Db 180 - Fiori Group

Transcript

TRANSLATION FROM ORIGINAL LANGUAGE en_UK DB 180 SELF LOADING CONCRETE MIXER USE AND MAINTENANCE MANUAL RIF. 9301432201 201 ed. 04 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 id.: DB 180 REV. 03 20/12/2016 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 consultation at any time, and must be handed over to the new owner if the machine is resold. CAUTION For reasons of clarity, some illustrations in this manual show the vehicle without guards. Never use the vehicle without the guards and do not start the engine when the engine guard is open unless expressly indicated in the maintenance operations. id.: DB 180 REV. 00 02/01/2012 CONTENTS 0 INTRODUCTION 1 TECHNICAL FEATURES 2 SAFETY PRECAUTIONS 3 OPERATION AND USE 4 MAINTENANCE 5 OPTIONAL EQUIPMENT 6 TECHNICAL ANNEXES id.: DB 180 REV. 00 02/01/2012 CONTENTS 1 INTRODUCTION 1.1. GENERAL RECOMMENDATIONS.................................................................................................. 13 1.2. SYMBOLS USED IN THE MANUAL ................................................................................................ 14 1.3. DIRECTION REFERENCES ............................................................................................................ 14 1.4. 1.4.1. 1.4.2. VEHICLE CONTROL AND DRIVING PHASES .............................................................................. 14 ROAD TRANSFER PHASE (PREFERENTIAL DRIVING DIRECTION) .......................................... 14 WORKING PHASE (SLOW SPEED DRIVING) ............................................................................... 14 1.5. INTENDED USE .............................................................................................................................. 15 1.6. UNAUTHORISED OR IMPROPER USE ......................................................................................... 15 1.7. DRIVER OF THE VEHICLE ............................................................................................................. 16 1.8. MANUFACTURER ........................................................................................................................... 17 1.8.1. TECHNICAL SERVICE REQUESTS ............................................................................................... 17 1.9. MACHINE IDENTIFICATION ........................................................................................................... 18 1.10. REGULATORY PROVISIONS ......................................................................................................... 20 1.11. DECLARATION OF CONFORMITY ................................................................................................ 21 2 TECHNICAL FEATURES 2.1. DIMENSIONS .................................................................................................................................. 23 2.2. TECHNICAL DATA ......................................................................................................................... 24 3 SAFETY PRECAUTIONS 3.0. FOREWORD ...................................................................................................................................... 27 3.1. 3.1.1. 3.1.2. 3.1.3. 3.1.4. 3.1.4.a 3.1.4.b 3.1.5. 3.1.6. 3.1.7. 3.1.8. 3.1.9. 3.1.10. 3.1.11. 3.1.12. 3.1.13. 3.1.14. 3.1.15. 3.1.16. 3.1.17. PRECAUTIONS OF USE ....................................................................................................................27 PERSONAL PROTECTION DEVICES (PPD) ................................................................................. 27 VEHICLE LIMITS ............................................................................................................................. 27 NOISE LEVEL .................................................................................................................................. 28 VIBRATION LEVEL ......................................................................................................................... 28 Vibration level on the “operator’s body” measured on the driver’s seat ........................................... 28 Vibration level on the “hands/arms” measured on the steering wheel. ............................................ 28 SAFETY DEVICE CHECKS ............................................................................................................ 28 PRECAUTIONS WHEN USING ACCESSORIES ........................................................................... 28 PROHIBITION TO TRANSPORT PERSONS OR OBJECTS .......................................................... 28 GETTING ON AND OFF THE VEHICLE ......................................................................................... 29 DRIVER’S SEAT .............................................................................................................................. 29 DRIVER’S CAB / OPERATOR’S PROTECTIVE STRUCTURE ....................................................... 29 ROPS (ROLL OVER PROTECTIVE STRUCTURE) ........................................................................ 29 FOPS (FALLING OBJECT PROTECTIVE STRUCTURE) ............................................................... 30 SEATBELTS .................................................................................................................................... 30 CHECKS BEFORE STARTING THE VEHICLE .............................................................................. 30 STARTING THE VEHICLE ............................................................................................................... 30 PRECAUTIONS WHILE DRIVING .................................................................................................. 31 PRECAUTIONS WHILE DRIVING IN REVERSE ............................................................................ 31 7 id.: DB 180 REV. 00 02/01/2012 CONTENTS 3.1.18. 3.1.19. 3.1.20. 3.1.21. 3.1.22. 3.1.23. 3.1.24. 3.1.25. 3.1.26. 3.1.27. 3.1.28. 3.1.29. 3.1.30. DANGEROUS WORKING CONDITIONS ....................................................................................... 32 WORKING AREA ............................................................................................................................ 32 VISIBILITY OF THE WORKING AREA ........................................................................................... 32 SITE CONDITIONS.......................................................................................................................... 33 PRECAUTIONS DURING OPERATIONS ....................................................................................... 33 WORKING ON SLOPES ................................................................................................................. 34 DRIVING ON ICY OR SNOW-COVERED SURFACES .................................................................. 34 ELECTRICAL LINES ....................................................................................................................... 34 CLOSED ENVIRONMENTS ............................................................................................................ 35 STOPPING THE VEHICLE .............................................................................................................. 35 PARKING THE VEHICLE ................................................................................................................. 35 TOWING AND RECOVERY............................................................................................................. 36 TRANSPORT ................................................................................................................................... 36 3.2. 3.2.1. 3.2.2. 3.2.3. 3.2.4. 3.2.5. 3.2.6. 3.2.7. 3.2.8. 3.2.9. 3.2.10. 3.2.11. 3.2.12. 3.2.13. 3.2.14. PRECAUTIONS AGAINST RESIDUAL RISKS ............................................................................... 