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DAVINO 120TW - USER AND MAINTENANCE MANUAL Rev.04

- Pag. 109

Chapter 14 – TROUBLE SHOOTING

Any maintenance

work or part replacement is to be performed by AMOG’s TECHNICAL SERVICE specialists.

However, this chapter lists the most common failures that may occur to the machine and a way to resolve them.
If further assistance is required to resolve the matter contact an AUTHORIZED AMOG SERVICE DEALER.

FAILURE

CAUSE

REMEDY

FAILED START-UP

Fuel empty

Check fuel tank

Dead battery

Check battery condition

Electrical fault

Check starter’s electrical unit

Starter

Check starter efficiency

IRREGULAR
PERFORMANCE

Fuel not suitable

Empty the system and fill with
the proper fuel

Hydrostatic transmission Have it checked by a technician

Insufficient oil level e

Check and replenish

Air filter clogged

Clean/replace

EXCESSIVE FUMES

Fuel pump

Check pump operation

Fuel not suitable

Replace

Air filter clogged

Clean/replace

ENGINE
OVERHEATING

Cooling system

Check fluid level

Fan

Check that the engine is being
ventilated

Radiator

Clean radiator

Fan belt

Check tension

INSUFFICIENT
POWER

Accleration controls

Check that the controls operate
properly

Hydrostatic unit

Check pressure of the
hydrostatic unit

Insufficient oil

Checl oil levels and repair any
leakage

Hydrostatic oil filter olio
idrostatico

Replace

NOISY PUMP

Inadequate/missing oil

Check oil type and change/top
up

Oil filters

replace

SLOW DUMP
MOVEMENTS

Tube/hydraulic cylinde
leakage

Check and repair the leakage

Hydraulic oil filter

Replace

Poor hydraulic pump
pressure

Contact service dealer

HYDRAULICS
INOPERABLE

Distributor failure

Concat Service Dealer

Insufficient oil

Check level and top up

Pump inlet ducts
damaged

Check ducts for any
leakage/repair

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Summary of Contents for D'AVINO 120TW

Page 1: ...so User Manual Manuel d Utilisation Manual de Uso AMOG srl Via Padula n 229 231 80031 Brusciano NA Italia P IVA 05818590639 Tel 081 6588361 Fax 081 8863398 e mail aftersales davinogroup biz http www davinomixer com Ed 04 Rel 04 ...

Page 2: ...DAVINO 120TW USER AND MAINTENANCE MANUAL Rev 04 Pag 1 ...

Page 3: ...and operated by previously instruced personnl on the vehicle and its safety regulations as well as be allowed to operate with the machine itself Therefore it is the duty of the Operator and those who are in charge of maintenance before starting work or maintenance to read and understand what is described and to know and familiarize with all the controls of the machine in order to avoid situations ...

Page 4: ...S FOR USE 18 3 2 PRECAUTIONS AGAINST RESIDUAL RISKS 26 3 3 PRECAUTIONS IN MAINTENANCE 31 3 4 STICKERS 35 3 5 SAFETY DEVICES 38 Chapter 4 PRELIMINARY INSTRUCTIONS AND RUNNING IN 45 4 1 PRELIMINARY INSTRUCTIONS 45 4 2 RUNNING IN 45 Chapter 5 INSTRUMENTS AND CHECKS 46 5 1 DRIVER S POSITION 47 5 2 DASHBOARD 51 5 2 1 DRIVING DIRECTION SELECTION MODE KEY 56 5 2 2 KEY SELECTION STEERING MODE 57 5 2 3 PAR...

Page 5: ...hapter 9 TOWING 77 Chapter 10 PRECAUTIONS FOR COLD WEATHER 79 Chapter 11 PRECAUTIONS FOR PROLONGED PERIODS OF INACTIVITY 80 Chapter 12 OPERATION PHASES 81 Chapter 13 MAINTENANCE 83 13 1 INTRODUCTION 83 13 2 EXTERNAL VISUAL INSPECTION 85 13 3 DASHBOARD SIGNALLING CONTROL 85 13 4 MAINTENANCE SUMMARY SHEET 86 13 5 OPERATIONS EVERY 8 HOURS 87 13 6 OPERATIONS EVERY 100 HOURS 91 13 7 OPERATIONS EVERY 25...

Page 6: ...n la macchina stessa Therefore it is compulsory for the operator and those who are in charge of maintenance before starting work or maintenance to read and understand what is described and to know and familiarize themselves with all the controls of the machine in order to avoid situations of danger for themselves and others The operator is also obliged to observe the safety and precautionary rules...

Page 7: ...d to oneself or to other people Conducting any earth moving machine always requires a particular skill and technical perparation as well as a high sens of responsibility The operator must therefore have specific psycho physical requirements to be able to carry out this work Therefore use of these means must be reserved only to qualified personnel Operators must be appropriately trained in the use ...

Page 8: ...ude in order to improve the overall levelof safety of the machineBefore starting work the operator must verify that all safety devices are active and functioning and have the obligation to rfuse to start oeprations if there are not conditions to work safely AMOG assumes no responsibility for damages caused to persons animals porperty or environment resulting from the use of the machine by operator...

