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AUSA D 1000 AP, Operator'S Manual

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AUSA D 1000 AP Operator'S Manual Download Page 49

D 900 AP / D 1000 AP / D 1000 APG

47

(fi

 g. 

3)

(fi

 g. 

2)

(fi

 g. 

1)

Periodic 

maintenance 

operations



Changing the oil and the filter cartridge of the gearbox and converter. 

(fig.1, 2)

WARNING!!

The first replacement of oil and filter cartridge for the gearbox and converter should take 
place after 50 hours of service. Initial maintenance is very important and must not be 
neglected.

-  Oil changes should be carried out when the oil is warm.
-  Secure the dumper on a level surface.
-  Remove the dipstick.
-  Clean the area around the oil drainage cap.
-  Place a container underneath the oil drainage cap.
-  Unscrew the oil drainage cap.

e. Oil drainage cap

Allow the oil to drain for a while.
Unscrew the filter cartridge located on the right side of the gearbox and converter and 
remove it from its support.

f.  Oil filter cartridge.

Clean the base and cover the joint of the new filter element with clean oil.
Screw in the filter element once again and tighten by hand; do not use mechanical tools.

WARNING!!

-  Clean any oil spillage.
-  Change the joint in the oil drainage cap.
-  Clean the area around the gearbox and converter, the oil drainage cap and 

replace the cap.

-  Refill the gearbox and converter as per the recommended oil level.
- See the 

LIQUIDS AND LUBRICANTS

 section of the Manual for capacities.

-  Ensure that there are no leaks in any of the oil filter areas and on the oil drainage 

cap.



Suction filter (fig. 3)

WARNING!!

The first cleaning of the suction filter for the gearbox and converter should take place 
after 50 hours of service. Initial maintenance is very important and must not be neglected.
To extract the filter, unscrew the two screws which secure the cover.
Once extracted, it must be thoroughly cleaned and dried.

g. Suction  filter

Once clean, place the filter inside its housing once again.
Fix the cover, replacing the seals for new ones.

 

e

f

g

Summary of Contents for D 1000 AP

Page 1: ...D 900 AP D 1000 AP D 1000 APG OPERATOR S MANUAL ENGLISH ORIGINAL MANUAL ...

Page 2: ......

Page 3: ...D 900 AP D 1000 AP D 1000 APG Above chassis number 63163011 ORIGINAL MANUAL ...

Page 4: ......

Page 5: ... use of the vehicle Please contact your official AUSA agent or dealer if you have any queries complaints or orders for spare parts For further information you may call write FAX or email to AUSA Center S L U P O B 194 08243 MANRESA Barcelona SPAIN Tel 34 938 747 552 938 747 311 Fax 34 938 736 139 938 741 211 938 741 255 E mail ausa ausa com Web http www ausa com AUSA is continually improving its p...

Page 6: ...Controls instruments equipment 17 Operating the dumper 22 Break in period 26 Before starting the dumper 27 Transporting the dumper 28 Liquids and lubricants 31 Special procedures 34 Periodic maintenance operations 36 Maintenance chart 57 Greasing points 59 Electric diagram 60 Hydraulic diagram D 900 AP D 1000 AP 66 Hydraulic diagram D 1000 APG 67 EC declaration of conformity 68 ...

Page 7: ...nance or repair operations Current legislation must be adhered to Highway Code when driving on public roads AUSA shall not be responsible for any possible harm caused by any modification carried out on the dumper without their express authorisation Improper use Improper use is understood to be the use of the dumper in such a way that it does not meet with the criteria and instructions of this manu...

Page 8: ... sure that the area is well ventilated in order to prevent the excessive build up of exhaust fumes Always turn the engine off when it is not needed To drive the dumper on public roads all necessary approvals and licenses must be obtained in accordance with the current country legislation also incorporating the signalling and safety elements included in the legislation Current legislation does not ...

Page 9: ...ig 2 3 4 If you notice any anomaly while using the dumper inform your superior or maintenance service immediately Keep hands feet and the whole body in general inside the area provided for the operator Pay special attention to work on slopes move slowly avoid being situated crosswise and do not operate slopes which exceed the recommended gradient A slope within the recommended gradient does not me...

