Thwaites Mach 440 Assembly instructions

Tier 2: issue 2 T0472
Mach 440, Mach 445, Mach 470,
Mach 473, Mach 479
3 – 4 Tonne (Manual)
Operator’s
Instruction
Manual
Mach 479 - 3 Tonne Hi-Swivel
Mach 470 - 3 Tonne Front Tip

Introduction
Safety Symbols
• Attention!
• Be alert!
• Your safety is involved!
• Correct action • Incorrect action/procedure
which should NOT be carried
out
Signal words:
Signal words are used on the machine and within this manual to identify levels of hazard seriousness:
DANGER WARNING CAUTION
Thwaites Limited puts Safety First
It is the policy of Thwaites Limited to promote safety in the
operation of its machines and to create a general awareness of
site safety and safe working practices for the operators of its
machines.
This Operator’s Instruction Manual is intended for both new and
experienced machine operators. It should remain with the
machine at all times. All operators should be aware of its
location and contents.
It is important that all operators are fully trained and familiar
with the machine and that they have read and understood the
information contained within this book before they attempt
to operate in the site conditions for which the machine was
designed.
This book details practices and operations which Thwaites
Limited recommends. DO NOT operate this machine in ways
other than those detailed within this book.
This machine is designed for customary construction site
operations, and the transportation of bulk materials commonly
carried on such sites; that is their ‘intended use’. Under certain
controlled conditions the dumper may be used for towing
wheeled loads.
Due to the varied nature of the operation of site dumpers and
the absence of an agreed test standard, any figures quoted by
Thwaites in relation to vibration values and exposure are for
reference purposes only. It is the responsibility of the employer
to assess vibration exposure based on the actual site
conditions, and operating practices, at the point of use.
Hand Arm Vibration - The daily exposure Action/Limit Values
of between 2.5 - 5.0m/s2 (A8) are unlikely to be exceeded in
an eight-hour reference period.
Whole Body Vibration - The daily exposure can only be
accurately determined at the point of use. This exposure must
be managed in respect of the Action/Limit Values of 0.5 and
1.15 m/s2 (A8) respectively.
Employers should not rely solely on published vibration figures
when undertaking risk assessments. Depending on the site
conditions, cycle times may need to be adjusted in order to
reduce operator exposure levels.
Vibration values based on typical duty cycles are available on
request from Thwaites. These may be used for reference
purposes only.

1
Complete Checks in Section Before Starting The Engine
Read this manual
Before operating this machine
Distributor
1 Contact your Thwaites dealer in case of further
questions
2 Learn to operate this machine
3 Ensure you are fit to operate
4 Wear correct safety clothing and ensure safety
equipment is available

1
Complete Checks in Section Before Starting The Engine
Walk Around The Machine
DO NOT OPERATE THE MACHINE UNTIL
ALL FAULTS HAVE BEEN RECTIFIED
Before operating this machine
Visually check the machine
1 Are the chassis lock and the skip lock disengaged?
2 Are the controls, crush zone and hydraulic rams
clean, and clear of debris?
3 Is the Roll-Over Protective frame (ROPS frame)
secure, fully upright and undamaged?
4 Is the seatbelt anchorage secure and serviceable?
5 Are the covers and mudguards secure?
6 Are the hoses free from fluid leaks?
7 Are all safety decals legible?
8 Are the tyres free of cuts or splits?
9 Are all bolts tight and in position?
10 Have the daily maintenance tasks been
performed? (See rear cover)
Report all faults immediately.

1
Complete Checks in Section Before Starting The Engine
WARNING
Seatbelt MUST BE WORN when operating machines
fitted with a ROPS frame.
Before operating this machine
Mount the machine and check the controls
1 Use the grabrails and foot steps provided to
manoeuvre into the seating position. Face the
machine at all times when mounting and
dismounting
2 Is the engine cover secure and locked?
3 Adjust the seat position for comfort and easy
access to controls
4 Fasten the seatbelt. Adjust accordingly for safety
and comfort
5 Is the hand brake ON?
6 Set the transmission to neutral
7 Does the foot brake feel firm?
8 Do not operate the machine without understanding
all its controls as described in the following pages