37 SLIPPING......................................................................................................................................... 37 MOVING PARTS ............................................................................................................................. 37 SHEARING OR TRAPPING............................................................................................................. 37 CRUSHING ..................................................................................................................................... 37 OVERTURNING .............................................................................................................................. 38 TYRE BURSTING ............................................................................................................................ 39 ELECTRICAL RISKS ...................................................................................................................... 39 RISK OF SHORT-CIRCUIT ............................................................................................................. 39 BATTERY ........................................................................................................................................ 39 HOT AND PRESSURISED FLUIDS ............................................................................................... 40 RISK OF BURNS ............................................................................................................................. 40 VENTILATION.................................................................................................................................. 40 INTOXICATION................................................................................................................................ 40 FIRE PREVENTION......................................................................................................................... 41 3.3. 3.3.1. 3.3.2. 3.3.3. 3.3.4. 3.3.5. PRECAUTIONS DURING MAINTENANCE OPERATIONS ........................................................... 42 CORRECT MAINTENANCE ........................................................................................................... 42 PRECAUTIONS DURING WELDING OPERATIONS ...................................................................... 45 FAULTS AND UNAUTHORISED MODIFICATIONS ........................................................................ 45 CLEANING THE VEHICLE .............................................................................................................. 45 WASTE FLUID/MATERIAL DISPOSAL........................................................................................... 46 3.4. 3.4.1. 3.4.2. WARNING AND SAFETY LABELS (RESIDUAL RISKS) ................................................................. 47 LOCATION OF THE WARNING AND SAFETY LABELS ............................................................... 47 3.5. SAFETY DEVICES ON THE VEHICLE .......................................................................................... 52 3.6. SAFETY DEVICES FOR ROAD USE ............................................................................................. 55 4 OPERATION AND USE 4.0. INTRODUCTION.............................................................................................................................. 57 4.1. 4.1.1. REFERENCES AND DESCRIPTIONS OF THE MAIN DEVICES ................................................. 58 INSTRUCTION LABELS ON THE MACHINE ................................................................................ 59 4.2. CONTROLS AND GAUGES ........................................................................................................... 61 MEANING OF THE WARNING AND SAFETY LABELS .................................................................... 49 8 DB 180 REV. 00 02/01/2012 id.: CONTENTS 4.2.1. 4.2.1.a 4.2.1.b 4.2.1.c 4.2.1.d 4.2.1.e 4.2.1.f 4.2.1.h 4.2.1.j 4.2.1.i 4.2.1.l 4.2.1.m 4.2.2. 4.2.2.a 4.2.2.b 4.2.2.c 4.2.2.d 4.2.2.e 4.2.2.f 4.2.2.g 4.2.2.h 4.2.2.i 4.2.2.k 4.2.2.l 4.2.2.m 4.2.2.n 4.2.3. 4.2.3.a 4.2.3.b 4.2.3.c 4.2.3.d 4.2.3.e 4.2.3.f 4.2.3.g 4.2.4. 4.2.5. 4.2.6. 4.2.7. 4.3. 4.3.1. 4.3.2. 4.3.3. 4.3.4. 4.3.5. 4.3.6. 4.37. 4.3.8. DRIVER’S SEAT .............................................................................................................................. 61 Steering wheel ................................................................................................................................ 61 Height- and depth-djustable driver’s seat with seatbelt ................................................................. 61 Service and emergency brake pedal .............................................................................................. 62 Accelerator pedal ........................................................................................................................... 62 Pivoting driving post locking lever .................................................................................................. 62 Parking brake button ...................................................................................................................... 62 (Mechanical) gearshift control lever ................................................................................................ 62 Fuses and Relays ........................................................................................................................... 63 Windscreen wiper ........................................................................................................................... 63 Cabin light ....................................................................................................................................... 63 Windscreen washer fluid tank ......................................................................................................... 63 DRIVING POST INSTRUMENT PANEL .......................................................................................... 64 Electronic control panel .................................................................................................................... 64 Water Liter counter........................................................................................................................... 65 Hour counter/revolution counter ....................................................................................................... 65 Maintenance schedule .................................................................................................................... 66 Forward/reverse gear selector ......................................................................................................... 66 Slow / fast gear selector .................................................................................................................. 66 Drum rotation switch ........................................................................................................................ 67 Reset button ..................................................................................................................................... 67 Water pumps control switch ............................................................................................................ 67 Hazard light toggle switch ............................................................................................................... 67 Working light switch (OPTIONAL) .................................................................................................... 67 Engine starter and stopping switch ................................................................................................. 68 Rotary switch with horn push button direction indicators toggle switch ........................................... 