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Fiori D 70 SL, Use And Maintenance Manual

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Fiori D 70 SL Use And Maintenance Manual Download Page 3

id.:

D 70SL 

     REV. 00       02/11/2009

CAUTION

For reasons of clarity, some illustrations in this 

manual show the vehicle without guards.

Never use the vehicle without the guards and do 

not start the engine when the engine guard is 

open unless expressly indicated in the mainte-

nance operations.

CAUTION

STUDY THIS MANUAL BEFORE USING THE MA-

CHINE!

Operators and maintenance staff must read this 
manual carefully before using the machine or car-
rying out maintenance work. In case of doubts, ask 
your Dealer or employer. Do not attempt to guess 
at the operations to perform, as this may cause 
serious personal injuries or property damage.

 

This manual must be kept onboard the machine 
for prompt consultation at any time, and must be 
handed over to the new owner if the machine is 
resold.

Summary of Contents for D 70 SL

Page 1: ...41034 FINALE EMILIA Modena Italia Tel 39 0535 92357 Fax 39 0535 90960 http www fiorigroup com en_UK TRANSLATION FROM ORIGINAL LANGUAGE USE AND MAINTENANCE MANUAL RIF 9301439202 9301439202 ed 02 id D 70 SL DUMPER D 70 SL REV 04 06 10 2014 ...

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Page 3: ...CAUTION STUDY THIS MANUAL BEFORE USING THE MA CHINE Operators and maintenance staff must read this manual carefully before using the machine or car rying out maintenance work In case of doubts ask your Dealer or employer Do not attempt to guess at the operations to perform as this may cause serious personal injuries or property damage This manual must be kept onboard the machine for prompt consult...

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Page 5: ...id D 70SL REV 00 02 11 2009 D 70 SL REV 02 01 04 2013 CONTENTS INTRODUCTION TECHNICAL FEATURES SAFETY PRECAUTIONS OPERATION AND USE MAINTENANCE OPTIONAL EQUIPMENT 1 0 2 3 4 5 6 ...

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Page 7: ...TECTION DEVICES PPD 25 3 1 2 VEHICLE LIMITS 25 3 1 3 NOISE LEVEL 25 3 1 4 VIBRATIONS LEVEL 26 3 1 4 a Vibration level on the operator s body measured on the driver s seat 26 3 1 4 b Vibration level on the hands arms measured on the steering wheel 26 3 1 5 SAFETY DEVICE CHECKS 26 3 1 6 PRECAUTIONS WHEN USING ACCESSORIES 26 3 1 7 PROHIBITION TO TRANSPORT PERSONS OR OBJECTS 26 3 1 8 GETTING ON AND OF...

Page 8: ...T CIRCUIT 37 3 2 9 BATTERY 37 3 2 10 HOT AND PRESSURISED FLUIDS 38 3 2 11 RISK OF BURNS 38 3 2 12 VENTILATION 38 3 2 13 INTOXICATION 38 3 2 14 FIRE PREVENTION 39 3 2 15 LOADING AND UNLOADING THE DUMP BODY 40 3 3 PRECAUTIONS DURING MAINTENANCE OPERATIONS 41 3 3 1 CORRECT MAINTENANCE 41 3 3 2 PRECAUTIONS DURING WELDING OPERATIONS 44 3 3 3 FAULTS AND UNAUTHORISED MODIFICATIONS 44 3 3 4 CLEANING THE V...

Page 9: ...zard light toggle switch 66 4 2 2 j Working light switch OPTIONAL 66 4 2 2 g Engine starter and stopping switch 67 4 2 2 h Rotary switch with horn push button direction indicators toggle switch 68 4 2 3 OPERATING CONTROL PANEL 69 4 2 3 a Dumper raising lever 69 4 2 3 b Power socket 69 4 2 3 c Windscreen water switch 69 4 2 3 d Water in fuel warning light 69 4 3 INSTRUCTIONS FOR USE 70 4 3 1 REFUEL...

Page 10: ... KIT 89 5 1 4 2 ROUTINE MAINTENANCE AND CHECKS 90 5 2 MAINTENANCE SCHEDULE 91 5 3 RUNNING IN AND SERVICE 91 5 4 SCHEDULED MAINTENANCE TABLE 92 5 5 ENGINE MAINTENANCE SCHEDULE 94 5 6 RECOMMENDED LUBRICANTS AND FLUIDS TABLE 96 5 7 GENERAL INSPECTIONS 97 5 7 1 GREASE 97 5 7 2 CLEANING AND DRAINING THE FUEL TANK 98 5 7 3 ACCELERATOR CABLE LUBRICATION 98 5 8 AXLE AND WHEELS 99 5 8 1 CLEANING THE AXLE A...

Page 11: ...NG THE ALTERNATOR BELT TENSIONING 114 5 11 6 FUEL SEDIMENT BOWL 114 5 11 7 AIR BLEEDING IN THE ENGINE FUEL SUPPLY SYSTEM 115 5 11 8 REPLACING THE ENGINE FUEL SUPPLY PRE FILTER AND FILTER 116 5 11 9 CHECKING AND TOPPING UP THE ENGINE OIL LEVEL 116 5 11 10 REPLACING THE ENGINE OIL FILTER 117 5 11 11 REPLACING THE ENGINE OIL 117 5 12 ELECTRIC COMPONENTS 118 5 12 1 FUSES AND RELAYS 118 5 12 2 ELECTRON...

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Page 13: ...d in good conditions at all times Do not use the machine if this manual is not in the cab and if you have not read all the instructions carefully If the manual is lost or becomes illegible pages torn dirty etc ask either your Dealer or the Manufacturer immediately for a new copy The machine must be used for its intended purpose only Any other use is to be considered improper and consequently dange...

Page 14: ... may result in serious injury or even death CAUTION Indicates a potential risk which if not avoided may result in injury of low or medium se verity It may also be used to prohibit operations involving risks and which may cause damages DANGER The position of the pivoting driving post determines the driving direction The right hand side RH or left hand side LH will be identified based on the current...

Page 15: ... underground works or in potentially explosive workplaces In the event of underground works contact FIORI to request information on the requirements to be observed for adjusting the machine so that it is suitable for such purposes Any unauthorised modification to the machine relieves the Manufacturer from any responsibility for property damage or personal injuries which may directly and or indirec...

Page 16: ... to the Manufacturer s purposes have an excellent ability to assess weight distance and size are able to drive and control the machine at the worksite have been trained on the operation of the machine and its maintenance know its technical specifications its overall dimensions as well as its performance and limitations are conscientious careful and aware of the problems of their own safety and tha...

Page 17: ...malfunction it is essential to follow the instructions below If the trouble persists do not try further actions or expedients Contact the nearest authorised FIORI SERVICE CENTRE or directly FIORI GROUP S p A Via per Ferrara 7 41034 FINALE EMILIA Modena Italia Tel 39 0535 780250 Fax 39 0535 90960 When you contact Fiori After Sales Service make sure you have all necessary details available which mus...

Page 18: ... and its main components are punched on metal plates which allow the machine to be identified by the After Sales Service by means of specific ID numbers and letters The following information show where the identification plates and punched numbers are located and give examples of the symbols found on the machine D 70 SL REV 01 02 01 2012 ...

Page 19: ...n your vehicle numbers in the space below for quick and easy reference MODEL No 2978 2200 1104D 44T SERIAL NUMBER D AXLE DATA PLATE The axle type and serial numbers are printed on the plate 1 found on the axle central case Write down the information in the space below for quick reference FRONT AXLE TYPE S128 10061 002 B01 SERIAL NUMBER REAR AXLE TYPE S128 40041 003 B01 SERIAL NUMBER E TRANSMISSION...

Page 20: ...NE Directive 2006 42 EC on Machinery Directive 2004 108 EC on Electromagnetic Compatibility Directive 2000 14 EC on Noise emission ENGINE Directive 2004 26 EC Emission of pollutants from internal combustion engines STAGE III A CABIN ROPS UNI 3471 FOPS LEVEL I ISO 3449 FOPS LEVEL II ISO 3449 QUALITY STANDARD FIORI GROUP S p A is a certified company ISO 9001 2008 Quality ISO 14001 2004 Environment D...

Page 21: ...m length 4 665 mm Maximum width 2 210 mm Maximum road transfer height 2 780 mm Front angle of attack 37 Ground clearance under the differentials 370 mm Minimum wheel radius 1 870 mm Minimum outside wheel radius 4 305 mm 2 1 DIMENSIONS D 70 SL REV 03 20 03 2014 ...

Page 22: ...e 392 Nm at 1 400 rpm Bore stroke 105 127 mm 4 cylinders total displacement 4400 cc Water cooling dry air filter AXLES AND WHEELS Front load bearing oscillating 7 and steering with planetary reduction gears on the wheel hubs Rear load bearing and steering with planetary reduction gears on the wheel hubs and directly flanged gearbox Front and rear tyres 12 5 18 16 PR STEERING Assisted by means of p...

Page 23: ...capacity 4 000 litres EQUIPMENT HYDRAULIC SYSTEM Gear pump Max flow rate 45 litres min Maximum pressure 180 bar 1 element distributor Aluminium heat exchanger for hydraulic oil cooling Pressurised closed circuit intake with oil filter replaceable from the outside CAB Closed cab with heating system designed in accordance with ROPS FOPS standards 180 pivoting driving post Anatomic seat with flexible...

