loading the Skip

Before the skip is loaded the operator should:-
• Park the machine safely.
• Apply parking brake and stop engine.
• Get off the machine and stand clear.

bWARNING
It is important to get off and stand clear of the machine when loading the dumper with a backhoe
loader, digger, loader shovel or similar to prevent injury from falling objects.
7.9 Skip Operation
bWARNING
The machine must be in the “straight ahead” position before tipping. Do not try to tip the load
when the machine is turned.
bWARNING
Only tip or lower the skip when sitting on the operators seat. It is prohibited to tip or lower the skip
from ground level.
bCAUTION
The centre of gravity will change when the load is being discharged. Take care when tipping
sticky loads or single large objects.
(1) To Tip the Load - Forward Tip Machines

Refer to Figure 7.8
COV00066
Figure 7.8. - Control Lever - Operation

PROCEDURE
1. Position the machine where the load is to be discharged.
2. Make sure the area is clear of bystanders.
3. Push the control lever forwards towards the front of the machine; the skip will tip and the
load will be discharged.
(2) To Lower the Skip
PROCEDURE
1. When the load has been discharged.
2. Move the control lever towards the back of the machine.
3. The skip will lower.
(3) To Tip the Load - Swing Skip Machines

Refer to Figure 7.8
PROCEDURE
3. Push the control lever forwards towards the front of the machine; the skip will tip and the
load will be discharged.
PROCEDURE
(5) To Rotate and Tip the Skip
PROCEDURE
3. Push the control lever forwards towards the front of the machine to raise the skip by 75mm
to enable the catch to clear the skip lock.
4. Move the control lever to the right or left; the skip will rotate.
5. Push the control lever forwards; the skip will tip and the load will be discharged.

PROCEDURE
(7) To Return the Skip to the Ahead (Travelling) Position
PROCEDURE
1. If necessary raise the skip to clear the lock.
2. Rotate the skip to the ahead position.
3. .Move the control lever towards the back of the machine; the skip will lower.
4. Make sure the skip is locked in the ahead position.
7.10 Parking the Machine After Use

At the end of the working day make sure the machine is parked safely and securely.
PROCEDURE
1. Find a safe, flat, well lit area to park the machine where it will not cause an obstruction or
danger to others.
2. Set the forward/reverse switch to the Neutral position and apply the parking brake.
3. Stop the engine and remove the start key.
4. Lift the engine cover, turn the battery isolator to OFF and remove the isolator key.
6. Close the engine cover, lock and remove the key.


8. Emergency Operating Procedures
8 Emergency Operating Procedures

In the event of an emergency or system failure the following procedures must be followed to
place the machine in a position of safety or in a safe condition.
Once the machine has been rendered safe the start key and battery isolator key must be
removed to prevent start up and a warning tag placed in a prominent position warning others not
to use the machine.
The fault or failure must be rectified before the machine is put back into use.
8.1 Running Out of Fuel on a Slope
PROCEDURE
1. If Possible place the machine across the slope in a safe position.
2. Apply parking brake.
3. Chock or block the wheels.
4. Re-fuel the machine.
8.2 To Support or Lower the Skip with the Engine “Dead”

If the skip is partially raised and the engine fails it will lower under gravity when the control lever
is moved to the “down” position.
If the skip is raised fully it may not lower by gravity and the skip prop or other suitable method of
support must be fitted. Once the fault has been rectified and the engine restarted the skip can be
lowered normally.
bDANGER
NEVER reach or work under a raised skip unless the prop or other support has been fitted.
8.3 “Jump Starting” the Machine
bDANGER
It is essential to avoid sparks when connecting cables to a discharged battery because the
battery generates inflammable gases and may pose a fire risk.
If the battery is frozen it may explode if the machine is “jump started” and the engine run.
It is possible to connect a slave battery to boost a discharged battery on the machine - Refer to
figure 8.1. When doing so you must wear the correct protective clothing, gloves and a face shield
- see Safety Section in this manual.
Observe the following points:-
• The discharged battery must not be frozen.
• The slave battery must be of the same nominal voltage as the discharged battery.
• The “jumper” cables are of sufficient capacity to carry the starting current.
It is necessary to remove the floor plate to gain access to the battery - see Battery Access in
Maintenance section.

1
2
6
4
5 COV00027
Figure 8.1. - Battery “Jump” Starting
1. Positive (+) Jump Lead.

2. Discharged Battery on Machine.
3. Machine Chassis.
4. Jump Lead Connection on Chassis.
5. Negative (-) Jump Lead.
6. Slave Battery.
PROCEDURE
1. Connect the positive jump lead from the positive terminal on the slave battery to the
positive terminal on the machine battery.
2. Connect the negative cable from the negative terminal on the slave battery to a suitable
point on the machine chassis.
3. Start the engine using the machines start key.
4. Allow engine speed to fall to idle.
5. Carefully remove the negative jump lead from the machine chassis. Do not let the cable
touch any part of the machine.
6. Remove the negative jump lead from the slave battery.
7. Carefully remove the positive jump lead from the machines battery.
8. Remove the positive jump lead from the slave battery.
8.4 Towing the Machine

In the event of a breakdown it is possible to tow the machine but before doing so it is necessary
to set the transmission pump to “freewheel” mode.
The machine should be towed at a maximum speed of 2km/h (1.2 m.p.h.) for a maximum
distance of 2 km (0.6 miles).

NOTICE
Failure to place the machine in “Freewheel” mode before towing will cause serious damage to
the pump, motor and hydraulic system.
1 2
2 1 COV00028
Figure 8.2. - Setting the Pump to “Freewheel”
1. Adjusting Screws.
2. Lock Nuts.
3. Pump.
1 To Set the Pump to Freewheel.

It is necessary to remove the floor plate to gain access to the pump - see Battery Access in
Maintenance section.
PROCEDURE
1. Slacken the lock nuts each side of the pump.
2. Screw in the adjusting screws until the top of the screw is level with the top of the nut.
3. Tighten the lock nuts.
4. The machine can now be towed with care.
2 To Reset the Pump
PROCEDURE
1. Slacken the lock nuts each side of the pump.
2. Unscrew in the adjusting screws until they reach their stops.
3. Tighten the lock nuts.


9. Maintenance
9 Maintenance & Lubrication

9.1 General Information
Regular maintenance and lubrication will prolong the life of the machine and keep it in a safe
working condition.
Refer to the Safety section of this manual and understand its contents before performing any
maintenance tasks on this machine.
Contaminated water, fluids and oils removed from the machine must be disposed of legally.
9.2 Maintenance Notes

Before carrying out any service or maintenance work make sure that the following precautions
have been taken.
• Park the machine on firm level ground.
• Stop engine and chock the wheels.
• Remove Start key to prevent accidental start up.
• Place a warning tag on the machine informing others not to use the machine.
• Only jack or raise the machine using the correct equipment.
• Make sure jacks, axle stands etc. are capable of supporting the weight of the machine.
• Always fit and lock in position a support before working under a raised skip.
• Always fit the articulation lock when working in the area of the centre pivot.
• Refer to and adhere to the Lubricating and Service Schedules detailed in this manual.
• When checking fluid levels park the machine on a firm, level surface, in a well ventilated
position away from naked flames, grinding sparks etc.
• Make sure the work area is clean and tidy before starting and on completion of any
maintenance.
• Make sure strict cleanliness is observed especially when dealing with hydraulic systems.
• Isolate electrical system by using the isolator switch or by disconnecting the battery.
• Make sure all guards and covers removed during maintenance are replaced before the
machine is put back into work.
• OIL - Refer to Safety Section BEFORE handling oil and other lubricants and observe and
adhere to all the warnings and precautions listed. Avoid skin contact with used oils and
lubricants.
• Always use genuine original equipment manufacturers parts.
9.3 Cleaning The Machine

Clean the dumper thoroughly, this will make it easier to find oil leaks and loose fittings etc.
• Take care to clean the oil and fuel tank filler necks.