69 OPERATING CONTROL PANEL .................................................................................................... 70 Control lever of bucket and drum lifting ........................................................................................... 70 Safety push-button ........................................................................................................................... 70 Safety lever for joystick locking ....................................................................................................... 70 Power socket ................................................................................................................................... 70 Hand accelerator lever ..................................................................................................................... 70 Rotating light switch ......................................................................................................................... 71 Windscreen washer switch............................................................................................................... 71 GROUND CONTROL PANEL (MIX CONTROL) ............................................................................ 72 OPERATION OF THE ELECTRONIC LITRE COUNTER AND MIX CONTROL PROGRAMMING ......... 73 WATER SUPPLY AND DISTRIBUTION CONTROLS ................................................................... 74 CHUTE CYLINDER MANUAL HYDRAULIC CONTROL (OPTIONAL)............................................ 75 INSTRUCTIONS FOR USE ............................................................................................................. 76 REFUELLING................................................................................................................................... 76 LEVEL CHECK ................................................................................................................................ 77 FILLING THE WATER TRANSFER PUMP BODY ......................................................................... 77 ADJUSTING THE SEAT .................................................................................................................. 77 ADJUSTING THE REAR-VIEW MIRROR ....................................................................................... 78 DRIVING POST PIVOTING ............................................................................................................ 78 STARTING THE ENGINE ................................................................................................................ 79 ENGINE OPERATION AT LOW RPM ..............................................................................................80 9 id.: DB DB 180 180 REV. REV. 00 02 02/01/2012 15/06/2016 CONTENTS 4.3.9. 4.3.10. 4.3.11. 4.3.12. 4.3.13. TESTING THE PARKING BRAKE ....................................................................................................80 STARTING AND DRIVING THE VEHICLE .......................................................................................81 STOPPING THE VEHICLE ...............................................................................................................82 STOPPING THE ENGINE .................................................................................................................82 PARKING THE VEHICLE ..................................................................................................................82 4.4. 4.4.1. TRANSPORTING THE VEHICLE ....................................................................................................83 LIFTING THE VEHICLE WITH A CRANE ........................................................................................84 4.5. 4.6. TOWING OR RECOVERY ...............................................................................................................85 DRIVING ON PUBLIC ROADS ........................................................................................................86 4.7. HOMOLOGATION FOR ROAD USE (ITALY) ...................................................................................87 4.8. PRECAUTIONS FOR USE IN COLD CLIMATE CONDITIONS ......................................................87 4.9. PRECAUTIONS IN THE EVENT OF LONG PERIODS OF INACTIVITY ........................................88 4.10. 4.10.1. 4.10.2. 4.10.3. 4.10.4. 4.10.5. 4.10.5.a 4.10.5.b 4.10.5.c WORKING PHASES ........................................................................................................................88 CORRECT USE OF THE VEHICLE ................................................................................................89 BEFORE GETTING ON THE VEHICLE (CHECKS AND WARNINGS) ............................................89 CORRECT USE ON SLOPES ..........................................................................................................89 CONCRETE COMPOSITION AND BATCHING TABLE....................................................................91 FIRST FILLING WITH MIXING WATER............................................................................................92 Filling the tanks with mixing water ....................................................................................................92 First filling with mixing water ............................................................................................................93 Activating the water transfer pump ...................................................................................................94 4.10.6. CEMENT LOADING ..........................................................................................................................94 4.10.6.a Cement in bags ................................................................................................................................94 4.10.6.b Cement in silos .................................................................................................................................95 4.10.7. AGGREGATE LOADING ..................................................................................................................96 4.10.7.a Heaped aggregate ............................................................................................................................96 4.10.8. MIXING AND SECOND FILLING WITH WATER .............................................................................97 4.10.9. CONCRETE UNLOADING................................................................................................................97 4.10.9.a Concrete unloading from chute ........................................................................................................98 4.10.9.b Concrete unloading from drum emergency door...............................................................................99 4.10.10. BUCKET, DRUM AND CHUTE WASHING ....................................................................................100 4.10.11. INTERNAL CLEANING OF THE MIXING DRUM ...........................................................................101 4.10.12.EXTRAORDINARY DRUM CLEANING OR BLADE REPLACEMENT ............................................101 5 MAINTENANCE 5.1. FOREWORD .....................................................................................................................................103 5.1.1. VISUAL EXTERNAL INSPECTION ...................................................................................................104 5.1.2. CLEANING THE VEHICLE .............................................................................................................104 5.1.3. CHECKING FOR DAMAGES ............................................................................................................105 5.1.4. ACCESS TO THE MAIN DEVICES ...................................................................................................105 5.1.4.1. PARTS CONTAINED IN THE TOOL KIT ...........................................................................................105 5.1.4.2. ROUTINE MAINTENANCE AND CHECKS.......................................................................................106 5.2. MAINTENANCE SCHEDULE ...........................................................................................................107 10 DB DB180 180 REV. REV.00 02 02/01/2012 15/06/2016 id.: CONTENTS 5.3. RUNNING-IN AND SERVICE ...........................................................................................................107 5.4. SCHEDULED MAINTENANCE TABLE .............................................................................................108 5.5. ENGINE MAINTENANCE SCHEDULE ............................................................................................ 