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SEBU8325-01

9

Safety Section

Fire Prevention and Explosion Prevention

Exhaust shields (if equipped) protect hot exhaust
components from oil or fuel spray in case of a line,
a tube, or a seal failure. Exhaust shields must be
installed correctly.

Do not weld on lines or tanks that contain flammable
fluids. Do not flame cut lines or tanks that contain
flammable fluid. Clean any such lines or tanks
thoroughly with a nonflammable solvent prior to
welding or flame cutting.

Wiring must be kept in good condition. All electrical
wires must be correctly routed and securely attached.
Check all electrical wires daily. Repair any wires
that are loose or frayed before you operate the
engine. Clean all electrical connections and tighten
all electrical connections.

Eliminate all wiring that is unattached or unnecessary.
Do not use any wires or cables that are smaller than
the recommended gauge. Do not bypass any fuses
and/or circuit breakers.

Arcing or sparking could cause a fire. Secure
connections, recommended wiring, and correctly
maintained battery cables will help to prevent arcing
or sparking.

Inspect all lines and hoses for wear or for
deterioration. The hoses must be correctly routed.
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 near open flames or sparks. Always
stop the engine before refueling.

g00704135

Illustration 9

Gases from a battery can explode. Keep any open
flames or sparks away from the top of a battery. Do
not smoke in battery charging areas.

Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter or
a hydrometer.

Incorrect jumper cable connections can cause
an explosion that can result in injury. Refer to
the Operation Section of this manual for specific
instructions.

Do not charge a frozen battery. This may cause an
explosion.

The batteries must be kept clean. The covers
(if equipped) must be kept on the cells. Use the
recommended cables, connections, and battery box
covers when the engine is operated.

Fire Extinguisher

Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations
on the instruction plate.

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Summary of Contents for DB 460

Page 1: ... FIORI GROUP S p A Via per Ferrara 7 41034 FINALE EMILIA Modena Italia Tel 39 0535 92357 Fax 39 0535 90960 http www fiorigroup com DB 460 USE AND MAINTENANCE MANUAL RIF 9301445205 ed 00 id SELF LOADING CONCRETE MIXER DB 460 REV 03 20 12 2016 ...

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Page 3: ... CAUTION STUDY THIS MANUAL BEFORE USING THE MACHINE Operators and maintenance staff must read this manual carefully before using the machine or carrying 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 consulta...

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Page 5: ...id DB 460 REV 00 02 01 2015 CONTENTS INTRODUCTION TECHNICAL FEATURES SAFETY PRECAUTIONS OPERATION AND USE MAINTENANCE OPTIONAL EQUIPMENT TECHNICAL ANNEXES 1 0 2 3 4 5 6 ...

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Page 7: ...NS OF USE 27 3 1 1 PERSONAL PROTECTION DEVICES PPD 27 3 1 2 VEHICLE LIMITS 27 3 1 3 NOISE LEVEL 28 3 1 4 VIBRATION LEVEL 28 3 1 4 a Vibration level on the operator s body measured on the driver s seat 28 3 1 4 b Vibration level on the hands arms measured on the steering wheel 28 3 1 5 SAFETY DEVICE CHECKS 28 3 1 6 PRECAUTIONS WHEN USING ACCESSORIES 28 3 1 7 PROHIBITION TO TRANSPORT PERSONS OR OBJE...

Page 8: ...RISK OF SHORT CIRCUIT 39 3 2 9 BATTERY 39 3 2 10 HOT AND PRESSURISED FLUIDS 40 3 2 11 RISK OF BURNS 40 3 2 12 VENTILATION 40 3 2 13 INTOXICATION 40 3 2 14 FIRE PREVENTION 41 3 3 PRECAUTIONS DURING MAINTENANCE OPERATIONS 42 3 3 1 CORRECT MAINTENANCE 42 3 3 2 PRECAUTIONS DURING WELDING OPERATIONS 45 3 3 3 FAULTS AND UNAUTHORISED MODIFICATIONS 45 3 3 4 CLEANING THE VEHICLE 45 3 3 5 WASTE FLUID MATERI...

Page 9: ...nter 67 4 2 2 c Hour counter revolution counter 67 4 2 2 d Maintenance schedule 68 4 2 2 e Forward reverse gear selector 68 4 2 2 f Slow fast gear selector 68 4 2 2 g Mechanical gear selector 69 4 2 2 h Drum rotation switch 69 4 2 2 i Reset button 69 4 2 2 k Water pumps control switch 70 4 2 2 l Hazard light toggle switch 70 4 2 2 m Working light switch 70 4 2 2 n Engine starter and stopping switc...

Page 10: ...TING SYSTEM 93 4 9 PRECAUTIONS IN THE EVENT OF LONG PERIODS OF INACTIVITY 94 4 10 WORKING PHASES 94 4 10 1 CORRECT USE OF THE VEHICLE 95 4 10 2 BEFORE GETTING ON THE VEHICLE CHECKS AND WARNINGS 95 4 10 3 CORRECT USE ON SLOPES 95 4 10 4 CONCRETE COMPOSITION AND BATCHING TABLE 97 4 10 5 FIRST FILLING WITH MIXING WATER 98 4 10 5 a Filling the tanks with mixing water 98 4 10 5 b First filling with mix...

Page 11: ...E FRONT AND REAR AXLES 124 5 8 3 REPLACING THE OIL IN THE FRONT AND REAR AXLES 125 5 8 4 CHECKING AND ADJUSTING THE TYRE PRESURE 126 5 8 5 REPLACING THE WHEELS 127 5 9 BRAKES 130 5 9 1 CHECKING AND TOPPING UP THE BRAKE FLUID LEVEL 130 5 9 2 CLEANING THE BRAKE FLUID TANK BLEEDERS 130 5 9 3 REPLACING THE BRAKING SYSTEM FLUID 131 5 9 4 EFFICIENCY OF THE HAND BRAKE 132 5 9 5 CHECKING THE WEAR CONDITIO...