9. Maintenance
• Drain plugs must also be cleaned.
• Using water or a pressure washer to wash down the exterior of the dumper with or without
detergent is generally all that is required.
• Avoid spraying electrical equipment with pressure washers.
• When cleaning the dumper it is preferable to use a biodegradable cleaner. Do not use
solvents or like products which can damage rubber and plastics.
(1) Safety Signs

All safety signs fitted to the machine must be legible, when cleaning only use mild soap and water
to clean the signs - DO NOT use solvent based cleaners because they may damage the safety
sign material. All safety signs MUST be replaced immediately they become damaged or
unreadable.
9.4 Battery Disposal

Refer to Section 12 - Storage, Decomissioning and Disposal.
9.5 Hydraulic Oil Under Pressure

Release any pressure in the hydraulic circuit before carrying out repairs to the hydraulic system
or components.
bWARNING
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. If skin is penetrated with Hydraulic Fluid, Get Immediate Medical Help. Fluid
injected into the skin must be surgically removed within a few hours by a doctor familiar with this
type of injury or gangrene will result.
To release pressure in the hydraulic system:- with the skip down and the engine stopped move
the control lever in all directions.
9.6 Skip Support
bDANGER
A skip support or other method of supporting the skip in the raised position MUST be fitted and
locked in position before working under a raised skip. Do not reach or work under a raised skip
unless a prop is fitted.
(1) To fit a Skip Support

Refer to Figure 9.1. A support is fitted and locked over the piston rod of the skip ram to prevent
the rod retracting. Refer to Figure 9.1.

9. Maintenance
COV00049
Figure 9.1 - Skip Support
PROCEDURE
1. Fully raise the skip.
2. Remove the support (1) from its storage position and place over the piston rod of the ram.
3. Fit the pin to the support and secure with the grip clip.
4. Carefully lower the skip until the weight is resting on the support.
9.7 Articulation Lock
bDANGER
The articulation lock must be fitted before working in the area of the centre pivot, failure to fit the
lock could cause a pinch point or trap that will result in death or serious injury.
(1) To Fit the Articulation Lock

Refer to Figure 9.2
2
1
3
COV00043
Figure 9.2 - Articulation Lock

1. Lock Bar
2. Pin
3. Grip Clip

9. Maintenance
PROCEDURE
1 To fit the lock bar remove the grip clip and pin from the bar.
2 Pivot the locking bar around until the holes in the bar are in line with the holes in rear
chassis bracket.
3 Re fit the pin through the holes and secure with the grip clip.
9.8 ROPS
Check for:-
• Worn, damaged or missing mountings. If there is excessive movement or rattling during
operation the ROPS mountings must be checked and replaced if necessary.
• Loose or missing nuts, bolts and washers. Missing items must be replaced with those of the
same grade/specification. Bolts and nuts should be tightened to the correct torque.
• Cracks in the ROPS and its mountings.
• Paint peeling and corrosion. If necessary take corrective action.
If the machine has rolled over or been involved in an accident in which the ROPS could have
been damaged the ROPS must be replaced.
If you have any doubts regarding the integrity of the ROPS and for replacement parts consult
your Mecalac dealer.
9.9 Floor Plate Removal

To gain access to the battery, hydrostatic transmission pump and various other components it
will be necessary to remove the floor plate - Figure 9.3 refers
.
COV00224
Figure 9.3 - Floor Plate Removal

1. Floor plate bolts

9. Maintenance
PROCEDURE
1. Open the engine cover.
2. Set battery isolator to OFF position.
3. Undo the 7 bolts and washers securing the floor plate.
4. Lift the floor plate clear of the machine.
9.10 Battery Removal
bDANGER
Battery Acid - Contact with battery acid can cause serious burns, blindness or even death.
Protective clothing, gloves and a face shield must be worn at all times when handling or working
on a battery.
Set battery isolator to OFF position. It will be necessary to remove the floor plate to gain access
to the battery - refer to para. 9-4.
To remove the battery refer to Figure 9.4.
1 2
COV00075
Figure 9.4 Battery Removal

1. Battery Clamp
2. Positive (+ve) Terminal
3. Negative (-ve) Terminal

9. Maintenance
PROCEDURE
1. Remove the protective covers from the battery terminals.
2. Disconnect the negative (-ve) cable from the battery.
3. Disconnect the positive (+ve) cable.
4. Undo the nuts and washers and remove the battery clamp.
5. Lift the battery clear of the machine.
With the battery removed clean battery terminals and cable connections. When the battery is
reconnected protect connections with grease or petroleum jelly before fitting the plastic terminal
covers.
9.11 Air Cleaner
(1) Daily Maintenance

To access the air cleaner lift the engine cover. Check the blockage indicator, Figure 9.5. If the
indicator is showing RED the air cleaner requires servicing. Check system for leaks.
NOTICE
Maximum protection against dust is only possible if the air cleaner is serviced at regular intervals.
Check the blockage indicator daily. In dusty conditions checks should be more frequent. If the
indicator shows RED clean or replace the filters immediately. Operating a machine with a
blocked filter can cause serious damage to the engine.
COV00061
Figure 9.5 Air Cleaner Blockage Indicator.

9. Maintenance
(2) Servicing
Refer to Figure 9.6 illustrating the major air cleaner components.
.
1
5
4
3
2
COV00019
Figure 9.6 - Air Cleaner

1. Sediment Cup.
2. Clamp
3. Blockage Indicator
4. Body
5. Secondary Element
6. Main Element
PROCEDURE
1. Clean the area around the air cleaner.
2. Loosen clamps holding the sediment cup to the air cleaner body and pull cup clear.
3. Remove the elements from the body.
4. Clean the main element by tapping gently on a firm object or by blowing gently with
compressed air from inside the element.
5. If the main element is damaged or severely contaminated it must be replaced.
6. DO NOT attempt to clean the secondary element; if contaminated it must be replaced.
7. Thoroughly clean the main body and sediment cup.
8. Re assemble the cleaner.
(3) Cleaning the Main Element

The main element should cleaned by tapping gently on a hard surface or by blowing gently from
the inside with compressed air line. Figure 9.7 refers.

9. Maintenance
COV00018
Figure 9.7 - Cleaning the Main Element
9.12 Engine Oil

Always refer to the engine manufacturers handbook, if available; when carrying out engine
maintenance. The engine oil must be changed after the first 50 hours operation and then every
200 hours thereafter.
(1) To Check the Level

A dipstick - Figure 9.8 for checking the engine oil level is accessible from within the engine
compartment.
COV00070
Figure 9.8 - Dipstick Location

1. Dipstick
The oil level should be between the MAX and MIN marks on the dipstick - Figure 9.?.

9. Maintenance
COV00033
Figure 9.9 - Dipstick MAX and MIN marks.

1. Maximum (MAX) Oil Level
2. Minimum (MIN) Oil Level
PROCEDURE
1. Open the engine cover.
2. Allow oil to settle for a few minutes.
3. Remove the dipstick, wipe clean with paper, check level and replace the dipstick.
4. If the oil level is below the MIN level oil must be added.
(2) To Add Oil.

Oil is added through the filler cap - Figure 9.10 accessible in the engine compartment. Refer to
the Lubrication Tables for the correct grade and quantity of oil.
COV00062
Figure 9.10. - Engine Oil Filler

9. Maintenance
PROCEDURE
1. Remove the engine oil filler cap.
2. Add clean, fresh oil of the correct grade to the engine.
3. While adding oil, check the level frequently to make sure it does not go over the MAX
level.
4. When the oil is up to the required level replace the filler cap.
5. Wipe up any spilt oil.
NOTICE
Do not overfill the engine. Too much engine oil may cause damage to the engine.
(3) To Drain the Engine Oil

When changing the engine oil the oil filter must be replaced. (Refer to the engine manufacturers
handbook). The engine must be warm when draining the oil.
PROCEDURE
1. Park the machine on firm, level ground, apply parking brake, place transmission in
neutral, remove the starter key, set the battery isolator to off and remove the battery
isolator key.
2. Place a suitable container under the machine and remove the drain plug and allow the old
oil to drain into the container.
3. When the oil has finished draining, replace the drain plug and securely tighten.
4. Replace engine oil filter.
5. Refill engine with the correct grade of oil.
6. Start the engine and check for any leaks.
9.13 Engine Coolant

The cooling system is pressurised to increase boiling point of the coolant and therefore extreme
caution must be taken when performing any maintenance on the cooling system when hot to
prevent scalding.
bWARNING
NEVER perform checks or maintenance on the cooling system when it is hot. NEVER remove
radiator cap when engine is hot - severe risk of scalding. NEVER remove radiator cap when the
engine is running. Antifreeze is TOXIC. If accidentally swallowed, medical advice must be
sought Immediately. Antifreeze is corrosive to the skin. If accidentally spilled on to skin, it must
be washed off immediately. Protective clothing and eye protection must be worn when handling
antifreeze.