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Page 25: ...Read and comply with all the SAFETY REGULATIONS given in this manual before carrying out any operation Prudence and judgement during appropriate use of the vehicle are essential and basic factors for the safety of the operator and of other people working near the vehicle Therefore before starting any work you must know exactly what the functions of all the controls and the stability characteristic...

Page 26: ... not responsible for injury accidents or faults deriving from use of unauthorised equipment or accessories Before installation and use of accessories read the instruction manual of the specific accessory and the general information on accessories given in this manual 3 1 4 a Vibration level on the operator s body measured on the driver s seat Based on measurements made in operating conditions on v...

Page 27: ...e Always keep the driver s seat clear of foreign objects especially if not secured Do not leave components or tools scattered around the cabin Do not use mobile phones in the cabin while driving or operating the vehicle Never take dangerous objects into the cabin for example flammable or explosive objects 3 1 10 DRIVER S CAB OPERATOR S PROTECTIVE STRUCTURE DO NOT modify repair or remove the operat...

Page 28: ...oning Before using the vehicle make sure that there is no dangerous condition Also check that you have enough fuel so as not to run the risk of being forced to stop perhaps during a criti cal manoeuvre Check that the steering controls and the brakes function perfectly In case of malfunctions notify the mainte nance manager and stop the vehicle Check that all the guards and safety devices are in th...

Page 29: ...out the protection and the lids For vehicles with a rotary unloader keep the longitudinal axis of the dump body oriented in the driving direction For vehicles with a self loading loader drive with the loader lifting arm horizontal to the ground and with the loader clearly visible While driving do not operate the control levers of the working equipment When driving on uneven ground drive slowly and...

Page 30: ...ct 3 1 18 DANGEROUS WORKING CONDITIONS Before starting any operation check that there are no dangerous working conditions in the surrounding area Areas where there are slopes humps trees demolished constructions escarpments gorges tilled soil ditches excavations heavy traffic crowded parking and service areas and closed places are classified as risk areas Check that there are no obstacles such as ...

Page 31: ...vehicle if any malfunctions are indicated Pay attention to any unusual noise from the engine the hydraulic device the transmission components the working equipment etc If you hear any suspicious noise immediately stop the vehicle and check what causes it If you need to continuously work in very noisy conditions wear a protective headset in accordance with the regulations in force If working in the...

Page 32: ...igh voltage cables do not allow anyone to approach the vehicle 3 1 23 WORKING ON SLOPES Moving or working on steep slopes hills river or lake embankments can be dangerous Always drive up and down slopes at low speed and pay attention Obstacles or changes in the gradient may cause you to lose control of the vehicle and consequently it might overturn Before starting work check the working area for a...

Page 33: ...r vehicles with a rotary loader position the dump body with the longitudinal axis in the driving direction For vehicles with a self loading loader position the loader on ground level Lock the equipment controls Always remove the key from the ignition block when you need to leave the vehicle parked to prevent accidental or unauthorised starting Secure and lock the vehicle when you have finished wor...

Page 34: ...to the transport vehicle Never steer on the ramps to correct the vehicle s position If necessary drive off the ramps correct the direction and then drive back up The vehicle must be positioned in such a way that the loads on the axles are as specified for the transport vehicle and that it is not unbalanced Securely tie the vehicle to the platform with chains or cables and block the wheels with wed...

Page 35: ...y hands or arms should they become entangled Always keep your hands and fingers away from gaps and or kinematic mechanisms Do not use your fingers or hands to line up holes but use appropriate tools Remove any burrs or sharp edges from replaced and or repaired parts Should you need to access a moving part always lock the working equipment and check that it is well secured The machine is a vehicle ...

Page 36: ...ng paths and avoid sudden braking acceleration and changes in direction The vehicle may be used on sloping ground only within the limits indicated by the manufacturer Where the ground is particularly steep and inaccessible it is advisable to have only experienced operators use the vehicle The vehicle may also overturn because of uneven ground the ground caving in especially when working near the e...

Page 37: ...re values and permitted speed specified in this manual correspond to the values specified by the manufacturer see the pressures and loads table For more information contact FIORI or the tyre manufacturer Any operation on the electric system or the battery must be carried out by a qualified person Before any operation on the electric system disconnect the battery by removing the key from the batter...

Page 38: ...able mask Avoid inhaling or contact with the battery acids which are highly toxic and cause serious burns Be careful not to come into contact with cement as perspiration and other body fluids cause an irritating alkaline reaction and in some people allergic reactions Use protective gloves and goggles 3 2 11 RISK OF BURNS 3 2 12 VENTILATION 3 2 13 INTOXICATION The hydraulic system is pressurised wh...

Page 39: ...le oil to clean the components Do not use Diesel and petrol as they are highly flammable To ensure safety in the workplace put all the cloths soaked with grease oil or flammable liquids in a safe metal container as they pose a risk of fire Store containers or cans only in their specifically allocated areas Do not pour flammable liquids into open large and low containers FIRE CAUSED BY BUILD UP OF ...

Page 40: ...ed in the driver s seat as there is a risk of being hit The weight of the material loaded into the dump body must never exceed the maximum load value indicated on the plate fixed on the vehicle When loading is complete and before moving off check that the load is correctly distributed and cannot unbalance the vehicle Check that the material loaded does not exceed the upper limit of the dump body a...

Page 41: ...or repair the vehicle when the engine is running except where expressly indicated in this manual Do not allow anyone to tamper with the danger signs or make them illegible Do not use parts of the vehicle such as handholds or supports to carry out the operations Absolutely do not use matches lighters torches or open flames to illuminate dark areas Use lights or lamps vehicle and auxiliary lights po...

Page 42: ...engine on Do not turn on the engine while the lid is raised Do not check or even less adjust the alternator belt tension with the engine on Do not adjust the fuel pump with the engine on When handling flammable materials keep at a certain distance from the exhaust manifold the silencer or hot points of the engine GREASING AND LUBRICATION Use only the products recommended by the manufacturer as ind...

Page 43: ...izes in the pressure and loads table Do not exceed the load for any given pressure Do not over or under inflate the tyres Never inflate a steering tyre to over the maximum pressure recommended by the manufacturer as indicated on the tyre or over the maximum pressure indicated in the pressures and loads table and when the tyre is not marked with the maximum pressure values Inflating a tyre to over ...

Page 44: ...arge so that the appropriate action can be taken Do not start the vehicle until the fault has been repaired No modifications may be made to the vehicle without prior authorisation from FIORI as modifications may create risks Before making any modification consult with FIORI FIORI is not responsible for any injury or damage caused by unauthorised modifications 3 3 3 FAULTS AND UNAUTHORISED MODIFICA...

Page 45: ...horities for the correct disposal procedures Always collect the oil drained from the vehicle into suitable containers Never drain the oil directly onto the ground or into drains rivers oceans or lakes For disposal of hazardous waste such as oil fuel coolant filters batteries and other waste materials observe the relative laws and regulations in force 3 3 5 WASTE FLUID MATERIAL DISPOSAL ...

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Page 47: ...Spare Parts Service Department Always keep the labels clean Use detergent and water to clean the labels Do not use organic solvents or petrol as they may damage the labels 1 Clean the labels with soap and water and dry them with a soft cloth 2 Replace the damaged or missing labels with original FIORI labels 3 If you need to replace a component bearing a safety or warning label make sure that the n...

Page 48: ...48 3 SAFETY PRECAUTIONS id D 70 SL REV 00 02 11 2009 VEHICLE EXTERIOR ...

Page 49: ...g parts as there is a risk of crushing your hands DANGER The acoustic signal indicates that the vehicle or parts of it are moving therefore stand well away from the vehicle and do not allow anyone to come into its range of action WARNING The engine compartment contains moving components fan belts that may cause serious injury Before opening the lid to carry out maintenance operations in the engine...

Page 50: ... than about 18 engage the mechanical low gear Shift gear when the vehicle is stationary and stable as it is not equipped with a synchronised gearbox WARNING This symbol indicates an area that emanates strong heat to prevent burning yourself approach it carefully and wait for it to cool down before carrying out any maintenance operation WARNING Many parts of the vehicle are a source of danger heat ...

Page 51: ...seatbelt when the vehicle is moving MANDATORY RULE This symbol indicates that a hardhat must be used wear a hardhat for your own protection MANDATORY RULE This symbol indicates that anti noise protection must be used the average exposure to noise is over 85 Lpa Use adequate anti noise protection in relation to your daily exposure to noise ...

Page 52: ...n the driving turret is turned in the working direction the fast gear cannot be engaged even if the SLOW FAST switch is in fast mode B PARKING BRAKE BUTTON fig 1 C MECHANICAL ROTATION LOCK FOR PIVOTING DRIVING POST fig 1 Allows locking the driving post in the two driving positions 3 5 SAFETY DEVICES ON THE VEHICLE CAUTION To check proper functioning of the safety devices and the cleaning and repla...

Page 53: ... battery master key does not have an emergency stop function Removing the battery master key when the engine is running does not turn off the engine but only damages the current alternator G DUMPER FALL STOP DEVICE fig 2 When the dump body is raised and the valve handle is turned the cylinders hydraulically lock even when the engine is off preventing accidental lowering during routine maintenance ...