Page 12: ...IC COMPONENTS 145 5 12 1 FUSES AND RELAYS 145 5 12 2 ELECTRONIC DASHBOARD WARNING LIGHTS 148 5 12 3 REPLACING THE LIGHT BULBS 149 5 12 4 CHECKING AND TOPPING UP THE BATTERY ELECTROLYTE LEVEL 150 5 12 5 BATTERY PINS CONTACT 151 5 12 6 BATTERY REPLACE 151 5 13 WATER SYSTEM 152 5 13 1 CHECKING AND MAINTAINING THE LITRE COUNTER 152 5 13 2 CHECKING THE WATER TRANSFER PUMP EFFICIENCY 152 5 13 3 WATER PU...

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: ...s involving risks and which may cause damages 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 driving position of the operator as shown in fig A B 1 4 VEHICLE CONTROL AND DRIVING PHASES 1 4 1 TRANSFER PHASE PREFERENTIAL SPEED The driving post is turned toward the front of the machine Driv...

Page 15: ...y 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 indirectly arise in connection therewith T...

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: ...t 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 must be provided...

Page 18: ...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 BF08H00900 1 2 C D A F E B ...

Page 19: ...8H A 0900 YEAR C ENGINE DATA PLATE The engine data plate is positioned on the power take off side Write down your vehicle numbers in the space below for quick and easy reference MODEL No 2612 2400 1104A 44T 3058 2200 1104D 44TA SERIAL NUMBER D AXLE DATA PLATE The axle type and serial numbers are printed on the plate found on the axle central case Write down the information in the space below for q...

Page 20: ...ndicated directives MACHINE Directive 2006 42 EC on Machinery Directive 2004 108 EC on Electromagnetic Compatibility Directive 2000 14 EC on Noise emission ENGINE STAGE 0 E U STAGE III A EPA Tier 3 CABIN ROPS UNI 11023 FOPS LEVEL I ISO 3449 FOPS LEVEL II ISO 3449 optional QUALITY STANDARD FIORI GROUP S p A is a certified company ISO 9001 2008 Quality ISO 14001 2004 Environment BS OHSAS 18001 2007 ...

Page 21: ... Measured sound power level dB A Guaranteed sound power level dB A Nominal drum output Att n For proper and safe machine use we recommend that you follow the instruc tions given in the Use and Maintenance Manual BF08H 106 108 4 FIORI GROUP S p A FIORI GROUP S p A DB460 BF08H00000 2015 1 11 DECLARATION OF CONFORMITY The EC Declaration of conformity is the document undersigned by the Manufacturer wh...

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Page 23: ... Minimum height with loader on the ground 3 105 mm Maximum road transfer height 4 030 mm Maximum hopper unloading height 2 130 mm Maximum chute unloading height 1 765 mm Minimum chute unloading height 1 635 mm Front angle of attack 41 Rear angle of attack 56 Ground clearance under the differentials 390 mm Minimum wheel radius 2 030 mm Minimum outside wheel radius 4 580 mm ...

Page 24: ... WHEEL DRIVE Hydrostatic automotive transmission with variable displacement pump and variable displacement hydraulic motor with electro hydraulic control and reverse gear control on the steering wheel Electro hydraulically controlled mechanical gearbox for working speed and road transfer speed SPEED 4 forward gears 2 reverse gears Ist 0 3 0 Km h 0 3 0 Km h IInd 0 7 2 Km h 0 3 0 Km h IIIrd 0 10 0 K...

Page 25: ...at the rear of the machine Drum raising up to the horizontal position by means of 2 double acting jacks Unloading chute with hydraulic tilting by means of a double acting jack and 180 rotation independent from the mixing drum inclination Removable chute for direct unloading from hopper 2 unloading chute extensions provided as standard equipment WATER SYSTEM Self priming volumetric water pump with ...

Page 26: ...tandards Sliding side window 180 pivoting driving post Anatomic seat with flexible suspension and height adjustment seat belts SERVICE REFILL CAPACITIES Fuel tank in polyethylene 95 litres Total hydraulic system capacity 125 litres Engine oil 7 96 kg WEIGHTS Operating weight 7 300 kg Max gross weight 16 500 kg load carring capacity 9 200 kg ...

Page 27: ...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 characteristics of the vehicle are The ...

Page 28: ...ned according to a cycle indicated in ISO 25398 with attribution of the times established by the company according to what are considered customary and probable vehicle operating conditions 3 1 4 b Vibration level on the hands arms measured on the steering wheel Based on measurements made in operating conditions on vehicles similar to this one it is declared that the mean level of vibrations on th...

Page 29: ...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 DO NOT modify repair or remove the operator protective structure Should it be structurally damaged or modified e g by welding or drilling the protecti...

Page 30: ...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 31: ... you have full control of it in any circumstances Do not use the vehicle with the front lid open or without its guards and covers While driving do not activate any of the working equipment control levers When driving on uneven ground drive slowly and do not steer sharply The vehicle might overturn Always keep at a safe distance from other vehicles or obstacles so that you always have the necessary...

Page 32: ...3 1 20 VISIBILITY OF THE WORKING AREA 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 p...

Page 33: ...ny 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 dark carefully check the working area turn on all the light...

Page 34: ... you have received confirmation that the power has been cut In addition do not allow anyone to approach the vehicle 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 ...

Page 35: ...l position Shift the gear lever to NEUTRAL and engage the control locking lever Engage the parking brake Remove the key from the ignition block Choose an area where no other vehicles are operating Park the vehicle on solid and possibly level ground and apply the parking brake Do not park the vehicle on embankments or beds of watercourses at the end of your shift or working day Never park on a slop...

Page 36: ...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 wedges Ensure that t...

Page 37: ... 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 t...

Page 38: ... great caution and carefully adapting to the ground and visibility conditions by adjusting the speed and changing 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...

Page 39: ...ures 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 battery master switch Check that the cables and terminals of the electrical connections show no sign of corrosion cracks or burns...

Page 40: ...ble 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 whe...

Page 41: ...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 42: ...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 positioning them in such a wa...

Page 43: ...ery correctly connect the auxiliary cables to the terminals Never short circuit them During battery recharging flammable hydrogen gas is produced therefore leave the battery compartment open to ensure more effective ventilation Never check the battery charge by placing metal objects on the terminals To lift and transport heavy parts use cranes or hoists of adequate capacity Sling the material as b...