Page 10: ...mper has the possibility of two axle traction consider that this must only be connected when required for surmounting a sloping obstacle or a slippery surface Drive at a reduced speed in order to preserve the tyres and do not subject the traction steering unit to excessive workloads Take care when loading and unloading the dumper Do not empty the contents of the cargo box near a bank which is not ...

Page 11: ... systems make sure there is no pressure in them and take steps to avoid unexpected spills Never use a flame to check fluid levels and leaks Regular checks should be carried out on the hydraulic system to detect any possible leaks or misalignment on the safety valves which could lead to a risk situation Regular checks should also be carried out on all those elements whose excessive wear or ageing c...

Page 12: ...oldering work on the dumper remove the electric and electronic equipment in order to avoid possible damage to the installations If the dumper to be towed is hydrostatically driven before doing so follow the instructions indicated in this manual for the disconnection of the drive shaft therefore facilitating towing and eliminating any risk to the hydrostatic unit When changing a tyre make sure that...

Page 13: ...D 900 AP D 1000 AP D 1000 APG 11 Identification plates and labels ...

Page 14: ...t Steering ORBITROL Hydraulic system driven by a hydraulic cylinder which controls the chassis articulation Work Pressure 115 bar Brakes Service Brake Multiple disc oil filled sealed units Hydraulically powered Parking Brake Multiple disc oil filled sealed units Mechanically powered Wheels All four wheels are the same Wheel sizes 500 60 22 5 16PR Inflation pressure front wheels See machine identif...

Page 15: ...Vibration and sound levels Sound power level Warrantee sound power according to 2000 14 EC sound emissions in the environment by machinery for outdoor use Lwa 102 dB A Sound pressure level on the operator s site A weighted sound pressure in the operator s ear measured following norms ISO 6394 Lpa 84 dB A Measurement uncertainty 2 5 dB A Vibration level produced by the machine Root mean square freq...

Page 16: ... 5225 5944 Optional Equipment Officially approved lighting equipment WARNING The seat belt is an important part of this safety system and must always be fastened before operating the dumper Failure to wear the seatbelt in the event of an accidental tip over could result in serious injury or death by crushing caused by the vehicle or the overhead protector itself Specifications ...

Page 17: ... D 1000 APG A 2480 2480 2480 B 2190 2380 2385 C 2440 2440 2440 E 1860 1820 1950 F 3530 3560 3560 G 490 490 490 H 1260 1260 1230 I 2450 2450 2450 J 1220 1220 1220 K 4518 4520 4990 L 2640 2710 3820 M 665 665 630 N 430 430 1100 T 3370 3370 3375 U 100 W 2550 2550 2550 Specifications ...

Page 18: ... plate fig 1 is located on the front part of the engine protector behind the gear stick It includes the CE trademark The frame number fig 2 is marked on the front part of the right side of the chassis The engine number fig 3 and 4 is marked on the left side of the block behind the fuel filter and on a label on the upper part of the valve cover The ROPS arch homologation plate fig 5 is located in t...

Page 19: ...his Manual indicate the sides of the vehicle from the driver s seat looking forward Identification of the components a Protector arch b Operator s seat with seatbelt c Rotating indicators d Cargo box e Joystick f Steering wheel g Gear stick h Parking Brake i Lights and signal lights optional a f d c b i a e a h a g ...

Page 20: ...wards and by pushing the back of the switch the machine will move backwards In each case the corresponding directional arrow will light up green forward and red reverse WARNING Do no make brusque changes in direction in order to avoid any breakage to the gearbox Changing gears fig 3 The vehicle has four gears which are selected using the gear stick d The positions of the gear stick d with which to...

Page 21: ... brake Skip s controls fig 2 3 4 5 D 900 AP and D1000 AP models fig 2 3 Skip operations are done with the joystick By pushing lever b to the front the skip tips forward and by pulling b back the skip tips backwards up to its rest position D 1000 APG models fig 4 5 By pushing lever b to the front tips the skip forward and by pulling it back the skip tips backwards up to its rest position The skip r...