Page 54: ...CTURE fig 2 Designed and constructed to safeguard the operator in the event of the vehicle overturning and objects falling from heights L REAR SIDE HORN fig 2 Grâce à un signal sonore prévient l utilisateur que le moteur va démarrer et que l engin fait marche arrière I REAR VIEW MIRROR fig 2 The rearview mirror is essential for visibility of the rear left hand side of the vehicle Correctly positio...

Page 55: ...N 2 STEERING WHEELS The dump body control lever must be mechanically locked with the special fork latch C EQUIPMENT CONTROL LEVER fig 3 D SLOW VEHICLE FLASHING WARNING LIGHT fig 4 The rotating beacon has a magnetic base for fitting on the cabin roof and operates with 12 V current the plug must be fitted in the socket on the operating control panel 4 D E D 70 SL REV 02 01 04 2013 Perform this opera...

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Page 57: ...sing the vehicle in the open on level ground and where there are no obstacles or persons around Learn to anticipate the reactions of the vehicle and its controls Only start using the equipment when you are sure that you have good command of the vehicle and can drive it safely Be careful when you use the equipment controls Practice in the open Do not allow anyone to come near the vehicle Do not act...

Page 58: ...t to know and understand them when mentioned further on in this manual Therefore it is important that you very carefully read the legend below A Pivoting driving post B Fuel tank C Front axle D Rear axle two speed gearbox E Dump body F Engine assembly hydraulic pumps G Hydraulic oil tank 4 1 REFERENCES AND DESCRIPTIONS OF THE MAIN DEVICES fig 1 1 A C D E F G B ...

Page 59: ...an Use detergent and water to clean the labels Do not use organic solvents or petrol as they may damage the labels 1 Clean the labels with soap and water and dry them with a soft cloth 2 Replace the damaged or missing labels with original FIORI labels 3 If you need to replace a component bearing a safety or warning label make sure that the new component has the same labels 4 When replacing labels ...

Page 60: ...N AND USE id D 70 SL REV 00 02 11 2009 Indicates the lever positions for dump body raising Indicates the engine coolant tank To fill the tank see the instructions in this manual Indicates the three types of steering ...

Page 61: ...y depends on your good judgement and care in using the vehicle Therefore you should know exactly where all the controls are positioned and what their function is Every vehicle has its limits before using it familiarise yourself with its speed braking steering stability and load capabilities This chapter provides all the useful information you need to quickly get to know and safely use the vehicle ...

Page 62: ... 2 1 f F Pivoting driving post locking lever fig 2 4 2 1 g G Mechanical gearshift control lever fig 2 A B Push the service brake pedal to slow down or stop the vehicle use the brakes to avoid picking up speed when you are going downhill CAUTION If driving down steep slopes never use only the brake pedal but also engage the lowest gear and depress the brake pedal intermittently so as not to overhea...

Page 63: ...ect the type of steering according to the situation you are in 2 RS Two front steering wheels CRAB Crab steering i e with the same steering angle on the front and the rear wheels 4 RS Four steering wheels with the rear wheels in the opposite direction to the front ones CAUTION Before any road transfers check that the four wheels are properly aligned see the procedure described in Chapter 4 3 8 It ...

Page 64: ...l pressure is low 6 red warning light indicates that the generator battery charge is low 7 red warning light indicates that the engine coolant is overheated 8 red warning light indicates that the engine air filter is clogged 11 red warning light indicates that the hydraulic oil filter is clogged 12 red warning light indicates that the hydraulic oil level is low 13 blue warning light indicates that...

Page 65: ...ent about 20 hours before the deadline set by FIORI The preset service interval is every 500 hours Therefore the warning light will flash after 500 1000 1500 2000 hours Once the vehicle has been serviced the flashing warning light can be reset and the counter reset to start the countdown to the next service To reset flashing hold the reset button E on the driving post instrument panel pressed down...

Page 66: ...ge reverse gear Press the selector to select the high speeds hare or low speeds tortoise provided by the minimum or maximum displacement of the hydraulic motor Unlike selection of the mechanical gears these can be selected when the vehicle is moving D 70 SL REV 02 01 04 2013 4 2 2 k D Hazard light toggle switch fig 6 Snap switch to turn on the four hazard warning lights This button is used to rese...

Page 67: ...ghts will signal the vehicle status by means of the generator warning light 6 and the engine oil warning light 5 Subsequently at the bottom of the numerical display 18 will be displayed simultaneously and for 5 seconds the hours remaining until the next service is due and the maintenance warning light 1 immediately followed by 5 seconds in which the actual total hours of vehicle operation will be ...

Page 68: ...ors Shift the direction indicators toggle switch 1 forward to indicate a left turn Shift the direction indicators toggle switch 1 backward to indicate a right turn Horn Press on the rotary switch 2 to activate the horn Light switch The lights come on only if the ignition key is inserted Position lights turn the rotary switch 3 forward by one click Low beams tturn the rotary switch 3 forward by 2 c...

Page 69: ...sition 2 dumper lowering 4 2 3 a A Dumper raising lever fig 9 4 2 3 b B Power socket fig 9 It draws current from the 12V battery by means of a bayonet coupling 4 2 3 c C Windscreen water switch fig 9 Allows you to pump the windscreen washer fluid 9 A B C D 4 2 3 d D Water in fuel warning light fig 9 Warning light that indicates that there is water in the fuel sediment bowl D 70 SL REV 02 01 04 201...

Page 70: ...that the vehicle has been equipped with all the required equipment Check that all the maintenance operations set out in Chapter 5 of this manual have been carried out If repairs were made check tightness of all the screws and nuts and the adjustments Refuel the vehicle with purified diesel fuel without water residues Use a pump equipped with filter with a delivery nozzle that goes down into the fi...

Page 71: ...Clean the contacts of the reverse gear microswitches 5 The procedures are described in chapter 5 on maintenance CAUTION Before starting the vehicle adjust and lock the seat in the most suitable and comfortable position so that you can easily reach all the controls and fasten the seatbelt Use the lever 1 to adjust the seat distance from the pedals and the lever 2 to adjust the springing hardness ac...

Page 72: ...transfer and backward B turned 180 for the alternative working phases Press the lever 1 to release the driving post turn it in the desired direction and relock the lever 1 If the driving post is not perfectly locked dedicated microswitches 2 will not allow vehicle movement 4 3 4 ADJUSTING THE REAR VIEW MIRROR fig 13 13 1 14 B A 2 1 2 CAUTION Operation to be carried out before starting the vehicle ...

Page 73: ...warning lights are off CAUTION Do not try to activate the starter motor with the key inserted for more than 20 30 seconds If the engine does not start wait 2 minutes before retrying allowing the starter motor to cool down When the engine has started let it run at about 1000 rpm for a few minutes to allow the oil to warm up and lubricate all the parts this is essential in cold climates CAUTION STAR...

Page 74: ...ee that the engine will be running at idle speed for a long period of time always turn it off Nonetheless if you need to keep the engine running make sure that the engine speed is sufficient to supply the necessary engine oil pressure indicated by the relative warning light on the instrument panel turning off CAUTION The steering must be selected with the machine stationary Whenever you drive on t...

Page 75: ...the gear lever C to position 1 for driving on steep slopes or to position 2 for flat stretches CAUTION Mechanical gears must only be selected with the vehicle stationary and stable Set the gear selector A to the desired driving direction This selection can also be performed while the vehicle is moving Check that you can safely move forward then start depressing the accelerator pedal D to move the ...

Page 76: ...view mirror 3 you have a wide view of the area behind the vehicle This allows you to safely reverse and approach the unloading area before tilting the dump body CAUTION To reset the display 2 refer to its user manual that comes with the vehicle 2 3 1 CAMERA FAR FILED OF VIEW CAMERA NEAR FIELD OF VIEW 1mt D 70 SL REV 02 01 04 2013 Check that the display 2 is properly set for direct visibility NO MI...

Page 77: ... and hands are clean and dry to prevent slipping and falling Where possible stop the vehicle on level and dry ground Remove the ignition key before leaving the vehicle Deactivate all the unnecessary switches Check that all the switches are deactivated before leaving the vehicle If necessary leave the hazard lights on Leaving and locking the vehicle Use the handles and steps to get off the vehicle ...

Page 78: ...he ground Make sure that the transport vehicle is adequate See the section Specifications for the vehicle weight and dimensions Have someone on the ground guide you in carrying out the manoeuvres Drive very slowly going up and down the ramps and on the platform limiting use of the accelerator and the steering wheel to the minimum indispensable Once the vehicle is positioned apply the parking brake...

Page 79: ...rt the weight of the vehicle see the section Specifications for the weights and dimensions CAUTION For lifting with a crane it is advisable to use adequate rocker arms in order not to damage parts of the vehicle when the chains tauten Use only the lifting points marked on the vehicle Hook the chains onto the special hooks During lifting stand well away from the vehicle and do not stand under the l...

Page 80: ...he vehicle sitting properly in the driver s seat with the seat belt on and the driving post facing the preferential direction of travel with the steering lever on 2RS for driving and stopping it If you need to steer make sure that you understand the actions of the driver of the towing vehicle Follow his instructions and comply with all the relative regulations Bear in mind that steering is harder ...