9. Maintenance
(1) To Top Up the Cooling System

This operation must only be performed by topping-up the plastic expansion tank, Figure 9.11 to
maintain coolant level within the Full (Maximum) (2) and Add (Minimum) (3) marks on expansion
tank. The tank is accessible when the engine cover is open.
When topping-up the system, always check the water hoses for damage or wear and for any
obvious leaks.
Only fill the system via the radiator cap, after draining the system
.
COV00055
Figure 9.11 - Cooling System Expansion Tank

1. Filler Cap
2. Full Mark
3. Add Mark
NOTICE
Never over fill the expansion tank. Do not use anti leak additives in the cooling system. Never
run the engine without coolant in the system.
(2) Coolant
The coolant used to top up the cooling system must be a pre-mixed solution of antifreeze and
water in the correct ratio for the temperature range the machine is to be used in. See notes about
antifreeze in Antifreeze section.

9. Maintenance
(3) Radiator Cap

To gain access to the radiator cap, Figure 9.12; open the engine cover.
Make sure radiator cap has been replaced and tightened before closing engine cover.
Only use the radiator cap orifice to fill the system during major servicing when hoses have been
removed or after the system has been drained down. At all other times use the filler on the
expansion tank.
COV00056
Figure 9.12 - Radiator Cap
bWARNING
NEVER remove the radiator cap when the cooling system when it is hot - severe risk of scalding.
9.14 Hydraulic System
bWARNING
Damaged hydraulic components and hoses can cause serious injury. Do not use a machine if a
component or hose is damaged.
During ANY maintenance extreme care must be taken to make sure the cleanliness of the
hydraulic circuit is maintained. By observing strict cleanliness the machine will benefit from fewer
hydraulic failures through contamination.
• Always thoroughly clean machine before any hydraulic maintenance. Use paper roll, not rag,
to wipe parts.
• Release hydraulic pressure before working on the system.
• Always use fresh, clean hydraulic oil from a sealed container.
• Always make sure old gasket particles and excess sealing compound etc. do not enter the
system. If they do clean them out.
• Always make sure new parts and fittings are kept in sealed bags etc. and they are stored
away from any contamination.

9. Maintenance
• Always remove flaking paint from around the area being maintained. Inspect the inside of new
tanks for debris etc.
• Never fit new hoses if both ends of the hose have not been protected with plastic caps.
• Never fit new valves, pumps, motors, filters etc. if all the ports have not been protected with
plastic plugs.
• Never use dirty containers for oil storage.
• Never use dirty containers or funnels for filling hydraulic system.
• Never store hydraulic components on the floor, in areas where welding or grinding is done, in
a dirty environment etc.
A description of the hydraulics, and circuit diagrams are contained in Section 4 of this manual.
The hydraulic system components are maintenance free other than the suction strainer and
return line filter.
9.15 Hydraulic Tank
5
3
4 COV00081
Figure 9.13 Hydraulic Tank

1. Breather/Dipstick
2. Suction Filter
3. Drain Plug
4. Mounting Spacer (4 off)
5. Line from Return Filter
6. Line from Control Valve
7. Line from Transmission Pump

9. Maintenance
(1) To Check the Hydraulic Oil Level

Refer to Figure 9.14
COV00052
Figure 9.14- Checking Hydraulic Oil Level

1. Full (Max.) Mark
2. Low (Min.) Mark
PROCEDURE
1. Stop the engine and unscrew the dipstick/breather and remove from the tank.
2. Wipe all traces of oil from the dipstick with clean paper and refit the dipstick.
3. Remove the dipstick again and check the level of the oil.
4. Never allow the oil level to go below the minimum mark - Min. (2) or above the maximum
mark - Max (1).
5. Add the correct grade of oil as required.
6. Check the level and replace the filler breather.
(2) To Add Hydraulic Oil

Refer to Figure 9.13. Make sure a clean container and clean, new oil is used.
PROCEDURE
1. Unscrew the dipstick/breather.
2. Add oil as required.
3. Use the dipstick/breather to check the level.
4. Continue adding oil until it reaches the upper mark on the dipstick.
5. Replace the dipstick/breather.
6. Wipe up any spilt oil.

9. Maintenance
(3) to Drain the Hydraulic Tank

Make sure the hydraulic oil is warm not hot before draining. Refer to Figure 9.13.
PROCEDURE
1. Park the machine on firm level ground and apply the parking brake.
2. Place a suitable receptacle, of sufficient capacity, under the drain plug to catch the oil.
3. Remove the drain plug.
4. Remove the dipstick/breather to vent.
5. When the oil has finished draining, clean the drain plug and replace the sealing washer.
6. Refit the drain plug and tighten.
7. Refill the hydraulic tank with the correct grade and quantity of hydraulic oil.
(5) Suction Filter

When servicing this filter it is recommended the tank is removed and cleaned. Refer to Figure
9.14.
1
2
COV00082
Figure 9.14 - Suction Filter.

1. Hydraulic Tank
2. Suction Filter
3. Seal
PROCEDURE
1. Thoroughly clean the outside of the tank in the area around the suction filter.
2. Drain off the hydraulic oil from the tank.
3. Undo hose clip on suction hose and pull hose from suction filter.
4. Unscrew suction filter from tank.
5. Clean the suction filter mounting face on the tank.
6. Clean or replace the suction filter.
7. Refit the suction filter using a new seal and fully tighten.
8. Refit the suction hose and fully tighten the hose clip.

9. Maintenance
9.16 Hydraulic Tank Removal

Thoroughly clean the tank and surrounding area before removal. Refer to Figure 9.15.
4
3
2 COV00083
Figure 9.15. - Hydraulic Tank Removal

1. Suction Hose (Pump)
2. Spacers (4off)
3. Return Line from Filter
4. Return Line from Control Valve
5. Return Line from Transmission Pump
PROCEDURE
1. Drain off the hydraulic oil from the tank.
2. Undo hose clip securing the suction hose and pull the hose (1) from suction filter.
3. Remove the return hoses.
4. Remove the nuts and bolts securing the tank.Take care not to loose the spacers (2).
5. Lift the tank from the machine.
With the tank removed the inside should be thoroughly cleaned and flushed out. When refitting
the tank make sure the spacers are in position before tightening the bolts. After refitting the tank
refit and tighten all hoses fill with oil and check for leaks.
9.17 Transmission Pump

Refer to figure 9.16. The transmission pump has an integral filter and is flitted with a filter
blockage indicator. The indicator band is normally GREEN. If the blockage indicator band shows
RED the transmission pump filter must be changed.
Otherwise the filter must be changed at the suggested service intervals shown in the Lubrication
Schedule.

9. Maintenance
COV00088
Figure 9.16 - Transmission Pump

1. Blockage indicator
(1) To change the Transmission Pump Filter
COV00089
Figure 9.17. - Transmission Pump Filter

1. Filter Bowl
PROCEDURE
1. Remove the floor plate.
2. Drain the hydraulic oil.
3. Clean the area around the filter.
4. Unscrew the filter bowl.
5. Remove the old filter element.
6. Clean the inside of the bowl and fit a new element.
7. Refit the filter bowl.
8. Refill the system with clean fresh oil and test for leaks.

9. Maintenance
9.18 Hydraulic System Return Filter

Refer to figure 9.18 which shows a typical return line filter. The return filter is fitted with a blockage
indicator.The indicator band is normally GREEN. If the blockage indicator band shows RED the
return filter must be changed.
COV00085
Figure 9.18 - Typical Hydraulic System Return Filter

1. Blockage Indicator
(1) To Change the Filter
PROCEDURE
1. Remove the floor plate.
2. Drain the hydraulic oil.
3. Clean the area around the filter.
4. Unscrew the filter cartridge.
5. Clean the sealing face on the filter body and smear with grease.
6. Smear hydraulic oil onto the sealing ring fitted to the new filter.
7. Screw on the new filter cartridge and tighten using hand pressure only.
8. Refill the system with clean fresh oil and test for leaks.
9.19 Hydraulic Hoses

Examine all hydraulic hoses for wear, damage and ballooning. Replace hoses with those of the
same size, specification and pressure rating. Hydraulic hoses must be replaced by genuine
manufacturers parts available from your dealer. Do not attempt to repair hoses - they must be
replaced.

9. Maintenance
9.20 Fuel System
bDANGER
Avoid sparks, naked flames etc. when filling or maintaining the fuel system. Do not smoke when
filling the fuel tank or maintaining the fuel system. Do not leave the engine running when filling/
working on the fuel system.
(1) To Add Fuel

The indicator gauge, Figure 9.19; mounted on the tank will indicate the amount of fuel remaining
in the tank. The gauge markings indicate when the tank is Empty, half full or Full.
COV00053
Figure 9.19 - Fuel Tank

1. Level Gauge
2. Filler Cap
PROCEDURE
1. Remove the filler cap.
2. Add fuel until the gauge reaches the full mark.
3. Refit the filler cap.
4. Clean up any spilt fuel.
(2) Fuel Filter - Canister Type Element

The fuel filter, Figure 9.20, has a removable canister (1) which must be replaced. It is not a
serviceable item.

