Winget 2 Series Service manual
INTRODUCTION I
The contents of this Handbook, although correct at the time of
publication, may be subject to alteration by the Manufacturers
without notice.
Winget Limited operate a policy of continuous product development,
therefore, some illustrations or text within this publication may differ
from your machine.
Operator’s book template
CONTENTS
Section Page
INTRODUCTION
Contents II
Introduction to the Handbook III
Machine identification III
Warranty Terms and Conditions IV
SAFE WORKING
Machine modification 1.1
Training 1.1
Running-in 1.1
Driving 1.1
Skips and loading 1.3
Towing 1.3
Gradients 1.3
Hydraulics 1.4
Servicing 1.4
Decal identification 1.6
OPERATION
Dumper controls 2.1
Running-in a new engine 2.3
Pre-start checks 2.3
Starting and stopping the engine 2.4
Gradients 2.7
Braking 2.7
Engaging the gear lever 2.7
Stopping the dumper 2.7
Leaving the dumper 2.7
Skip operation 2.8
Towing with the dumper 2.8
Towing the dumper 2.8
Section Page
SERVICE
Service Safe Working 3.1
Service schedule chart 3.2
Engine 3.4
Lubrication oil and filter 3.4
Fuel system 3.6
Air cleaner 3.7
Gearbox 3.8
Front axle 3.9
Wheels and tyres 3.10
Battery 3.11
Steering valve 3.12
Greasing 3.13
Hydraulic system 3.14
Braking system 3.18
TECHNICAL INFORMATION
Dimensions 4.1
Specifications 4.2
General dumper specifications
Vibration declaration
Road speeds
Lubricants and fluids
Capacities – fluids
Adjustments
Pressures
Noise levels
Drawbar loads
Load capacities
Main electrical circuit 4.4
Road lights electrical circuit 4.5
PARTS
Illustrations of all dumper components.
II INTRODUCTION
.
INTRODUCTION III
THE HANDBOOK MUST NOT BE REMOVED FROM THE MACHINE.
The Handbook should be kept clean and in good condition. Additional copies of the
Handbook can be obtained from your Distributor.
The contents of this Operator's Handbook are designed as a guide to the machine's
controls, operation, working capacities and maintenance. It is not a training manual.
Only trained operators should use this machine. Consult your Distributor for details o
f
authorised training courses.
THE HANDBOOK
The operator must read all the Handbook and fully understand its contents
before attempting to operate the machine.
In this Handbook are WARNING notes. They are preceded by this symbol:
These notes are used to indicate that the procedure being described in the
Handbook must be followed to avoid serious injury or death to yourself or to
others; or damage to the machine.
The warnings are also used to protect the machine from unsafe servicing
p
ractices.
Pay particular attention to the warnings given in the Handbook.
If you have any doubts about any aspect of the machine's capability or servicing
procedures, you must consult the manufacturer.
The contents of this Handbook, although correct at the time of publication
may be subject to alteration by the Manufacturers without notice.
Winget Limited operate a policy of continuous product development.
Therefore, some illustrations or text within this publication may differ from
your machine.
MACHINE IDENTIFICATION
Please record the model and serial numbers of your dumper in the spaces provided and
quote them when ordering parts.
Model – Year ………………………….…….
Dumper serial no. ………………….……….
Key, start .……………………………..……..
Engine serial no. …………………..……….
Gearbox serial no. …………………..……..
Front axle serial no. …………..…………….
Ram, tipping, L.H. ……...…….…..…………
Ram, tipping, R.H. …..……………………...
Front tyre size ………………………..……..
Rear tyre size ……………………………………...
IV INTRODUCTION
WARRANTY TERMS & CONDITIONS
The Manufacturer assures you that if any part of the machine becomes defective due to
faulty manufacture or materials within 12 months from the date of purchase, the part will
be repaired or replaced under warranty free of charge by any authorised Winget
Distributor. Warranty repairs must be carried out by Winget Distributors.
This Warranty is given to the first owner and may be transferred to subsequent owners fo
r
the balance of the Warranty period.
The Manufacturer’s liability only extends to the costs of repair or replacement of the faulty
parts and necessary labour charges involved in the repairs. The Company accepts no
liability for any consequential loss, damage or injury, resulting directly or indirectly from any
defect in the goods.