Page 44: ...zes 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 t...

Page 45: ... on the vehicle When carrying out repairs by means of welding the paint may get burned by the welding heat or dangerous gases may be released Before starting to weld remove the paint from the part to be welded Do not use a torch to weld or cut a tube containing a combustible solution this may cause fire or explosion 3 3 2 PRECAUTIONS DURING WELDING OPERATIONS 3 3 3 FAULTS AND UNAUTHORISED MODIFICA...

Page 46: ...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 ...

Page 47: ...abels 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 new component has the same labels 4 When replacin...

Page 48: ...48 3 SAFETY PRECAUTIONS id DB 460 REV 00 02 01 2015 VEHICLE EXTERIOR ...

Page 49: ...heel Vehicle equipped with ROPS protection DANGER When the vehicle is moving do not come close or let anyone else come close to the moving parts as there is a risk of crushing your hands DANGER Vehicle with crab steering When the driving post is facing the drum steering is inverted with respect to steering wheel rotation in this case it is prohibited to use this function as it is very easy to make...

Page 50: ...g the negative ground cable CAUTION Using low gear on a dangerous slope before driving on slopes with a gradient of more 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 DANGER This symbol indicates that the safety stop on the lifting cylinder must be engaged before accessing the area underneath the ...

Page 51: ...of the use and maintenance manual read the manual before starting to work with the vehicle MANDATORY RULE This symbol indicates that the seatbelt must be used always fasten the 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 av...

Page 52: ...h the engine running The vehicle is automatically braked when the engine is off with the key in the 0 position D 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 replacement intervals refer to chapter 5 4 SCHEDULED MAI...

Page 53: ...g to disconnect the battery terminals CAUTION The 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 L ROTATING BEACON fig 2 Fixed on the cabin roof it signals the presence of the vehicle M OPERATOR S PROTECTION CABIN WITH FOPS ROPS STRUCTURE fig 2 Designed and c...

Page 54: ...ket arm is raised it prevents accidental lowering of the arm during transfer and transport T ARM DESCENT SWITCH fig 3 Once the drum has rotated beyond 180 towards the front the loading arms cannot be lowered CAUTION During front unloading always check that the arm is raised During front unloading never touch the arm control lever It is advisable to engage the CONTROL LOCK C When the drum is raised...

Page 55: ...POSITIONED ON 2 STEERING WHEELS B DRIVER S SEAT fig 4 Turned forward concrete mixer behind in preferential driving direction and locked with the latch 2 C HAND ACCELERATOR MICROSWITCH fig 4 If the hand accelerator lever is not in the initial position it is impossible to move the vehicle 3 6 SAFETY DEVICES FOR ROAD USE U CAMERA Standard only for specific countries fig 3 It enables a complete view o...

Page 56: ...t be horizontal to the vehicle and locked with the special pin F NUMBER PLATE fig 5 Check that the number plate is clean before driving on the road G CONCRETE UNLOADING CHUTE fig 5 The unloading chute 1 must be turned crosswise and locked with the special screw pin 2 H LOADING ARM fig 5 The arm 1 must be locked in a vertical position with the special steel wire 2 I DOORS fig 5 Keep the doors close...

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: ...ortant 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 Mixing drum F Loading bucket G Unloading hopper H Unloading chute I Water tank L Engine assembly hydraulic pumps M Hydraulic oil tank N Water system O ROPS FOPS protection P Rotary frame Q Hydraulic bucket hatch R Mix Control 4 1 REFERENCES AND DESCRIPTIONS OF THE M...

Page 59: ...S ON THE MACHINE 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 new component h...

Page 60: ...xed Indicates the joystick positions for arm raising bucket rotation and hydraulic hatch closing opening Indicates the lever positions for chute tilting Indicates the functions to run to directly fill the drum or the tanks with water with the warning to open the cap to avoid the tank from swelling Indicates the position of the hand accelerator that allows you to adjust the engine rpm when the vehi...

Page 61: ...too powerful jets of water which might compromise functioning of the electric system Indicates that when turning the drum counterframe towards front unloading you need to check that the arms are fully raised so that they do not interfere with or touch the engine compartment lid Indicates functioning of the litre counter and the water pump It stands for the exact position of the intake filter above...

Page 62: ...s 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 controls The legend below divides this information into well defined groups Driver s seat Driving post instrument panel Operating control panel 4 2 1 DRIVER S S...

Page 63: ...c C Service and emergency brake pedal fig 2 4 2 1 d D Accelerator pedal fig 2 4 2 1 e E Parking brake button fig 2 This lever allows you to select 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 th...

Page 64: ...the vehicle stationary and stable and the gear selector in neutral position This operation may be carried out while you are seated on the driver s seat Check that it is locked into place at the end of the operation A B Turns on the fan for defrosting the windows or heating the closed cabin 4 2 1 m M Heating defrosting fan adjuster fig 2 4 2 1 n N Windscreen water switch fig 2 Allows you to pump th...

Page 65: ...of the control panel to access the tank for filling open the rear cover by undoing the retaining screws The fuses and relays are positioned inside the driving post Using the key provided open the door to access the fuses and the relays 4 2 1 r R Rear windscreen wiper fig 3 4 2 1 s S Cabin light fig 3 4 2 1 t T Windscreen washer fluid tank fig 3 4 2 1 u U Fuses and Relays fig 3 3 R S T U ...

Page 66: ...ed warning light indicates that the engine oil 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 9 Yellow warning light function not available 10 Yellow warning light indicates that there is water in the fuel sediment bowl 11 R...

Page 67: ...our counter revolution counter fig 5 When turning on with the ignition key in position 1 vehicle power the instrument panel runs a brief test turning on all the segments of the display after which the instrument panel warning lights will show the vehicle status Subsequently at the bottom of the numerical display 18 the hours remaining until the next service is due are shown for 5 seconds These are...