1
Complete Checks in Section Before Starting The Engine
Control locations & functions
1 Steering wheel
2 Direction indicator selector -
Forward = left turn - back = right turn*
3 Lights - twist 1 = sidelights ON - Twist 2 =
Dipped headlights ON*
4 Up = Flash. Down = main beam*
5 Hazard warning light switch*
6 Beacon switch*
7 Foot brake pedal
8 Throttle pedal
9 Hand brake lever
10 Engine oil pressure warning light
11 Water temperature warning light
12 Headlamp main beam pilot light*
13 Direction indicator pilot light*
14 Heat/start pilot light
15 Battery charging warning light
16 Horn push
17 Skip-tip lever (Front Tip model)
Skip-tip and rotate-skip lever (Powerswivel model)
17a Skip-raise lever (Hi-Swivel model only)
18 Gear lever
19 Clutch pedal
20 Circuit breakers (push to reset)
21 Ignition & hand brake warning buzzer
22 Ignition switch
23 Maxi fuse (under engine cover)
*Optionalitems
CB1 Fuel/direction solenoids
CB2 Instrumentation/warning
CB3 Lights*
CB4 Flash*
CB5 L/H sidelights*
CB6 R/H Sidelights*
Layout of controls

1
Complete Checks in Section Before Starting The Engine
Control functions - in depth
Throttle pedal - right foot
• Apply pressure to increase speed
• Release pressure from the pedal to reduce speed
Foot brake pedal - right foot
• Push down on the pedal to slow/stop the machine
Clutch pedal - left foot
• Press down before each gear change - select gear and release
Startinhibitor fitted- pressdown clutchpedal beforestarting engine
Seatbelt (if fitted)
• Adjust length of belt when seated on machine
• Press buckle blade into buckle lock
• Pull belt webbing through buckle blade to remove slack
Seatbelt should not be worn loose. It should pass comfortably across the
hips and not the abdomen
Seat adjustment
Type 1:
A – Push down to set driver weight (seat empty)
Push fully down and release to reset (seat empty)
B – Lift to slide seat assembly forwards/backwards
C – Lift to slide cushion forward and set backrest
Type 2:
E – Turn knob to set driver weight
F – Lift to slide seat assembly forwards/backwards
G – Lift handle to adjust backrest Type 1 Type 2

1
Complete Checks in Section Before Starting The Engine
Hand brake lever - right hand
When the machine is stationary (or in an emergency):
• Pull up to apply
• Pull catch and lower to release
An audible warning device is fitted to your machine. This will sound when the
hand brake is engaged and the engine is running
Gear lever - left hand
Forward-left Forward-right
Third Gear First Gear
Neutral
Back-left Back-right
Second Gear Reverse
Opening and closing the engine cover
• Insert ignition key and turn anti-clockwise to unlock
• Pull handle to release and raise cover
• Lower cover, secure and lock before driving
Control functions - in depth

1
Complete Checks in Section Before Starting The Engine
Steering wheel – both hands
• Turn the wheel clockwise to turn machine right
• Turn the wheel anticlockwise to turn machine left
When using the spinner knob for low-speed single-handed steering ensure
the non-steering hand is on the engine cover grabrail
Skip-tip lever (Front tip and Powerswivel models) – left
hand
• Push forward to raise skip
• Push backwards to lower skip
Skip-rotate lever (Powerswivel and Hi-Swivel model) – left hand
• Tip skip 100 mm (4”) to disengage pivot centring lock
Rotateskip,fullyloweredtocentretoautomaticallyengagecentringlock.
• Push lever to the right to rotate skip to right
• Push lever to the left to rotate skip to left
• An increased engine speed will reduce cycle times
Movement of the skip is disabled if the steering wheel is moved (priority
steering)
Skip-raise lever (Hi-Swivel model) – left hand
• push forward to raise skip
• push backwards to lower skip
Control functions – in depth
Hi-SwivelPowerswivel