Page 9: ...ENERAL INFORMATION 1 1 SYNOPTIC TABLE Please take time to carefully read the following legend and familiarize yourself with the basic terminology and characteristics of the machine 6 4 1 3 5 2 1 Frame 2 Front Axle 3 Rear Axle 4 Right front mudguard 5 Oil tank 6 Cabin ...

Page 10: ...DAVINO 120TW USER AND MAINTENANCE MANUAL Rev 04 Pag 9 7 11 8 9 10 12 13 7 Dump 8 Engine hood 9 Engine 10 Battery compartment 11 Left front mudguard 12 Fuel tank 13 Swivel Frame ...

Page 11: ...he direction of advancement in WORKING condition driving position facing the rear of the machine rotated by 180 with respect to the transfer condition is represented for the operation of the machine on site for approaching phases and Manoeuvre for loading and unloading of material For traveling on the ROAD for shorter or longer journeys with or without the transport of material it is mandatory the...

Page 12: ...TURER The dumpers and similar commercialized models bearing the trademark D AVINO are exclusively manufactured at 1 5 TECHNICAL SUPPORT REQUEST In case of malfunctions follow the instructions below Consult the TROUBLESHOOTING GUIDE in this manual chap 14 If the fault could not be found or resolved using the aforementioned methods DO NOT ATTEMPT to repair it Such attempts may cause injury to you an...

Page 13: ...nders n 4 in line Total displacement 3 600 l Max power 90 kW R P M 2 400 rpm Max Calibration Torque 500 Nm 1 400 rpm Bore stroke 98 x 120 mm Air Filter Dry cartridge Cooling System Water Conformity exhaust gas EU STAGE V USA EPA Tier 4 Manufacturer Perkins Model 1104D 44TA Type Diesel 4 strokes TurboAftercooled Electronic Control Direct Injection Cylinders n 4 in line Total displacement 4 400 l Ma...

Page 14: ...tion with negative cylinder Emergency brake assembled in the service brake STEERING Hydrostatic supplied by an independent pump Two steering wheel front by a double steering cylinder Hydraulic Power Steering Pump displacement 125 cc Max Pump pressure max 160 bar Power steering pump capacity 20 cc DUMP Reinforced with Tipping by N 1 Telescopic Hydraulic Cylinder Struck capacity 4 900 l SAE heaped c...

Page 15: ...LS In conformity to the decree by the Italian Ministry dated 05 08 91 appendix 2 of the Italian State Code have established the following noise values With vehicle in motion 7 m 83 dBA With vehicle idling 7 m 82 dBA EQUIPMENT Tools for ordinary maintenance License plate MAXIMUM PERFORMANCE The highest level of overall machine performance is optimized for the functional testing phase before deliver...

Page 16: ...DAVINO 120TW USER AND MAINTENANCE MANUAL Rev 04 Pag 15 2 2 FIGURE ...

Page 17: ... laws and also meets the standards of the following standards MACHINE European Directive 2006 42 Machine safety Euorpean Directive 2004 108 Electromagnetic compatibility European Directive 2000 14 Acoustic emission ENGINE EU STAGE V EPA Tier 4 CAB ROPS ISO 3471 FOPS LEVEL II ISO 3449 STANDARD QUALITY AMOG srl is a certified company ISO 9001 2015 ...

Page 18: ...hat may result from it The CE declaration of conformity is the document signed by the manufacturer that guarantees and certifies that the machine complies with the European regulatory provisions regarding the product This document is delivered together with all the documentation upon delivery of the machine must be kept with care and must follow the machine until it is completely taken out of serv...

Page 19: ...rotective goggles protective gloves noise canceling headphones if provided Reflective clothing Waterproof for bad weather Protective mask for loads of dusty materilas MACHINE LIMITS The highest performance level of the machine is defined during the functional testing phase before delivery Do not use the machine beyond the limits defined during the design overcoming these limits can be dangerous an...

Page 20: ... area around the operator seat clean Do no put any object at the foot of the operator seat or around the pedals and do not hang anything on the control levers The latter could be unintentionally driven causing uncontrolled displacement of the machine or the operation of the work equipment and therefore of danger situations Arrange items that are not necessary for driving operations in the place th...

Page 21: ...RT THE MACHINE It is forbidden to start the machine if DAMAGED Before using the machine make sure there is no danger condition Also make sure you have sufficient autonomy to avoid the risk of a forced shutdown of the machine perhaps during a critical maneuver Check that the steering and working controls and brakes are working properly In case of irregularities warn the maintenance manager and stop...

Page 22: ...o keep the roadside and be careful to leave space avaialbe to the center for other vehicles In dark conditions carefully check the working area make use of all available lights do not access areas with too low visibility Do not make rapid movements for example steer left and right which can cause the machine to overturn Perform overtaking maneuvers only when absolutely essential When crossing brid...

Page 23: ...gs or structures such a safety distance that even in the case of accidental maneuver there is no danger of contact with such structures VISIBILITY OF THE WORKING AREA Always make sure that no people are in the vicinity of the machine before starting work Before climbing the vehicle take a round of inspection around the machine Dust smoke fog etc may impair visual capabilities and cause accidents A...