Page 68: ...r the 2 seconds the new service interval will appear on the display and after another 3 seconds the panel returns to normal display If you cut the power by disconnecting the battery master switch or remove the key before the operation is complete or you do not carry out the sequence as described above flashing will not be reset CAUTION It may be reset only after the pre set due date and not before...

Page 69: ...ing In neutral position the set speed remains fixed Anticlockwise drum rotation during concrete unloading Repeatedly act on the selector to increase the drum rotation speed Act on the selector in opposite direction to reduce the speed or until stopping the drum CAUTION Because of minimal hydraulic leakage the drum tends not to remain stationary Periodically check drum rotation by acting on the sel...

Page 70: ...four hazard warning lights 4 2 1 l G Hazard light toggle switch fig 6 Snap switch to turn on the rear working lights 4 2 1 m H Working light switch fig 6 This switch controls the operation of the vehicle water pump Follow the instructions below 1st click Pump on warning light S1 on 2nd click Pump off warning light S1 off ...

Page 71: ...arning light that indicates that there is water in the fuel sediment bowl 10 will emit only a test flash Subsequently at the bottom of the numerical display 18 will be displayed simultaneously and for 5 sec onds 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 display...

Page 72: ...d 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 turn the rotary switch 3 forward by 2 clicks 4 2 2 o Rotary switch with horn push button directio...

Page 73: ...l Position 2 Drum lowering The lever controls rotation of the fifth wheel of the drum Before turning the drum lift it from its seat by releasing the safety stop see chapter 3 5 Fig 3 O Position 1 Clockwise drum traverse swinging Position N Neutral Position 2 Anticlockwise drum traverse swinging 4 2 3 a A Drum traverse swinging lever fig 9 4 2 3 b B Drum raising lever fig 9 9 A C B D ...

Page 74: ...D Joystick for arm raising and bucket loader rotation fig 9 10 The joystick controls arm raising and loader rotation Arms hydraulic hatch Position 1 Arm lowering only with button E pressed to prevent accidental manoeuvres Position 2 Arm raising without pressing button E Bucket loader Position 3 Downward loader rotation Press button F to close the hydraulic loader hatch Position 4 Upward loader rot...

Page 75: ...ource or from the vehicle tank Position 2 Water delivery to the tank from an external source C Litre counter Totals the amount of water pumped into the drum and shows it on the driving post and the Mix Control display D Water suction pump Self priming volumetric pump with bronze impeller E Flexible suction hose with suction filter F To be positioned in the water source involved reservoir ditch ext...

Page 76: ...nloading C Water pump jog switch Up to activate the water pump red LED on Activate it again to stop the pump LED off D Litre counter switch Up to program the litres programs the litres of water to be pumped into the mix Holding it down for 3 4 seconds the number of litres set is shown and each time it is pressed again the value increases Down to reset resets the litres shown on the display E or de...

Page 77: ...A Initial status the display E indicates 0 and the lever D is always in central position B Push the lever upwards and hold it until the display indicates After about 5 seconds the display will indicate a flashing 0 zero C Release the lever for a second and while 0 continues flashing program the volume of water by pushing the lever upwards to obtain an increase in steps of ten 0 10 20 etc or downwa...

Page 78: ...se or carry out maintenance on the vehicle always read the safety regulations for the operations to be carried out as set out in Chapter 3 4 3 INSTRUCTIONS FOR USE 4 3 1 REFUELLING fig 13 DANGER It is essential that the first time you use this vehicle you familiarise yourself with the use of all the controls Therefore practice all the vehicle handling procedures both during the working phase and d...

Page 79: ...cts of the reverse gear microswitches 5 The procedures are described in chapter 5 on maintenance 4 3 2 LEVEL CHECK fig 14 1 2 C D 15 A B For proper operation of the self priming pump this must contain water Remove the closing cap C and take out the pre filter D Check that it contains water through the suction pipe union A If there is no water refit the pre filter D fill the pump body with water th...

Page 80: ...o adjust the springing hardness according to your weight Use the knob 3 to adjust the seat height 16 3 2 1 4 3 4 ADJUSTING THE SEAT fig 16 4 3 5 ADJUSTING THE REAR VIEW MIRROR fig 17 CAUTION Operation to be carried out before starting the vehicle To adjust the field of vision of the sideview mirror 1 turn it so that you can see the rear left hand side of the vehicle as shown in the figure delivery...

Page 81: ...on the driver s seat Check that it is locked into place after the operation The driving post must always face forward A during road transfer and backward B turned 180 for the drum loading 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 1...

Page 82: ...he key and check that the engine oil pressure battery low and coolant temperature 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 w...

Page 83: ...e would stop suddenly reducing the efficiency of the brake To disengage it turn the button 1 and release it For temporary stops on slopes or where necessary engage the parking brake by pressing the button 1 To release the brake in the event of a braking system failure see chapter 4 5 1 4 3 10 PARKING BRAKE fig 19 DANGER CAUTION The steering must be selected with the machine stationary Whenever you...

Page 84: ...same time turning the steering wheel to the right and left so as to facilitate the meshing of the gear with lever E in position 4RS If you are unable to engage the desired gear re engage the previously selected gear Set the gear selector to low gear for driving on steep slopes or to high gear for flat stretches CAUTION Mechanical gears must only be selected with the vehicle stationary and stable S...

Page 85: ...LD OF VIEW 1mt 1 Looking at the images on the display 2 transmitted by the camera 1 and using the rearview mirror 3 you have a wide view of the area behind the vehicle This allows you to safely reverse from and approach the unloading area CAUTION For the display 2 operation refer to its user manual that comes with the vehicle Check that the display 2 is properly set for direct visibility NO MIRROR...

Page 86: ...dows and the door if present Check that the fuel tank cap and the engine compartment lid are locked 4 3 15 PARKING THE VEHICLE CAUTION Before proceeding always read the safety regulations for the operations to be carried out as set out in Chapter 3 CAUTION Whenever you interrupt work for any reason always set the joystick safety switch to locked position Before leaving the vehicle set all the cont...

Page 87: ...ransport 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 Raise the bucket 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 lower the bucket and apply the parki...