9. Maintenance
COV00059
Figure 9.20 - Fuel Filter.
PROCEDURE
1. Unscrew the filter canister.
2. Dispose of the filter canister in an environmentally safe way.
3. Smear the rubber ring on the new filter canister with grease.
4. Screw on the filter canister.
5. Hand tighten only - do not use grips etc.
(3) Fuel Filter - In Line

.Refer to Figure 9.21.The in line fuel filter (2) is located below the electric fuel pump (1). is not a
serviceable item and must be replaced. It is not possible to dismantle and clean the filter.
COV00060
Figure 9.21 - In Line Fuel Filter

1. Electric Fuel Pump
2. In Line Filter

9. Maintenance
PROCEDURE
1. Loosen the hose clips either side of the filter.
2. Pull the hoses off the filter; there may be some fuel spillage.
3. Discard the old filter.
4. Reconnect the hoses to the new filter.
5. Tighten the hose clips.
6 Clean up any spilt fuel.
9.21 Braking System
(1) Brake Arrangement

Oil immersed multi-plate brakes are fitted to the front axle only and are operated hydraulically.
The brake system is charged with mineral oil not conventional brake fluid. A mechanically
applied parking brake is incorporated.
NOTICE
The braking system uses mineral oil not conventional brake fluid. Only use mineral oil to top up
the brake reservoir. Never use conventional brake fluid. Never purge the brake system and refill
with brake fluid as this will damage rubber components in the brake system and may cause brake
failure.
(2) Maintenance
Maintenance on the braking system is limited. The fluid level in the reservoir on the master
cylinder should be checked daily.
The brakes adjust automatically for wear but over a period of time it will be necessary to replace
the friction discs and slave cylinder seals.
Check the pipe work and components for leaks or damage at regular intervals. When
components are replaced it will be necessary to bleed the system.
(a) Access to Master Cylinder
The master cylinder reservoir is located under the floor plate. The cover plate, Fig 9.22 is
unlocked with a removable key.

9. Maintenance
COV00040
Figure 9.22 - Cover Plate

(b) To Check the Fluid Level
Refer to Figure 9.23
COV00057
Figure 9.23 - Brake Reservoir

1. Filler Cap
2. Full Mark
PROCEDURE
1. Clean the area around the filler cap.
2. Unscrew the cap and check that the fluid is level with the “Full” mark on the reservoir.
3. Fill as necessary.
4. Replace the filler cap.
5. Clean up any spilt fluid.

9. Maintenance
(c) Parking Brake

The parking brake lever, Figure 9.24 is of the over centre type with a safety release lever
preventing the parking brake being released accidentally.
COV00080
Figure 9.24
1. Parking Brake Lever
2. Release Lever
(d) Parking Brake Test
With the parking brake adjusted correctly the engine should stall without movement of the
machine. The machine must not be used if it fails the parking brake test, it must be checked
immediately by a qualified engineer. Test as follows:-
PROCEDURE
1. Place the machine on level ground.
2. Make sure there is 20 metres (65 feet) of clear area in front of the machine.
3. Apply the parking brake.
4. Start the engine.
5. Select ‘Fast’ speed (‘Hare’ light comes on) lower switch LH side of dash.
6. Select ‘Forward’ top switch left hand side of dash.
7. Increase engine speed gradually up to maximum RPM for 2 - 4 seconds.
8. If the machine moves abort the test immediately and have the adjustment rechecked by
a qualified service engineer.
bWARNING
Do not use the machine until the parking brake is adjusted correctly and passes the above test
procedure. Make sure all personnel are clear of the area before performing the parking brake
test. Danger of the machine moving unexpectedly.

9. Maintenance
9.22 Axle Breathers

The axle breathers, Figure 9.27 should be checked regularly; refer to the Servicing Schedule. If
blocked the breather should be cleaned or replaced.
COV00086
Figure 9.27
1. Axle Breather
9.23 Front Axle

For servicing intervals refer to the Servicing Schedule in this book.
(1) To Check the Oil Level

Figure 9.28 illustrates the position of the level, fill and drain plugs.
3
2
COV00022
Figure 9.28. - Front Axle

1. Fill Plug
2. Level Plug
3. Drain Plug

9. Maintenance
PROCEDURE
Park the machine on firm, level ground.
Clean the dirt from around the plugs.
Remove the oil level plug - 2.
The oil should be level with the bottom of the hole.
To add oil, remove the filler plug - 1.
Add the correct grade of oil through the filler plug until it begins to discharge from the level
hole.
Re fit and tighten the level and filler plugs.
(2) To Change the Oil

To ease draining make sure the oil in the axles is warm.
PROCEDURE
1. Park the machine on firm, level ground.
2. Clean the dirt from around the plugs.
3. Place a suitable container under the drain plug
4. Remove the filler plug and drain plug and permit the oil to drain.
5. When oil has fully drained clean and refit the drain plug.
6. Remove the level plug.
7. Add the correct grade of oil through the filler plug until it begins to discharge from the level
hole.
8. Re fit and tighten the level and filler plugs.
9.24 Rear Axle/Transfer Box

The rear axle and transfer box are a combined unit illustrated in Figure 9.24. For servicing
intervals refer to the Servicing Schedule in this book
.
1
3 2
4
5
COV00023
Figure 9.24 - Rear Axle/Transfer Box

9. Maintenance
1. Axle Fill Plug

2. Axle Level Plug
3. Axle Drain Plug
4. Transfer Box Level/Fill Plug
5. Transfer Box Drain Plug
(1) To Check the Oil Level in the Axle
PROCEDURE
3. Remove the oil level plug - 2.
4. The oil should be level with the bottom of the hole.
5. To add oil, remove the filler plug - 1.
6. Add the correct grade of oil through the filler plug until it begins to discharge from the level
hole.
(2) To Change the Oil in the Axle
PROCEDURE
3. Place a suitable container under the drain plug - 3.
4. Remove the filler plug - 1 and drain plug - 3 and permit the oil to drain.
5. When oil has fully drained clean and refit the drain plug.
6. Remove the level plug.
7. Add the correct grade of oil through the filler hole until it begins to discharge from the level
hole.
(3) To Check the Oil Level in the Transfer Box
PROCEDURE
1. Make sure the oil is warm not hot.
2. Park the machine on firm level ground, stop the engine and remove the start key.
3. Clean any dirt from around the level/fill plug - 4
4. Remove the plug -the oil should be level with the level/fill plug hole.
5. If necessary add oil of the correct specification until it just starts to flow from the hole.
6. Refit the plug and tighten.
7. Clean up any spilt oil.

9. Maintenance
(4) To Change the Oil in the Transfer Box
PROCEDURE
1. Make sure the oil is warm not hot.
2. Park the machine on firm level ground, stop the engine and remove the start key.
3. Clean any dirt from around the drain plug -5.
4. Place a suitable container under the drain plug.
5. Remove drain plug and allow the oil to drain.
6. Remove the filler/level plug to aid draining.
7. Refit and tighten drain plug.
8. Add the correct grade of oil through the filler hole until it begins to discharge from the hole.
9. Refit filler level plug and tighten.
9.25 Axle Bolts

The tightness of the axle bolts; Figure 9.25. must be checked every 800 hours or Annually which
ever comes first.
COV00054
Figure 9.5. - Axle Location Bolts
9.26 Centre Pivot
(1) Pivot Lock Screws

The pivot pin locking screws, Figure 9.26 (1); should be checked periodically and if necessary
re-tightened to a torque of 45Nm (33 lbf/ft).

9. Maintenance
COV00046
Figure 9.26.- Pivot Lock Screws
(2) Protective Caps

The protective caps fitted over the centre pivot bearings must be checked regularly. If split or
otherwise damaged they must be replaced to prevent the ingress of dirt or moisture into the
bearings.
COV00078
Figure 9.27. - Protective Caps

1. Protective Cap
(3) Lubrication
Lubrication of the centre pivot is very important and must be carried out every 50 hours. - See
Service Schedule.