Items not covered by Warranty and considered to be the customer’s responsibility include
normal maintenance services; replacement of service items and consumables;
replacement required due to abuse, accident, misuse or improper operation; replacement
of wearable items e.g. pins, bushes, brake linings, clutch linings etc.
The Warranty will not apply where the equipment is modified, converted, or used fo
r
purposes other than those for which it was designed, unless clearance for the
modifications etc. have been granted by the Manufacturer, in writing.
The Pre-Delivery Inspection and Warranty Registration Document must be completed
correctly and returned to the Manufacturer within 7 days of sale date. Failure to do so may
result in the claim being subsequently rejected.
Tyres and tubes are not covered by Warranty, but are covered by the tyre manufacturer’s
own warranty system which provides against defects in material or workmanship.
Engines are covered separately by the engine manufacturers, and engine warranty repairs
must be handled by the relevant engine manufacturers’ distributors.
No claim will be considered if other than genuine Winget Limited parts, which must be
obtained from Winget Limited via an authorised Distributor, are used to effect a repair, or i
f
lubricants other than those recommended by Winget Limited are used.
The equipment must be serviced in accordance with the service schedules laid down by
Winget Limited. Evidence that these have been complied with may be required before
Warranty Claims are reimbursed.
The Manufacturer’s policy is one of continuous improvement. Winget Limited reserve the
right to change specifications without notice. No responsibility will be accepted fo
r
discrepancies which may occur between specification of machines and the descriptions
contained in publications.
TRAINING
RUNNING-IN
DRIVING
SAFE WORKING 1.1
Safety is the responsibility of the persons working with this machine. Think “safety” at all
times. Read and remember the contents of this Handbook.
The safe working recommendations for specific tasks are found with the instructions
for the relevant operation in this Handbook.
MACHINE MODIFICATION
Any modifications to the machine will affect its working parameters and safety
factors. Refer to the Manufacturers before fitting any non-standard equipment o
r
parts.
The manufacturers accept no responsibility for any modifications made after the
machine has left the factory, unless previously agreed by the Manufacturers in
writing. The Manufacturers will accept no liability for damage to property,
personnel or the machine if failure is brought about due to such modifications, o
r
fitment of spurious parts.
Only trained operators should use this machine.
Operators should hold an appropriate full motor vehicle driving licence
and undergo both a safety awareness course and a driver training course
for Site dumpers run by the C.I.T.B. or equivalent body leading to the
award of a CTA.
It is strongly recommended that operators read the H.S.E. publication
"Safe Working with Small Dumpers" which is available from government
bookshops (HMSO) or from other bookshops quoting the following
number ISBN 011 8836935. Another useful publication is British Standard
number BS 6264, "Procedure for Operator Training For Earth Moving
Machinery" available from the British Standard Institution.
While a gradual 'running-in' of a new engine is not necessary, it is
extremely important that the instructions given in Section 2 "Operation" on
"Running-in a new engine" should be followed very closely during the first
fifty hours of operation.
NEVER use the machine for purposes other than those for which it
was designed. This machine was designed to carry loads such as soil,
clay, sand, wet concrete, stone or other similar materials. It was not
designed to carry loads which may move around in the skip
uncontrollably, nor to carry any loads or materials which overhang the
skip in any way. If in any doubt as to the suitability of this machine for a
particular task, contact your nearest Distributor or the Manufacturer for
advice.
A
LWAY
S
be aware of local and national regulations governing the use of the
machine.
NEVER commence work with the machine until the “Daily (or every ten hours)”
service checks have been made. (See Service Section for details)
A
LWAY
S
check wheel nut tightness daily.
Never carry passengers.
Ensure that the seat is securely fixed to the machine. Where seat belt
restraints are fitted as part of Rops/Fops protection they must be worn. Check
that the seat belt is in good condition, free from cuts and frayed edges.
A
LWAY
S
remain in the driving seat whenever the engine is running. Neve
r
attempt to operate any controls unless seated.
A
LWAY
S
apply the parking brake before leaving the driver’s seat.
NEVER dismount with the engine running, and never leave the machine
unattended with the key in the start switch.
When battery Isolators are fitted they must be activated only when the engine
is turned off except in cases of emergency.