Page 24: ...le person Always pay attention to the orders give by those responsible Always command hydraulic services on the driver seat make sure that there are no people within the range of the machine and report any maneuvers with the horn To prevent accidents due to impact on other objects always operate the machine at a safe speed to carry out such operations especially if you are in limited spaces and in...

Page 25: ...nimum Evne passing near high voltage cables can cause electric shock so burns or even death Prepare for every possible emergency war shoes and rubber gloves Place a rubber sole on the operator seat and be careful not to touch the frame with uncoated body parts Appoint a person to report when the machine gets too close to the electrical wiring During operations near the high voltage cables do not a...

Page 26: ...the devices used are securely fastened before pulling Never tow a sloping machine Do not allow people to stay near towing vehicles Maintain visual contact with the operators Perform all the provisions in the specific chapter TRANSPORT To load or unload the car from the transport vehicle choose a flat area that offers a solid support to the carriage or truck wheels Make sure that the vehicle intend...

Page 27: ... work equipment is modified with the risk of causing serious injury to the body hands or arms of the operators who may be entangled Always keep your hands and fingers away from interstices and or kinematics Do not use your fingers or hands to align the holes use special tools Remove any burrs and edges from the replaced and or repaired pieces If you need to access a moving part always lock the wor...

Page 28: ...n only withing the limits indicated by the manufactuer it is advisable to entrust the mediumto highly experienced operators in the presence of particularly rough and uneven ground Do not steer sharply at high speed during driving The center of gravity of the machine can move in relation to the size and position of the load the slope of the ground and the movement of the machine During the tilting ...

Page 29: ...d tires Never inflated tires with gases other than compressed air The tire pressure values and the speed allowed in this manual correspond to the values provided by the manufactuer For details refer to the AMOG or tire manufactuer DANGER OF ELECTRICAL NATURE Any type of intervention on the electrical system or the battery must be carried out by competent personnel Before working on the electrical ...

Page 30: ...ore starting any operations Even when the coolant has cooled down before removing the cap loosen it gradually to lower the pressure inside the radiator To prevent burns when checking or unloading the oil wait for the oil to cool down to a temperature at which it is possible to touch the cap with the hand before starting any operations Even when the oil has cooled down before removing the cap loose...

Page 31: ...s they represent a risk of possible fire Do not leave containers and tanks with flammable materials in areas not intended for storage Do not pour flammable liquids into open wide and low containers Fire caused by accumulation of flammable material Remove dry leaves splinters pieces of paper dust or other flmaable materials that are accumulated or attached to the engine exhaust manifold muffler bat...

Page 32: ...f fire and it is easier to locate broken components and detached parts Do not lubricate or repair the machine while holding the engine running except in the cases expressly required by this manual Avoid signs indicating danger are tampered with or rendered unreadable Do not use parts of the machine such as hangers or supports to perform jobs Do not use free matches lighters flashlights or flames t...

Page 33: ...ension with the motor in motion Do not adjust the power pump with the motor inmotion Handling flammable materials stay at a certain distance from exhaust manifold silencer or hot engine points BATTERY Always disconnect the battery by using the disconnect switch before anyoperation on the lectrical system If replacing the battery first disconnect the negative cable then the positive one To reconnec...

Page 34: ...side Never inflame with inflammable gas or compressed air from alcohol injectors Tighten the wheel fixing nuts on the axle to the specified torque after reassembling the wheel Check the pair of nuts every day until it stabilizes SUPPLIES Only use products recommended by the manufactuer in the lubricating chart of this manual Make sure that supplies or refills are carried out accordin to the times ...

Page 35: ...mage or damage caused by unauthorized modifications CLEANING THE MACHINE Oil or grease implants scattered tools or broken pieces are harmful to people because they can cause slips and cause falls Always keep the machine and work place clean and in order Careful cleaning of the floor handrails instrumentation nameplates headlamps and cabin glasses Use compressed air to clean the parts protect the e...

Page 36: ...e damaged or missing decals with orginal AMOG 3 if replacement of a component wiht safety decals and warning is required make sure that the new component has the same decals 4 when replacing the decals make sure the bottom is clean dry and free from oil or grease The manufactrer declines any laibility for damages to persons or property resulting in non complaince with the behavioral rules reported...

Page 37: ...aeve the driving seat but cling firmly to the steering wheel Ma chine equipped with ROPS type protection DANGER with machine in motio do not apporach and do not move strangers to moving parts danger of crushing the limbs DANGER the acoustic signal indicates that the machine or mechanical devices are in movement Ensure that all persons stay clear of the machine s work radius ...

Page 38: ... manual before performing any action on the machine WARNING This symbol indicates the presence of a seatbelt always wear a seatbelt when operating the machine WARNING This symbole indicates that an helmet must be worn WARNING this symbol identifies the requirement for the use of noise protection in case of an average noise exposure greater than 85 Lp Depending on the daytime exposure use adequate ...

Page 39: ...is greater the ROPS structure is not able to fulfill its security functions OPERATOR S SEAT MICROSWITCH Transfer of the machine can only occur if the operator is seated properly The advancement of the machine can only be achieved through two distinct actions moving the direction control lever and the presence of an operator in the seat Therefore two conditions are necessary For the advancement of ...