110 5.6. RECOMMENDED LUBRICANTS AND FLUIDS TABLE ................................................................... 112 5.7. GENERAL INSPECTIONS ................................................................................................................ 113 5.7.1. GREASE ........................................................................................................................................... 113 5.7.2. CLEANING AND DRAINING THE FUEL TANK ................................................................................ 114 5.7.3. ACCELERATOR AND PARKING BRAKE CABLE LUBRICATION ................................................. 114 5.8. AXLE AND WHEELS ........................................................................................................................ 115 5.8.1. CLEANING THE AXLE AND DIFFERENTIAL BLEEDERS ............................................................... 115 5.8.2. CHECKING AND TOPPING UP THE OIL LEVEL IN THE FRONT AND REAR AXLES ................... 115 5.8.3. REPLACING THE OIL IN THE FRONT AND REAR AXLES ............................................................. 116 5.8.4. CHECKING AND ADJUSTING THE TYRE PRESURE ..................................................................... 117 5.8.5. REPLACING THE WHEELS ............................................................................................................ 118 5.9. 5.9.1. 5.9.2. 5.9.3. BRAKES ............................................................................................................................................121 CHECKING AND TOPPING UP THE BRAKE FLUID LEVEL ..........................................................121 CLEANING THE BRAKE FLUID TANK BLEEDERS ........................................................................121 REPLACING THE BRAKING SYSTEM FLUID .................................................................................122 5.9.4. TESTING THE HAND BRAKE ..........................................................................................................123 5.9.5. CHECKING THE WEAR CONDITION OF THE BRAKING SYSTEM ...............................................123 5.10. HYDRAULIC SYSTEM .....................................................................................................................124 5.10.1. CHECKING THE HYDRAULIC OIL ..................................................................................................124 5.10.2. REPLACING THE HYDRAULIC OIL TANK BLEEDER ....................................................................124 5.10.3. 5.10.4. 5.10.5. 5.10.6. CHANGE THE HYDRAULIC OIL FILTER CARTRIDGE...................................................................125 REPLACING THE HYDRAULIC OIL ................................................................................................126 CHECKING AND TOPPING UP THE DRUM REDUCTION GEAR OIL LEVEL ...............................127 DRUM REDUCTION GEAR OIL CHANGE .......................................................................................127 5.11. ENGINE ............................................................................................................................................128 5.11.1. CLEANING THE ENGINE AIR FILTER SEPARATOR ....................................................................128 5.11.2. CLEANING OR REPLACING THE ENGINE AIR FILTER CARTRDIGE .........................................128 5.11.3. CHECKING AND TOPPING UP THE COOLANT LEVEL ...............................................................129 5.11.4. REPLACING THE ENGINE COOLANT ...........................................................................................130 5.11.5. CHECKING AND ADJUSTING THE ALTERNATOR BELT TENSIONING ........................................130 5.11.6. AIR BLEEDING IN THE ENGINE FUEL SUPPLY SYSTEM ............................................................130 5.11.7. REPLACING THE ENGINE FUEL SUPPLY PRE-FILTER AND FILTER .........................................130 5.11.8. CHECKING AND TOPPING UP THE ENGINE OIL LEVEL .............................................................131 5.11.9. .REPLACING THE ENGINE OIL FILTER ..........................................................................................132 5.11.10. REPLACING THE ENGINE OIL ......................................................................................................132 5.12. ELECTRIC COMPONENTS ..............................................................................................................133 5.12.1. FUSES AND RELAYS .......................................................................................................................133 5.12.2. ELECTRONIC DASHBOARD WARNING LIGHTS ...........................................................................136 5.12.3. REPLACING THE LIGHT BULBS ....................................................................................................137 5.12.4. CHECKING AND TOPPING UP THE BATTERY ELECTROLYTE LEVEL ......................................138 5.12.5. BATTERY PINS CONTACT ..............................................................................................................139 11 id.: DB DB 180 180 REV. REV. 00 02 02/01/2012 15/06/2016 CONTENTS 5.12.6. BATTERY REPLACE.........................................................................................................................139 5.13. WATER SYSTEM .............................................................................................................................140 5.13.1. CHECKING AND MAINTAINING THE LITRE COUNTER ...............................................................140 5.13.2. CHECKING THE WATER TRANSFER PUMP EFFICIENCY ...........................................................141 5.13.3. WATER PUMP EMERGENCY ACTIVATION ...................................................................................141 5.13.4. CLEANING PRE-FILTER OF THE WATER PUMP...........................................................................142 6 OPTIONAL EQUIPMENT ...............................................................................................................143 143 TECHNICAL ANNEXES ................................................................................................................................147 12 DB DB180 180 REV. REV.00 02 02/01/2012 15/06/2016 id.: INTRODUCTION 1 This manual has been designed to provide a practical guide for proper and safe use of the machine, as well as for its correct routine maintenance. Thorough and ongoing observance of the instructions contained herein will help ensure the machine optimal performance, its operation economy as well as its longest life. In addition, this will allow you to use the machine properly, thus helping to avoid the most common accidents which may occur during operation or maintenance. 