9. Maintenance
9.27 Skip
In the lowered (travelling) position the skip rests on two support pads, Figure 9.28; so that the
weight is not supported by the ram.
The maximum clearance between the skip; in the lowered position, and the chassis must no
greater than 10 mm. If necessary shims must be added to or removed from the support pads to
obtain this clearance.
COV00079
Figure 9.28 - Skip Support Pads
9.28 Wheels and Tyres

Check the tyres regularly for damage by cuts and embedded particles, i.e. nails, steel, glass etc.
A valve; Figure 9.29., is fitted to inflate and check the pressure in the tyres. The pressures should
be checked and adjusted if necessary weekly using valve (1).
COV00021
Figure 9.29 - Tyre Inflation Valve

1. Tyre Inflation Valve

9. Maintenance
9.29 Maintenance Schedule

The following service schedules are for guidance only. Under extreme operating conditions the service schedules should be
adjusted accordingly to allow for the local working environment.
Before carrying out any service or maintenance work ensure ALL safety precautions have been taken.
Always follow the instructions given in the engine manufacturers handbook when servicing, adjusting and especially when
starting and stopping the engine.
ALL Faults MUST be Reported Immediately and Corrected BEFORE the Machine is Used
Check tyre condition and pressures.
Check ROPS for damage etc. Report ALL faults immediately.
Check seat belt.
Check the air cleaner blockage indicator. Squeeze the air cleaner dust ejector.
Remove air cleaner and clean in dusty environments.
Check fuel tank level - NEVER allow the fuel tank to empty. Fill at the end of each shift.
Check engine oil level and top up as necessary.
Check hydraulic oil level.
10 Hours
Check all warning lights and gauges are working correctly.
Check engine coolant level - expansion tank (engine cold).
Check brake fluid reservoir level.
Check operator platform and steps are clean and free from damage and obstructions.
Check start inhibitors are functioning correctly.
Check skip prop is present and functional.
Check articulation lock is present and functional.
Visually check machine for fluid leaks, damage, missing parts, unreadable safety signs etc.
As for 10 hours and including :-

Lubricate the centre pivot.
Lubricate all other grease nipples including prop shaft UJ’s and slip joints - see lubrication chart.
Oil all control pivots, e.g. throttle etc.
Check handbrake adjustment.
50 Hours
Check wheel nut torque.
Check, clean and grease battery connections.
Check for air leaks on the air inlet/filter system.
Remove the end cap on the cyclone type air cleaner and inspect elements. Clean or replace as necessary.
Replace any damaged safety signs.

Drain engine and refill with fresh, clean oil.
Replace engine oil filter.
Replace inline fuel filter.
200 Hours
Check engine cooling fan and alternator belt for damage and tension - adjust/replace if necessary.
Check front and rear axle/transfer box oil levels - top up as necessary.
Check tightness of centre pivot lock screws.
Check hoses for chaffing, adjust as necessary.

Drain and clean fuel tank.
Replace fuel filter element.
Change hydraulic filter(s).
400 Hours Drain hydraulic tank and clean hydraulic suction strainer. Renew return line filter. Refill hydraulic system with
clean, fresh oil.
Drain front and rear axles/transfer box and refill with clean, fresh oil.
Remove and clean or replace axle breathers.
Check engine coolant antifreeze / water ratio - especially in sub zero conditions.
600 Hours As for 200 hour service

Drain and bleed brake system and refill with new mineral oil.
800 Hours Check axle location bolts.
Check engine valve clearances - adjust as necessary.
Check centre pivot pin nut torque setting.
As for 800 hours and including:-

1600 Hours Remove and check engine injector nozzles - adjust pressure or replace as necessary.
Drain and replace engine coolant.
Only Perform the Applicable Service Checks Above

Thoroughly Clean the Machine BEFORE Performing ANY Service or Maintenance Tasks

9. Maintenance
9.30 Lubrication Schedule Forward Tip
A P B A
R R
D
C
C
M
K
J
G F
Figure 9.30 - Lubrication Diagram - Forward Tip Skip

9. Maintenance
Service Hours
Item Component Lubricant International Specification

Check
Change
or Apply
A Skip pivot pins
B Skip Ram
Multi Purpose Grease EP2 Lithium Grease - Gr Li, NLGI2 50 --
C Steering Ram Pins
D Prop Shaft
E Hydraulic Oil Tank Shell Tellus S2 V46 High VI Hydraulic Oil HV ISO 46 10 400
BASF Glysantin G48 / Water

F Radiator Extended Life Antifreeze 10 Autumn
Mixture 50%
API: CH-4, CG-4, CF-4, CF

G Engine Sump Shell Rimula R3X 15W/40 ACEA: ES, E3 10 200
SAE 15W/40
H Fuel Tank Diesel DERV to EN590 10 400
J Rear Axle Shell Spirax S4 TXM - 200 400
K Transfer Box Shell Spirax S4 CX 10W - 200 400
L Brake Reservoir Shell Tellus S2 V46 High VI Hydraulic Oil HV ISO VG 46 10 800
M Pedals Multi Purpose Grease EP2 Lithium Grease - Gr Li, NLGI2 50 -
N Centre Pivot Starplex All Purpose Grease EP2 Lithium Complex Grease Gr Li, NLGI 2 50 -
P Front Axle Shell Spirax S4 TXM - 200 400
Parking Brake
R Multi Purpose Grease EP2 Lithium Grease - Gr Li, NLGI2 50 -
Lever Pivots

9. Maintenance
9.31 Lubrication Schedule - Swing Skip
A B U A
C C
S S
B
D
C
C
R
T
P
M
D
L
E N
J
G
Figure 9.31 Lubrication Diagram - Swing Skip

9. Maintenance
Service Hours
Item Component Lubricant International Specification

Check
Change
or Apply
A Skip pivot pins
B Skip Ram
C Slew Ram Pins Multi Purpose Grease EP2 Lithium Grease - Gr Li, NLGI2 50 -
D Steering Ram Pins
E Prop Shaft
F Hydraulic Oil Tank Shell Tellus S2 V46 High VI Hydraulic Oil HV ISO 46 10 400
BASF Glysatin G48 / Water

G Radiator Extended Life Antifreeze 10 Autumn
Mixture 50%
API: CH-4, CG-4, CF-4, CF

H Engine Sump Shell Rimula R3X 15W/40 ACEA: ES, E3 10 200
SAE 15W/40
J Fuel Tank Diesel DERV to EN590 ASTM D975 10 400
K Rear Axle Shell Donax S4 TXM - 200 400
L Transfer Box Shell Spirax S4 CX 10W - 200 400
M Brake Reservoir Shell Tellus S2 V46 High VI Hydraulic Oil HV ISO VG 46 10 800
N Pedals Multi Purpose Grease EP2 Lithium Grease - Gr Li, NLGI2 50 -
P Centre Pivot Starplex All Purpose Grease EP2 Lithium Complex Grease Gr Li, NLGI 2 50 -
R Swing Turn Table Multi Purpose Grease EP2 Lithium Grease - Gr Li, NLGI2 50 -
S Front Axle Shell Donax S4 TXM API GL4 M1135 200 400
Parking Brake
T Multi Purpose Grease EP2 Lithium Grease - Gr Li, NLGI2 50 -
Lever Pivots

10. Troubleshooting
10. Troubleshooting
10.1 General Troubleshooting
(1) Engine will not start
Check fuel level.
Check electrical supply (see Electrical Troubleshooting).
Incorrect type or grade of fuel.
(2) “Low” engine oil pressure light comes on

Low engine oil level.
Consult dealer before using the machine.
(3) “High” coolant temperature light comes on

Check if fan belt is loose or missing.
Check coolant level on header tank (Do NOT add coolant until system is cold).
(4)Loss of coolant
Loose hose clips
Split coolant hose.
Radiator leaking.
10.2 Electrical Troubleshooting

(1) Circuit breaker keeps “tripping out”.
Check wiring for damage and short circuits.
Check beacon socket (if the rubber cover is split or fitted incorrectly water can enter).
(2) System Dead

Check battery isolator is set to “ON”.
Check battery connections.
Check circuit breaker has not “tripped”.
(3) Charge warning light remains On with engine running

Check if fan belt is loose or missing.
(4) Lights and direction indicators do not work

Check circuit breaker has not “tripped”.
Check if bulb has blown.
TA3H, TA3SH &TA3.5SH Page 10 - 1

10. Troubleshooting
10.3 Hydraulic Troubleshooting

(1) No Pressure
Check if sufficient oil in tank.
(2) Machine will not steer

Check steering lock is NOT fitted.
Check steering ram hoses for leaks.
(3) Skip will not tip or rotate

Check hoses for leaks.

