Winget 4B2000 Service manual

DUMPER
4B2000
OPERATORS HANDBOOK
Manual MANS524 March 2013
WINGET LIMITED, P.O. Box 41, Edgefold Industrial Estate, Plodder Lane, Bolton, BL4 0LR, England
Tel: [phone] Fax: [phone]
E mail:[e-mail],[e-mail]
www.winget.co.uk

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.
INTRODUCTION I
Dumper
4B2000

CONTENTS
Section Page
INTRODUCTION
Contents II
Introduction to the Handbook III
Machine identification III
Warranty Terms & 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
Controls layout 2.1
Running-in a new engine 2.3
Pre-start checks 2.3
Driving the dumper 2.3
Starting and stopping the engine 2.4
Gradients 2.10
Braking 2.10
Engage gear lever 2.10
Stopping the dumper 2.10
Leaving the dumper 2.10
Skip operation 2.11
Towing 2.12
Section Page
SERVICE
Safe working 3.1
Service schedule chart 3.2
Engine 3.4
Fuel System 3.6
Air Cleaner 3.9
Gearbox 3.10
Transfer box 3.11
Propeller shafts 3.12
Battery 3.13
Hydraulic system 3.14
Greasing 3.19
Braking systems 3.20
Wheels & Tyres 3.22
Axles 3.23
TECHNICAL INFORMATION
Dimensions 4.1
Specifications 4.2
General dumper
Lubricants & fluids
Adjustments
Pressures
Tyres
Load capacities
Machine weight
Vibration declaration
Electrical circuit, without road lights 4.5
Electrical circuit, road lights 4.6
PARTS SECTION
II INTRODUCTION

THE HANDBOOK
WARNING The Operator must read all the Handbook and fully understand its contents
before attempting to operate the machine.
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 Operators 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 of
authorised training courses.
In this Handbook are WARNING notes. They are preceded by this symbol:
WARNING 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
others; or damage to the machine.
The warnings are also used to protect the machine from unsafe servicing
practices.
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.
MACHINE IDENTIFICATION
Please record the model and serial numbers of your machine in the spaces provided and
quote them when ordering parts.
Model - Year
Dumper serial no.
Key, start
Engine
Gearbox
Transfer box
Front axle
Rear axle
Ram steering
Ram, tipping, L.H.
Ram, tipping, R.H.
Tyre manufacturer & size
INTRODUCTION III

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
for 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 operaton; 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 for
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’ distrubutors.
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
if 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 for
discrepancies which may occur between specification of machines and the descriptions
contained in publications.
IV INTRODUCTION
WARRANTY TERMS & CONDITIONS

Safety is the responsibility of all 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
WARNING Any modifications to the machine will affect its working parameters and
safety factors. Refer to the Manufacturers before fitting any non-standard
equipment or 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, or fitment of spurious parts.
TRAINING
WARNINGOnly 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.ITB 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 O11 8836935. Another useful publication is British Standard number
BS 6264, “Procedure for Operator Training For Earth Moving Machinery”
available from the British Standard Institution.
RUNNING-IN
WARNINGWhile a gradual ‘running-in’ of a new engine is not necessary, it is extremely
important that the instructions given in Section 1 “Operation” on “Running-in
a new engine” should be followed very closely during the first fifty hours of
operation.
DRIVING
WARNING 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.
SAFE WORKING 1.1

ALWAYS 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)
ALWAYS 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.
ALWAYS remain in the driving seat whenever the engine is running. Never
attempt to operate any controls unless seated.
ALWAYS 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 starter 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 any 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 skip was supplied with a
special skip support always ensure that it is used.
1.2 SAFE WORKING