1.1 GENERAL RECOMMENDATIONS This use and maintenance manual is an integral and essential part of the machine and must be delivered to the user. Read this manual carefully and thoroughly before starting, using and performing maintenance, refuelling or any other operation on the machine. The machine shall be entrusted to and operated by skilled staff only, which must have been duly trained on the use of self-propelled vehicles of this type and on the relative safety rules and regulations. The operator must observe all safety and accident prevention regulations as well as the Road Traffic Regulations if the vehicle is road driven. Furthermore, it is essential to carefully read the safety CAUTIONs found on the machine plates and labels, and to strictly observe the instructions contained therein before starting, operating or repairing the machine or performing maintenance operations on the same. Each machine comes equipped with a copy of this manual. The manual must be properly and safely stored in its compartment in the driver’s cab. It must be kept within reach and 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 Dealaer 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 dangerous. Thorough and ongoing observance of the instructions contained herein will help ensure a longer service life and reduction of maintenance and stop times. In addition, this will help you to avoid the most common accident causes which may occur during operation or maintenance. It is of mutual interest to observe the aforementioned instructions, and that the buyer undertakes to ensure that this manual is an integral part of the machine, that it is actually consulted by the operator and by maintenance staff and that the instructions provided are strictly observed, assuming full responsibility in relation thereto. The buyer and the operator of the vehicle must read the use and maintenance manual carefully the first time they are using the machine. If this vehicle is subject to a use or lease agreement, it is the owner’s duty to make sure that the new user reads and understands this use and maintenance manual. In addition, make sure that the new operator has fully inspected the vehicle and is knowledgeable with all of its labels, decals and equipment, and that he has tested all the controls to understand and verify their proper functioning. The Manufacturer reserves the right to make any and all modifications for product improvement purposes, without updating this documentation. For additional information, please feel free to contact your Dealer or the Manufacturer at your convenience. 13 id.: DB 180 REV. 00 02/01/2012 1 INTRODUCTION 1.2 SYMBOLS USED IN THE MANUAL To provide a clearer understanding of the information contained in this manual, major information or information regarding danger is shown with the following symbols: DANGER: Indicates a situation of imminent risk that, if not avoided, may result in serious injury or even death. CAUTION: Indicates a potential risk which, if not avoided, may result in injury of low or medium severity. It may also be used to prohibit operations involving risks and which may cause damages. 1.3 DIRECTION REFERENCES A B FRONT REAR 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. Driving the machine on short or long stretches, with or without carrying material. 1.4.2 WORKING PHASE (SLOW SPEED DRIVING) The driving post is turned toward the rear of the machine. Driving the machine for bucket and materials loading. Driving the machine at work sites, for approaching and manoeuvring steps to dump materials. 14 DB 180 REV. 00 02/01/2012 id.: INTRODUCTION 1 1.5 INTENDED USE This machine has been designed and manufactured to load aggregates, cement and water in the appropriate quantities, and mix them homogeneously directly on the worksite, to produce quality concrete for on-site casting. Use of the machine on public roads is subject to road traffic regulations in force in the country of use. This machine must be used by the driver only and cannot be used to transport other people. This machine has been designed and manufactured for its intended use and purpose. Therefore, its technical features shall be considered binding in order to use the machine for its intended purpose. No modifications can be made to the machine without prior authorisation from FIORI, as they may lead to dangerous situations. It is always necessary to strictly observe the safety rules and regulations illustrated in this use and maintenance manual. 1.6 UNAUTHORISED OR IMPROPER USE It is strictly forbidden to use the machine for any operation other than those described herein. Under no circumstance may FIORI be held responsible for any other use of the machine or for non-observance of the instructions provided by the Manufacturer. The machine shall not be used for underground works or in potentially explosive workplaces. In the event of underground works, contact FIORI to request information on the requirements to be observed for adjusting the machine so that it is suitable for such purposes. Any unauthorised modification to the machine relieves the Manufacturer from any responsibility for property damage or personal injuries which may directly and/or indirectly arise in connection therewith. The Manufacturer and its Distribution and After Sales Service Network accept no responsibility for any damage which may arise in connection with not approved and malfunctioning components fitted on the machine during maintenance or repair operations. No objects of any kind may be transported on the machine or inside the driver’s cab. Therefore no warranty, of any kind whatsover, is provided in relation to the product manufactured or traded by the Manufacturer for damages due to non-approved malfunctioning parts and/or components. DANGER: If the machine is used for any purpose other than its intended and allowed use, the operator shall be responsible for his own safety as well as for the safety of any other person involved. CAUTION: FIORI accepts no responsibility for personal injury or property damage which may derive from non observance of the provisions and instructions contained in this manual and from non observance of safety and accident prevention regulations. 15 id.: DB 180 REV. 00 02/01/2012 1 INTRODUCTION 1.7 DRIVER OF THE VEHICLE Road driving of the vehicle is naturally governed by Road Traffic Regulations, and therefore the driver shall be equipped with a driving license as required. In order to use the machine on the worksite, the operator must be of the minimum age established by applicable legislation in the country of use. The operator may use the machine only after receiving adequate and specific training. This training must ensure that the machine is used correctly in relation to the risks which may arise for the driver or other people. Driving an earth moving machine always requires technical skills and training, in addition to a strong sense of responsibility. The operator must therefore have specific psychophysical requisites to qualify for this job. Therefore, only authorised personnel may use these vehicles. The operators must be duly trained on the use of the machine and instructed about any possible risks at the workplace. We recommend that all staff follow a training course aimed at learning how to use the machine safely and efficiently and getting specific knowledge on the engine and hydraulic system operation, in order to perform cleaning and maintenance operations. The machine must only be driven and serviced by persons who: - have an excellent eyesight and colour perception, good hearing, co-ordination and sharp reflexes; - are physically and mentally eligible for this type of job, and are able to meet the requirements connected with the machine operation at peak performance levels; - refrain from operating the machine when they are tired, unwell or under the influence of drugs, alcohol or