Page 22: ...ction or a broken alternator belt or water pump K Air filter lamp Indicates when the air filter is dirty or obstructed The filter element must be cleaned or changed immediately L Engine oil pressure lamp When the contact is activated it will light and will turn off when the engine is in operation If the engine is functioning and the warning light is lit the engine must be stopped immediately to pr...

Page 23: ...ned on By pushing the lever down the high beam is turned on Pulling the lever upwards selects the dazzle lights Horn Activated by pressing the end of the multifunction switch Use of accessories and equipment In the case of the vehicle being equipped with accessories before using them carefully read the specific instructions manual for the accessory provided by its manufacturer and supplied togethe...

Page 24: ...e lever the backrest unlocks Adjust the backrest and release the leaver to lock again Ensure that you fasten your seatbelt Seatbelt fig 4 5 6 To fasten the seatbelt insert the snap e into the fastener f until your hear the locking click To unfasten the seatbelts press button g The seat belt adapts the body of the passenger using it giving them freedom of movement but adjusting the belt to the phys...

Page 25: ...s could cause changes to the handling of the dumper with the possibility of an accident occurring which could cause serious injury or even death to the operator The relation between the dumper and the load is conditioned by changes in The use of attachments Changes in the dumper movement and type of terrain in which the vehicle moves Smoothness and stability must be maintained whilst these factors...

Page 26: ...mal way 5 Disconnect the cables from the terminals first the positive terminals and then the negative terminals Parking the dumper and stopping the engine Whenever the dumper is parked either at the end of the day or in order to carry out any maintenance work it should be parked on level ground Apply the dumper s parking brake Keep the engine in idle for 1 minute if the dumper has been working at ...

Page 27: ...he bolts k located on each side of the ROPS protector arch 2 Remove the bolts k 3 Carefully fold the top part of the ROPS protector arch h backwards to the Transport position 4 Once it is correctly positioned fig 4 replace the bolts k and then the locks j Working position To place the ROPS protector arch in this position follow the instructions in the reverse order WARNING Carefully ensure you pos...

Page 28: ...ion and speed variations contribute to a good break in Continued wide open throttle accelerations prolonged cruising speeds and engine overheating are detrimental during the break in period First inspection 50 hours As with any precision part of a mechanical element we suggest that after the first 50 hours or 30 days from purchase whichever is reached first the dumper is inspected by an authorised...

Page 29: ...c oil coolant and brake fluid levels Check for oil leaks on the engine in the transmission components or in the hydraulic circuit Clean the lights and the lamps if there are any Ensure that the engine protector is correctly covered Ensure that the seatbelts are correctly secured Before starting the day carefully inspect this devices with special attention to Cuts or threading on the belt Wear or d...

Page 30: ...uel tank full Make certain your seatbelt is properly fastened Move the dumper slowly and carefully up or down the loading ramps Apply the dumper s parking brake Connect the gear stick in such a way that it creates additional retention for the dumper in case of the parking brake failing Stop the engine and remove the key from the ignition Apply chocks to the front and rear wheels Firmly secure the ...

Page 31: ...he counterweight fig 3 Always carry out this operation with the machine unloaded Before hoisting check that the cable or sling is firmly hooked and that both the crane and the cable or sling have sufficient capacity to lift the load During hoisting do not allow any person to be on the truck or any spectators within a 5m radius Always undertake this operation on flat and horizontal ground Use guide...

Page 32: ...s disconnected Failure to take this precaution may cause severe damage to the transmission Remove the parking brake Drive slowly and carefully without exceeding 10 km h 6 Mph complying with the country regulations relating to the towing of an off road vehicle on roads and highways The dumper must be towed using a solid towbar to avoid any sideways oscillation and always with the chassis fixed rigi...

Page 33: ...dance with ISO 6743 4 HM DIN 51524 461 00001 00 14 3 TORQUE CONVERTER AND POWER SHUTTLE 10W or 10W 30 Grade mineral oils or automatic transmission fluids which meet at least one of the following SPECIFICATIONS are allow able for use in ambient temperatures of between 20 and 40 Deg C SAE 10W or 10W30 A P I GL4 Allison C3 MIL L 2105B or Caterpillar TO2 See GEARBOX AND CONVERTER OIL in this section 4...