Page 40: ... fastened the seat belt is also used by the operator to maintain control of the machine in case it should swing violently or encounter other critical conditions Make sure your seat belt is mounted correctly The seat belt and related parts should be inspected periodically Immediately replace the entire belt if it appears worn unstitched or with the winder not working properly Replace the seat belt ...

Page 41: ...perly regulated and intact Place the mirrors correctly before starting the machine checking that you have as much visibility as possible towards the tires and the sides of the caisson The use of the machine with limited visibility can cause serious accidents When the machine is transported the mirrors must be bent to avoid damage Left Rear View Mirror Allows to see the left outside side of the mac...

Page 42: ...e Always Return the swivel frame to the locked position during the transfer phase To release the rotation of the trailer slightly lift the body so as to release it from the plug MANUAL PUMP FOR CAISSON DESCENT It allows the descent of the caisson in case of sudden engine failure machine off if necessary do the following 1 free the control lever of the pump unscrewing the n 2 fixing knobs 2 rotate ...

Page 43: ... locks the accidental descent of the dump Always Insert the retainer to carry out maintenance operations requiring the lifting of the dump When not in use the plug can be placed in the tubular pin holder inside the swivel frame CABLES FOR END OF TRAVEL Present on both sides of the dump ensure the mechanical end of the dump during the lifting phase ...

Page 44: ... the differential distributing evenly the torque available on the two shafts In this way even in the hypothesis of a single wheel with proper adhesion the vehicle is able to continue its march by transmitting the driving force to the ground To actuate the rear axle differential lock press and hold the button on the manipulator Port armrest Once the obstacle is exceeded release the button To operat...

Page 45: ...ate the battery switch when the motor is running it does not turn off the motor but only damages the current alternator LIGHT WAIT TO DISCONNECT Operate the battery switch only when the light is off When the machine panel is turned off the motor automatically activates a cycle for emptying the DEF circuit to prevent any fluid spills from damaging the parts of the circuit During this cycle the ligh...

Page 46: ...is field tested using all it s components prior to shipping Therefore upon arrival the required Breaking In period is 50 hours of operational use During the Breaking In period operate with light to medium loads and at reduced speeds This will allow the oil and hydraulic systems to reach normal operating temperature evenly Allow the cooling system to reach normal operating temperature prior to maxi...

Page 47: ... knows the position and function of all machine controls Every machine has it s limitations before operation familiarize yourself with it s abilities characteristics velocity braking steering stability and load capabilities The following is a well defined illustrated overview of the machine s controls and instrum 1 Guide seat 2 Operator s console dashboard 3 Cab instrumentation 4 Joy stick Steerin...

Page 48: ...m of the steering column Before starting the machine adjust and lock the steering column in the most suitable and comfortable position in order to be able to reach all the controls with ease and precision BUZZER Nr 2 buzzer indicates specific conditions or anomalies In particular upper buzzer indicates that the tilt of the dump in the exhaust is greater than 45 alerting the operator to greater att...

Page 49: ...ds to select the gear back THE SELECTIONFOR THE NEXT AND BACK GUIDE SHOULD ABSOLUTELY WITH STOPPED AND STABLE MACHINE RIGHT HAND MANIPULATOR Enables the following functions Direction indicators Move the manipulator forward and backward to actuate the direction indicators and indicate respectively the right and left turn respectively Lights position Low Beam High Beam Rotate the manipulator counter...

Page 50: ...west gear and intervene on the pedal by pressing intermittently to not overheat the brakes For downhill running ALWAYS use the first mechanical gear 1 and the slow Hydraulic gear turtle If necessary check the speed of the machine using the brake pedal Pay attention to the downhill gear especially in the case of strong slopes long distances and in full load conditions of the machine INCHING CONTROL...

Page 51: ...ight and other one for the fuel level left n 19 alarms signal pilot indicators n 7 external switches to access to display functions DISPLAY Following measures can be visues Gears In the upper right part of the display are displayed the mechanical and hydraulic gears a Mechanical gears There are two mechanical gears working gear turtle 1st mechanical gear transfer gear hare 2nd mechanical gear ...

Page 52: ...ounting Tachometer In the left side is displayed the number of revolutions of the engine DEF level In the middle right side is displayed the level of the DEF If the DEF drops below the reserve level the red light lights up in the lower right corner ANALOG INDICATORS Engine coolant temperature Indicates the temperature of the engine coolant If the indicator needle moves to the red sector the red li...

Page 53: ...h and stop of the engine is on position 2 L3 Engine oil pressure Red Stay lighted when the contact key is turned on bifore to start the machine Once the engine starteed it switches off to signal the corect oil engine presure L4 Parking Red It lightes when the parking brake is inserted L5 Shutdown Lamp buzzer Red In combination with the Warning Lamp it allows the diagnostics of the motor fault cond...

Page 54: ...r To indicate that the DPF is in need of regeneration L10 DPF Disabled Lamp Amber Indicates that a regeneration has been inhibited L11 Steering Alignment Amber Signals the misalignment of the rear wheel axle to light Turns off when the wheels are perfectly in the axle with the machine L12 Service Amber Lights up when the number of hours that are missing from the service drops below 20 units When t...