SKIPS AND LOADING
WARNINGNEVER 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.
ALWAYS 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.
ALWAYS take extra care when tipping non free running loads, particularly
with Rotary Skips and High Discharge machines.
NEVER use the skip in a tipped position to bulldoze heaped materials level
or to backfill material into excavations.
NEVER leave the machine with the skip raised or rotated.
TOWING
WARNINGNEVER attempt to tow a dumper before first reading ‘Towing the dumper’
(see Contents page).
Dumpers are not designed as towing vehicles, but loads (including weight of
trailer) not exceeding the rated payload of the dumper may be towed on dry,
level ground in first gear, providing the dumper skip is loaded with half the
rated payload to ensure tyre adhesion when braking.
NEVER attempt to start the engine of a dumper by towing or pushing.
ALWAYS use a purpose made towing pin.
NEVER tow loads up, down or across gradients.
GRADIENTS
WARNINGNEVER operate on any gradients which exceed 25% (1 in 4), or across
gradients which exceed 16% (1 in 6).
ALWAYS remember that slippery or loose surface conditions can adversely
affect safe machine operation, including braking, particularly on gradients.
ALWAYS choose routes that avoid steep, slippery or loose gradients.
NEVER coast down gradients. Always negotiate gradients in first gear.
ALWAYS drive forwards up gradients when loaded.
ALWAYS reverse down gradients when loaded.
ALWAYS keep the load facing uphill.
NEVER park on a gradient. If this is unavoidable, ALWAYS chock the
wheels.
NEVER attempt to turn on a gradient
NEVER tow up, down or across a gradient.
NEVER operate high discharge or rotating skips on gradients.
SAFE WORKING 1.3

HYDRAULICS
WARNINGALWAYS “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.
ALWAYS purge hydraulic rams before commencing work. With the engine
running operate the hydraulic control to fully extend and retract the rams.
ALWAYS practise the greatest cleanliness in maintaining hydraulic
components.
SERVICING
WARNING ALWAYS report any defect at once, before an accident or consequential
damage can occur.
ALWAYS conform to service schedules except where:
1 Warning lights or warning indicators call for immediate attention.
2 Adverse conditions necessitate more frequent servicing.
ALWAYS wear correctly fitting protective clothing. Loose or baggy clothing
can be extremely dangerous when working on running engines or machinery.
ALWAYS, where possible, work on or close to engines or machinery only
when they are stopped. If this is not practical, remember to keep tools, test
equipment and all parts of your body well away from the moving parts.
ALWAYS “Dump” pressure from the hydraulic system before carrying out any
kind of maintenance or adjustment. (see Service - Hydraulic system).
ALWAYS avoid contact with exhaust pipes, exhaust manifolds and silencers
when the engine is running; these can be very hot.
ALWAYS 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.
ALWAYS 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.
1.4SAFE WORKING

ALWAYS 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.
ALWAYS 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 of waste
oil into drains or water courses or to bury it.
Equipment which includes friction materials will sometimes contain asbestos.
When removing friction material dust from components, such as when
servicing brakes or clutches, 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 accumlated 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 skip was supplied with a
special skip support always ensure that it is used.
ALWAYS ensure that 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).
SAFE WORKING 1.5

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.
1.6 SAFE WORKING
DECALS
Attached to the dumper are several pictorial warning decals
Ensure that all decals fitted to the dumper 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.
Descriptions of the decals are as follows:

CE (EC machines only)
Always reverse down gradients when
loaded
Forks and buckets are not to be used to
push or lift the dumper.
Keep hands away from moving parts.
ISO Skip Support, when used, is pinned
around the tipping ram rod to prevent the
ram from closing.
Beware of electrical hazards
These surfaces may be hot.
The figures shown on these decals are
the maximum loads for the skips onto
which the decals are fastened.
Always wear eye protection.
Stand clear of the articulation area of the
dumper
SAFE WORKING 1.7

1.8 SAFE WORKING

1Hydraulic oil filler cap
2 Skip control, tip/return
3 Clutch
4 Gear lever
5Steering wheel
6Seat
7Foot Brake
8Accelerator
9Parking brake
10 Fuel filler cap
11 Key start switch (where fitted)
12 Engine starting handle (stowage)
OPERATION 2.1
CONTROLS AND SERVICE POINTS

2.2 OPERATION
ROAD LIGHTS SWITCH PANEL
20 Horn
21 Switch: Side and head lights
22 Switch: Hazard warning lights
23 Flasher unit
24 Fuse box
25 Switch: Direction indicators
26 Warning light: Direction indicators

Safety warnings
Read also the “Safe Working” Section
before operating the dumper.
WARNINGALWAYS 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
WARNINGNEVER 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.
4 Do 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
WARNING 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 that they all 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

