AUSA D 201 RH Operator'S Manual Download

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D 201 RH
D 201 RHS
D 201 RHG
D 201 RHGS

OPERATOR’S
MANUAL

ENGLISH

Original Manual

Summary of Contents for D 201 RH

Page 1: ...D 201 RH D 201 RHS D 201 RHG D 201 RHGS OPERATOR S MANUAL ENGLISH Original Manual ...

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Page 3: ...D 201 RH D 201 RHS D 201 RHG D 201 RHGS Original Manual Above chassis number 62439 ...

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Page 5: ... be the responsibility of AUSA In the event of query complaint or to place an order for spares please contact your Official AUSA Agent Distributor For further information please contact AUSA Center S L U Apartado P O B 194 08243 MANRESA Barcelona SPAIN Tel 34 93 874 75 52 93 874 73 11 Fax 34 93 873 61 39 93 874 12 11 93 874 12 55 E mail ausa ausa com Web http www ausa com AUSA is continually impro...

Page 6: ...ety Messages 14 Dumper main components Identification 20 Instrument Panel 24 Fuel 27 Dumper Operation 29 Special Procedures 33 Maintenance General comments 35 General maintenance and lubrication chart 36 Liquids and lubricants 41 Periodic Maintenance Operations 43 Dumper Transport 60 Towing the dumper 62 Electric Diagram 63 Hydraulic Diagrams 69 EC Certificate of Conformity 75 ...

Page 7: ...uld be taken to ensure compliance with the current legislation for this type of dumper Highway Code AUSA does not accept responsibility for possible damage as a result of any modification to the dumper made without their express authorization Texts marked with this symbol provide information about recycling and environmental protection Inappropriate use Inappropriate use is understood to mean the ...

Page 8: ...t includes the EC mark Chassis number fig 2 This is engraved on the right hand front cross of the chassis Chassis number fig 3 4 This is engraved on the right hand side of the engine below the exhaust manifold and is also given on a label on the rocker arm cover Identification plates for the main components The identification plates corresponding to all those components not directly constructed by...

Page 9: ...in 3ft 92in F 8ft 46in 8ft 46in G 0ft 84in 84in H 2ft 9 in 3ft 03in I 5ft 38in 5ft 38in J 2ft 35in 2ft 35in K 9ft 91in 9ft 91in L 7ft 37in 8ft 74in M 9in 1ft 76in N 1ft 87in 3ft R 6ft 84in 6ft 84in S 13ft 13ft T 5ft 22in 5ft 22in U 71in S Dumper equipped with self loading shovel V maximum visibility with the shovel fully retracted patented system Technical Specifications ...

Page 10: ...0 1750 D 185 185 E 1195 1195 F 2580 2580 G 255 255 H 885 925 I 1640 1640 J 715 715 K 3020 3020 L 2245 2665 M 275 535 N 570 930 R 2085 2045 S 3980 3980 T 1590 1590 U 215 S Dumper equipped with self loading shovel V maximum visibility with the shovel fully retracted patented system Technical Specifications ...

Page 11: ...n the top of the joystick when a movement mode is selected Steering ORBITROL hydraulic system Drive is in the rear axle through a double act cylinder Minimum external turning radius D 201 RH RHS RHG RHGS 4190 mm 13 ft 8 96 in Maximum speed 20 Km h 12 mph Gradient negotiable 1st gear 42 with full load Brakes Brakes On front axle mechanical action Multidisc oil bathed Park brake Cable operation appl...

Page 12: ...ools monoblock control valve and solenoid selector for the self loading shovel movements models RHS and RHGS Restrictor valve for controlling lowering speed of the bucket when loaded Operating pressure Hydraulic circuit 320 bar 4641 2 PSI Control valve 190 bar 2755 17 PSI Steering 80 bar 1160 3 PSI Hydraulic oil tank capacity 40 l 8 79 US Gal Electric equipment Starter Glow plugs 1 2 kW starter mo...

Page 13: ...in countries Shovel teeth Homologated lighting equipment FOPS ROPS protective roof with seatbelt rotating beacon and rear view mirror Passenger s seat Grass tires Closed cabin with front windshield and wiper Towing hitch Backhoe loader only available in RHG RHGS models When the dumper comes equipped with accessories fitted by the factory please read the relevant Instruction Manual for each accesso...