Page 34: ...sity fig 1 If oils of different brand names are used ensure that you completely empty the crankcase before adding the new oil AUSA recommends REPSOL AUSA EFFICIENT for Diesel engines p n 461 00099 00 Coolant Always use ethylene glycol antifreeze containing corrosion inhibitors especially for internal combustion aluminium engines The cooling systems must be filled with distilled water and antifreez...

Page 35: ...PER TRANSMISSION S o BP TRACTAN 8 ESSO Torque Fluid Type 56 o 62 AGRICASTROL AS Special GULF Universal Tractor Fluid Transfer box oil The oil recommended by the manufacturer is MOBILUBE HD 90 CASTROL DEUSON EP 90 SHELL SPIRAX 90 EP BP HYPO GEAR 90 Brake fluid Brake fluid type LHM green with mineral base as per ISO VG32 CAUTION To avoid serious damage to the brake system do not use fluids other tha...

Page 36: ...ions rinsing the dumper is recommended to preserve the dumper and its components NOTE Never use high pressure water to clean the dumper ONLY USE LOW PRESSURE WATER High pressure water can cause electrical and mechanical damage 3 Overturning In the event that the dumper overturns it is important that the driver avoids being trapped between the machine and the ground To prevent this we recommend Try...

Page 37: ...t procedures are not followed before starting the engine WARNING Ask an authorised AUSA Utility dealer to fully inspect the fuel system as stated in the LUBRICATION AND MAINTENANCE CHART 5 Storage and pre season preparation When a dumper is not in use for more than one month proper storage is necessary Equally after being store for a long period of time consult an authorised AUSA dealer for the co...

Page 38: ...engine during maintenance operations Disconnect the battery before carrying out any operation on the electrical system with the disconnector fig 1 Never use a flame to check fluid levels Be environmentally friendly When changing oils or other fluids use an appropriate container to collect the fluid and ensure that you are not harming the environment during the operations and take all replaced mate...

Page 39: ... to avoid the descent of the cargo box fig 4 There is a prop to avoid the lifted bucket box from descending when maintenance operations are being carried out d Lifted bucket prop This ensures that you work on the machine in complete safety Chassis articulation linking bar fig 5 Before carrying out any intervention which requires you to be located between the two parts of the chassis immobilise the...

Page 40: ... preferably meets 98 70 CEE standard amended by standard 2003 17 or the equivalent EN 590 standard In Spain RD 1728 1999 applies For the USA market it must meet Grades 1D and 2D of the ASTM D975 standard in supplies which do not meet these standards the sulphur content should never exceed 0 5 mass In principal the use of REM type biodiesel or similar is not recommended In case of use the proportio...

Page 41: ... spillage from the vehicle Water separator fig 1 2 This is located at the rear of the machine in the left wheel arch fig 1 a Support b Deposit c Tap The fuel used may contain water which is deposited inside the deposit b of the water tank which is located between the pre filter and the electric fuel pump It is of vital importance in order to protect the injection system that the water is emptied a...

Page 42: ...circumstances should you attempt to clean it Access the lower rear of the dumper under the engine counterweight as follows e Pre filter f Flanges Remove the fixing flanges and the filter Ensure that the new filter is located in the correct direction as indicated by the arrow marked on the filter housing Changing the fuel filter fig 3 Unscrew the fuel filter cartridge located on the left part of th...

Page 43: ...ll the oil level dipstick a remove it from its housing and clean it with a clean cloth fig 1 Place the dipstick in its housing Remove it once again from the housing and check the oil level It must be up to or equal to the upper level marked fig 2 b Full c Add d Operating range Add oil up to the upper level mark if required To add oil remove the oil level dipstick Place a funnel in the oil filling ...

Page 44: ... drainage hose Allow the oil to drain for a while Unscrew the oil filter cartridge located on the left side and remove it from its support g Oil filter cartridge fig 2 Clean the base and cover the joint of the new filter element with clean oil Screw in the filter element once again and tighten by hand do not use mechanical tools WARNING Clean any oil spill on the engine Clean the oil drainage hose...

Page 45: ...replace the maintenance access panel NOTE A cooling system which requires coolant frequently indicates that there are leaks or engine problems See an authorised AUSA dealer Changing the coolant fig 2 3 b Cylinder block drainage cap c Lower radiator hose This change should be carries out every 1000 hours or when the circuit is emptied for repair To do so the following operations are carried out Loo...