Page 55: ...ne exceeds 110 c L17 Emission System Malfunction Red It turns on signaling a malfunction condition of the exhaust system L18 Riserva DEF Red It lights up when the DEF drops below the reserve level L19 Position Lights Green Turns on when you insert the position lights L20 Direction indicators Green Lights up intermittently when you insert the direction indicators L21 Dazzling lights Blue It lights ...

Page 56: ...mode see section 5 2 2 STEERING MODE SELECTION KEY 5 Emergency lights switch It operates the four turn signals in flashing mode To be used to signal emergency conditions for example if you are forced to stop at a place where the car poses a danger to other road users 6 Mechanical Gear Shift Key It Allows the change of the mechanical gears see Paragr 5 2 4 MECHANICAL Gear SHIFT KEY 7 Parking brake ...

Page 57: ... 5 2 1 DRIVING DIRECTION SELECTION MODE KEY The button allows you to choose the mode of selection of the direction of travel 0 Manipulator Left Steering Column Devioguide see parag 5 1 DRIVER SEAT 1 Right Manipulator Handle button see parag 5 4 MANIPULATOR ...

Page 58: ...s with the rear in the opposite direction of the front for a lower angle of steering Before operating the machine transfer manoeuvres check the correct alignment of the four wheels 5 2 3 PARKING BRAKE KEY The button activates the parking brake to lock the machine during the working stops with the motor running with motor off the parking brake is automatically inserted To Lock the machine press the...

Page 59: ...r The selection of mechanical gears must be mandatory with a stationary and stable vehicle To change the mechanical gear proceed as follows 1 completely STOP the machine and OPERATE THE SERVICE BRAKE 2 INSERT the desired mechanical gear The correct gear change is signalled by a beep If The sound signal persists the gear is not engaged To Insert it correctly do the three actions to follow SIMULTANE...

Page 60: ...s B2 Rear wiper control button 2 speeds B3 Front work headlights control keys optional C1 Work headlights command key optional C2 Work headlights command key optional C3 Work headlights command key optional D Knob On Off Air Conditioning 3 speeds E Knob On Off Heating F Cooling intensity knob G Air conditioning vents H Vents recirculating air conditioning Working lights must be turned off when roa...

Page 61: ...b D and select the desired fan speed 3 speeds 2 Move the knob to the On position And 3 Bring the knob F to zero 4 Orient as desired the nozzles G In both cases to activate the air recirculation function of the passenger compartment when the outside temperature is too hot in summer or too cold in winter close the external air intake on the rear side of the cab and operate the vents H CURRENT OUTLET...

Page 62: ...locking cylinder only if you really need to Returning the button to the rest position resets the automatic cylinder operation KEY 2 STEERING INVERSION CONTROL GUIDE POSITION ROTATION Reverses the operation of the steering wheel allowing the driver s seat to rotate To place the driver s seat follow these steps 1 operate the KEY 2 STEERING INVERSION COMMAND ROTATION DRIVER SEAT 2 Operate the pedal t...

Page 63: ... The movement along the X X axis of the manipulator allows the rotation of the chassis swivel to the right and to the left To obtain the rotation of the dump proceed as follows Lift the dump slightly so as to release the swivel frame from the rotating locking pin Turn the dump to the desired position ...

Page 64: ... the lever towards the operator the tank returns to the resting position descent The movements of the dump must be performed slowly and progressively During the loading phase place the machine for stability reasons on a stable and well leveled ground Avoid loading on soft and low level terrain The weight of the material loaded on the body must never exceed the maximum load value indicated in the l...

Page 65: ...n To operate the differential lock proceed as follows 1 align the rear wheels until the special indicator on the dashboard is switched off 2 Select the 2RS steering mode front wheels only so that the rear wheels are locked 3 align the front wheels until the yellow light on the locking button is lit 4 Press and hold the lock button Once the obstacle is exceeded release the key or steer to release t...

Page 66: ...oke of the control cylinder of the dump increasing the unloading angle of the dump normal run unloading angle 50 extra run unloading angle 78 Operate the button only if really necessary wet compact material etc making sure that the machine is positioned on a stable and well leveled ground PREDISPOSITION ...

Page 67: ... on the machine always read chapter 3 the safety regulations regarding the operations to be carried out 6 2 REFUELLING Before checking or refueling the fuel tank make sure there are no free flames or smokestacks in the area Do not refuel with the motor in motion do not use matches lighters or torches as a light Refill the machine with decanted diesel and no water residue Use a filter pump with a d...

Page 68: ...cause the release of ammonia vapors Do not breathe ammonia vapors Do not clean up any leaks with bleach To refuel the DEF proceed as follows 1 Remove the DEF cap from the tank The opening on the DEF tank has a special diameter When refilling the DEF tank be sure to use the correct nozzle 2 Fill the tank with the required amount of DEF When refueling be careful not to get dirt into the tank Do not ...

Page 69: ...position in order to be able to reach all the controls with ease and precision and fasten the seat belt Act on the lever in the figure on the left until you position the reference hand in the center of the ladder to proceed with the adjustment of the seat suspension according to the weight of the operator Act on the lever in the figure on the right to adjust the distance of the seat from the pedal...