Page 88: ...ehicle when the chains tauten Use only the lifting points marked on the vehicle Turn the drum as you would for road transfer Raise the loader arm and lock it with a tie rod 1 Hook the chains onto the special hooks During lifting stand well away from the vehicle and do not stand under the load Sudden movements or the chains snapping may cause injury and even death 4 4 1 LIFTING THE VEHICLE WITH A C...

Page 89: ...with the seat belt fastened and the driving turret facing the preferential direction of travel with the steering lever on 2RS in order to control and stop it If the vehicle has to be steered make sure you understand the actions of the person driving the towing vehicle Follow his instructions and comply with all the relative regulations Bear in mind that the steering wheel is harder to turn if the ...

Page 90: ...n 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 4 5 2 GEARSHIFTING TO NEUTRAL fig 26 26 4 3 2 Loosen the two hydraulic pipings 2 Loosen the plug 3 using a no 22 socket wrench not reinforced and move the shaft 4 until it offers no resistance meaning that the...

Page 91: ...hift the gear lever to 2nd gear for transfers on flat surfaces or moderate slopes 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 speci...

Page 92: ...s with an appropriate viscosity see the RECOMMENDED LUBRICANTS AND FLUIDS TABLE This vehicle is classified as an operating vehicle according to Italian law In order to circulate on the road it must be homologated and registered Pursuant to the regulations in force the vehicle is equipped with an additional danger signalling device The yellow rotating beacon must always be turned on when circulatin...

Page 93: ...r or when temperatures are higher than 20 C it is best to shut off the heating circuit espe cially if you intend to use the A C optional Open the engine compartment lid the valve is located on the cabin side engine placed next to the radiator turn the lever 90 CW to close the circuit During the winter or when temperatures are low open the heating circuit by turning the valve lever 90 CCW DANGER ...

Page 94: ...g 6 Mixing and second filling with mixing water 7 Concrete unloading 8 Bucket drum and chute washing CAUTION During road transfer the driving post must face forward CAUTION Always fasten the seatbelts In order to protect the chrome plated parts against atmospheric agents during long periods of inactivity take some basic precautions Vehicles that remain outdoors e g on a yard for long periods of ti...

Page 95: ...e table in chapter 5 and make any necessary repairs 4 10 2 BEFORE GETTING ON THE VEHICLE CHECKS AND WARNINGS CAUTION Before proceeding always read the safety regulations for the operations to be carried out as set out in Chapter 3 When working on slopes take some precautions to prevent risks to yourself and others in the vicinity Carry out the following checks and operations Always check the worki...

Page 96: ...diagonal movements or even worse with the vehicle axis turned 90 with respect to the direction of the slope 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 DANGER CAUTION Observing the recommended gradient limits does not mean that...

Page 97: ...tity of water 2 Add all the cement 3 Add all the gravel 4 Add all the sand 5 Add the remaining percentage of water Approximate mixing time 4 5 minutes Approximate total cycle time aggregate loading adding water mixing unloading 15 minutes FOR A YIELD OF 1 SQUARE METRE OF CONCRETE approximate values TYPE OF CONCRETE OR AGGREGATE CEMENT kg AGGREGATE MIXTURE GRAVEL m3 SAND m3 WATER lt STANDARD FOR FO...

Page 98: ...ld damage the pump propeller Remove the closing cap C checking that the pre filter is fitted insert the flexible suction hose E into the suction pipe filler neck A of the pump Insert the tube leading to the tank into the delivery filler neck H Move the valve B to the correct position with delivery to tank 2 Position the flexible suction hose E in the relative water source reservoir external tank d...

Page 99: ...e drum with mixing water Filling with water from the vehicle tank When the tank is full set the switching valve B to position 1 checking that the coupling of the hose leading from the vehicle tank is connected to the suction pipe union A of the pump 4 10 5 c Activating the water transfer pump fig 34 Check that all the control levers are in neutral position Start the engine Rotate the drum Increase...

Page 100: ...res and hold it in fully tilted position with the hatch closed Calculate the quantity of cement to be loaded referring to the CONCRETE COMPOSITION AND BATCHING TABLE in chapter 4 10 4 Manually fill the bucket with cement tearing open the bags on the serrated blade of the bucket Remove the paper bags Raise the arm to its maximum height Open the unloading hatch and wait until the cement has poured i...

Page 101: ...d at the same time raise the arm that way filling the bucket with a larger 4 10 6 b Cement in silos fig 36 4 10 7 AGGREGATE LOADING 37 4030 36 Keep the drum rotating at top speed Raise the bucket arm to its maximum height 4030 mm Move to underneath the unloading point of the silo Calculate the quantity of cement to be loaded referring to the CONCRETE COMPOSITION AND BATCHING TABLE in chapter 4 10 ...

Page 102: ...arm Approach the heap again while lowering the arm Repeat the operations described above at least 8 9 times This is the bucket yield on average to obtain optimal drum loading CAUTION You can shift to reverse gear even if the vehicle has not completely stopped 4 10 8 MIXING AND SECOND FILLING WITH WATER fig 38 Keep the drum rotating for about 2 minutes after the last aggregate loading phase Add the...

Page 103: ...raised and the fluidity of the concrete Raise the drum but not necessarily to its maximum height Visually inspect regular concrete unloading 4 10 9 CONCRETE UNLOADING 39 C A D B E CAUTION Always set the gear selector to neutral position Move the arms up to the maximum height with the hydraulic hatch closed CAUTION If someone on the ground assists you during unloading be extremely careful in carryi...

Page 104: ...k into place after unloading as this is essential for road transfer Turn and lock the chute B with the mouth facing the outside of the vehicle and secure it with a setscrew Raise the loader arm to its maximum height then turn the counterframe to the desired position making sure that the arms are completely raised so as not to interfere with the engine compartment lid Then continue with the normal ...

Page 105: ...ne parallel to the unloading line Stop the vehicle Arrange any extensions in the unloading chute Bring the engine rpm up to a medium speed Direct the rotary frame by operating the lever B that drives fifth wheel rotation Move the chute A directing it to the correct unloading position Invert the drum rotation direction for unloading by acting on the selector in the cabin Accelerate the engine and a...