Page 81: ... 1 1 1 1 Carry out this operation on a flat surface after blocking the wheels with wedges Tighten the four screws 1 of the axles using a no 14 wrench tightening them by one turn each one after another in sequence until they are at the end of travel mechanically releasing the brake To resume the brake original conditions follow the above procedures in reverse order ...

Page 82: ...es or to 1st gear for medium to steep slopes Keep an eye on the instruments and check that they function properly Strictly observe the road regulations If traffic slows down move onto the hard shoulder to allow faster vehicles to pass CAUTION If you need to change a tyre make sure that the type and tread are those specified by the MANUFACTURER Not all tyres are homologated for road circulation wit...

Page 83: ...arried out as set out in Chapter 3 4 9 WORKING PHASES It is essential that the operator becomes familiar with all the controls and for a first period of time practices in a relatively isolated area where he will freely perform all the manoeuvres and operations which will soon become routine operations by regularly using the vehicle This chapter analyses all the working phases that should be carrie...

Page 84: ...earview mirrors are positioned so that you have the best possible visibility of the area behind the vehicle Remove grime and dirt from the pins and the radiator Make sure that the steps and handhold are clean and dry Clean all the adhesive safety labels Replace any illegible or missing labels Damage Check that there are no damaged or missing parts Check that all the articulation pins are properly ...

Page 85: ...cle axis turned 90 with respect to the direction of the slope To change direction set a wide steering radius especially with articulated vehicles If the fuel reserve warning light comes on while you are working on a slope immediately refuel given that the vehicle is inclined the engine may take in air and stall unexpectedly posing a grave danger to your safety RIGHT WRONG 24 D 70 SL REV 01 02 01 2...

Page 86: ...ter unloading CAUTION Before proceeding always read the safety regulations for the operations to be carried out as set out in Chapter 3 4 9 6 DUMPING CORRECTLY ON SLOPES fig 25 CAUTION Observing the recommended gradient limits does not mean that you can manoeuvre the vehicle in total freedom in all load ground or manoeuvring conditions on a slope In any event it is advisable to halve the gradient ...

Page 87: ...the care that needs to be taken to remove and refit parts of the vehicle the persons that physically carry out the operations are responsible for their success and assuring that functionality is restored CAUTION For extraordinary maintenance contact your nearest AUTHORISED FIORI WORKSHOP CAUTION Carefully read all the safety regulations set out in Chapter 3 in particular the general and specific W...

Page 88: ... costs and the vehicle stop times Check the following A Dump body articulation B Hydraulic system and pipes C Instruments and gauges D Engine and radiator E Tyres F Transmission G Jacks and pins 1 C F D A E G B 5 1 2 CLEANING THE VEHICLE Clean the vehicle with water Pay particular attention to the bottom of the vehicle Do not let mud to deposit under the engine and the transmission Check that the ...

Page 89: ... fitted and tightened ROPS FOPS structures Modified or improperly repaired ROPS FOPS structures are dangerous Do not repair them following an accident and do not use the vehicle until the structure has been checked and repaired by qualified personnel The vehicle may not be used without the ROPS structure Check the structure for mechanical damage Check that the retaining screws are all in place wel...

Page 90: ...g brake applied Driving post To access the use and maintenance manual open the driving post door A with the key provided To access the relays undo the screws of the panel B Engine compartment lid Unlock the lid C with the key provided and raise it to access the following parts Engine oil cap level gauge and filter Engine accelerator cables Starter motor and alternator Hydraulic oil tank cap Radiat...

Page 91: ...rly check tightness of the screws and nuts After the first 500 hours of operation in addition to the routine maintenance operations to be carried out as set out in chapter 5 it is advisable to carry out some additional operations SERVICES which subsequently will be required at longer intervals Servicing includes a series of operations to be carried out on the vehicle Engine oil change Hydraulic oi...

Page 92: ... HYDRAULIC CYLINDER ROD CONDITIONS DRAINING THE FUEL TANK WASHER STUB AXLE PINS PROTECTIVE STRUCTURE AIR FILTER GASKETS CLEANING THE AIR FILTER SEPARATOR TYRE WHEEL TIGHTENING TORQUES AXLE AND DIFFERENTIAL BLEEDERS AXLE GEARBOX OR DIFFERENTIAL OIL BRAKING SYSTEM WEAR CONDITION BRAKING SYSTEM TANK CAP BLEEDER PARKING BRAKE TEST BRAKING SYSTEM FLUID NEGATIVE PARKING BRAKE OPERATION OF THE HYRAULIC S...

Page 93: ...ECTRIC EQUIPMENT OPERATION INSTRUMENT PANEL BATTERY ELECTROLYTE LEVEL BATTERY PINS PIVOTING POST MICRO SWITCHES ELECTRIC COMPONENTS WORKING AREA EVERY 8 HOURS OR DAILY REGULAR MAINTENANCE INTERVALS EVERY 500 HOURS OR 12 MONTHS EVERY 1000 HOURS OR 24 MONTHS EVERY 2000 HOURS OR 48 MONTHS ...

Page 94: ... Every 500 hours of operation V Belts Inspect Adjust Replace Every 250 hours of operation or 1 year Battery electrolyte level Check Add SCA Coolant Test Add Crankcase bleeder filter box Replace Engine air filter double Clean Replace Engine oil and filter Replace Primary fuel system filter water separator Replace Secondary fuel system filter Replace Hoses and clamps Inspect Replace Radiator Clean E...

Page 95: ...spect Turbocharger Inspect Water pump Inspect Every 3000 hours of operation Alternator belt Check Adjust Replace Fuel injector Test Replace Every 3000 hours of operation or 2 years Cooling system coolant commercial for heavy duty Replace Every 4000 hours of operation Aftercooler radiator core Clean Test ...

Page 96: ... 68 27 25 10 35 3 45 BRAKING SYSTEM 0 75 l PSA B 712710 ISO 7308 20 CTS 40 50 VARIOUS GREASING PRODUCTS 0 5 kg 40 50 50 ETHYLENE GLYCOL 50 WATER ENI SIGMA TRUCK PLUS SAE 15W 40 ACEA E7 E5 E3 B3 API GL4 API CE SF CCMC D4 G4 MIL L 2104 D 110 mm2 s 40 15W 40 ENI GR LP1 ENI LHM SUPER GREASE NLGI 1 DEVICE TO BE REFILLED Q TY AMBIENT TEMPE RATURE IN C VISCOSITY INTERNATIONAL CLASSIFICATION RECOMMENDED L...

Page 97: ...n flat ground and lower the arm Remove the ignition key and apply the parking brake CAUTION Daily grease the drum rollers to keep them free of concrete residues Do not use graphite grease on the bearings The vehicle must be greased regularly in order to keep it in efficient operating conditions Grease using the pump A provided and stop greasing as soon as fresh grease starts flowing out from the o...

Page 98: ... vehicle on level ground turn off the engine engage the parking brake lower the dump body and remove the ignition key CAUTION Before proceeding always read the safety regulations for the operations to be carried out as set out in Chapter 3 Extinguish all smoking materials and open flames as there may be flammable vapours With the engine off position an adequately sized container under the fuel tan...

Page 99: ...D TOPPING UP THE OIL LEVEL IN THE FRONT AND REAR AXLES fig 6 DANGER CAUTION Before proceeding always read the safety regulations for the operations to be carried out as set out in Chapter 3 Park the vehicle on level ground turn off the engine apply the parking brake lower the arm and remove the ignition key D 70 SL REV 03 20 03 2014 Unscrew the filler cap 2 3 and the level gauge caps 4 5 in horizo...

Page 100: ...ans under the front and rear axles by the draining caps Unscrew the draining caps 1 2 and 3 Position the cap 3 at the bottom by turning the planetary reduction gear Unscrew the level gauge cap 4 and 5 Drain out all the oil and screw the draining caps 1 and 2 back on Turn back the planetary reduction gear so that the plug 3 is in the position as shown in the figure Using a funnel add the required t...

Page 101: ...s Before inflating a tyre check that the wheel is properly fitted Only use air pumps fitted with a pressure regulator to be set to no more than 1 bar above the specified tyre inflation pressure Make sure that the flexible air hose is properly connected to the tyre valve CAUTION Check and tighten the rim bolts before each work shift alternately going from one bolt to the one diametrically opposite ...

Page 102: ...e 10 9 CAUTION Before proceeding always read the safety regulations for the operations to be carried out as set out in Chapter 3 CAUTION Tyre maintenance and inflation are potentially dangerous operations If possible it is advisable to have tyre maintenance and fitting carried out by a SPECIALISED CENTRE or SKILLED PERSONNEL It is prohibited to change a tyre on a slope or near canals or ditches to...

Page 103: ...urn posing a grave risk to anyone working in the vicinity CAUTION Pay attention to the support area underneath the jack this area must be capable of supporting the entire weight of the vehicle Fit the jack A under the central body B of the front axle To replace the rear tyres fit the jack A under the screwed on plate C of the axle shaft or in the case of a round section axle shaft fit an adapter f...