Page 70: ...ne for the transfer manoeuvres and towards the back of the machine rotated by 180 during the working phases To position the guide seat see Parag 5 3 CABIN INSTRUMENTATION 6 8 START UP ENGINE Before starting the engine make sure that no nearby people are present and if necessary alert Do not operate the machine in closed and ventilated areas Check that the travel selector is in a neutral position o...

Page 71: ...d 6 9 WHEEL ALIGNMENT Before each transfer it is imperative to check the correct alignment of the 4 wheels to avoid translational problems In the event of aligning the 4 wheels proceed as follows position the steering mode selector lever in the Crab position 1 o 4 WD 3 act on the steering wheel to bring the rear wheels in a straight line with the machine their alignment will turn off the special l...

Page 72: ...s needed Depending on the visibility of movement and the condition of the road surface adjust the speed of the car but always proceed with extreme caution so that the march is comfortable and safe High speed can cause accidents with serious or fatal injuries Always proceed slowly downhill cornering on uneven surfaces and on slippery surfaces Constantly make sure of the presence of people in the ar...

Page 73: ...lat dry ground Remove the starter key before leaving the machine Bring all commands to a neutral position if necessary leave the emergency lights on Abandon and close the machine To get out of the car use the appropriate handles and steps If you leave the machine close and lock all the crystals and lock the door if any Check that the tank cap and engine hood are locked 6 14 USING THE MACHINE DOWNH...

Page 74: ...the loading phase place the machine for stability reasons on a stable and well leveled ground Avoid loading on soft and low level terrain The weight of the material loaded on the dump must never exceed the maximum load value indicated in the license plate placed on the vehicle Once the dump is loaded before you start moving check that the load arrangement has been carried out correctly and that it...

Page 75: ...er slip material Use a marker that keeps a general view of the machine floor and operator Lower the dump Maintain a very low climb or drop speed both on the ramps and on the floor limiting the use of the throttle and steering to the minimum indispensable Carry out the machine as described above Attach the machine securely to the floor and lock the wheels with special wedges Make sure that all door...

Page 76: ... Observe the instrumentation frequently and check that it is working properly Strictly observe the code of the road code In the event of a traffic slowdown take a sideways ride to the dock to facilitate the flow of the vehicles faster When replacing the tires make sure that the type and tread pattern conform to those recommended by the MANUFACTURER Not all tires are homologated for road traffic at...

Page 77: ... and in any situation to indicate a risk of movement Anyone who circulates on the road with an operating machine that does not comply with the law is punished by administrative sanction For road traffic of the vehicle the manufacturer of the conformity declaration must be delivered by the BUILDER These documents will then be presented to the provincial engineer s headquarters by the purchaser for ...

Page 78: ...not intended to tow other vehicles or trailers To tow the machine in case of failure follow the instructions below Stop the engine Unlock the parking brake Unlock the transmission Hook a suitable tow bar into the hook Turn on the emergency lights and the rotating lamp Keep an operator aboard the machine properly seated at the driver s seat with belt loops and a steering wheel in the right directio...

Page 79: ...on screws must be screwed alternately by rotatin them by 30 al a time do not fully screw one of the screws and then the other one It is not necessary to screw the screws completely you must stop as soon as the brake is unlocked Proceed reverse to reset the negative brake To place the gear in neutral proceed as follows loosen the two hydraulic hoses 4 and 5 loosen the shaft 6 until it is no longer ...

Page 80: ...t completely in order to avoid violent high temperature steam emission Before mixing in the radiator rinse the cooling system using a specific product Use a recommended type and brand antifreeze product in the REFINING TABLE and determine the water to freeze percentage based on room temperature using the table AMBIENT TEMPERATURE WATER FROST 15 C 60 40 25 C 50 50 35 C 40 60 Completed the supply to...

Page 81: ...to the lowest dead spot Make a few turns to the engine in order to distribute the veil of oil on the cylinders Refit the injectors Remove the battery and place it in an environment that can not reach the low temperatures and reload at least once a month Charge the battery with a slow charge Before connecting the cables make sure that the polarities are respected Do not short circuit the terminals ...

Page 82: ...rried out to ensure the machine s functionalityt and to ensure the safety of the operator or anyone working around the machine Cleaning check Clean the glasses headlights and mirrors and ensure that the mirrors are correctly positioned for maximum visibility at the back of the machine Remove trash and or dirt from pins and radiator Make sure the step and the lift handle are dry and clean clean all...

Page 83: ...k air and stop suddenly endangering the operator s safety LOADING DUMP No specific explanations are required to load the box manually under silos or other mechanical means unless recommended by the safety regulations Do no stay in the driving seat while loading UNLOAD DUMP Get closer to the discharge area while keeping away from safety Stop the machine Slowly raise the drain box Lower the drump wh...

Page 84: ... The warnings in this publication are therefore not comprehensive If you take procedures equipment or methods not specifically recommended ensure that work is performed safely for those who perform it and for others Carefully read all the safety instructions in the User s guide especially those regarding general and specific MAINTEANCE NOTES Always switch off the engine and wait for the machine to...

Page 85: ...ns Before and after lubrication clean any covers lubricating points and caps to avoid particles from entering Always add suggested amount of oil An excessive or insufficient amount of oil can cause a malfunction When changing the oil always replace respective filter at the same time The filters are extremely important parts that prevent possible problems due to impurities Never attempt to clean a ...