Page 46: ... hands when it is hot Use gloves to remove external residues from the radiator Allow the radiator to cool before cleaning If water is available in the proximity rinse the radiator fins with a hose Be careful not to damage the radiator when cleaning the fins Do not use any object or tool that could damage the fins The fins are thin parts which therefore allow the radiator to cool correctly See an a...

Page 47: ...st be cleaned or replaced as soon as possible CAUTION Do not start the engine when water is found in the air filter box When liquids or residues are found the air filter must be inspected dried or replaced independently of the condition in which it is found Remove the air filter as explained below Removing the air filter fig 2 3 4 5 CAUTION Never remove or modify any filter component Otherwise poo...

Page 48: ...evel in the following way Pull the oil level dipstick a remove it from its housing and clean it with a clean cloth Place the dipstick in its housing Remove it once again from the housing and check the oil level It must be up to or equal to the upper level marked fig 2 b Full c Add d Operating range Add oil up to the upper level mark if required To add oil remove the dipstick and place a funnel in ...

Page 49: ... base and cover the joint of the new filter element with clean oil Screw in the filter element once again and tighten by hand do not use mechanical tools WARNING Clean any oil spillage Change the joint in the oil drainage cap Clean the area around the gearbox and converter the oil drainage cap and replace the cap Refill the gearbox and converter as per the recommended oil level See the LIQUIDS AND...

Page 50: ...rom the oil drainage cap WARNING Clean any oil spillage Oil level in planetary reductions fig 2 3 WARNING Never remove the drain plug of the final reductions when the oil is hot The gases formed in the interior may cause injury Planetary reduction Checking the level Turn the wheel until the mark Oil Level on the reducer is horizontal To check the oil level in the final reductions use the cap c Pla...

Page 51: ...ap can also be used for filling differential oil Changing differential oil Oil changes should be carried out when the oil is warm Clean the area around the drainage cap Place a container underneath the oil drainage cap Unscrew the oil drainage cap c Oil drainage cap Change the seal in the oil drainage cap Clean the shaft seal area and the oil drainage cap and replace the cap Refill the differentia...

Page 52: ... located above the brake pump under the floor panel With the dumper on a level surface the brake liquid must be between the MIN and MAX levels marked b Brake fluid tank NOTE Never exceed the maximum level Use a funnel to avoid spills Place and tighten the filling cap correctly and close the cover NOTE A brake system which frequently required brake fluid indicates that there are leaks See an author...

Page 53: ...system that requires frequent top ups indicates that there are leaks See an authorised AUSA dealer Changing the hydraulic oil fig 3 4 b Suction filter c Tank drainage cap Draining fuel is done via the cap situated on the lower part of the tank Clean the area around the drainage cap Place a container underneath the oil drainage cap Unscrew the cap In the hydraulic circuit there is a suction filter ...

Page 54: ... direction to increase the hydraulic pressure and anti clockwise to reduce it Circuit pressure regulation valve Remove the plastic cover then loosen the counter but and turn the screw a clockwise direction to increase the hydraulic pressure and anti clockwise to reduce it Hydraulic hoses All hydraulic hoses must be changed at least every 6 years 11 Electrical circuit Battery The battery is located...

Page 55: ...FG3 glow lamps 50A Instrument and control panel fuses fig 2 F1 Warning Lamps 7 5A F2 Reverse gear acoustic signal position lights 5A F3 Position lights 5A F4 Low beam lights 10A F5 Road lights 10A F6 Joystick power 7 5A F7 Front rear electrovalves horn 10A F8 Starter motor Stop solenoid 10A F9 Instrument and control panel lamps 7 5A F10 Rotating beacon 15A F11 Optionals fuse 10A To remove the fuse...

Page 56: ...p Inflating the wheels could be dangerous if the operation is not carried out with caution If possible it is recommended that this operation be carried out by specialists in the field We recommend that the following instructions are followed Park the dumper on flat ground with the engine off Always inflate tyres when they are cold and to the pressure indicated in the SPECIFICATIONS section of this...