Activating a Battery Isolator when the engine is running can result in damage
to the electrical components and circuits.
NEVER fill the fuel or hydraulic tanks with the engine running.
ALWAYS drive only on surfaces that are known to be stable.
ALWAYS keep the floor plates and walkways clean.
NEVER drive the machine close to the edge of any excavation. Always use
effective wheel stops to prevent the machine running close to the edge. Make
sure that the stops are in proportion to the size of the wheels and are set
sufficiently far enough back from the edge of the excavation to prevent the
weight of the load causing a collapse.
NEVER adjust the tyre pressures in an attempt to improve traction on soft
ground or obtain a softer ride on hard ground. Incorrectly adjusted tyres can
affect the steering and handling characteristics.
NEVER attempt to free a machine which is “bogged down” by pushing with the
bucket of a backhoe loader, tracked excavator or other similar machine.
NEVER make unnecessary “crash stops” when travelling at speed, especially
in forward direction.
Never work under an unpropped skip. If the dumper was supplied with a
special skip support always ensure that it is used.
1.2 SAFE WORKING
SKIPS AND LOADING
TOWING
GRADIENTS
SAFE WORKING 1.3
NEVER exceed the rated payload. The weights of all loads above skip
water level must be checked.
NEVER remain on the machine when loading the skip with
excavators or loaders. Stop the engine, apply the parking brake,
dismount, and stand well clear.
A
LWAYS ensure that the load is evenly distributed in the skip.
NEVER carry loads or heap materials in such a manner as to affect the
forward vision.
A
LWAYS take extra care when tipping non free running loads.
NEVER use the skip in a tipped position to bulldoze heaped materials level
or to backfill material into excavations.
NEVER try to operate the skip whilst steering on hydraulic power steering
models, there is no priority flow to the steering
NEVER attempt to start the engine of a dumper by towing or pushing.
Dumpers are not designed as towing vehicles. However, trailers may be
towed provided that:
1The combined weight of the trailer and its load does not exceed the
dumper "drawbar pull of 250kg (2500N)" and dumper "drawbar load
of 50kg (500N)".
2Trailers may be towed in first gear on level dry ground, provided a
purpose made towing pin is used.
3The dumper skip must be loaded with half the rated payload to
ensure tyre adhesion when braking.
NEVER tow loads up, down or across gradients.
NEVER operate Two Wheel Drive rigid chassis dumpers on any
gradients which exceed 10% (1 in 10), or across gradients which
exceed 10% (1 in 10).
A
LWAYS remember that slippery or loose surface conditions can adversely
affect safe machine operation, including braking, particularly on
gradients.
A
LWAYS choose routes that avoid steep, slippery or loose gradients.
NEVER coast down gradients. Always negotiate gradients in first gear.
A
LWAYS drive forwards up gradients when loaded.
ALWAYS reverse down gradients when loaded.
HYDRAULICS
SERVICING
1.4 SAFE WORKING
A
LWAYS keep the load facing uphill.
NEVER park ona gradient. Ifthis isunavoidable, ALWAYS chock thewheels.
NEVER attempt to turn on a gradient.
NEVER tow up, down or across a gradient.
A
LWAYS "Dump" residual pressure from the system before leaving the
machine or before carrying out any maintenance or adjustments.
If maintenance work requires the skip to be in the raised position, then it must
be raised and supported before dumping the pressure.
Dump pressure by switching off the engine, then moving the hydraulic
control lever several times in each direction.
NEVER leave the machine unattended with pressure in the system.
A
LWAYS purge hydraulic rams before commencing work. With the engine
running operate the hydraulic control to fully extend and retract the rams.
A
LWAYS practise the greatest cleanliness in maintaining hydraulic components.
ALWAYS report any defect at once, before an accident or consequential
damage can occur.
A
LWAYS conform to service schedules except where:
1 Warning lights or warning indicators call for immediate attention.
2Adverse conditions necessitate more frequent servicing.
A
LWAYS wear correctly fitting protective clothing. Loose or baggy clothing can
be extremely dangerous when working on running engines or machinery.
A
LWAYS, where possible, work on or close to engines or machinery onl
y
when they are stopped. If this is not practical, remember to keep tools, tes
t
equipment and all parts of your body well away from the moving parts.