medicines which may affect their physical abilities or sharpness of their reflexes; - are able to read and properly understand the instructions contained in this manual, according 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 that of other people, animals, property, the machine itself and the environment; - are knowledgeable with the safety rules and regulations applicable to the workplace. The Legal Representative of the company which owns the vehicle shall appoint the staff who possess the above said requisites to perform the tasks required. The operator is also responsible for and shall assure that: - nobody approaches the machine when it is working; - no unauthorised and untrained personnel may use the machine; - the safety procedures learnt during the training course are observed every day; - potential hazards in the workplace are recognised and avoided; - the caution and warning labels and plates have been read and understood, and their instructions observed (see Section 3 “Safety Labels and Decals”); - the machine has been inspected and its proper working condition checked before starting the work shift; - report any operational problems encountered before, or while operating the machine; - reckless or careless actions, which may endanger his own safety as well as other people’s safety, are avoided; - common sense is used at all times and safety has absolute priority. The machine is manufactured and supplied for its intended use, as specified in this manual. Operators are reminded that, when using the machine, they must always and under all circumstances behave following active safety principles, in order to enhance the overall safety level of the machine. Prior to commencing work, the operator must check that all the safety devices are active and functioning properly: he/she is obliged to refuse to start work in the event that the requirements for safe working are not met. 16 DB 180 REV. 00 02/01/2012 id.: INTRODUCTION 1 CAUTION: FIORI accepts no responsibility for any damage to persons, animals, property or the environment resulting from the machine being operated and used by staff without the required prerequisites. 1.8 MANUFACTURER The machine and any offspin models are manufactured exclusively by: 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 1.8.1 Technical Service Requests In the event of any machine failure or malfunction, it is essential to follow the instructions below: - If the trouble persists, do not try further actions or expedients. Contact the nearest authorised FIORI SERVICE CENTRE or directly: FIORI GROUP S.p.A. Via per Ferrara, 7 41034 FINALE EMILIA (Modena) Italia Tel. +39.0535.780250 - Fax +39.0535.90960 When you contact Fiori After Sales Service, make sure you have all necessary details available, which must be provided to the Service staff so as to immediately identify the machine model and understand the problem. - Provide all data shown on the identification plate secured on the machine. - Make sure you have all diagrams and layouts contained in this manual available and within reach. - Give a brief and very clear description of the current failure or malfunction. 17 id.: DB 180 REV. 00 02/01/2012 1 INTRODUCTION F C 2 E 1 A *BF03S0100* D B 1.9 MACHINE IDENTIFICATION The identification data of the machine and its main components are punched on metal plates, which allow the machine to be identified by the After Sales Service by means of specific ID numbers and letters. The following information show where the identification plates and punched numbers are located, and give examples of the symbols found on the machine. 18 DB DB180 180 REV. REV.00 02 02/01/2012 15/06/2016 id.: INTRODUCTION 1 A - VEHICLE SERIAL NUMBER The serial number is punched on the bumper side, on the right-hand side of the machine (with respect to the driving direction). CAUTION: This number must always be provided whenever requesting assistance from the FIORI After Sales Service Network. The serial number is also required to facilitate identifying the machine in the event of theft. B - VEHICLE AND MANUFACTURER’S DATA PLATE The vehicle and Manufacturer’s data plate is found on the front right-hand bumper, as shown in the figure. Please fill in the following data concerning your vehicle: MODEL/TYPE ................................................................................................................... DB 180 / BF03S SERIAL NUMBER ................................................................................................................... •BF03S0100• 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. ................................................................................................................................ 4TNV88-M SERIAL NUMBER ......................................................................................................................................... D - AXLE DATA PLATE The axle type and serial numbers are printed on the plate 1 found on the axle central case. Write down the information in the space below for quick reference: FRONT AXLE TYPE ......................................................................................................... • 853611.C041 • SERIAL NUMBER ......................................................................................................................................... REAR AXLE TYPE ............................................................................................................ • 859651.B041 • SERIAL NUMBER ......................................................................................................................................... E - TRANSMISSION DATA PLATE The serial number and type are punched on the pump (1) and engine (2) plates. Write down the information in the space below for quick reference: 1- PUMP MODEL ...................................................................................................................... • M4PV58 • SERIAL NUMBER .................................................................................................................................. 2- ENGINE MODEL ................................................................................................................. • M4MV58 • SERIAL NUMBER .................................................................................................................................. F - OPERATOR PROTECTION PLATE The ROPS - FOPS operator’s protection plate is found inside the upper section of the structure. 19 id.: DB 180 REV. 00 02/01/2012 1 INTRODUCTION 1.10 REGULATORY PROVISIONS The machine has been built in compliance with applicable European directives and laws, and conforms to the standards of the indicated directives: MACHINE - Directive 2006/42/EC on “Machinery” - Directive 2004/108/EC on “Electromagnetic Compatibility” - Directive 2000/14/EC on “Noise emission” ENGINE - Directive 2004/26/EC “Emission of pollutants from internal combustion engines” STAGE III A CABIN - ROPS UNI 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” 20 DB 180 REV. 00 01 02/01/2012 01/04/2013 id.: 1 INTRODUCTION 1.11 DECLARATION OF CONFORMITY The EC Declaration of conformity is the document undersigned by the Manufacturer which warrants and certifies that the machine complies with all European regulatory provisions concerning the product. This document is provided with the entire documentation on machine delivery. It must be carefully kept on board and shall always accompany the machine until its end-of-life scrapping. The declaration shows the machine identification data, the manufacturer’s details and applicable law provisions. Below is an EC declaration facsimile: Declaration of conformity CE for a new industrial machine As a representative I declare that the following machine 1, Category 2, Mark/Model 3, Model 4, Chassis number 5, Manufacturer 6, Year of manufacture : : : : : : Self loading concrete mixer FIORI - DB180 BF03S *BF03S0000* FIORI GROUP S.p.A. 2012 is designed and manufactured in compliance with the following European Directives: - Directive 2006/42/CE "Safety of machinery" - Directive 2004/108/CE "Electromagnetic compatibility" - Directive 2000/14/CE "Noise emission" according to the contents of Annex V (internal production control) with the technical documentation retained by the manufacturer. 