Page 57: ...direction Removing the wheel fig 1 Loosen the nuts and raise the dumper Place a support beneath it Remove the nuts and then remove the wheel When assembling apply lubricant to the threads Slowly tighten the nuts in a criss cross sequence applying a final torque of 425 Nm a Coned part of the wheel nut WARNING Always use the recommended wheel nuts If you use different wheel nuts the wheel may be dam...

Page 58: ...e condition and tighten all dumper supports Retighten if necessary Seatbelt Check the fixture and lock of the seatbelt Before starting the day carefully inspect this devices with special attention to Cuts or threading on the belt Wear or damage to anchor points Poor functioning of the seat belt buckle or the retracting roller Loose threads or poor stitching Consult an authorised AUSA dealer for th...

Page 59: ... DEALER Injection pump timing 2 I DEALER Fuel injection timer 2 I DEALER COOLING SYSTEM Radiator hoses and clamps bands I R USER Radiator C DEALER Coolant I R USER POWERSHUTTLE AND TORQUE CONVERTER Oil and filter 1 R R USER Oil Strainer 1 C C DEALER ELECTRICAL SYSTEM Battery electrolyte I I USER Battery connections I USER Dash panel indicators Warning lights 3 I USER Battery I I R USER Electric ha...

Page 60: ... I DEALER Cardan joint fixation screws torque I DEALER Flange fixation nut torque I DEALER Adjust wheel hub bearings I CLIENTE Condition of tires and pressures I USER BRAKES Brake fluid 3 I R DEALER Handbrake adjustment 3 I I USER BODY FRAME ROPS frame I USER Seat belt 3 I USER Foot plate access steps and handles 3 I C USER Guards and covers 3 I USER Plates and decals 3 I C USER Central pivot nut ...

Page 61: ...r one on each articulation axle 1 nipple e on each articulation of the cargo box lifting system 2 nipples f on the parking brake cable articulation on the front axle 8 nipples g in the swing crown only in D 1000 APG model 1 nipple h on the brake pedal pin See the LUBRICATION AND MAINTENANCE CHART for greasing intervals See the LIQUIDS AND LUBRICANTS section for the type of grease to be used fi g 4...

Page 62: ... Yellow H Gray L Blue M Brown N Black R Red S Pink V Green Z Violet Single color wire Two lengthways colors wire Two crossways colors wire NOTE The colour of the two coloured cables is indicated by the signals painted above them For example Y G Yellow Green crossways Y G Yellow Green lengthways ...

Page 63: ...D 900 AP D 1000 AP D 1000 APG 61 Electric diagram H1 ...

Page 64: ...D 900 AP D 1000 AP D 1000 APG 62 Electric diagram H2 ...

Page 65: ...D 900 AP D 1000 AP D 1000 APG 63 Electric diagram H3 ...

Page 66: ...D 900 AP D 1000 AP D 1000 APG 64 Electric diagram H4 ...

Page 67: ...12 Dashboard buzzer 2 H15 Reverse relay 2 HF Parking brake sensor 2 K1 Permision start relay 1 K2 Forward relay 2 K3 Reverse relay 2 K4 Reverse alarm relay 2 Name Description Pag K5 Parking brake relay 2 K5 Horn relay 4 K6 Dashboard buzzer relay 2 K6 Low beam light relay 4 K7 High beam light relay 4 K8 Flasher relay 4 K18 Starter motor relay 1 K19 Pre heating relay 1 L1 Air filter blockage warning...

Page 68: ...D 900 AP D 1000 AP D 1000 APG 66 Hydraulic diagram D 900 AP D 1000 AP ...

Page 69: ...D 900 AP D 1000 AP D 1000 APG 67 Hydraulic diagram D 1000 APG ...

Page 70: ... las siguientes Directivas comunitarias Directiva de Compatibilidad Electromagnética 2004 108 CE Directivas sobre Nivel Sonoro de Equipos que Trabajan en el exterior 2000 14 CE y 2005 88 CE Directiva sobre Emisiones de Escape 97 68 CE y 2004 26 CE y las reglamentaciones nacionales que las transponen Real Decreto 1580 2006 aplicación de la directiva CE de Compatibilidad Electromagnética Reales Decr...

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