Petter PH2 engines (UP TO 1988)
To start Petter PH2 engines:
Ensure the parking brake is in the raised
“ON” position.
Ensure gear lever is in the neutral
position.
WARNINGIf a starting handle is to be
used, see that the shaft is
greased. Make sure the
starting handle can be freely
withdrawn.
On the engine, lift the overload stop (A)
and move the fuel pump rack (D) in the
direction of the arrow to the fully open
position.
Operate the fuel pump priming lever (C)
approximately six times. (This is
unnecessary with a warm engine.)
Lift the decompression lever (B) to the
vertical position. Crank the engine as fast
as possible or use the starter motor.
When the engine is turning at a good
speed, knock down the lever (B). The
engine should now fire.
If the engine does not fire, lift the
decompressor lever (B) and slowly turn
the engine a few times before attempting
to start again. Do not operate the starter
motor for more than 20 seconds at a time.
.
Note:If it is necessary to bleed and prime
the fuel system, consult the PH2
Engine Operators Handbook.
To stop PH2 engines:
WARNING NEVER stop the engine by
using the decompressor lever.
This will lead to damaged
valve seats and cylinder head
joints.
DO NOT stop the engine by
allowing the tank to run dry.
This will make it necessary to
bleed and prime the system.
DO NOT remove or alter the
setting of the overload stop.
It is advisable to run on light load for a
few minutes before stopping.
Raise the priming lever (C) to the vertical
position, or move and hold the fuel pump
rack (D) away from the fly wheel until the
engine stops.
2.4 OPERATION
DRIVING THE DUMPER

Lister ST2 engines (UP TO 1988)
To hand start Lister ST2 engines:
Ensure the parking brake is in the raised
“ON” position.
Ensure gear lever is in the neutral
position.
Move the decompressor lever over
towards the flywheel (F).
Pull the control lever outwards and allow it
to rotate anticlockwise so that it abuts
against the top stop and is in a vertical
position (G).
IMPORTANT: Ensure that the starting
handle is of the correct type and is fully
servicable. Lightly oil the end of the
starting shaft and the starting handle.
Check the arrow on the handle for correct
rotation, then turn the handle in the
opposite direction to that required to start
engine. This is done in order to check that
the clutch pin will disengage from the
keyway, and does not bind on the starting
shaft.
ENSURE THERE ARE NO BURRS ON
THE SHAFT.
IMPORTANT: With the starting handle,
turn the engine slowly from 3 to 20 turns
according to the temperature and period
of standing unused, in order to prime the
combustion chamber and the lubricating
oil system.
Turning the starting handle in the correct
rotation, crank the engine really fast and
when maximum cranking speed is
reached move the decompressor lever
away from the flywheel (H). Retain a firm
grip on the starting handle and continue to
crank until the engine fires. Remove the
starting handle from the shaft.
WARNING It is dangerous to allow the
handle to rotate on the
running shaft.
IMPORTANT:As soon as the engine
reaches normal speed, turn the control
lever clockwise to the horizontal position
so that it abuts the horizontal stop (J).
OPERATION 2.5
DRIVING THE DUMPER

To key (Electric) start Lister ST2
engines:
Ensure the parking brake is in the raised
“ON” position.
Ensure gear lever is in the neutral
position.
Depress and hold down the accelerator.
Pull the control lever outwards and allow it
to rotate anticlockwise so that it abuts
against the top stop and is in a vertical
position (G).
Turn the starter key and release
immediately the engine fires. Do not
motor the engine continuously for more
than 20 seconds.
Release the accelerator pedal.
IMPORTANT: As soon as the engine
reaches normal speed, turn the control
lever clockwise to the horizontal position
so that it abuts the horizontal stop (J).
Cold Starting Below -10oC (14oF)
A cup and plunger is fitted to the
combustion air intake port on ST engines.
Operate as follows:
Withdraw the plunger (K) and fill one
third of the cup (L) 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. When hand
starting, turn the engine 20 revolutions
with the fuel on after injecting the oil,
before attempting to start.
To stop engine
Turn the control lever clockwise in the
direction of the arrow (M) and hold it until
the engine stops.
2.6 OPERATION
DRIVING THE DUMPER

TS/TR2 engines
Description
ADipstick
BLubricating oil filler
CEngine control
DDecompressor levers
FCold start oil cup
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 -10oC (14oF)
A cup and plunger is normally fitted to the
combustion air intake port on TR and TS
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.
WARNING The device must not be used
more than three times in
succession during the same
attempt to start the engine.
OPERATION 2.7
DRIVING THE DUMPER