Page 104: ...el tighten the nuts in the order shown in the figure illustrating wheel nut tightening 12 D If you want to invert a wheel operate as shown in the figure you cannot interchange the tyres crosswise because of the type of tread Fit the wheels with the tyre tread facing in the direction shown in the figure CAUTION If present always fit the flexible washer together with the nut 13 D 70 SL REV 01 02 01 ...

Page 105: ...N In the event of malfunctioning immediately contact the nearest AUTHORISED FIORI WORKSHOP The brake fluid tank is installed to the side of the revolving driving post Always check the brake fluid level before you start using the vehicle Never use petrol solvents or flammable liquids in general for cleaning Use only non flammable and non toxic commercial solvents Always wear protective goggles with...

Page 106: ...fluid tank B with the recommended fluid Bleed the air from the system as described below Ask someone to assist you by getting onto the driving post to depress the brake pedal Unscrew the bleeder A by half a turn and have your colleague depress the brake pedal until bubble free fluid flows from the bleeder Repeat the operation on all the axle bleeders A Regularly top up the brake fluid tank CAUTION...

Page 107: ...ulations for the operations to be carried out as set out in Chapter 3 Before testing the efficiency of the parking brake check that there is no one near the vehicle The efficiency of the hand brake helps ensure that the machine will remain still under full load on a gradient of 25 Ensure that the parking brake button 1 is fully pressed down If you notice that the vehicle moves contact an AUTHORISE...

Page 108: ...ugh the filler neck CAUTION Slowly loosen the bleeder cap to release the residual pressure Carry out this operation only with the engine off Move the vehicle onto flat ground engage the parking brake turn off the engine and remove the ignition key CAUTION Before proceeding always read the safety regulations for the operations to be carried out as set out in Chapter 3 CAUTION Slowly loosen the blee...

Page 109: ...ated even when the oil is hot 35 C the suction filter needs to be replaced Raise the engine compartment lid Remove the level gauge and filler cap A and the filter cover C Remove the cartridge D Manually refit the new cartridge D taking care to correctly position the seals Clean and refit the filter cover C taking care to correctly position the seal Check the level in the tank with the dipstick A a...

Page 110: ...ove the vehicle onto flat ground engage the parking brake turn off the engine and remove the ignition key Raise the engine compartment lid Remove the bleeder and filler cap A Unscrew the drain cap B and drain all the oil from the tank into a container When the tank is empty screw the drain cap B back in and fill the tank with the recommended oil until reaching the required level checking with the ...

Page 111: ... off the engine and remove the ignition key Always wear protective goggles with side screens when working with compressed air Limit the pressure to 2 bar according to the regulations in force Move the vehicle onto flat ground engage the parking brake turn off the engine and remove the ignition key DANGER 21 A B C 20 A CAUTION Before proceeding always read the safety regulations for the operations ...

Page 112: ...artridge and make sure that it is properly in place Close the cover A It is essential to keep a stock of spare cartridges B which can be ordered from the AUTHORISED FIORI SERVICE CENTRES or directly from FIORI SPARE PARTS DEPARTMENT 5 11 3 CHECKING AND TOPPING UP THE COOLANT LEVEL fig 22 22 MIN A CAUTION Use only coolant of the type and brand recommended by the manufacturer as indicated in the Rec...

Page 113: ...t WATER ANTIFREEZE percentages CAUTION In addition to the operations described below also refer to the engine manufacturer s instruction manual Wait until the fluid reaches the ambient temperature Slowly unscrew the radiator cap A To fully drain out the fluid unscrew the drain cap B positioned on the side of the engine monobloc to allow the fluid to flow out Position a receptacle under the radiato...

Page 114: ... work on the belt refer to the engine manufacturer s manual attached CAUTION Before proceeding always read the safety regulations for the operations to be carried out as set out in Chapter 3 Move the vehicle onto flat ground engage the parking brake turn off the engine and remove the ignition key DANGER Open the lid only with the engine off CAUTION If you have any doubts about the operating proced...

Page 115: ...o be carried out as set out in Chapter 3 The air must be bled from the fuel system in the following cases Long periods of inactivity Filter and or pipe replacement Fuel tank completely empty 5 11 8 REPLACING THE ENGINE FUEL SUPPLY PRE FILTER AND FILTER Open the lid only with the engine off CAUTION If you have any doubts about the operating procedures also refer to the instruction manual provided s...

Page 116: ...ons described below also refer to the engine manufacturer s instruction manual CAUTION Before proceeding always read the safety regulations for the operations to be carried out as set out in Chapter 3 Move the vehicle onto flat ground engage the parking brake turn off the engine and remove the ignition key Wait until the oil reaches the ambient temperature Unscrew the cap B Check that the oil leve...

Page 117: ...ly from FIORI SPARE PARTS DEPARTMENT Move the vehicle onto flat ground engage the parking brake turn off the engine and remove the ignition key 5 11 11 REPLACING THE ENGINE OIL Open the lid only with the engine off CAUTION If you have any doubts about the operating procedures also refer to the instruction manual provided separately from this manual Where necessary ask an AUTHORISED FIORI SERVICE C...

Page 118: ...S AND RELAYS 26 17 1 2 5 6 3 4 7 8 9 10 11 13 14 16 15 12 POS AMPERAGE COLOR 1 7 5A brown 2 7 5A brown 3 7 5A brown 4 7 5A brown 5 15A blue 6 5A beige 7 15A blue 8 15A blue 9 5A beige POS AMPERAGE COLOR 10 10A red 11 7 5A brown 12 10A red 13 15A blue 14 15A blue 15 15A blue 16 10A red D 70 SL REV 04 06 10 2014 ...

Page 119: ...Acoustic indicator power supply windscreen washer kit optional 08 optional switch power supply cabin connector 09 Accelerator micro switch power supply 10 Emergency switch direction indicators cabin connector power supply 11 Stop switch power supply 12 LCD instrument panel power supply 13 Socket and cabin connector power supply 14 Available 15 Available 16 Available 17 Spare fuses 18 19 27 CAUTION...

Page 120: ...ned above the engine power take off fig 29 4 Starter motor relay 5 Engine preheating relay Relays driving station fig 28 1 Start enable micro relay 2 Presence of water micro relay 3 Intermittent direction indicator relay CAUTION If a fuse blows or a relay burns find the cause before replacing it with a new one 29 4 5 28 2 3 1 D 70 SL REV 04 06 10 2014 ...

Page 121: ...he event of malfunctioning of the electronic panel contact the nearest AUTHORISED FIORI SERVICE CENTRE or FIORI SPARE PARTS DEPARTMENT directly In the event of replacement the panel is delivered already programmed CAUTION Note down the hours of operation before replacing the electronic control panel 30 ...

Page 122: ...Before replacing a burnt bulb check that the contacts are not oxidised Burnt bulbs must be replaced with new ones of the same type Bulbs with insufficient power provide poor light whereas too powerful bulbs absorb too much energy After replacing a headlight bulb always check the orientation for safety reasons DANGER A Position light bulb 12V 4W T08 Low beam high beam bulb 12V 60 55W H4 B Direction...

Page 123: ...ollute the environment The batteries are classified as polluting and hazardous waste according to the law The battery installed requires little maintenance therefore in normal conditions of use the electrolyte does not need to be topped up Nevertheless every 6 months check that the electrolyte level is between the MAX and MIN notches marked on the battery Before operating on the battery remove the...

Page 124: ... layer of Vaseline grease Refit the battery into place and reconnect it by inserting the key in the battery master switch CAUTION For this operation contact an electrical repair shop and always replace the battery with one of the same amperage CAUTION Do not pollute the environment Keep the old battery in a suitable container and send it to companies specialised in storage and disposal of pollutin...

Page 125: ...1 04 2013 6 6 CONTENTS CONTENTS 6 1 6 1 AIR CONDITIONER AIR CONDITIONER 126 126 6 1 1 6 1 1 OPERATION OPERATION 126 126 6 1 2 6 1 2 MAINTENANCE MAINTENANCE 127 127 6 1 3 6 1 3 TECHNICAL DATA 127 127 6 1 4 6 1 4 SCHEDULED MAINTENANCE TABLE 127 127 ...

Page 126: ... cooling HEATING Start the engine Turn the knob D to the left Adjust the fan speed as desired using the knob on the switch A Adjust the temperature as desired using the knob on the thermostat B Direct the air flow through the adjustable air vents C COOLING Start the engine Turn the knob D to the right Adjust the fan speed as desired using the knob on the switch A Note the air conditioner is only a...

Page 127: ...special containers and send them to companies specialised in storage and disposal of polluting and hazardous waste 6 1 4 SCHEDULED MAINTENANCE TABLE AIR CONDITIONER GAS Gas type R134A Quantity 0 85 kg Recharging pressure 9 12 bar 6 1 3 TECHNICAL DATA DANGER DANGER Description of the symbols used in the table Check and repair Replace Clean Grease or lubricate WORKING AREA EVERY 8 HOURS OR DAILY REG...

Page 128: ......

Page 129: ...SEBU8325 01 July 2012 Operation and Maintenance Manual 1104D Mech Industrial Engine NK Engine NL Engine NM Engine ...