Page 86: ...ove the spilled fluid If you find a leak find the source and repair If you suspect a leak check the fluid levels more often than normal until the leak is detected and repaired or until the suspect becomes unfouded Check all the lights indicators of the machine and replace any burnt bulbs or broken housings Try horn operation Repair or replace it if necessary Check that all safety decals are in pla...

Page 87: ...easers Control Battery Control Clamping bolts and wheels Control Differentials oil Control Epicycloidail reducers oil Control Gear oil Control Oil reducer Control Alternator belt tension Cleaning Tank gasoil Cleaning Motor radiator First 100 Engine oil Engine oil filter Fuel filter Hydrostatic oil filters Hydraulic oil Differentials oil Epicycloidal reducers Wheel reducer Gear Oil Brakes oil Cooli...

Page 88: ... Follow this maintenance procedure with engine off Allow engine to cool before checking the oil level to prevent burns In the presence of signals of insufficient engine oil however or for a daily check it is necessary to follow these guidelines Set machine on level ground and shutt off the engine Wait about 10 minutes before proceding Remove the dipstick and wipe the oil with a clean cloth Insert ...

Page 89: ...ENISHING COOLANT LEVEL See Engine Manual Open the hood only after shutting down the engine As the fluid is pressurized slightly rotate the filling cap to discharge the pressure before removing it Do not remove the cap if the engine is still hot Park the machine on a flat area Shutdown the engine Wait until the liquid has reached ambient temperature Slowly unscrew the cap and check that the liquid ...

Page 90: ... inside the filter and remove the dirt when needed Also check that there are no tears or holes in the filter elements and the filter gasket is not damaged Operating conditions dust dirt and debris may require service of the air filter element more frequent In any case replace the air filter element at least once a year regardless of the number of times the element has been cleaned Always use safet...

Page 91: ...cted area with respect to the side wall of the tire Never inflate by using flammable gases or compressed air systems with alcohol injectors Before removing elements embedded in the tire you need to deflate it The incorrect inflation may cause drawbacks and damage to the tires both insufficient inflation and excessive inflation should be avoided Along with the tire pressure checking also check the ...

Page 92: ...IFFERENTIAL OIL PLANETARY GEARBOXES AND GEARBOX For control operations and possible oil refill proceed according to following indications Set machine on level ground Rotate wheel hubs up to bring level control plugs in a horizontal position Unscrew the level plugs If oil is dripping it is not necessari to top it up If however it is not dripping topping up is required Fill with oil using a tubular ...

Page 93: ...DAVINO 120TW USER AND MAINTENANCE MANUAL Rev 04 Pag 92 Wheel shub Plug level Charge Discharge Gearbox A Plug discharge oil B Plug charge oil C Plug breather oil ...

Page 94: ...the load due to the older one is loose This additional load on the new belt will break it If belts are too loose the vibrations resulting cause unnecessary wear of the belts and pulleys A slack belt may slip enough to cause overheating To control the belt tension properly use an appropriate indicator As an alternative check that the belt between the alternator and the drive pulley has an approxima...

Page 95: ... Keep the used oil in a suitable container and deliver it to the companies responsible for the storage and disposal of polluting and hazardous waste CHANGING THE FUEL FILTERS see Engine Manual Open the hood only with the engine switched off Avoid environmental contamination Keep the filters in suitable containers and deliver them to the companies responsible for the storage and disposal of polluti...

Page 96: ...container This oil should be re used to refill the level It is essential to maintain a stock of spare filters available from your AUTHORIZED SERVICE CENTERS or directly to AMOG SPARE PARTS SUPPORT SERVICE Avoid environmental pollution Store old filters in adequate containers and consign them to authorized companies for the treatment of harmful and polluting waste DIESEL FUEL TANK CLEANING Set the ...

Page 97: ...turer and suggested in the lubricant table AXLE AND GEAR OIL CHANGE Bring the machine on level ground Turn off the engine and insert the parking brake Place two containers under the front and rear axles Unscrew the drain plugs of the differentials and planetary gearboxes taking care to bring for every planetary gearbox the oil level drain plug in the lower position by rotation Unscrew the drain pl...

Page 98: ...ding of the system as follows Seek the assistance of an operator that goes on the driving turret to operate the brake pedal Unscrew the vent by half turn and press the brake pedal until fluid free from air bubbles comes out from the vent Repeat this process on all the vents of the axles Top up the level The presence of air in the brake system makes the braking ineffective Always proceed to the air...

Page 99: ...urn off the engine Wait until the liquid has reached room temperature Slowly unscrew the radiator cap Completely drain the liquid through the valve on the engine crankcase into a prepared container Slowly pour the recommended fluid through the filler neck of the radiator until full coverage Put the cap back Close the hood Run the engine for a few minutes Allow engine to cool Top up the level Only ...

Page 100: ...ENTS FUSE AND RELAY TABLE If a fuse or relay is burning find the cause before replacing it with a new one Relay X122 Pos DESCRIPTION R1 15 INSERT MICROWAY INSERT GEAR BUZZER R2 15 ENGINE R3 CLACSON R4 RESET GEAR STOP LIGHTS SUPPLY STEERING R5 RELIEF VENTILATION CONSENT R6 BUZZER ...