107 108 1,1 Measured sound power level Guaranteed sound power level Nominal drum output dB(A) dB(A) mc For proper and safe machine use, we recommend that you follow the instructions given in the "Use and Maintenance Manual". Att. n°: 0000 Finale Emilia, lì FIORI GROUP S.p.A. 21 id.: DB 180 REV. 00 02/01/2012 TECHNICAL FEATURES 2 2.1 DIMENSIONS - Minimum road transfer length ...........................................................................................................4,520 mm - Maximum length with loader on the ground .....................................................................................5,280 mm - Maximum width ................................................................................................................................1,790 mm -Minimum height with loader on the ground .......................................................................................2,600 mm - Maximum road transfer height ..........................................................................................................3,280 mm - Maximum hopper unloading height ...................................................................................................1,690 mm - Maximum chute unloading height......................................................................................................1,280 mm - Minimum chute unloading height.......................................................................................................1,160 mm - Front angle of attack ................................................................................................................................... 38° - Rear angle of attack ................................................................................................................................... 44° - Ground clearance under the differentials ............................................................................................285 mm - Minimum wheel radius...................................................................................................................... 2,300 mm - Minimum outside wheel radius ......................................................................................................... 4,060 mm 23 id.: DB 180 180 DB REV. 01 00 REV. 02/01/2012 01/04/2013 2 TECHNICAL FEATURES 2.1 TECHNICAL DATA DIESEL ENGINE YANMAR ...............................................................................................................4TNV88, naturally aspirated Mechanical control with direct injection Max. power ............................................................................................................................ 36.9 kW - (49 Hp) Adj. power ..............................................................................................................32 kW (44 Hp) at 2,600 rpm Max. torque ...................................................................................................................... 139 Nm at 1,200 rpm Bore/stroke: ....................................................................................................................................... 88/90 mm 4 cylinders - total displacement 2190 cc Water cooling, dry air filter ELECTRIC SYSTEM Alternator: ........................................................................................................................................ 12 V - 40 A Battery: .............................................................................................................................. 12 V - 80 Ah (400 A) Road light and signalling system. 4X4 FOUR-WHEEL DRIVE Hydrostatic “automotive” transmission with variable displacement pump and variable displacement hydraulic motor with electro-hydraulic control. Electro-hydraulically controlled mechanical gearbox for “working speed” and “road transfer” speed. SPEED 4 forward gears 2 reverse gears I° 0 - 5,0 Km/h 0 - 5,0 Km/h II° 0 - 7,2 Km/h 0 - 5,0 Km/h III° 0 - 14,2 Km/h 0 - 14,2 Km/h IV° 0 - 20,2 Km/h 0 - 14,2 Km/h Traction / weight ratio ................................................................................................................................. 55% AXLES AND WHEELS Front load-bearing, oscillating (± 7°) and steering with planetary reduction gears on the wheel hubs. Rear load-bearing and steering with planetary reduction gears on the wheel hubs and directly flanged gearbox. Tyres ....................................................................................................................................... 12.0/75-18 12PR BRAKES Internal oil-bath disc service and emergency brakes acting on the 4 wheels, activation with pump on independent dual circuit. Drum parking brake on the front axle with lever control. STEERING Assisted by means of load-sensing power steering acting on 2 half-frames by means of two opposed jacks. 24 DB 180 REV. 00 02/01/2012 id.: 2 TECHNICAL FEATURES EQUIPMENT HYDRAULIC SYSTEM Gear pump Max. flow rate: ............................................................................................................................... 35 litres/min. Maximum pressure: ............................................................................................................................... 170 bar 3-element distributor with joystick. Aluminium heat exchanger for hydraulic oil cooling. Pressurised closed-circuit intake with oil filter replaceable from the outside. MIXING AND POURING Double-cone drum with double-spiral mixing screws Geometrical drum volume: ...............................................................................................................2,560 litres Drum rotation speed: ............................................................................................................................. 20 rpm. Class S1 concrete produced as : ......................................................................................................... 1.8 cu m Drum rotation by means of a piston pump with variable flow rate and an orbital hydraulic motor in closed circuit with infinitesimal electrical control positioned in the cabin and at the rear of the machine. Drum raising up to the horizontal position by means of 2 double-acting jacks. Chute with manual tilting independent of the mixing drum inclination and 180° rotation. Removable chute, for direct unloading from hopper. 1 chute extensions provided as standard equipment. WATER SYSTEM “Self-priming” volumetric water pump with quick-suction. Max. capacity: .............................................................................................................................. 140 litres/min. Maximum head: ......................................................................................................................................... 3 bar One sheet tank on the engine side with a capacity of ........................................................................240 litres. Mix Control system for programmable and controlled management of water feeding to the drum and of mixing and unloading from the ground panel. Water feeding to the drum controlled by means of electromagnetic flow meter and fed litre reading on both the cabin display and at the rear of the vehicle. Water pump activation from the driver’s seat and from the ground panel. Suction selection from the ground with quick-coupling pipes. LOADING SHOVEL Loading arms with fixed loader and automatic unloading hatch. Volumetric capacity: ............................................................................................................................ 