Page 130: ...ning explains the hazard and can be either written or pictorially presented Operations that may cause product damage are identified by NOTICE labels on the product and in this publication Perkins cannot anticipate every possible circumstance that might involve a potential hazard The warnings in this publication and on the product are therefore not all inclusive If a tool procedure work method or o...

Page 131: ...10 Engine Starting 10 Engine Stopping 11 Electrical System 11 Product Information Section Model Views 13 Product Identification Information 18 Operation Section Lifting and Storage 20 Gauges and Indicators 22 Features and Controls 23 Engine Starting 24 Engine Operation 27 Engine Stopping 28 Cold Weather Operation 29 Maintenance Section Refill Capacities 33 Maintenance Interval Schedule 50 Warranty...

Page 132: ...e schedule are referenced to detailed instructions that follow Recommended service should be performed at the appropriate intervals as indicated in the Maintenance Interval Schedule The actual operating environment of the engine also governs the Maintenance Interval Schedule Therefore under extremely severe dusty wet or freezing cold operating conditions more frequent lubrication and maintenance t...

Page 133: ...micals could loosen the adhesive that secures the warning signs The warning signs that are loosened could drop off of the engine Replace any warning sign that is damaged or missing If a warning sign is attached to a part of the engine that is replaced install a new warning sign on the replacement part Your Perkins dealer or your distributor can provide new warning signs 1 Universal Warning Do not ...

Page 134: ... result in an explosion and personal injury g01154809 Illustration 3 Typical example The ether warning label 1 is located on the inlet manifold cover Refer to illustration 2 i02677370 General Hazard Information g00104545 Illustration 4 Attach a Do Not Operate warning tag or a similar warning tag to the start switch or to the controls before you service the equipment or before you repair the equipm...

Page 135: ...tection includes goggles or a protective face shield The maximum air pressure for cleaning purposes must be below 205 kPa 30 psi The maximum water pressure for cleaning purposes must be below 275 kPa 40 psi Fluid Penetration Pressure can be trapped in the hydraulic circuit long after the engine has been stopped The pressure can cause hydraulic fluid or items such as pipe plugs to escape rapidly if...

Page 136: ... hot components to contact the skin Batteries Electrolyte is an acid Electrolyte can cause personal injury Do not allow electrolyte to contact the skin or the eyes Always wear protective glasses for servicing batteries Wash hands after touching the batteries and connectors Use of gloves is recommended i02813488 Fire Prevention and Explosion Prevention g00704000 Illustration 7 All fuels most lubric...

Page 137: ...ed The lines and hoses must have adequate support and secure clamps Tighten all connections to the recommended torque Leaks can cause fires Oil filters and fuel filters must be correctly installed The filter housings must be tightened to the correct torque g00704059 Illustration 8 Use caution when you are refueling an engine Do not smoke while you are refueling an engine Do not refuel an engine ne...

Page 138: ... fan blades will throw objects or cut objects When objects are struck wear protective glasses in order to avoid injury to the eyes Chips or other debris may fly off objects when objects are struck Before objects are struck ensure that no one will be injured by flying debris i02675470 Before Starting Engine The initial start up of a new engine or a engine that has been serviced or repaired make pro...

Page 139: ...ting of the engine and accelerated wear of the engine components Use the Emergency Stop Button if equipped ONLY in an emergency situation Do not use the Emergency Stop Button for normal engine stopping After an emergency stop DO NOT start the engine until the problem that caused the emergency stop has been corrected Stop the engine if an overspeed condition occurs during the initial start up of a ...

Page 140: ...tion Electrical System All grounds should be tight and free of corrosion The engine alternator must be grounded to the negative battery terminal with a wire that is adequate to handle the full charging current of the alternator ...

Page 141: ...SEBU8325 01 13 Product Information Section Model Views Product Information Section Model Views i02693072 Model View Illustrations ...

Page 142: ...ine Model Views g01351713 Illustration 10 Typical example 1 Pulley 2 Alternator 3 Front Lifting Eye 4 Water Outlet 5 Valve Mechanism Cover 6 Rear Lifting Eye 7 Air Intake 8 Secondary Fuel Filter 9 Fuel Injection Pump 10 Oil Filter 11 Crankshaft Pulley 12 Water Pump ...

Page 143: ...wheel Housing 15 Oil Filler Cap 16 Exhaust Manifold 17 Turbocharger 18 Oil Gauge 19 Oil Pan 20 Starting motor 21 Oil Drain Plug 22 Primary Fuel Filter Note The primary fuel filter may be mounted off the engine i04430909 Engine Description The engines are available in the following types of aspiration ...

Page 144: ...se Valve Lash Setting Inlet 0 20 mm 0 008 inch Valve Lash Setting Exhaust 0 45 mm 0 018 inch Engine Cooling and Lubrication The cooling system consists of the following components Gear driven centrifugal water pump Water temperature regulator which regulates the engine coolant temperature Gear driven oil pump gear type Oil cooler The engine lubricating oil is supplied by a gear type pump The engin...

Page 145: ...ation and Maintenance Manual as a guide for required engine maintenance Expected engine life is generally predicted by the average power that is demanded The average power that is demanded is based on fuel consumption of the engine over a time period Reduced hours of operation at full throttle and or operating at reduced throttle settings result in a lower average power demand Reduced hours of ope...

Page 146: ...ical serial number plate 2 Temporary Parts List number 3 List number 4 Serial number 5 Type The Serial Number Plate 1 is located on the left side of the cylinder block to the rear of the engine The following information is stamped on the Serial Number Plate Engine serial number Model and Arrangement number i02677372 Reference Numbers Information for the following items may be needed to order parts...

Page 147: ..._____ Total Cooling System Capacity _________ ________________ Air Cleaner Element _________ ______________________________ Fan Drive Belt _________ _____________________________________ Alternator Belt _________ _____________________________________ i02690481 Emissions Certification Film g01350379 Illustration 15 Typical example ...

Page 148: ...rage after a period in service Your Perkins dealer or your Perkins distributor can assist in preparing the engine for extended storage periods Condition for Storage The engine must be stored in a water proof building The building must be kept at a constant temperature Engines that are filled with Perkins ELC will have coolant protection to an ambient temperature of 36 C 32 8 F The engine must not ...

Page 149: ...coolant system must be sealed once the vapor phase inhibitor has been introduced The effect of the vapor phase inhibitor will be lost if the cooling system is open to the atmosphere For maintenance procedures refer to this Operation and Maintenance Manual Monthly Checks The crankshaft must be rotated in order to change the spring loading on the valve train Rotate the crankshaft more than 180 degre...

Page 150: ...emperature range is 71 to 96 C 160 to 205 F The maximum allowable temperature with the pressurized cooling system at 48 kPa 7 psi is 110 C 230 F Higher temperatures may occur under certain conditions The water temperature reading may vary according to load The reading should never exceed the boiling point for the pressurized system that is being used If the engine is operating above the normal ran...

Page 151: ... Controls i02690464 Fuel Shutoff The fuel shutoff solenoid is located on the fuel injection pump When the fuel shutoff solenoid is activated the solenoid moves to the Open position When the fuel shutoff solenoid is deactivated the solenoid moves to the Closed position ...

Page 152: ...n on priming the fuel system Engine exhaust contains products of combustion which may be harmful to your health Always start and operate the engine in a well ventilated area and if in an enclosed area vent the exhaust to the outside Do not start the engine or move any of the controls if there is a DO NOT OPERATE warning tag or similar warning tag attached to the start switch or to the controls Ens...

Page 153: ...tion of the battery can be rechecked after the engine has been switched OFF NOTICE Using a battery source with the same voltage as the electric starting motor Use ONLY equal voltage for jump starting The use of higher voltage will damage the electrical system Do not reverse the battery cables The alternator can be damaged Attach ground cable last and remove first When using an external electrical ...

Page 154: ...t one half full rpm no load on the engine before operating the engine under load This is not possible in some applications Operate the engine at low idle until all systems achieve operating temperatures Check all gauges during the warm up period Note Gauge readings should be observed and the data should be recorded frequently while the engine is operating Comparing the data over time will help to ...

Page 155: ...esign and technology in manufacturing provides maximum fuel efficiency in all applications Follow the recommended procedures in order to attain optimum performance for the life of the engine Avoid spilling fuel Fuel expands when the fuel is warmed up The fuel may overflow from the fuel tank Inspect fuel lines for leaks Repair the fuel lines as needed Be aware of the properties of the different fue...

Page 156: ...ication with an emergency stop button For more information about the emergency stop button refer to the OEM information Ensure that any components for the external system that support the engine operation are secured after the engine is stopped i02678906 After Stopping Engine Note Before you check the engine oil do not operate the engine for at least 10 minutes in order to allow the engine oil to ...

Page 157: ...on shutdown This means that an engine can be shut down for a period of time and the engine can still have the ability to start readily Install the correct specification of engine lubricant before the beginning of cold weather Check all rubber parts hoses fan drive belts etc weekly Check all electrical wiring and connections for any fraying or damaged insulation Keep all batteries fully charged and...

Page 158: ...up completely the carbon deposits become thicker This will cause the following problems Free operation of the valves is prevented Valves become stuck Pushrods are bent Other damage to valve train components can result For this reason when the engine is started the engine must be operated until the coolant temperature is 71 C 160 F minimum Carbon deposits on the valve stems will be kept at a minimu...