11. Recovery
11. Recovery
11.1 Towing
bCAUTION
With the engine dead the hydraulic system will not function, the steering will still operate but
under these circumstances steering wheel loads are high and the dumper must only be towed at
very slow speeds.
NOTICE
The machine may be towed at a maximum speed of 2km/h (1.2 mph) for a maximum distance of
1 km (0.6 miles). Exceeding this speed or distance may damage the pump, motor and hydraulic
system. Before the machine can be towed it is necessary to set the transmission pump to
“freewheel” mode. For instructions on this procedure refer to Section 8 - Emergency Operating
Procedures.
The machine may be towed for short distances; see notice above, by attaching a suitable strap,
chain or rope to the rear towing eye of the machine or either or both of the tie down and recovery
eyes at the front of the machine. Take care if placing ropes etc. around the front axle as there is
a risk of damaging or deforming brake pipes or other components.
11.2 Lifting with a Crane

Refer to section 5 - Transportation for details of lifting the machine with a crane. It is important
that the articulation lock is fitted before lifting operations commence.

11. Recovery

12. Storage, Decomissioning & Disposal
12 Storage, Decomissioning & Disposal

12.1 Long Term Storage
The machine must be stored in a dry environment protected from the elements and on a hard
standing. Any contaminated Water / Fluids / Oils removed from the machine must be disposed
of legally.
12.2 Decomissioning
Before placing the machine into storage:-
• Thoroughly wash down the exterior of the machine and remove any build up of dirt etc.
• Repair all damaged paint work o prevent further corrosion.
• Grease all greasing points.
• Start and warm up the engine. Drain the engine oil and refill with clean fresh oil. Refer to the
engine manufacturers handbook for further information on prolonged engine storage with
regards to anti corrosion oils and fluids.
• Check hydraulic oil level and top up as required.
• Drain and refill cooling system with water/antifreeze mixture of the correct ratio.
• Fill the diesel tank to prevent corrosion of the tank walls.
• Store the machine on solid level ground which is not liable to flooding, standing water or
airborne contamination.
• Chock the wheels securely to prevent the dumper moving.
• Smear exposed metal parts with grease.
• Remove the battery, store in a safe place and keep fully charged.
• Seal off the air intake opening on the air cleaner and the exhaust opening.
• Leave the parking brake in the OFF position.
12.3 Recomissioning
Before putting the machine back into use the following operations must be carried out:-
• Clean grease or other protective film from piston rods and other exposed metal parts.
• Remove seals or covers from the air cleaner inlet and exhaust pipe.
• Check the condition of the air filter elements and replace if necessary.
• Thoroughly clean the machine.
• Make sure the battery has remained fully charged and re-connect to the machine.
• Carry out all measures for putting the engine back into use described in the engine
manufacturers manual.
• Check all other fluid levels.

12. Storage, Decomissioning & Disposal
• Lubricate machine in accordance with lubrication diagram
• Examine tyres and inflate to correct pressure.
(a) If stored for more than a period of 6 months:-

• Replace hydraulic filters.
• Examine hydraulic oil for degradation and replace if necessary.
• Drain and replace oils in transfer box and axles.
12.4 Disposal
At the end of its life the machine must be disassembled by a competent person using safe
working practices, wearing the appropriate Personal Protective Equipment and working in
accordance with local regulations.
The appropriate lifting equipment, chocks and stands must be used to maintain a stable machine
as components are removed and the machines centre of mass changes.
Care must be taken when dealing with flammable liquids and the machine parts that contained
those liquids. Any process that could ignite flammable materials must not be used on
components that have contained flammable liquids in them or have residual flammable liquids
on them.
Fire extinguishers must be readily available if cutting/welding equipment is so used.
Fluids must be drained off into suitable containers and if possible recycled or otherwise disposed
of in an environmentally friendly way in accordance with local regulations.
Where possible recyclable materials must be separated out and processed in accordance with
local regulations using an authorised agent.
12.5 Disposal of Used Batteries

When the battery reaches the end of its usual life it must be removed from the machine and
recycled in an approved way in accordance with local environmental regulations.
This service is usually operated by battery vendors.
Machine users that cannot find a suitable battery recycling facility should contact Mecalac for
assistance.

13. Glossary
13 Glossary of Terms
ANSI - American National Standards Institute.
Articulation Lock - Device preventing chassis elements moving during maintenance, transport
etc.
Battery Isolator - Device to shut of electrical supply from the battery.
Chock - Device placed in front of and behind wheels to prevent movement.
Hour Meter - An instrument that records and displays the total number of hours the engine has
been running.
Hydrostatic Drive - Method of transfering engine power to the front and rear axles using a
hydraulic pump and motor.
ISO - International Standards Organisation
Linch Pin - Pin with spring loaded retaining clip.
Orbitrol - Hydrostatic steering unit - a valve controlled by the machines steering wheel that
meters oil to the steering ram to turn the machine to the left or right.
Parking Brake - Mechanical device to prevent machine moving when not in use.
R Clip - A spring steel clip inserted through a hole in a pin to retain the pin in place.
ROPS - Roll Over Protective Structure - roll over bar.
Skip - Load carrying body.
Skip Prop - Mechanical device supporting a raised skip to prevent it lowering should the
hydraulic system fail.
Slew - To rotate either side of the center line of the machine.
Slew Ring -Turntable to enable skip to rotate.
Swing Skip - Skip that can be rotated either side of the machine to discharge the load.
Transfer Box - Device to enable front and rear axles to be driven by the engine.
VIN Plate - Plate fixed to the machine recording the serial number and other identifying
information.
TA3H, TA3SH & TA3.5SH Page 13 -1

13. Glossary
Page 13 -2 TA3H, TA3SH & TA3.5SH

Appendices
Appendix 1 - Electrical Diagrams
TA3H, TA3SH & TA3.5SH Appendices - 1

8005-0844-A
N65
NU44
N65 W32
Appendices - 2
NR32
Appendices
W32 W32
15 A 30A
15
2
NW44 NU44
3 A 600 V
DIODA
YB32
1-amperske 400-voltne diode
W28 R28
W32 GY32
14
30 GU32
18
50a R2 BY32
15/54 19 17
93
87 GY32
01 23
86
30
R1 R4
R R Y R Y R
30 77
87a
30 WR44 85
P
NR32
NW44 NY32
9
BW32
1
6
5
WN32 YN32 YR32 GU32

19
17
Electrical Diagram 1
WR44
W32 W32 W32
N65
12
BW32
10
13
11
16
1
7
30
POVLECI
3
4
ZADRŽI R1
20
23
87
2
WR32
B32
B65 B32
YR32
WR32
MOŽNOST Z VODNO GLADINO
0 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52
M McD 27-08-07 1 OD 3 VEZALNA SHEMA TA2H – TA3H

Appendices
1 Warning Light - Fast Speed Selected Colour Codes
2 Audible Warning RD - Red
3 Switch - Low Engine Coolant Level WH - White
4 Switch - Engent Coolant Temperature YE - Yellow
5 Warning Light - Engine Coolant Temperature GN - Green
6 Warning Light - Cold Start BU - Blue
7 Switch - Engine Oil Pressure GY - Grey
8 Warning Light - Battery Charge OR - Orange
9 Warning Light - Engine Oil Pressure BK - Black
10 Solenoid - Run/Stop PU - Purple
11 Hour Meter PK - Pink
12 Alternator BN - Brown
13 Starter Motor
14 Switch - Engine Key Start
15 Circuit Breakers
16 Solenoid - Starter
17 Battery Isolator
18 Battery - 12v
19 Warning Light - parking Brake
20 Switch - Parking Brake

8005-0844-B
N65
NU44 NU44
Appendices - 4
W32 W32
NR32
Appendices
N65 W32 WR32 W32 W32 W32

WP32 WP32 W32
A
L
30
5
1
8
85 86
C
B
50
87 WB32
15
11
12
WG32 PB32 PW32 PG32 WO32 Y32 W32
RY65
13
10
+
2
Electrical Diagram 2
B32
16
9
14
6
4
86 7 86 86 YR32
+
+
30
R4 R2 R3 R3
-
-
47 19 102 96
85 87
85 85
B32 B32
YR32
WR32
54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106
M McD 27-08-07 2 OD 3 VEZALNA SHEMA TA2H – TA3H