Page 14: ...brication specifications 2 Main functions of the joystick model RH 3 Main functions of the joystick model RHS 4 Main functions of the joystick model RHG 5 Main functions of the joystick model RHGS 6 Engine lubrication 7 Warning sign for engine cooling fan 8 Lifting point 9 Identification of the model RH 10 Identification of the model RHS 11 Identification of the model RHG 12 Identification of the ...

Page 15: ...ssure indication for the Tires 19 Reminder that it is prohibited to carry passengers in a dumper without a specific seat 20 Warning against using high pressure washing 21 Authorized use of the machine 22 Sign warning that use of seatbelt is obligatory 23 The use of protective earmuffs is obligatory 24 Warning sign indicating that the bucket must be lowered before leaving the dumper 25 Warning sign...

Page 16: ... is the drive axle and the rear axle the steering axle although versions exist in which both axles are drive axles The front of the dumper is equipped with the bucket and depending on the version the self loading shovel The unit formed by both is designed to lift and tilt the load forwards and backwards making handling easier Rudiments of static equilibrium So that the dumper is able to handle loa...

Page 17: ...e speeds while the dumper is unladen or when the load is raised Rough ground sharp braking or accelerating or shifts in the load make these conditions worse The centre of gravity and the dumper capacity Do not overload the dumper or handle loads which shift the centre of gravity beyond that for which it is designed Manoeuvre slowly especially when changing direction on slippery ground The load and...

Page 18: ...r presence is necessary the pedestrians should move in areas which have been duly marked as such and they should be easily distinguished for example by wearing reflective jackets If the area is closed it should be well ventilated and the dumper must be equipped with lighting and exhaust gas purifier systems The dumper operator should be able to communicate normally with pedestrians If the surround...

Page 19: ... cab clean help to make the work safer To do so follow the GENERAL MAINTENANCE AND LUBRICATION CHART given in this Manual strictly and keep the operator position clean and free of earth gravel mud oil or other objects which may cause falls Do not carry objects in the operator cab These may injure the operator or accidentally activate the dumper controls fig 1 ...

Page 20: ...g certain instructions concerning the circulation of dumpers and pedestrians If you are not aware of these regulations please check with your supervisor Study the movements of the dumper to avoid making manoeuvres which are unnecessary or involve risk to the surrounding areas Find out which paths are suited to the type of dumper you are driving and the load carried If it is necessary to drive alon...

Page 21: ...k on gradients of more than 20 in wet conditions and more than 30 in dry conditions Parking the dumper A badly parked dumper may represent a grave danger Leave the dumper parked in the areas designed for this purpose without blocking passages exits or entrances to emergency stairs and equipment Park on level ground If it is necessary to park the dumper on a gradient in addition to using the park b...

Page 22: ...terms right left forwards and backwards used in this Manual are defined viewed from the driver s seat facing forwards Description of parts 1 Park brake 2 Joystick 3 Protection arch 4 Rotating beacon 5 Operator seat with seat belt 6 Steering wheel 7 Bucket 8 Headlamps and indicator lights ...

Page 23: ...is controls the direction of the dumper and the movements of the bucket and the self loading shovel models RHS and RHGS Driving direction The driving direction is shifted by using the electric switch located on the lower part of the joystick In each case the corresponding arrow showing the driving direction lights up When the direction arrows are off the direction of travel is in NEUTRAL By pressi...

Page 24: ...trols The movements of the bucket and the self loading shovel are controlled by the joystick RH Model Tipping the bucket Pushing the joystick forwards tips the bucket for unloading and pulling back lowers the bucket into rest position fig 2 RHG Model Tipping the bucket Pushing the joystick forwards tips the bucket for unloading and pulling back lowers the bucket into rest position fig 3 Turning th...

Page 25: ...oading position above the bucket fig 3 RHGS Model Tipping the bucket Holding in the button 1 and pushing the joystick forward tips the bucket for unloading Holding in the button 1 and pulling back lowers the bucket into rest position fig 1 Turning the bucket Holding in the button 1 and pushing the lever to the left swivels the bucket to the left holding in the button 1 and pushing the lever to the...