Page 159: ...ower and the engine s fuel efficiency When Group 2 diesel fuels are used the following components provide a means of minimizing problems in cold weather Glow plugs if equipped Engine coolant heaters which may be an OEM option Fuel heaters which may be an OEM option Fuel line insulation which may be an OEM option There are three major differences between Group 1 fuels and Group 2 fuels Group 1 fuel...

Page 160: ...vals and refueling of the fuel tank This will help prevent water and or sediment from being pumped from the fuel storage tank and into the engine fuel tank Fuel Filters A primary fuel filter is installed between the fuel tank and the engine fuel inlet After you change the fuel filter always prime the fuel system in order to remove air bubbles from the fuel system Refer to the Operation and Mainten...

Page 161: ... Compartment or System Liters Engine Only 7 L 1 5398 Imp gal External System Per OEM 1 1 The External System includes a radiator or an expansion tank with the following components heat exchanger and piping Refer to the OEM specifications Enter the value for the capacity of the External System in this row i04478615 Fluid Recommendations General Lubricant Information Because of government regulation...

Page 162: ...es are not appropriate for DHD 1 oils This feature reduces the variation in performance that can occur when base stocks are changed in commercial oil formulations DHD 1 oils are recommended for use in extended oil change interval programs that optimize the life of the oil These oil change interval programs are based on oil analysis DHD 1 oils are recommended for conditions that demand a premium oi...

Page 163: ...y an oil with a high TBN These deposits can lead to a loss of control of the oil consumption and to the polishing of the cylinder bore NOTICE Operating Direct Injection DI diesel engines with fuel sulphur levels over 0 5 percent will require shortened oil change intervals in order to help maintain adequate wear protection Table 5 Percentage of Sulfur in the fuel Oil change interval Lower than 0 5 ...

Page 164: ...ubricants is limited in cold weather conditions Perkins recommends the following lubricants for use in cold weather conditions First Choice Use oil with an EMA DHD 1 Recommended Guideline Use a CH 4 oil that has an API license The oil should be either SAE 0W20 SAE 0W30 SAE 0W40 SAE 5W30 or SAE 5W40 lubricant viscosity grade Second Choice Use an oil that has a CH 4 additive package Although the oil...

Page 165: ...engine to cool first NOTICE If the engine is to be stored in or shipped to an area with below freezing temperatures the cooling system must be either protected to the lowest outside temper ature or drained completely to prevent damage NOTICE Frequently check the specific gravity of the coolant for proper freeze protection or for anti boil protection Clean the cooling system for the following reaso...

Page 166: ...Boiling Freezing Cavitation of the water pump For optimum performance Perkins recommends a 1 1 mixture of a water glycol solution Note Use a mixture that will provide protection against the lowest ambient temperature Note 100 percent pure glycol will freeze at a temperature of 23 C 9 F Most conventional antifreezes use ethylene glycol Propylene glycol may also be used In a 1 1 mixture with water e...

Page 167: ...ignited gas engines Heavy duty diesel engines Automotive applications The anti corrosion package for ELC is different from the anti corrosion package for other coolants ELC is an ethylene glycol base coolant However ELC contains organic corrosion inhibitors and antifoam agents with low amounts of nitrite Perkins ELC has been formulated with the correct amount of these additives in order to provide...

Page 168: ...ine until the engine is warmed to 49 to 66 C 120 to 150 F NOTICE Incorrect or incomplete flushing of the cooling system can result in damage to copper and other metal com ponents To avoid damage to the cooling system make sure to completely flush the cooling system with clear water Continue to flush the system until all the signs of the cleaning agent are gone 7 Drain the cooling system into a sui...

Page 169: ...rkins SCA that is required when the cooling system is initially filled Table 12 Equation For Adding The SCA To The Heavy Duty Coolant At The Initial Fill V 0 045 X V is the total volume of the cooling system X is the amount of SCA that is required Table 13 is an example for using the equation that is in Table 12 Table 13 Example Of The Equation For Adding The SCA To The Heavy Duty Coolant At The I...

Page 170: ...ency of the United States General Information NOTICE Every attempt is made to provide accurate up to date information By use of this document you agree that Perkins Engines Company Limited is not responsible for errors or omissions NOTICE These recommendations are subject to change with out notice Contact your local Perkins distributor for the most up to date recommendations Diesel Fuel Requiremen...

Page 171: ...o equivalent test ISO 3675 ISO 12185 Distillation C 10 at 282 C 539 6 F maximum 90 at 360 C 680 F maximum D86 ISO 3405 Flash Point C legal limit D93 ISO 2719 Thermal Stability Minimum of 80 reflectance after aging for 180 minutes at 150 C 302 F D6468 No equivalent test Pour Point C 6 C 42 8 F minimum below ambient temperature D97 ISO 3016 Sulfur 1 4 mass 1 maximum D5453 D26222 ISO 20846 ISO 20884 ...

Page 172: ...ith fuels that do not meet the Perkins rec ommendations can cause the following effects Start ing difficulty poor combustion deposits in the fuel in jectors reduced service life of the fuel system de posits in the combustion chamber and reduced ser vice life of the engine Engines that are manufactured by Perkins are certified with the fuel that is prescribed by the United States En vironmental Pro...

Page 173: ... of the fluid describes the ability of the fluid to reduce the friction between surfaces that are under load This ability reduces the damage that is caused by friction Fuel injection systems rely on the lubricating properties of the fuel Until fuel sulfur limits were mandated the lubricity of the fuel was believed to be a function of fuel viscosity The lubricity has particular significance to the ...

Page 174: ... biodiesel in the United States This biodiesel is derived from soybean oil Soybean oil or rapeseed oil are the primary feedstocks These fuels are together known as Fatty Acid Methyl Esters FAME Raw pressed vegetable oils are NOT acceptable for use as a fuel in any concentration in compression engines Without esterification these oils gel in the crankcase and the fuel tank These fuels may not be co...

Page 175: ... to check the quality of the engine oil if biodiesel fuel is used Ensure that the level of biodiesel in the fuel is noted when the oil sample is taken Performance Related Issues with B20 Due to the lower energy content than the standard distillate fuel B20 will cause a power loss in order of 2 to 4 percent In addition over time the power may deteriorate further due to deposits in the fuel injector...

Page 176: ...market Fuel Additives NOTICE Perkins does not warrant the quality or performance of non Perkins fluids and filters When auxiliary devices accessories or consumables filters additives which are made by other manufac turers are used on Perkins products the Perkins war ranty is not affected simply because of such use However failures that result from the installation or use of other manufacturers dev...

Page 177: ...SEBU8325 01 49 Maintenance Section Refill Capacities Detailed instructions on the rate of which the fuel cleaner must be use are on the container ...

Page 178: ...st Replace 76 Every 500 Service Hours or 1 Year Battery Electrolyte Level Check 53 Cooling System Supplemental Coolant Additive SCA Test Add 58 Crankcase Breather Canister Replace 59 Engine Air Cleaner Element Dual Element Clean Replace 60 Engine Oil and Filter Change 64 Fuel System Primary Filter Water Separator Element Replace 68 Fuel System Secondary Filter Replace 70 Hoses and Clamps Inspect R...

Page 179: ...f the aftercooler core Remove any other trapped debris 7 Wash the core with hot soapy water Rinse the core thoroughly with clean water Personal injury can result from air pressure Personal injury can result without following prop er procedure When using pressure air wear a pro tective face shield and protective clothing Maximum air pressure at the nozzle must be less than 205 kPa 30 psi for cleani...

Page 180: ...ries should be kept charged The batteries should be kept warm because temperature affects the cranking power If the battery is too cold the battery will not crank the engine When the engine is not run for long periods of time or if the engine is run for short periods the batteries may not fully charge A battery with a low charge will freeze more easily than a battery with a full charge i02690445 A...

Page 181: ...n order to help prevent the battery from freezing If batteries are correctly charged the ammeter reading should be very near zero when the engine is in operation All lead acid batteries contain sulfuric acid which can burn the skin and clothing Always wear a face shield and protective clothing when working on or near batteries 1 Remove the filler caps Maintain the electrolyte level to the FULL mar...

Page 182: ... and mandates NOTICE Keep all parts clean from contaminants Contaminants may cause rapid wear and shortened component life Clean the cooling system and flush the cooling system before the recommended maintenance interval if the following conditions exist The engine overheats frequently Foaming is observed The oil has entered the cooling system and the coolant is contaminated The fuel has entered t...

Page 183: ...ant Additive to the coolant For the correct amount refer to the Operation and Maintenance Manual Fluid Recommendations topic Maintenance Section for more information on cooling system specifications Do not install the cooling system filler cap 3 Start and run the engine at low idle Increase the engine rpm to high idle Run the engine at high idle for one minute in order to purge the air from the ca...

Page 184: ... sure 1 Stop the engine and allow the engine to cool Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap g01356026 Illustration 21 Typical example 2 Open the drain cock or remove the drain plug 1 on the engine Open the drain cock or remove the drain plug on the radiator Allow the coolant to drain NOTICE Dispose of used engine coolant or...