A
LWAYS "Dump" pressure from the hydraulic system before carrying out any
kind of maintenance or adjustment. (see Service - Hydraulic system).
A
LWAYS avoid contact with exhaust pipes, exhaust manifolds and silencers
when the engine is running; these can be very hot.
A
LWAYS work out of doors, or in a well-ventilated area.
NEVER run an engine in an enclosed space. Exhaust fumes in enclosed areas
can kill.
SAFE WORKING 1.5
A
LWAYS disconnect battery cables and remove battery before using an
external charger, carrying out welding repairs or to prevent unauthorised
usage when unattended or during a repair.
NEVER allow unqualified personnel to attempt to repair, remove or replace
any part of the machine, or anyone to remove large or heavy components
without adequate lifting tackle.
NEVER attempt to modify or repair Rops Frames or Fops Canopies by
welding, drilling or any other means. Attempts to do so will invalidate
Rops/Fops Certification.
A
LWAYS obtain advice before mixing oils; some are incompatible. If in
doubt drain and refill.
NEVER allow oils and fuels to come into regular contact with skin. This
can lead to serious skin diseases including, medical evidence suggests,
skin cancer. ALWAYS wear protective gloves when handling oils and fuels
whether topping up, draining or refilling. ALWAYS wash hands if oils or fuels
come into contact with the skin.
Many liquids used in this machine are harmful if taken internally or
splashed into the eyes. In the event of accidentally swallowing oils, fuels,
anti-freeze, battery acid etc, DO NOT encourage vomiting, seek qualified
medical assistance immediately.
A
LWAYS dispose of waste oils and fuels into waste oil storage tanks. If
storage tanks are not available consult your distributor or local authority for
addresses of local designated disposal points. It is illegal to dispose o
f
waste oil into drains or water courses or to bury it.
A
LWAYS dispose of unserviceable batteries safely. Comply with local
byelaws and national regulations on the disposal of hazardous waste.
Consult your local authority for addresses of local designated disposal points.
Equipment that includes friction materials will sometimes contain asbestos.
When removing friction material dust from components, such as when
servicing brakes or clutch, do not blow out with an airline; it could be
harmful to inhale the dust. Remove the dust with a vacuum cleaner or
wipe clean with a damp rag. Waste should be placed in a sealed
container, marked, and disposed of in accordance with local or national
regulations.
The accumulated dust found in clutch housings may contain lead/antimony.
No food should be eaten at a work place contaminated by this dust. Hands
must be washed before eating. Do not blow out dust with an airline.
NEVER work under an unpropped skip. If the dumper was supplied with a
special Skip Support always ensure that it is used.
A
LWAYS ensure, when using a starting handle, that it is clean and in
good condition. Keep the engine starting dog and the part of the starting
handle that mates with it lightly lubricated (Refer to the Engine Handbook).
Fuel tank filling point.
Fuel tank filling point.
Hydraulic oil filling point.
Remove starting handle.
Attach lifting hooks to this eye.
Wear ear protection.
The battery isolator is situated close to this
decal.
Read Operators Handbook, or Operators
Handbook storage place.
The battery negative terminal is connected
to earth.
DECALS
A
ttached to the dumper are several pictorial warning decals
Ensure that all warning decals fitted to the mixer are legible. If any should become
detached, they must be replaced immediately.
For detailed information on how to safely use the items described by the decals, see the
"Safe working, Operation and Servicing" sections of this Handbook.
Brief descriptions of the pictorial decals are as follows:
1.6 SAFE WORKING
Wear eye protection.
This decal indicates the maximum loads
that the dumper towbar can carry and pull.
Forks and buckets are not to be used to
push or lift the dumper.
The figure shown on this decal is the
maximum load for the skip onto which this
decal is fastened.
Beware of electrical hazards.
These surfaces may be hot.
When loaded, always REVERSE down
gradients.
ISO Skip Support, when used, is pinned
around the tipping ram rod to prevent the
ram from closing.
SAFE WORKING 1.7
1.8 SAFE WORKING
20 Key start switch
21 Warning light: battery charging
22 Switch: direction indicators
23 Warning light: direction indicators
24 Switch: hazard warning lights
25 Switch: side and head lights
27 Horn
2.2 OPERATION
ELECTRICAL CONTROLS
Safety warnings
Read also the "Safe Working" Section
before operating the dumper.