Page 106: ... acting on the selector in the cabin or the one on the ground Adjust the drum rotation speed The concrete unloading speed depends on the engine speed the drum rotation speed the height to which the drum is raised and the fluidity of the concrete 42 A C B 43 2130 2130 The concrete can be unloaded directly from the hopper by removing the unloading chute A In this way you can use a maximum height of ...

Page 107: ... to the next area after completing unloading in the first area follow the instructions below Lower the drum if it is still relatively full and reposition it on the longitudinal axis Revert the drum rotation direction to mixing clockwise Approach and position in the new unloading area and follow all the instructions given above This operation must be performed by Authorised FIORI Workshops qualifie...

Page 108: ... and gravel following the procedures as described above chapter 4 10 5 in a quantity sufficient to dilute and detach the concrete residues Connect the washing nozzle G to the pump delivery Set the switching valve B to position 2 Externally wash the bucket drum and chute as well as all the parts normally soiled with concrete Raise the drum Change drum rotation from clockwise to anticlockwise Drain ...

Page 109: ...onto wet and slippery parts of the vehicle and be extremely careful in all the movements you make CAUTION Do not insert the washing nozzle in the drum mouth when it is rotating The main device of the vehicle for which it was designed is the drum It is essential to thoroughly clean the inside of the drum to prevent concrete encrustations from reforming on the mixing blades for as long as possible T...

Page 110: ......

Page 111: ...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 112: ... maintenance costs and the vehicle stop times Check the following A Arm bucket articulations B Hydraulic system and pipes C Instruments and gauges D Engine and radiator E Tyres F Transmission G Jacks and pins 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 ra...

Page 113: ... are properly 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...

Page 114: ...the use and maintenance manual and the fuses and relays open the driving post door A with the key provided To access the windscreen washer water tank 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 ca...

Page 115: ...M after each cold start Do not run the engine at high RPM for long periods of time Always use it at 50 to 80 of its maximum power Regularly check for water or oil leaks Regularly 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 operat...

Page 116: ...SPECIFIC TABLE ACCELERATOR CABLES 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 TANK CAP BLEEDER NEGATIVE PARKING BRAKE PARKING BRAKE TEST BRAKING SYSTEM FLUID OPERATION OF THE HYRAULI...

Page 117: ...BATTERY ELECTROLYTE LEVEL PARKING BRAKE BUTTON BATTERY PINS HAND ACCELERATOR MICROSWITCH PIVOTING POST MICRO SWITCHES LITER COUNTER WATER TRANSFER PUMP PRE FILTER WATER TRANSFER PUMP ELECTRIC COMPONENTS WATER SYSTEM REDUCTION GEARS 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 118: ...ion Every 50 hours of operation or weekly Fuel tank water and sediment Drain Every 500 hours of operation V Belts Inspect Adjust Replace Every 500 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 ...

Page 119: ...mounts Inspect Starter motor Inspect 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 120: ...SL80W API GL 4 72 CTS 80W 25 50 HYDRAULIC SYSTEM DIN51524 PARTE 3HVLP CETOP RP 91H HV ISO L HV DENISON HF0 HF2 125 l ENI ARNICA 22 ARNICA 46 ARNICA 68 22 46 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 DRUM REDUCTION GEAR 2 5 kg ENI BLASIA 150 ISO L CKD DIN 51517 TEIL 3 CLP ANSI AGMA 9005 94 CAS 1013...

Page 121: ...ease using the pump A provided and stop greasing as soon as fresh grease starts flowing out from the openings 1 PIVOTING DRIVING POST 1 X 2 AXLE HUBS 4 4 X 3 TRANSMISSION SHAFT 3 X 4 OSCILLATING CHASSIS 2 X 5 MIXER ROTATION SAFETY STOP DEVICE 1 X 6 DRUM LIFTING CYLINDERS 2 2 X 7 ARM LIFTING CYLINDERS 2 2 X 8 LOADER CONNECTING ROD AND TIE ROD 3 3 X 9 LOADER CYLINDERS 2 2 X 10 MIXER ROLLERS 1 1 X 11...

Page 122: ...A and let the fuel flow out until it is clean and free of impurities that have remained at the bottom of the tank 5 7 3 FIFTH WHEEL LUBRICATION fig 5 Park the vehicle on flat ground and make sure the drum is empty After the drum has been raised engage the drum descent stop lock by turning the two handles A of the lifting cylinder cocks lastly turn it so the rack can be accessed easily Turn the eng...

Page 123: ...APER BLADE AND LOADING BUCKET HATCH BELLOWS fig 6 6 B A Check the wear and tear of the scraper blade A on the loading bucket and replace it if damaged Check that bellows B protecting the cylinder rods are in proper working order and replace them if damaged ...

Page 124: ...g 7 CAUTION Before proceeding always read the safety regulations for the operations to be carried out as set out in Chapter 3 CAUTION The gearbox housing A is connected to the axle B therefore the optimal oil level of the axle corresponds to that of the gearbox housing Unscrew the filler cap 2 and the level gauge caps 3 4 in horizontal position If oil trickles from the level gauge caps 3 4 it is n...

Page 125: ... be set in lower position through the planetary reduction gear rotation Loosen the oil level cap 3 Let oil flow out completely Move the planetary reduction gear with cap 2 back into position as shown in the figure Loosen the filling up plug 4 With a funnel put the recommended type of oil in through the filling up cap 4 until it starts dripping from the level hole 3 and 2 Park the vehicle on level ...

Page 126: ... pressure also determines the weight a tyre can support Identify the tyre sizes in the pressure and loads table Do not over or under inflate the tyres Incorrect tyre inflation causes tyre problems therefore do not under inflate A or over inflate B If a tyre has completely deflated call in a mechanic who will use an inflation cradle and suitable tools Before inflating a tyre check that the wheel is...

Page 127: ...ance and fitting carried out by a SPECIALISED CENTRE or SKILLED PERSONNEL When you need to change a tyre first of all engage the parking brake shift the gear selector to neutral turn off the engine and remove the ignition key Position a wedge under the wheel diametrically opposite the one to be changed as shown in the figure It is prohibited to change a tyre on a slope or near canals or ditches to...