1
Complete Checks in Section Before Starting The Engine
Beacon stowage
• Unplug and remove beacon
• Secure beacon on bracket provided beneath bonnet
Battery isolator (beneath engine cover)
• Turn key anti-clockwise to isolate the battery power supply
Lowering and raising the folding ROPS frame
• Remove linch pins and withdraw frame lock pins
• Lower frame and insert lock pins and linch pins in new position
• Reverse the procedure to raise the frame
• Ensure all pins are secure before driving
Control functions – in depth
Skip-tip lever lock (if fitted)
• Place yoke over tipping lever and secure with linch pin to lock
• Fold back the yoke and secure using linch pin when not in use

2
Complete Checks In Section Before Loading The Machine
To start the engine
• Depress clutch pedal
(Startinhibitorfitted)
• Depress accelerator pedal fully and turn the key
clockwise to the start position ‘S’
Allpanel lightsself-test(illuminate) andshould extinguish
onstart-up.
• Allow the engine to turn for 15 seconds max
If the engine does not start within 15 seconds return key to
‘O’ and wait 30 seconds. Turn to ‘S’ again
• When the engine fires, release key
(the key will automatically turn to 'Run' position ‘R’)
• Reduce accelerator pedal pressure to prevent over-
revving
ColdStart Aid-
Turn key to position ‘H’. When panel light extinguishes, start
the engine (as above)
To stop the engine
• Turn key to position ‘O’
How to START and STOP the engine
WARNING
Do not start the engine unless you are sitting in the
driver’s seat.
CAUTION
• Do not use unauthorised starting aids
• Do not tow or bump start
• If a panel light remains on, switch off engine (key to
‘O’), and investigate the problem

2
Complete Checks In Section Before Loading The Machine
Function checks – engine ON
Brakes
• Does the foot brake pedal feel firm?
• Carry out hand brake test (Described on next page).
Steering
• Rotate steering clockwise and anti-clockwise
Electrics
• Does the horn sound?
• Does the reverse alarm sound? (Optional).
• Does the beacon flash?
• Do all the lights function correctly? (Optional):
* Side
* Main
* Stop
* Indicators
* Hazards
Skip-tip and skip-rotate lever
• Tip and return skip
• Rotate skip clockwise and anti-clockwise (Powerswivel
and Hi-Swivel models).
Skip-raise lever (Hi-Swivel model)
• Raise and lower skip
Preliminary checks

2
Complete Checks In Section Before Loading The Machine
If any of the following tests result in failure, consult the service book
for instructions for hand brake adjustment.
1 Start engine.
2 With the handbrake applied, engage first gear and release clutch
slowly, with engine revs at tick-over; the machine should move
forward.
3 Release throttle and apply clutch and footbrake.
4 With the handbrake applied, engage second gear and release
clutch slowly, with full engine revs; the machine should stall.
5 If the machine moves forward, release throttle and apply clutch
and footbrake.
6 Select Neutral
7 Switch engine off.
Alternatively the handbrake can be checked by measuring the load
required to apply the handbrake. The required force for applying the
handbrake is a 12 kg pull (+/- 0.5 kg), measured from the end of the
grip handle.
How to test the hand brake
WARNING
• Before testing handbrake, ensure that the machine is on firm,
level ground and that the area is clear of people.
• Do not operate a machine that has failed the handbrake test.
• The handbrake must not be over-tightened, as this may cause
damage to the axle.

2
Complete Checks In Section Before Loading The Machine
Moving from rest and stopping
• Depress clutch pedal
• Select first gear
• Slowly depress accelerator pedal, release clutch pedal
and hand brake lever and move slowly
• Hold steering wheel with both hands
• Remove foot from accelerator pedal
• Brake gently to a halt, using foot brake pedal, and
press clutch pedal to prevent stalling
• Apply hand brake and select neutral when stationary
Changing speed/direction
• Release accelerator pedal
• Depress clutch pedal
• Select next gear
• Release clutch pedal and press accelerator pedal
• The machine must be stationary and the hand brake
must be engaged before changing direction (forward/
reverse).
After operating – park safely
• Always leave skip empty when not in use
• Ensure machine is on firm, level ground
• Apply hand brake
• Engage gear lever in neutral
• Hydraulic system at rest in a safe condition
• Stop engine and remove key
• Lock engine cover
Driving procedure and safe parking
CAUTION
• Novice operators should always start with forward
motion on clear, level ground.
• A low gear should always be selected when a driver
is unfamiliar with machine type.