Page 101: ...A F3 SUPPLY STEERING 15 A F4 30 15 A F5 DEUTZ ENGINE PUMP 25 A F6 DEUTZ ENGINE PUMP 25 A F7 MAIN RELE 5 A F8 BRAKE MICROSWITCH 10 A Relay X124 Pos DESCRIPTION AMPERE F1 30 MICROSWITCH EMERGENCY 15 A F2 30 DISPLAY 5 A F3 IN HIGH BEAM LIGHTS 15 A F4 IN DIPPED HEADLIGTHS 15 A F5 CEILING 5 A F6 OUT HIGH BEAM LIGHTS 10 A F7 HIGH BEAM LIGHTS 10 A F8 OUT DIPPED HEADLIGHTS 10 A F9 DIPPED HEADLIGHTS 10 A F...

Page 102: ...CRIPTION R1 15 ENGINE ENGINE PUMP DEUTZ R2 15 Fuses X140 Pos DESCRIPTION AMPERE F1 15 ENGINE 60 A F2 30 STARTER 30 A F3 RELAY GLOW 60 A F4 RELAY VENTILATION 30 A F5 30 FROM FUSE FAN HYDRAULIC OIL EXCHANGER 30 A F6 30 40 A Relay X131 Pos DESCRIPTION R1 DEUTZ GLOWS ENGINE R2 FAN ...

Page 103: ...lacement the panel is already pre programmed Take note of the hours worked before replacing the electronic dashboard BULBS REPLACEMENT Changes or repairs to the lectrical system incorrectly and without taking into account the technical characteristics of the system can cause malfunctions of operation with fire hazards When no light is operating check that the corresponding fuse is intact before re...

Page 104: ... Do not invert the connection of the battery cables Do not weld on the machine without first disconnecting the battery In case of partial discharge of the battery connect the auxiliary battery or other one respecting the connection positive and negative Avoid environmental pollution batteries are classified according to law as polluting and harmful waste Remove the batteries by providing storage i...

Page 105: ... below the front or rear axle respectively and slowly lift the machine to release the deflated wheel from the ground on which it is leaning then proceed to its restoration Lift the machine ONLY with the empty dump and in the rest position Be careful that there are always 3 wheels resting on a stable and level ground The front axle is tilted and during lifting can create a danger of crushing the ar...

Page 106: ...o avoid a motor fault condition To enable regeneration you must park the car with the engine running at idle insert the parking brake make sure that the engine temperature is 60 C If even one of the previous conditions engine at idle parking brake inserted engine temperature 60 C is not verified the regeneration is not activated Alarms The engine is equipped with integrated diagnostic functions th...

Page 107: ...s SPN and FMI and promptly contact AMOG or Perkins technical support To view the engine error cidics SPN and FMI press the TEST button for about 5 seconds Depending on the specific failure and severity of the problem the engine may continue to operate apparently in a normal way or with reduced power In any case investigate the causes of the failure as soon as possible to avoid further damage to th...

Page 108: ...he number of hours left before the service falls below 20 units It becomes flashing when the number of hours left before service becomes negative ie when the range of hours is exceeded Once the service is completed to update the missing hours to the next service proceed as follows Drive mode default mode of the dashboard screen at the starting of the machine press touch A during 5 seconds to enter...

Page 109: ...Pag 108 Once the Service is zeroed the fields are updated Current service range and Hours missing at the next service The update is indicated by the flashing for about 5 seconds of the field Current service range Press touch A to return to Drive mode ...

Page 110: ...nd replenish Air filter clogged Clean replace EXCESSIVE FUMES Fuel pump Check pump operation Fuel not suitable Replace Air filter clogged Clean replace ENGINE OVERHEATING Cooling system Check fluid level Fan Check that the engine is being ventilated Radiator Clean radiator Fan belt Check tension INSUFFICIENT POWER Accleration controls Check that the controls operate properly Hydrostatic unit Check...

Page 111: ...age air suction GEAR LEVER INOPERABLE Electrical disconnection Test LED lamp on the hydrostatic pump solenoid and on the hydrostatic motor Electrical disconnection Check fuse n 18 Check solenoid coil Motor and pump INSUFFICIENT BRAKING Pedal disconnect check Insufficient brake oil check Brake fluid leakage check Loose tie rods adjust DISTRIBUTOR LEVERS HARD TO MOVE Hydraulic oil dirty contact spec...

Page 112: ... Hub 1x4 Oil Differentials 8 5x2 Oil Gearbox 1 4 Oil Brakes 0 8 Gasoil tank capaicty 95 DEF 19 Antifreeze mix 50 7 15 2 FLUIDS AND LUBRICANTS TABLE LUBRIFICANTS Oil Engine SAE 15W40 API CJ4 Oil Hydraulic AGIP OSO 46 68 ISO L HM MIL L 2105 Oil Axles GEAR BASIC 90 LS 85w90 Oil Brakes AGIP Arnica 22 ISO L HV Antifreeze Antifreeze Fuel EN 590 DIN 51628 ULSF DEF AD Blue ...

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