Page 128: ...rave 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 fork in the jac...

Page 129: ...he vehicle under the axles After fitting the wheel tighten the nuts in the order shown in the figure illustrating wheel nut tightening 13 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 14 ...

Page 130: ...e to 2 bar according to the regulations in force Unscrew the bleeder cap A Clean the cap surface with a brush and solvent Clean the bleeder hole with a pointed tool and then dry it with a blast of compressed air Screw the bleeder cap A back on DANGER CAUTION It is essential to use only the fluid indicated in the RECOMMENDED LUBRICANTS AND FLUIDS TABLE using unsuitable fluids will damage the brakin...

Page 131: ...p the brake 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 ...

Page 132: ...e 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 AUTHORISED FIORI SERVICE CENTRE CAUTION Do not use the vehicle if the parking brake is not fully efficient DANGER 5 9 5 CHECKING THE WEAR CONDITION OF THE BRAKING S...

Page 133: ... neck CAUTION Slowly loosen the bleeder cap to release the residual pressure Carry out this operation only with the engine off 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 bleeder cap to release the residual pressure Carry out this operation only with the engine off The bleeder cap A is disposabl...

Page 134: ...ted 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 an...

Page 135: ...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 136: ...e filler cap B then drain out all the oil into a prearranged container Screw the level gauge cap back on and then turn the drum so that the level gauge hole A is in horizontal position and the filler cap hole B positioned at the top Fill with the recommended oil using a syringe Screw the filler cap B back on 21 A C B CAUTION Before proceeding always read the safety regulations for the operations t...

Page 137: ...oils in special containers and send them to companies specialised in storage and disposal of polluting and hazardous waste Move the vehicle onto flat ground engage the parking brake turn off the engine and remove the ignition key Work from underneath the vehicle to access the reduction gear Unscrew the drain cap A and drain out all the oil into a prearranged container Add the specified oil through...

Page 138: ... 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 CAUTION Before proceeding always read the safety regulations for the operations to be carried out as ...

Page 139: ...f the seals C and replace them if necessary Refit the cartridge 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 CAUTION Use only coolant of the type and brand recommended by the manufacturer as indicated in the Recommended L...

Page 140: ...IFREEZE 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 radiator and remov...

Page 141: ...rk 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 procedure...

Page 142: ... 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 se...

Page 143: ...cribed 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 level is be...

Page 144: ...y 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 CE...

Page 145: ...rown 3 10A red 4 5A beige 5 15A blue 6 7 5A brown 7 15A blue 8 10A red 9 10A red 10 5A beige 11 5A beige 12 3A violet POS AMPERAGE COLOUR 13 7 5A brown 14 7 5A brown 15 15A blue 16 3A violet 17 3A violet 18 15A blue 19 15A blue 20 15A blue 21 15A blue 22 5A beige 23 10A red DB 460 REV 03 20 12 2016 11 10 13 12 9 8 23 21 20 19 22 1 2 3 5 4 7 6 17 16 15 14 18 29 ...

Page 146: ...rol 06 F106 Relay power supply K107 07 F107 Power supply for parking brake control neutral enable on forward drive control relay K103 neutral relay 08 F108 Power supply for acoustic indicator and rear camera optional 09 F109 Power supply for direction indicators and stop light bulb 10 F110 Power supply for drum rotation control frame rotation pressure gauge 11 F111 Power supply for water in the fu...

Page 147: ...cro relay 08 K108 Micro relay for start enable without water in the fuel 09 K109 A C compressor micro relay optional 10 K110 Micro relay for rear working lights 11 K111 Micro relay for machine operating acoustic indicator control 12 K112 Diode module for neutral and gearshift enable 13 K113 Flashing hazard lights direction indicators 14 K114 Micro relay available 15 K115 Micro relay available 16 1...

Page 148: ...e 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 33 ...

Page 149: ...e 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 34 A C D G F B B E A low beam bulb 12V 55W H7 B direction indicator bulb 12V P21W position light side marker bulb 12V R5W C S...

Page 150: ... 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 battery d...

Page 151: ...AUTION Before proceeding always read the safety regulations for the operations to be carried out as set out in Chapter 3 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 polluting...

Page 152: ...mp in good working condition run clean water through the duct at the end of each daily work shift Every six months or in the event of malfunctioning clean the duct of the litre counter and the relative pipes with a special non aggressive detergent for the parts in rubber nylon brass polypropylene and stainless steel Keep the engine running at 2000 rpm Activate the transfer pump M Check by means of...

Page 153: ...ally 5 13 4 CLEANING PRE FILTER OF THE WATER PUMP fig 39 C D 39 Before starting the daily work shift you must clean the pre filter of the water pump Remove the closing cap C from the pump take out the pre filter D and check whether it is dirty inside To remove it use a jet of clean water or compressed air Finally reposition it inside the filler neck and refit the closing cap C CAUTION Check that t...

Page 154: ......

Page 155: ...ES AND DESCRIPTIONS OF THE MAIN DEVICES 158 158 6 2 4 6 2 4 USING THE POWER JET CLEANER 159 159 6 2 5 6 2 5 PRECAUTIONS FOR USE IN COLD CLIMATE CONDITIONS 160 160 6 2 6 6 2 6 SCHEDULED MAINTENANCE TABLE 160 160 6 2 7 6 2 7 CLEANING OR REPLACING THE FILTER CARTRIDGE 161 161 6 3 6 3 AIR CONDITIONER AIR CONDITIONER 162 162 6 3 1 6 3 1 OPERATION OPERATION 162 162 6 3 2 6 3 2 MAINTENANCE MAINTENANCE 16...

Page 156: ...e hatch opens automatically when the counterframe is lifted using the lever B in the cabin as described in chapter 4 2 3 b The hatch is closed automatically when the counterframe is lowered by means of lever B Do not climb on the machine do not place your limbs or parts of your body in the drum opening risk of crushing if the hatch is closed inadvertently Do not use the arms as lifting device 6 1 ...