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DANGER IMMEDIATE HAZARDS WHICH WILL RESULT IN SEVERE PERSONAL
INJURY OR DEATH
Powerswivel and Hi-Swivel
Front Tip
WORKING ON GRADIENTS
DO NOT exceed maximum stated gradients
DO NOT turn across gradients
DO NOT brake suddenly in wet, muddy, icy conditions or when
operating on loose surfaces
DO NOT run down hill with controls in neutral
Travel straight up, down or along a gradient
Keep speed to a minimum and use the foot brake to reduce speed
when travelling down gradients
Always position swivel skip in central lock
Always engage hand brake when stopped on sloping ground to
prevent movement, and, in addition, chock wheels securely when
leaving the machine unattended
DO NOT operate raise mechanism on sloping ground (Hi
swivel model) - Check spirit-level indicator

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DANGER IMMEDIATE HAZARDS WHICH WILL RESULT IN SEVERE PERSONAL
INJURY OR DEATH
Before operating, sound the horn to warn people in the
immediate area
VISIBILITY
Check ahead and behind machine before operation
Be aware of low-visibility areas when operating
Never operate the machine’s controls when standing on either
side of machine
CRUSH ZONE
Stay clear of articulation area when the engine is running.
WORKING UNDER A RAISED SKIP
Lock skip safety prop during maintenance
When using skip safety prop engage skip-tip lever lock (If
fitted)
Never work under an un-propped skip

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WARNING HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN SEVERE
PERSONAL INJURY OR DEATH
LOADING THE MACHINE
DO NOT exceed the machine’s rated capacity
Apply hand brake, set transmission to NEUTRAL, turn engine
OFF, disembark the machine and STAND CLEAR
Clear debris from controls
Reduce payload if materials being carried are not free
flowing
Ensure SAFE STABLE LOW load which allows good visibility
UNLOADING THE MACHINE
Use STOPBOARDS and SUPPORT walls on trenches
DO NOT discharge load when working on sloping ground
DO NOT tip skip if load is sticking

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WARNING HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN SEVERE
PERSONAL INJURY OR DEATH
DRIVING
Site hazards to avoid:
adverse weather
conditions; icy
surfaces; people
DO NOT drive with the
skip tipped
(bulldozing)
DO NOT carry
passengers
DO NOT operate with
the ROPS frame folded
NEVER dismount from
a moving machine
Avoid confined work
areas - exhaust fumes
and noise can be a
hazard

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WARNING HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN SEVERE
PERSONAL INJURY OR DEATH
TOWING A TRAILER
Place ballast load in skip. This load should be a minimum of
25% of the machine’s rated payload.
The gross weight to be towed plus the ballast load MUST NOT
exceed rated payload of machine
DO NOT exceed maximum tow bar pull or vertical load
Towing must not be carried out on sloping ground
Always use a Thwaites-approved towing pin
TRANSPORTATION
Reverse machine slowly onto a suitable trailer
1 Apply parking brake
2 Stop engine
3 Chock wheels (to prevent movement)
4 Engage chassis locking bar
5 Secure to trailer
6 Ensure legal load (Height/weight)
DO NOT drive the machine forwards when loading

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CAUTION HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN MINOR
PERSONAL INJURY OR PRODUCT OR PROPERTY DAMAGE
Hi-Swivel
HAND BRAKE
DO NOT apply hand brake if the machine is moving (except in
an emergency)
SLOPING SURFACES
DO NOT step on the rear the mudguards’ sloping surfaces
USING A CRANE TO LIFT THE MACHINE
Tip skip fully forward
Place the locking channel over the tipping ram-rod, then reset
the skip until it is impeded by the channel
Engage chassis locking bar
Lift using centre eye provided
SCISSOR LIFT (HI-SWIVEL MODEL ONLY)
In order to secure the skip in a raised position, place the locking
channel over the lifting-ram rod
Front Tip and Powerswivel
HINGED ROPS
Use grab handles, tread grips (if fitted) and steps when standing
on the machine to lower the ROPS frame
Avoid wet surfaces