Page 26: ... light E Preheating warning light F Fast gear indicator G Battery charge warning light H Fuel reserve warning light I Fuse box J Rotating beacon switch K Working lights switch L Hazard warning lights switch M Turning indicators switch N Lights switch O Low beam high beam light switch P Starting switch Q Acoustic warning light R Hourmeter A B C D F E H G I R Q P O N M J K L ...

Page 27: ...switch off press the button again Instrument panel indicators Operation fig 4 J Air filter warning light This lights up when the air filter is dirty or clogged The filter element should be cleaned or replaced immediately K Engine oil pressure warning light When the ignition is turned on this lights up then switches off when the engine is working If this light comes on and a warning signal is emitt...

Page 28: ...nt Panel fi g 1 R Hourmeter counter fig 1 The hourmeter r records the total operating time of the engine and enables control of the service intervals See the section PERIODIC MAINTENANCE OPERATIONS and table of LIQUIDS AND LUBRICANTS ...

Page 29: ...glasses and gloves when handling fuel When refuelling from a tank bucket or barrel using a siphon the following precautions should be taken If refuelling is by gravity from a raised tank open the fuel output valve of the tank slowly If the tank or barrel does not have an output valve use a suitable vacuum pump WARNING Never suck the fuel into the pipe by mouth to start the siphoning The fuel and i...

Page 30: ...S Clean the fuel cap and surrounding area with a cloth if they have been soiled Do not allow dust water or any other substance to enter the tank Open the fuel cap turning to the left Fill the tank without exceeding the volume specified for the dumper 40 litres Take care not to spill fuel outside the tank If you do clean immediately and dry the surface well Close the fuel cap rotating it to the rig...

Page 31: ...ards to the desired position The suspension of the seat can be adjusted between 60 and 120 Kg 132 and 264 lbs according to the weight of the operator by turning the knob fig 3 b Normally seats are adjusted to a weight of 90 Kg 198 lbs Using the wheel fig 4 c it is possible to adjust the seat backrest angle The seat backrest tilts backwards when the knob is turned to the right and forwards when tur...

Page 32: ...end of the day or for purposes of maintenance it should be left on level ground Lower the bucket completely lock the park brake and place the driving control switch and the joystick in NEUTRAL If the dumper has been operating to full capacity keep the engine running at idle for 1 minute To stop the engine rotate the ignition key fig 1 counter clockwise to the position A Remove the key from the ign...

Page 33: ...bility for all manoeuvres For this reason always concentrate on the work environment When changing direction ensure that the manoeuvre area is free of danger pedestrians other dumpers obstacles etc Whenever possible self loading operations should be done from a direction where the wind carries dust away Such dust could cause a momentary loss of vision and as a result a distraction from the surroun...

Page 34: ...ntrols are operating correctly Check that the steering moves freely Depress the throttle pedal several times to ensure that it moves freely It should always return to the initial position Press the brake pedal to ensure that the brakes are working correctly It should always return to the initial position Check that alarm and signalling devices are operating correctly for example acoustic warning a...

Page 35: ...protect the dumper and its components from rust We recommend lubricating the metal components This should be carried out at the end of every day of service When the dumper has been working in muddy areas it should be washed with freshwater to protect the dumper and keep the lights clean Note Never use high pressure water to clean the dumper USE ONLY LOW PRESSURE WATER High pressure water may cause...

Page 36: ...rized AUSA dealer Immersion of the dumper If the dumper becomes submerged under water it will be necessary to take it to an authorized AUSA dealer as soon as possible WARNING DO NOT START THE ENGINE The immersion of the dumper may cause serious damage to the engine if the starting procedure is not followed correctly Arrange for an authorized AUSA dealer to carefully inspect the supply system as sh...

Page 37: ...he environment When changing oil or other fluids use a suitable container to collect the old one Take care not to cause damage to the environment and take all the replaced materials batteries coolant etc to the appropriate recycling centres In the event of leaks of substances which may be harmful to persons or to the environment immediately take the necessary measures to reduce their impact for ex...

Page 38: ...ade by ENGINE Oil Change CUSTOMER Oil filter Change CUSTOMER SUPPLY CIRCUIT FUEL Fuel pre filter Change CUSTOMER HYDRAULIC CIR CUIT Oil and intake filter Change CUSTOMER Fuel tank internal filter fuel tank suction Clean DEALER Drain plug magnet Clean DEALER Hydraulic cartridge Change CUSTOMER ELECTRICAL SYSTEM Battery Inspect CUSTOMER AXLES FRONT AND REAR Oil Change CUSTOMER Tightening of bolts fa...