Appendices
1 Switch - Speed Colour Codes
A = Slow RD - Red
B = Fast WH - White
2 Solenoid - Fast Speed YE - Yellow
3 Inhibitor Switch - Seat GN - Green
4 Reverse Alarm (Optional) BU - Blue
5 Switch - Direction GY - Grey
A = Forward OR - Orange
B = Neutral BK - Black
C = Reverse PU - Purple
6 Solenoid - Drive - Reverse PK - Pink
7 Solenoid - Drive - Forward BN - Brown
8 Horn
9 Horn Button
10 Fuel Pump
11 Fuse 3A (In Engine Compartment)
12 Fuse 10A
13 Switch - Beacon
14 Beacon
15 Engine Glow Plug Timer (In Engine Compartment)
16 Engine Glow Plugs

8005-0844-C
BN/BU44 BK32
Appendices - 6
WH32
GN/PU32 BU/BN32
Appendices
49 30b 31
BN/BU44 GN/PU32
L
0 1
A
P
Y R
B
1
10
11
87
R5
12
C
136 15 30 L R 49a 58
13
30 WH32
RD32 BU/RD32 GN/PU32 GN/BN32 RD32 GN/WH32

BN/BU32 GN/RD32
GN/BN32
A
2
B
C
RD32 RD32 RD32 RD32 RD32 RD32 GN/PU32 GN/PU32 BK32 BU/RD32 BU/RD28 BU/RD28 BK32
GN/RD32 GN/WH32 GN/RD32 GN/WH32
9
8
7
6
5
4
3
86
R5
Electrical Diagram 3 - Optional Highway Light

W W R R W W R R W W A A A A
139
85
108 110 112 114 116 118 120 122 124 126 128 130 132 134 136 138 140 142 144 146 148 150 152 154 156 158 160
3 OF 3 WIRING DIAGRAM TA2H - TA3H

Appendices
1 Hazard Warning Light Switch Colour Codes
2 Direction Indicator Switch RD - Red
A - Left Turn WH - White
B - Off YE - Yellow
C - Right Turn GN - Green
3 Direction Indicator Lights - Rear BU - Blue
4 Direction Indicator Lights - Front GY - Grey
5 Head Lights OR - Orange
6 Brake Lights BK - Black
7 Registration Plate Lights PU - Purple
8 Side Lights - Rear PK - Pink
9 Side Lights - Front BN - Brown
10 Light Switch
A - Off
B - Side Lights
C - Head Lights
11 Brake Light Switch
12 Flasher Unit
13 Warning Light - Direction Indicators

Appendices
Appendices - 8 TA3H, TA3SH & TA3.5SH

Appendices
Appendix 2 - Hydraulic Diagrams

11
12
13
Appendices - 10
Appendices
1
T R
P L
R T
T A1 B1 P
SD5/1
2
L P
210bar L
Boost Pressure
25 bar
T1 b a
420bar
R T2 Ps Fa MB
B
U B
10
Hydraulic Diagram - TA3H
6.1cc/rev
9
A G T
X1 X2 G MH S MA
420bar
8
7
6
5
4

Appendices
1 Hydraulic Cylinder - Skip Tip

2 Control Valve - Skip Tip - SD5/1
3 Hydraulic Motor - A6VM80
4 Hydraulic Pump - A4VG40
5 Strainer - 100 micron
6 Hydraulic Tank
7 Filter - 10 microns - 1 bar
8 Oil Cooler
9 Engine - Kubota V2203-M -32.4kW @ 2800 rpm
10 Auxillary Pump 11.2cc/rev
11 View on Steering Unit Ports - T = Tank, R = Right, P = Pressure, L = Left
12 Hydraulic Cylinder - Steering System
13 Steering Unit - Orbitrol OSPB200 ON

12
13
14
11
Appendices - 12
Appendices
5 bar-1mm
T R
P L
5 bar-1mm
1
R T
T A2 B2 A1 B1 P
L P
2
210bar L
Boost Pressure
25 bar
T1 b a
420bar
R T2 Ps Fa MB
B
U B
10
Hydraulic Diagram - TA3SH & TA3.5SH
6.1cc/rev
9
3
A G T
X1 X2 G MH S MA
420bar
8
7
6
5
4

Appendices
1 Hydraulic Cylinder - Skip Tip

2 Control Valve - Skip Tip/Rotate - SD5/1
3 Hydraulic Motor - A6VM80
4 Hydraulic Pump - A4VG40
5 Strainer - 100 micron
6 Hydraulic Tank
7 Filter - 10 microns - 1 bar
8 Oil Cooler
9 Engine - Kubota V2203-M -32.4kW @ 2800 rpm
10 Auxillary Pump 11.2cc/rev
11 View on Steering Unit Ports - T = Tank, R = Right, P = Pressure, L = Left
12 Hydraulic Cylinder - Steering System
13 Steering Unit - Orbitrol OSPB200 ON
14 Hydraulic Cylinders - Skip Rotate