Page 185: ...e cooling system filler cap is damaged discard the old cooling system filler cap and install a new cooling system filler cap If the gasket that is on the cooling system filler cap is not damaged use a suitable pressurizing pump in order to pressure test the cooling system filler cap The correct pressure for the cooling system filler cap is stamped on the face of the cooling system filler cap If th...

Page 186: ...f the filler cap does not retain the correct pressure install a new filler cap 4 Inspect the cooling system for leaks i02675604 Cooling System Supplemental Coolant Additive SCA Test Add Cooling system coolant additive contains alkali To help prevent personal injury avoid contact with the skin and the eyes Do not drink cooling system coolant additive Test for SCA Concentration Heavy Duty Coolant An...

Page 187: ...50307 Illustration 24 Typical example 1 Place a container under the canister 1 2 Clean the outside of the canister Use a suitable tool in order to remove the canister 3 Lubricate the O ring seal 2 on the new canister with clean engine lubricating oil Install the new canister Tighten the canister to 12 N m 8 lb ft Do not overtighten the canister 4 Remove the container Dispose of the old canister an...

Page 188: ... system Refer to the OEM information for the correct procedure If the air cleaner element becomes plugged the air can split the material of the air cleaner element Unfiltered air will drastically accelerate internal engine wear Refer to the OEM information for the correct air cleaner elements for your application Check the precleaner if equipped and the dust bowl daily for accumulation of dirt and...

Page 189: ...ation in order to determine the number of times that the primary air cleaner element can be cleaned Do not clean the primary air filter element more than three times The primary air cleaner element must be replaced at least one time per year Cleaning the air filter element will not extend the life of the air filter element Visually inspect the primary air cleaner element before cleaning Inspect ai...

Page 190: ...s or seals Discard damaged primary air cleaner elements i02676010 Engine Air Cleaner Element Single Element Inspect Replace Refer to Operation and Maintenance Manual Engine Air Cleaner Service Indicator Inspect NOTICE Never run the engine without an air cleaner element installed Never run the engine with a damaged air cleaner element Do not use air cleaner elements with damaged pleats gaskets or s...

Page 191: ...icator will not reset the hole for the service indicator may be restricted The service indicator may need to be replaced frequently in environments that are severely dusty i02690451 Engine Air Precleaner Check Clean g00287039 Illustration 29 Typical example 1 Wing nut 2 Cover 3 Body Remove wing nut 1 and cover 2 Check for an accumulation of dirt and debris in body 3 Clean the body if necessary Aft...

Page 192: ... the oil filler cap and add oil if necessary Clean the oil filler cap Install the oil filler cap i04478611 Engine Oil and Filter Change Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin Do not drain the oil when the engine is cold As the oil cools suspended waste particles settle on the bottom of the oil pan The waste particles are not ...

Page 193: ... inspect the oil filter for metal debris An excessive amount of metal debris in the oil filter may indicate early wear or a pending failure Use a magnet to differentiate between the ferrous metals and the nonferrous metals that are found in the oil filter element Ferrous metals may indicate wear on the steel and cast iron parts of the engine Nonferrous metals may indicate wear on the aluminum part...

Page 194: ...w the oil to drain back to the sump for a minimum of 10 minutes g01165836 Illustration 34 Y MIN mark X MAX mark 4 Remove the oil level gauge in order to check the oil level Maintain the oil level between the MIN and MAX marks on the engine oil dipstick i02171102 Engine Valve Lash Inspect Adjust This maintenance is recommended by Perkins as part of a lubrication and preventive maintenance schedule ...

Page 195: ... runs erratically High fuel consumption Black exhaust smoke The engine knocks or there is vibration in the engine Excessive engine temperature Removal and Installation of the Fuel Injectors Work carefully around an engine that is running Engine parts that are hot or parts that are moving can cause personal injury Make sure that you wear eye protection at all times during testing When fuel injectio...

Page 196: ...2 lb ft 3 Start the engine and run the engine at idle for 1 minute NOTICE Do not crank the engine continuously for more than 30 seconds Allow the starting motor to cool for two minutes before cranking the engine again 4 Cycle the throttle lever from the low idle position to the high idle position three times The cycle time for the throttle lever is one second to six seconds for one complete cycle ...

Page 197: ...e screw 1 and tighten the screw to a torque of 8 N m 6 lb ft 9 Remove the container and dispose of the fuel safely 10 Open the fuel supply valve 11 Prime the fuel system Refer to the Operation and Maintenance Manual Fuel System Prime for more information i02699081 Fuel System Primary Filter Water Separator Drain Fuel leaked or spilled onto hot surfaces or elec trical components can cause a fire To...

Page 198: ...vent possible injury turn the start switch off when changing fuel filters or water separator elements Clean up fuel spills immediately NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over discon nected fuel system component Element filter Turn the valves for the fuel lines if equipped to the O...

Page 199: ...he element into the filter bowl 7 Install the filter bowl 1 into the top of the filter head 3 8 Tighten the filter bowl by hand until the filter bowl contacts the filter head Rotate the filter bowl through 90 degrees Note Do not use a tool to tighten the filter bowl 9 Open the valves for the fuel lines if equipped Spin on filter Turn the valves for the fuel lines if equipped to the OFF position be...

Page 200: ...asses through the fuel system and the fuel returns to the fuel tank This causes water to accumulate in fuel tanks Draining the fuel tank regularly and obtaining fuel from reliable sources can help to eliminate water in the fuel Drain the Water and the Sediment Fuel tanks should contain some provision for draining water and draining sediment from the bottom of the fuel tanks Open the drain valve on...

Page 201: ...loosen This can result in leaks A constant torque hose clamp will help to prevent loose hose clamps Each installation application can be different The differences depend on the following factors Type of hose Type of fitting material Anticipated expansion and contraction of the hose Anticipated expansion and contraction of the fittings Replace the Hoses and the Clamps Refer to the OEM information f...

Page 202: ...ergent and hot water Thoroughly rinse the core with clean water If the radiator is blocked internally refer to the OEM Manual for information regarding flushing the cooling system After cleaning the radiator start the engine Allow the engine to operate at low idle speed for three to five minutes Accelerate the engine to high idle This will help in the removal of debris and the drying of the core S...

Page 203: ...for correct operation Check the electrical connections and clean the electrical connections Refer to the Systems Operation Testing and Adjusting Manual Electric Starting System Test for more information on the checking procedure and for specifications or consult your Perkins dealer or your Perkins distributor for assistance i02677378 Turbocharger Inspect If Equipped A regular visual inspection of ...

Page 204: ...ssibility of a failed turbocharger oil seal The presence of oil may be the result of extended engine operation at low idle The presence of oil may also be the result of a restriction of the line for the intake air clogged air filters which causes the turbocharger to slobber 3 Inspect the bore of the housing of the turbine outlet for corrosion 4 Fasten the air intake pipe and the exhaust outlet pip...

Page 205: ...ldup Make repairs as needed The guards must be in the correct place Repair damaged guards or replace missing guards Wipe all caps and plugs before the engine is serviced in order to reduce the chance of system contamination NOTICE For any type of leak coolant lube or fuel clean up the fluid If leaking is observed find the source and correct the leak If leaking is suspected check the fluid levels m...

Page 206: ...ct the wiring and the wiring harnesses for loose connections and for worn wires or frayed wires Inspect the ground strap for a good connection and for good condition Disconnect any battery chargers that are not protected against the current drain of the starting motor Check the condition and the electrolyte level of the batteries unless the engine is equipped with a maintenance free battery Check ...

Page 207: ...y with exhaust emission standards and gaseous emission standards that are prescribed by the law at the time of manufacture and this engine may be covered by an Emissions Warranty Consult your authorized Perkins dealer or your authorized Perkins distributor in order to determine if your engine is emissions certified and if your engine is subject to an Emissions Warranty ...

Page 208: ...n Equipment Check 59 E Electrical System 11 Grounding Practices 11 Emergency Stopping 28 Emissions Certification Film 19 Emissions Warranty Information 79 Engine Clean 59 Engine Air Cleaner Element Dual Element Clean Replace 60 Cleaning the Primary Air Cleaner Elements 61 Servicing the Air Cleaner Elements 60 Engine Air Cleaner Element Single Element Inspect Replace 62 Engine Air Cleaner Service I...

Page 209: ...ir and Water 7 H Hoses and Clamps Inspect Replace 73 Replace the Hoses and the Clamps 73 I Important Safety Information 2 L Lifting and Storage 20 M Maintenance Interval Schedule 50 Maintenance Section 33 Model View Illustrations 14 1104 Engine Model Views 14 Model Views 13 O Operation Section 20 P Product Identification Information 18 Product Information Section 13 Product Lifting 20 Product Stor...

Page 210: ...82 SEBU8325 01 Index Section W Walk Around Inspection 77 Inspect the Engine for Leaks and for Loose Connections 77 Warranty Information 79 Warranty Section 79 Water Pump Inspect 78 ...

Page 211: ...Maintenance Manual Delivery Date Product Information Model Product Identification Number Engine Serial Number Transmission Serial Number Generator Serial Number Attachment Serial Numbers Attachment Information Customer Equipment Number Dealer Equipment Number Dealer Information Name Branch Address Dealer Contact Phone Number Hours Sales Parts Service ...

Page 212: ... 2012 Perkins Engines Company Limited All Rights Reserved ...

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