Page 39: ...OMER HYDRAULIC CIRCUIT Damage to hydraulic hoses and fittings Inspect CUSTOMER EVERY 400 HOURS Tasks To be made by COOLING SYSTEM Radiator caps cool ing system pressure verification Inspect DEALER FUEL LINE Fuel filter cartridge Change CUSTOMER BODY CHASSIS Chassis and chassis fastenings Inspect DEALER EVERY 500 HOURS Tasks To be made by ENGINE Alternator belt Change DEALER COOLING SYSTEM Radiator...

Page 40: ... magnet Clean DEALER Hydraulic cartridge Change CUSTOMER AXLES FRONT AND REAR Oil Change CUSTOMER EVERY 1500 HOURS Tasks To be made by FUEL LINE Fuel injection nozzle injection pressure Inspect DEALER EVERY 3000 HOURS Tasks To be made by COOLING SYSTEM Radiator condition cleaning Clean CUSTOMER FUEL LINE Fuel lines hoses clamps Inspect CUSTOMER Injection pump ad justment Inspect DEALER Fuel inject...

Page 41: ...AXLES FRONT AND REAR Oil Inspect CUSTOMER Oil leaks Inspect CUSTOMER Tighten wheel nuts Inspect CUSTOMER Tire condition and pressures Inspect CUSTOMER TRANSFER BOX COMPEN SYSTEM Oil Inspect CUSTOMER Oil leaks Inspect CUSTOMER BRAKES Service brake Inspect CUSTOMER Parking brake Inspect CUSTOMER GREASING POINTS Nipples see lubrication points Grease CUSTOMER BODYWORK CHASSIS Protection roof Inspect C...

Page 42: ...OMER EVERY YEAR Tasks To be made by ENGINE Oil Change CUSTOMER Oil filter Change CUSTOMER FUEL LINE Air filter element Change CUSTOMER AXLES FRONT AND REAR Oil Change CUSTOMER TRANSFER BOX COMPEN SYS TEM Oil Change CUSTOMER EVERY 2 YEARS Tasks To be made by ENGINE Alternator belt Change DEALER COOLANT CIRCUIT Radiator hoses and clamps Change CUSTOMER Coolant Change CUSTOMER FUEL LINE Air intake ho...

Page 43: ...n this section 461 00099 01 5 75 1 51 ENGINE COOLANT Ethylene glycol antifreeze with corrosion inhibitors for aluminum engines with internal combustion 30 glycol and 70 distilled water for a standard machine See COOLANT in this section 45 00075 01 5 1 32 HYDRAULIC CIRCUIT Hydraulic oil VG 46 according to DIN 51524 See HYDRAULIC OIL in this section 461 00099 06 40 10 56 FRONT AXLE OIL Transmission ...

Page 44: ...rands of oil are used the sump should be completely drained first before adding the new oil AUSA RECOMMENDS REPSOL AUSA Efficient FOR DIESEL ENGINES p n 461 00099 01 Coolant Always use ethylene glycol antifreeze as this contains rust inhibitors for internal combustion aluminium engines The cooling system should be filled with distilled water and anti freeze in the following proportions 70 water 30...

Page 45: ...tension of the alternator belt regularly Also check for cracks or other damage Refer to an authorized AUSA dealer for the replacement of the alternator belt Engine oil Oil level Checking With the dumper on a level surface while the engine is cold and switched off check the oil level as follows Pull out the dipstick and clean on a clean cloth Replace the dipstick in its casing Remove it again and r...

Page 46: ... by turning to the left Clean the base of the filter and oil the seal of the new filter element Screw in the new filter element and tighten by hand without using mechanical means Dispose of the used oil filter cartridge in an authorized waste disposal centres Engine oil Filling up Remove the dipstick and place a funnel in the opening of the oil filler neck located above the rocker arm cover Fill t...

Page 47: ...e a container below the radiator Disconnect the lower radiator hose in order to drain the radiator through this point Open the drainage cock located on the left hand side of the engine to drain the coolant fig 2 Coolant circuit Filling and bleeding Before filling the circuit re connect the lower radiator hose Close the engine drainage cock The circuit is filled through the coolant reservoir Propor...