ALWAYS wear correctly fitting
protective clothing. Loose or
baggy clothing can be
extremely dangerous when
operating or servicing
machinery.
Only skilled personnel are
permitted to work with this
machine.
ALWAYS be aware of local
and national regulations
governing the use of this
machine.
Starting the engine
NEVER use ether type
starting aids.
ALWAYS stop the engine if
the battery charge warning
light (where fitted) fails to
cancel.
ALWAYS stop the engine if
warning lights illuminate.
Detect the fault before
continuing.
DO NOT PROCEED IF A
FAULT IS EVIDENT
NEVER attempt to start the
dumper by pushing or towing.
NEVER operate controls
unless you are seated on the
machine, and ALWAYS
remain in the driving seat
whenever the engine is
running.
Running-in a new engine
While a gradual 'running-in' of a new
engine is not necessary, it is
EXTREMELY IMPORTANT that the
following instructions should be followed
very closely during the first fifty hours of
operation.
1Avoid overloading the engine.
2Use the lower gears when
operating with heavy loads, and
avoid continuous operation at constant
engine speeds.
3 Check the instruments frequently, and
keep the oil compartments and the
hydraulic reservoirs filled to their
recommended levels.
4Do not operate the engine at high
speeds without a load.
5Do not allow the engine to run at idle
speeds for long periods; this may
cause bore glazing and an
increase in oil consumption.
Operating in this way throughout the
machine's life will prove beneficial to its
overall performance and efficiency.
Pre-start Checks
NEVER commence work with
the machine until the checks
detailed in "Every 10 operating
hours, or daily" have been
carried out. (See Service
Schedule).
Check that all controls are clean and not
slippery, and thattheyall function correctly.
Check that the areas around pivot points,
rams and linkages are all free from mud, ice
and debris.
Check that all grab handles, steps and
platforms are clean and dry.
Check the machine for any obvious
damage or faults.
Check that all decals can be clearly read.
OPERATION 2.3
DRIVING THE DUMPER
TR2 engines
Description
ADipstick
B Lubricating oil filler
CEngine control
D Decompressor levers
EFuel tank
FCold start oil cups
GFuel lift pump
Automatic Exess Fuel Device
The engine is fitted with an automatic
excess fuel device which becomes
operative, ready for the next start,
when the engine is stopped.
If the engine stops other than by the
operation of the engine control, the
control (C) must be turned anti-
clockwise to the 'STOP' position and
released before the device can
operate.
As the engine runs up to speed the
excess fuel device will automatically
reset to the normal running position.
Cold Starting Below -10°C (14°F)
A cup and plunger is normally fitted to
the combustion air intake port on TR
engines.
With the fuel turned on, turn the
engine for up to 20 revolutions to
prime the fuel and lubrication
systems.
Withdraw the plunger (H) and fill
one third of the cup (J) with the
same type of lubricating oil as used
in the engine.
Replace the plunger and inject the
oil just before starting the engine.
The device must not be used
more than three times in
succession during the same
attempt to start the engine.
2.4 OPERATION
DRIVING THE DUMPER
Hand starting TR2 engines
Ensure the parking brake is in the
raised "ON" position.
Ensure gear lever is in the neutral
position.
Always use the correct starting handle
which has been designed for the
engine.
Ensure there are no burrs on the handle.
Before attempting to use the handle,
clean and lightly oil that part of it which fits
onto the engine.
Do not attempt to use a
handle if it is damaged in
any way.
Turn the engine control lever anti-
clockwise to the "STOP" position (L)
and release it.
Move the decompressor levers towards
the flywheel (M).
Insert the correct handle into the
starting housing.
Turn the engine slowly for up to 20
turns to prime the combustion chamber
and lubricating oil system.
Maintaining a firm grip on the starting
handle, crank the engine really fast
and when sufficient speed is obtained
move the decompressor levers away from
the fly wheel (N) and continue to crank
until the engine fires.
Retain a firm grip on the handle and
remove it from the engine.
DRIVING THE DUMPER
OPERATION 2.5
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