Page 157: ...lly driven water cleaner pump Maximum oil flow rate 25 l min Maximum water output flow rate 16 8 l min Maximum oil input pressure 190 bar Maximum water output pressure 228 bar 6 2 2 INSTRUCTION LABELS ON THE MACHINE Indicates that the water filter of the power jet cleaner system must periodically be cleaned Indicates the positions of the lever for use of the power jet cleaner or the water suction ...

Page 158: ...es the pressure and anticlockwise increases the pressure E Switch Position 1 Water suction pump activation Position 2 Power jet cleaner pump activation F High pressure hose Connects the pump to the power jet cleaner G Water pressure gauge Shows the pressure of the water flowing from the pump H Water pump Positioned at the rear of the chassis in the tool compartment I Switch Turn switch lever E to ...

Page 159: ...ctivate the power jet cleaner pump H Open the catches and extract the power jet cleaner A unwind the high pressure hose F from its reel and screw it onto the power jet cleaner Turn the valve D on the power jet cleaner until the low pressure nozzle B is completely open Hold the trigger of the power jet cleaner pulled and let the pump run until all the air has been expelled from the tubes and the wa...

Page 160: ... jet cleaner open Use the breather valve to drain out the residual water in the pump cover 6 2 6 SCHEDULED MAINTENANCE TABLE POWER JET CLEANER PUMP POWER JET CLEANER FILTER Pull the trigger of the power jet cleaner to discharge all the residual pressure in the tubes to ground CAUTION If during use you notice that the pump becomes noisier and the jet discontinuous it means that it is taking in air ...

Page 161: ...he cartridge B and clean it with a blast of dry compressed air from the inside to the outside After cleaning the cartridge check that there is no internal damage using a torch to illuminate the inside If light filters through to the outside the cartridge must be replaced Also replace the cartridge when the rubber seal is damaged Before refitting the cartridge clean the inside of the filter body an...

Page 162: ...ling inside the driver s cabin Open the lid only with the engine off and cold During the summer or when temperatures are higher than 20 C it is best to shut off the heating circuit espe cially if you intend to use the A C optional Open the engine compartment lid the valve is located on the cabin side engine placed next to the radiator turn the lever 90 CW to close the circuit DANGER ...

Page 163: ...ENANCE MAINTENANCE For specific maintenance operations on the air conditioning system e g cleaning of the condenser radiator air filter and refrigerant refilling please contact an Authorised FIORI Service Centre or Workshop Failure to observe this instruction may lead to serious damages The refrigerant in the air conditioning system is extremely dangerous If it is sprayed into the eyes or comes in...

Page 164: ...n of the symbols used in the table Check and repair Replace Clean Grease or lubricate Gas type R134A Quantity 0 85 kg Recharging pressure 9 12 bar 6 3 3 TECHNICAL DATA WORKING AREA REGULAR MAINTENANCE INTERVALS AIR CONDITIONER GAS AIR CONDITIONER GAS FILTER EVERY 250 HOURS EVERY 500 HOURS EVERY 1200 HOURS EVERY 2000 HOURS ...

Page 165: ...165 TECHNICAL ANNEXES DB 460 REV 00 02 01 2015 id CAUTION For a better consultation you can ask for the vehicle s wiring hydraulic diagrams in PDF format at the FIORI email address info fiorigroup com ...

Page 166: ...166 TECHNICAL ANNEXES DB 460 REV 00 02 01 2015 id HYDRAULIC DIAGRAM ...

Page 167: ...VE BRAKE CONTROL UNIT GEARBOX 10 NEGATIVE BRAKE 11 MECHANICAL GEARBOX 12 SOLENOID VALVE FOR ARM LOWERING ENABLE 13 BUCKET CONTROL SELECTOR HATCH 14 SAFETY VALVES 15 WATER PUMP MOTOR 16 FRONT AXLE 17 REAR AXLE 18 CHECK VALVE 19 STEERING SELECTION DISTRIBUTOR 20 FLOW INVERTER 21 HYDRAULIC STEERING 22 PRIORITY VALVE 23 RETURN OIL COLLECTION BLOCK 24 HEAT EXCHANGER 25 HYDROSTATIC TRACTION MOTOR 26 DRU...

Page 168: ......

Page 169: ...SEBU8325 01 July 2012 Operation and Maintenance Manual 1104D Mech Industrial Engine NK Engine NL Engine NM Engine ...

Page 170: ...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 171: ...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 172: ...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 173: ...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 174: ... 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 175: ...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 176: ... 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 177: ...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 178: ... 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 179: ...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 180: ...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 181: ...SEBU8325 01 13 Product Information Section Model Views Product Information Section Model Views i02693072 Model View Illustrations ...

Page 182: ...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 183: ...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 184: ...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 185: ...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 186: ...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 187: ..._____ Total Cooling System Capacity _________ ________________ Air Cleaner Element _________ ______________________________ Fan Drive Belt _________ _____________________________________ Alternator Belt _________ _____________________________________ i02690481 Emissions Certification Film g01350379 Illustration 15 Typical example ...

Page 188: ...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 189: ...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 190: ...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 191: ... 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 192: ...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 193: ...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 194: ...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 195: ...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 196: ...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 197: ...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 198: ...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 199: ...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 200: ...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 201: ... 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 202: ...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 203: ...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 204: ...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 205: ...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 206: ...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 207: ...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 208: ...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 209: ...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 210: ...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 211: ...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 212: ...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 213: ... 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 214: ... 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 215: ... 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 216: ...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 217: ...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 218: ...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 219: ...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 220: ...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 221: ...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 222: ... 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 223: ...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 224: ... 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 225: ...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 226: ...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 227: ...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 228: ... 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 229: ...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 230: ...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 231: ...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 232: ... 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 233: ... 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 234: ...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 235: ... 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 236: ...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 237: ...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 238: ...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 239: ...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 240: ...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 241: ...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 242: ...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 243: ...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 244: ...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 245: ...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 246: ...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 247: ...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 248: ...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 249: ...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 250: ...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 251: ...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 252: ... 2012 Perkins Engines Company Limited All Rights Reserved ...

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