Page 48: ...hand clamps of the filter cover and remove the cover To clean the filter element blow high pressure air maximum 5 bar through the element from the inside to the outside while turning Also clean the interior of the filter housing Air filter clogged warning lamp Check operation Disconnect the air filter clogged indicator sender Make a jump between the connector s contacts using for example a small d...

Page 49: ...ilter element otherwise the circuit may suction air from the outside causing faults in the supply to the engine Dispose of remains of fuel in authorized waste disposal centres Park brake fig 2 3 Adjusting If the dumper is not correctly immobilized when the park brake is locked then the brake cable must be tightened in the following manner Place the park brake lever in released position Tight the p...

Page 50: ...eath may also be tight on the pedal support WARNING The brake pedal should have a clearance of about 1 to 1 5 mm 0 03 to 0 05 in The cables should be free of tension To replace the brake discs contact an authorized AUSA dealer Oil for TRANSFER BOX COMPEN SYSTEM fig 4 Checking the level To check the oil level unscrew the cap a The oil should be at the level of the housing Draining To drain the oil ...

Page 51: ...vel To check the oil level unscrew the cap a The oil should be at the level of the housing Draining To drain unscrew the plug b located in the lower part Topping up Fill with the specified oil through the opening of the plug a See the Table of LIQUIDS AND LUBRICANTS references and capacities in this Manual for oil type and capacity Dispose of used oil in authorized waste disposal centres Oil level...

Page 52: ...e of LIQUIDS AND LUBRICANTS references and capacities in this Manual for oil type and capacity Dispose of used oil in authorized waste disposal centres Hydraulic circuit fig 3 Checking the level The verification must be done with the dumper on horizontal ground the bucket in the lowest position the self loading shovel in rest position and is the engine stopped Note The oil tank is equipped with an...

Page 53: ...d waste disposal centres Hydraulic hoses All the hydraulic hoses should be replaced at least every 6 years Hydraulic system safety valves adjustment fig 3 4 There are two safety valves for preventing overpressure one on the steering circuit and one on the operating circuit The first is located on the hydraulic steering e and the second on the pump outlet f These valves are set to the correct press...

Page 54: ...f the valve g is not opened then the hydraulic circuit will be emptied resulting in a serious fault in the pump when the engine is started Check whether the filter needs replacing clogged indicator fig 2 The filter support has a filter clogged indicator vacuum meter In order to visualize the indicator use the inspection window located under the right hand side floor plate When the engine is runnin...

Page 55: ...horizontal ground the bucket in the lowest position the self loading shovel in rest position and is the engine stopped Wheel removed Place the tire in a cage or other device suitable for inflating tires of this nature Wheel nuts Tightening torque The tightening torque of the wheel nuts should be checked every week The exact values of the wheel nut torques are given in the attached table Use a torq...

Page 56: ...gularly grease the dumper to ensure it is effective and extend its life Inject lubricating grease via the grease nipples using a pump Stop greasing as soon as fresh grease appears through the holes Greasing points are indicated in the following figures This symbol indicates greasing points with pump nipples Lubrication Rear axle 4 nipples two on each wheel reduction joint fig 1 2 Cardan shafts 1 n...

Page 57: ... g 2 fi g 3 fi g 4 RH and RHS 2 nipples one on each end of the hydraulic operating cylinder fig 1 2 RHG and RHGS 2 nipples one on each end of the hydraulic operating cylinders fig 3 2 nipples on the rotation crown models RHG and RHGS fig 4 one on each side a a a a a ...

Page 58: ...ion models RHS and RHGS 4 nipples one on each end of the hydraulic operation cylinders on the shovel arms fig 1 2 6 nipples one on each joint in the shovel arms with the chassis fig 3 4 nipples one on each end of the hydraulic tipping cylinders for the shovel fig 4 a a a a a a a a a a a a a a a a ...

Page 59: ...nd power Working lights bulbs fig 2 Replacing Extract the bolts b and remove the work light rear housing Remove the connector from the bulb Undo the clip fastening the bulb by pressing it inwards and to the right at the same time Replace the bulb with a new one of the same type and power CAUTION Do not touch the surface of the bulb glass If it is dirty wipe gently using a clean dry cloth Secure th...