Appendices
Appendices - 14 TA3H, TA3SH & TA3.5SH

STANDARD LIMITED NEW PRODUCT WARRANTY - CONSTRUCTION
Mecalac Construction Equipment UK Limited (“Mecalac Construction”), warrant the new Products manufactured or sold by it, to be free, under normal use and service, of any defects in
manufacture or materials for the period of 12 months from (a) delivery to, and placement into service by the first user (including as a demonstrator) or (b) delivery to the first retail purchaser, or
(c) will activate 6 months from delivery of the machine to the dealer regardless of use, whichever occurs first; provided that Mecalac Construction receives written notice of the defect within
thirty (30) days of its discovery and Buyer establishes that (i) the equipment has been maintained and operated within the limits of rated and normal usage and (ii) the defect did not result in any
manner from the intentional or negligent action or inaction by Buyer, its agents or employees. If requested by Mecalac Construction, Buyer must return the defective equipment to an
authorized distributor of the Products (“Distributor”) and defective parts to Mecalac Construction, and if Buyer cannot establish that conditions (i) and (ii) above have been met, then this
warranty shall not cover the alleged defect. The term “Products” shall include only the following equipment manufactured by the following Mecalac Construction: Tractor loader backhoes, site
dumpers, compaction equipment, rollers
The obligation and liability of Mecalac Construction under this warranty is expressly limited to, at Mecalac Construction’s sole option, repairing or replacing, with new or remanufactured parts or
components, any part, which appears, upon inspection by Mecalac Construction that manufactured or sold the equipment, to have been defective in manufacture or materials. Such parts shall
be provided at no cost to the owner, FCA Mecalac Construction’s parts facility from which the parts were purchased. This warranty shall be null and void if parts (including wear parts) other
than genuine OEM Mecalac Construction parts are used in the equipment. No warranty shall cover any item on which serial numbers have been altered, defaced or removed. In addition, the
foregoing warranty shall apply to powertrain and major structural components only on site dumpers, rollers and tractor loader backhoes, for a period of 24 months or 2,500 hours, whichever
comes first.
BHL:
Powertrain – Engine, gearbox, axles, prop shaft (not inc U/J’s & retaining hardware)
Structures – Chassis, ROP’s/cab frame, loader arm, boom, dipper, mast casting
Dumper:
Powertrain – Engine, gearbox, dropbox , axles, prop shaft (not inc U/J’s & retaining hardware)
Structures – Chassis, ROP’s, seat support, cross-members/rear panel
Roller: TV
Powertrain – Engine, drive motor, vib motor, belt drive
Structures – Frame/Chassis, seat support, cross-members/rear panel, drum legs
Roller : MBR
Powertrain – Engine, Transmission Unit
Structure - Bedplate/chassis
Normal maintenance, adjustments, or maintenance/wear parts are not covered by this warranty and are the sole maintenance responsibility of Buyer.
No employee or representative is authorized to modify this warranty unless such modification is made in writing and signed by an authorized officer of Mecalac Construction sought to be bound
by such modification. The obligations of Mecalac Construction under this warranty shall not include duty, taxes, environmental fees, including without limitation disposal or handling of tires,
batteries, petrochemicals, or any other charges whatsoever, or any liability for indirect, incidental, or consequential damages. Improper maintenance, improper use, abuse, improper storage,
operation beyond rated capacity, operation after discovery of defective or worn parts, or alteration or repair of the equipment by persons not authorized by Mecalac Construction shall render
this warranty null and void.
Mecalac Construction reserves the right to inspect the installation of its respective Products and review maintenance procedures to determine if the failure was due to improper maintenance,
improper use, abuse, improper storage, operation beyond rated capacity, operation after discovery of defective or worn parts, or alteration or repair of the equipment by persons not authorized
by Mecalac Construction. Mecalac Construction reserves the right to make improvements or changes to its Products without incurring any obligation to make such changes or modifications to
Products previously sold.
Parts Warranty: Mecalac Construction warrant the parts ordered from their respective Parts Departments to be free of defect in manufacture or materials for a period of 12 months from date
of retail sale to the owner / user. Parts fitted during an equipment warranty repair will take on the remaining equipment warranty.
TRANSFERABILITY OF WARRANTY: The unexpired portion of this warranty may be transferred, provided that (i) the warranty has not been voided or breached by the transfer or prior to
transfer, (ii) Mecalac Construction has received warranty registration for the relevant Product and (iii) the transferee completes and returns to the appropriate Mecalac Construction the
appropriate warranty transfer documentation which shall be provided on request. Contact your local Distributor for additional details.
THIS WARRANTY IS EXPRESSLY IN LIEU OF AND EXCLUDES ALL OTHER WARRANTIES, EXPRESS OR IMPLIED (INCLUDING THE WARRANTIES OF MERCHANTABILITY AND
FITNESS FOR A PARTICULAR PURPOSE) AND ALL OTHER OBLIGATIONS OR LIABILITY ON THE PART OF MECALAC CONSTRUCTION. THERE ARE NO WARRANTIES THAT
EXTEND BEYOND THE LIMITED WARRANTY CONTAINED HEREIN.
ITEMS NOT COVERED BY THIS WARRANTY
The following items are NOT covered under this Warranty (the following list is not exhaustive):
1. Non-Distributor Sales: Items sold by any individual, corporation, partnership or any other organization or legal entity that is not an authorized Distributor.
2. Replacement of assemblies: Mecalac Construction has the option to repair or replace any defective part or assembly. It is the policy of Mecalac Construction to refuse claims for the
replacement of a complete assembly that is field repairable by the replacement or repair of defective part(s) within the assembly.
3. Normal Operational Maintenance Services and Wear Parts: Maintenance services and wear parts are excluded from warranty claims. Maintenance services not covered include, but are
not limited to, such items as: tune-up, lubrication, fuel or hydraulic system cleaning, brake inspection or adjustment, or the replacement of any service items such as filters or brake linings made
in connection with normal maintenance services.
4. Transportation: Any damage caused by carrier handling is a transportation claim and should be filed immediately with the respective carrier.
5. Deterioration: Repairs, work required or parts exposed as the result of age, storage, weathering, lack of use, demonstration use, or for transportation of corrosive chemicals.
6. Secondary Failures: Should the Buyer continue to operate a machine after it has been noted that a failure has occurred, Mecalac Construction will not be responsible under the warranty for
resultant damage to other parts due to that continued operation.
7. Workmanship of Others: Mecalac Construction does not accept responsibility for improper installation or labor costs of personnel other than authorized Distributor personnel.
8. Stop and Go Warranty: Mecalac Construction does not recognize “Stop and Go” warranties; after the period of warranty commences, it shall not be tolled for any reason. No action by
either party shall operate to extend or revive this limited warranty without the prior written consent of Seller
9. Incidental or Consequential Damage: LIMITATIONS ON LIABILITY: NOTWITHSTANDING ANYTHING TO THE CONTRARY CONTAINED IN THIS WARRANTY, MECALAC
CONSTRUCTION SHALL NOT BE LIABLE FOR ANY, AND SPECIFICALLY DISCLAIMS ALL, INDIRECT, CONSEQUENTIAL, INCIDENTAL AND OTHER DAMAGES OR LOSSES OF
ANY KIND (INCLUDING, BUT NOT LIMITED TO, LOST PROFITS, LOSS OF PRODUCTION, LOSS OF USE, DOWNTIME OR HIRE CHARGES, INCREASED OVERHEAD, LOSS OF
BUSINESS OPPORTUNITY, DELAYS IN PRODUCTION, COSTS OF REPLACEMENT COMPONENTS, PENALTIES OF ANY KIND, FAILURE OF EQUIPMENT TO COMPLY WITH ANY
APPLICABLE LAWS AND INCREASED COSTS OF OPERATION) THAT MAY ARISE FROM ANY BREACH OF THIS WARRANTY, WHETHER OR NOT CAUSED DIRECTLY OR
INDIRECTLY BY ANY NEGLIGENCE OF MECALAC CONSTRUCTION. Nothing in this paragraph, however, shall operate to exclude Mecalac Construction’s liability for death or
personal injury. Buyer’s sole remedy for breach of this warranty shall be limited to (at the sole option of Mecalac Construction) repair or replacement of the defective part.
10. Labor: Mecalac Construction shall not be responsible for related travel expenses such as meals and lodging; overtime or premium labor rates.
Mecalac Construction neither assumes nor authorizes any other person to assume for Mecalac Construction any other liability in connection with the sale of any Mecalac Construction’s
equipment. This warranty shall not apply to any Mecalac Construction equipment or any part thereof which has been subject to misuse, alteration, abuse, negligence, accident, acts of God or
sabotage. No action by any party shall operate to extend or revive this limited warranty without the prior written consent of Mecalac Construction . The aggregate liability of Mecalac
Construction shall in no event exceed the purchase price of the equipment, provided that nothing herein shall exclude liability of Mecalac Construction for death or personal injury.
MECALAC CONSTRUCTION EQUIPMENT UK LIMITED

Central Blvd – ProLogis Park
Coventry CV6 4BX
England
EUROPE (Rev March 2017)
Warranty Certificate Warranty - 1

Warranty - 2 Warranty Certificate
Mecalac #mecalac Mecalac
MECALAC Construction Equipment UK Ltd - Central Boulevard, ProLogis Park - Coventry, CV6 4BX, UK - Tel. +44 (0)2476 339 400
www.mecalac.com

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Site Dumper

TA3H, TA3SH & TA3.5SH

Tel: +44 (0)24 7633 9400

TA3H, TA3SH & TA3.5SH Table of Contents - 1

4.5 Chassis .......................................................................................4.4

Table of Contents - 2 TA3H, TA3SH & TA3.5SH

9.6 Skip Support ............................................................................... 9.2

TA3H, TA3SH & TA3.5SH Table of Contents - 3

Table of Contents - 4 TA3H, TA3SH & TA3.5SH

1.2 Safety Alert System

1.3 Intended Use

1.4 Operations Manual

TA3H, TA3SH & TA3.5SH Page 1 - 1

Figure 1.1 - Operations Manual Location

1.5 Identification Plate

Figure 1.2 - Vehicle Identification Number Plate Location

Page 1 - 2 TA3H, TA3SH & TA3.5SH

Figure 1.3 - Vehicle Identification Plate Information - CE Machines

Figure 1.4 - Vehicle identification Plate - German

Figure 1.5 - Vehicle Identification Plate Non CE

TA3H, TA3SH & TA3.5SH Page 1 - 3

1.6 Warranty Registration

1.7 Warranty Terms and Conditions

1.8 Service and Replacement Parts Enquiries

1.9 Official Documents European Community Only

Page 1 - 4 TA3H, TA3SH & TA3.5SH

Figure 1.6 - Copy of CE Certificate

Contents of the EC Declaration of Conformity

Manufacturer: Mecalac Construction Equipment UK Limited

Name of Person to Compile Technical File: Steve Price

Address of Person to Compile Technical File: Mecalac Construction Equipment

Generic Denomination: Compact Dumper

Machine Function: Earth-moving machinery

Model / Type : TA3H

Place of Issue: Coventry, United Kingdom

TA3H, TA3SH & TA3.5SH Page 1 - 5

1.10 California Proposition 65

Warning: This product contains and/or emits lead and

Warning: This product contains and/or emits lead, lead

1.11 Bulletin Compliance

1.12 Contacting the Manufacturer

Page 1 - 6 TA3H, TA3SH & TA3.5SH

1.13 Transfer of Machine ownership

TA3H, TA3SH & TA3.5SH Page 1 - 7

2.1 Safety Alert System

2.2 ANSI Hazard Classification System

TA3H, TA3SH & TA3.5SH Page 2 - 1

(2) Property Damage

Page 2 - 2 TA3H, TA3SH & TA3.5SH

2.3 Personal Protective Equipment (PPE)

Protective A protective helmet must Safety Safety boots must be worn

Ear Ear protection must be Safety Safety glasses must be

Protective Protective gloves must be Face A face shield must be worn

Protective Protective clothing must be

Safety Safety glasses must be Safety Safety boots must be worn

Protective Protective clothing must be Protective Protective gloves must be

TA3H, TA3SH & TA3.5SH Page 2 - 3

2.4 General Safety Information

Warnings about the Operator