Page 60: ...it Unhook the plate b from the attachment fig 2 for the bulb by pressing inwards and to the left at the same time Replace the bulb with a new bulb of the same type and power CAUTION Do not touch the surface of the bulb glass If it is dirty wipe gently using a clean dry cloth Fasten the plate holding the bulb by pressing it inwards and to the right at the same time fi g 1 a ...

Page 61: ...en filament b a Fuse b Metal strip Remove blown fuses and replace with a new one of the same type CAUTION Do not use fuses of a higher value this could cause major damage Battery fuses Checking fig 4 Switch off the ignition Remove the fuse guard by pressing on the attachment tabs e Check the fuse continuity using a multimeter Remove the burnt fuse and replace with a new fuse of the same type CAUTI...

Page 62: ... platform using suitable securing systems chains belts or slings taking into account that these are sufficiently strong and suitable for this purpose FRONT AXLE over the front axle a REAR AXLE Using the rear counterweight towing bolt b Safety measures for loading the dumper onto a lorry or trailer bed using a crane fig 3 WARNING The lorry or trailer bed should be clean and never greasy or frozen T...

Page 63: ... Loading the dumper onto a lorry or trailer using a crane fig 1 2 Lifting should be done from the following locations FRONT SECTION Using the ears welded to the front part of the bucket REAR SECTION Using the ears on the protection bar overhead protector ...

Page 64: ...hould be towed over short distances and at low speeds Place the park brake lever in release position Before towing the dumper rotate clockwise 2 turns the central studs of the by pass valves of the hydrostatic pump To do so loosen the counter nuts a After fixing the dumper rotate again counter clockwise 2 turns the central studs of the by pass valves of the hydrostatic pump and re tighten the coun...

Page 65: ...cation of colors In the case of two colour cables the first letter of the code indicates the dominant colour The arrangement of the figures using the letters given on the colour chart is as follows G V Yellow Green Horizontal stripes G V Yellow Green Vertical stripes Legend R1 5 2 1 RED CABLE 1 5 mm section GOING TO PAGE 2 ROW 1 R1 5 3 3 RED CABLE 1 5 mm Section COMING FROM PAGE 3 ROW 3 ...

Page 66: ...D201RH RHS RHG RHGS 64 Electric Diagram H1 ...

Page 67: ...D201RH RHS RHG RHGS 65 Electric Diagram H2 ...

Page 68: ...D201RH RHS RHG RHGS 66 Electric Diagram H3 ...

Page 69: ...D201RH RHS RHG RHGS 67 Electric Diagram H4 ...

Page 70: ...icator 2 H8 Low fuel level indicator 3 H15 Reverse acoustic warning 2 H38 Control panel acoustic warning breakdown warning light 1 K1 Indicator relay 4 K2 Main beam relay 4 K3 High beam lighting relay 4 Name Description Diag K4 Starter permit relay 1 K5 Reverse gear relay 2 K6 Reverse acoustic warning relay 1 K7 Forward direction relay 2 K18 Starter relay 1 M9 Starter motor 1 M99 Fuel pump 1 P44 H...

Page 71: ...e flow pump Hydromotor Filter Radiator Pressure relief valve One way valve One way valve with spring Auxiliary connection valve Restrictor valve Control valve Deviation valve Orbitrol power steering Actuator cylinder Two ways cylinder Brake pump Service brake negative brake ...

Page 72: ...D201RH RHS RHG RHGS 70 D 201 RH hydraulic diagram ...

Page 73: ...D201RH RHS RHG RHGS 71 D 201 RHS hydraulic diagram ...

Page 74: ...D201RH RHS RHG RHGS 72 D 201 RHG hydraulic diagram ...

Page 75: ...D201RH RHS RHG RHGS 73 D 201 RHGS hydraulic diagram ...

Page 76: ...D201RH RHS RHG RHGS 74 Transmission hydraulic diagram ...

Page 77: ...ibility Directive 2004 108 EC Sound level Directives of machinery used outdoors 2000 14 EC and 2005 88 EC Exhaust emissions Directives 97 68 EC and 2004 26 EC and also it conforms with the following harmonized European Standards EN 474 1 Earth moving machinery Safety Part 1 General requirements EN 474 6 Earth moving machinery Safety Part 6 Requirements for dumpers The certification procedure has b...

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