470 litres Number of shovelfuls per load ................................................................................................................... 5 - 6 Production capacity: up to 4 cycles/hour CAB Open cab designed according to ROPS/FOPS criteria, windows on three sides. 180° pivoting driving post. Anatomic seat with flexible suspension and height adjustment, seat belts. Driving and equipment controls with ergonomic arrangement. 25 id.: DB 180 01 REV. 00 01/04/2013 02/01/2012 2 TECHNICAL FEATURES SERVICE REFILL CAPACITIES Fuel tank, ...............................................................................................................................................46 litres Total hydraulic system capacity: ............................................................................................................67 litres Engine oil: .............................................................................................................................................. 7.07 kg WEIGHTS Operating weight: ................................................................................................................................ 3,700 kg Max gross weight: ................................................................................................................................ 8,400 kg load-carring capacity: .......................................................................................................................... 4,700 kg 26 DB180 180 DB REV. 02 00 15/06/2016 02/01/2012 id.: SAFETY PRECAUTIONS 3 3.0 FOREWORD This manual is intended as a practical and rational guide to proper use and prevention of the most common causes of accidents during work and maintenance. Below are the main rules that must strictly be followed: - Carefully read this manual before any starting, use, maintenance, refuelling or other operations. - Read and comply with all the SAFETY REGULATIONS given in this manual before carrying out any operation. - Prudence and judgement during appropriate use of the vehicle are essential and basic factors for the safety of the operator and of other people working near the vehicle. Therefore, before starting any work, you must know exactly what the functions of all the controls and the stability characteristics of the vehicle are. 3.1 PRECAUTIONS OF USE 3.1.1 PERSONAL PROTECTION DEVICES (PPD) Wear clothing suited to the work to be carried out on the site and do not wear loose or hanging clothes such as ties, scarves, unbuttoned jackets, unzipped garments or sleeves with wide cuffs, which may get caught up in the moving parts. Do not wear rings, wrist watches or any other jewellery. The following protective clothing is to be worn as prescribed by the site regulations: - Hardhat - Non-slip shoes - Protective goggles - Protective gloves - Anti-noise headsets (where applicable) - Reflecting garments or vests - Raincoats in bad weather - Protective mask for cement loading 3.1.2 VEHICLE LIMITS - The maximum overall performance level of the vehicle is optimised during functional testing before delivery. - Do not use the vehicle outside the limits defined during design; exceeding these limits may be dangerous and cause damage to the vehicle. - Do not attempt to improve vehicle performance with unapproved modifications. - Any alteration will lead to forfeiture of the warranty on the vehicle as well as on functional and accessory equipment. 3.1.3 NOISE LEVEL In compliance with directive 2000/14/EC the following sound power values were measured according to ISO 6394: -Sound power level measured ...........................................................................................................107 dB(A) -Sound power level guaranteed .........................................................................................................108 dB(A) -Equivalent sound pressure level measured at the operator’s ears according to ISO 6394 ............... 88 dB(A) 27 id.: DB 180 REV. 00 02/01/2012 3 SAFETY PRECAUTIONS 3.1.4 VIBRATIONS’ LEVEL 3.1.4.a Vibration level on the “operator’s body” measured on the driver’s seat Based on measurements made in operating conditions on vehicles similar to this one, it is declared that the mean level of vibrations on the “operator’s body” is equal to ......................................................... 1,25 m/sec² This value is to be understood as RMS, weighted using the “broadband” method in compliance with ISO 7096 and ISO 2631-1 and determined 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 the “hand/arms” is less than or equal to ................................................ 2.5 m/sec² This value is to be understood as RMS, weighted using the “broadband” method in compliance with ISO 2631-1 and determined according to a cycle indicated in ISO 25398 with attribution of the times established by the company according to what are considered customary vehicle operating conditions. 3.1.5 SAFETY DEVICE CHECKS - Check that all the safety devices are properly installed and that they function properly and are undamaged. - If any irregularities are found make the appropriate repairs. - Incorrect use of the safety devices may cause serious accidents with the consequent risk of injury or death. - Make sure that you use the safety devices correctly. 3.1.6 PRECAUTIONS WHEN USING ACCESSORIES - During installation of optional components or equipment, problems may occur that put your safety at risk. Therefore, always ask FIORI for advice before installation. - FIORI is not responsible for injury, accidents or faults deriving from use of unauthorised equipment or accessories. - Before installation and use of accessories, read the instruction manual of the specific accessory and the general information on accessories given in this manual. 3.1.7 PROHIBITION TO TRANSPORT PERSONS OR OBJECTS - The vehicle is not homologated for transport of persons other than the operator, who must be seated on the driver’s seat. - During all working phases, do not allow anyone to come close to the vehicle. - Do not allow anyone to climb onto the working equipment. - Do not carry people onboard the vehicle. - Do not use the vehicle to transport objects, except those needed for the job and equipped with special couplings. - Do not use the vehicle as platform or scaffolding and under no circumstances use it for any function not specified by the manufacturer. 28 DB 180 REV. 00 02/01/2012 id.: SAFETY PRECAUTIONS 3 3.1.8 GETTING ON AND OFF THE VEHICLE - To get on the vehicle, use the steps and the handholds in proximity of the driver’s seat; it is prohibited to use the control levers and devices as handholds. - If the vehicle starts moving when you are not on it, do not jump on to try and stop it. - It is prohibited to get on and off the vehicle when it is moving. - Get off the vehicle only when it has come to a complete halt and is stable. - Do not get on and off the vehicle by jumping or holding tools in your hands. - Always face the vehicle when getting on and off the driver’s seat or other raised parts and support yourself by keeping both hands and one foot or both feet and one hand on the steps and the handrail. - Do not climb onto the engine compartment lid or other parts of the vehicle. 3.1.9 DRIVER’S SEAT - Before getting into the operator’s cabin, always remove mud and oil from the soles of your shoes. If you push a pedal with mud or oil on the soles of your shoes, your foot might slip causing accidents. - Keep the area around the driver’s seat clean. - Do not place any object at the foot of the driver’s seat or around the pedals and do not hang anything on the control levers. The levers might accidentally be activated causing uncontrolled vehicle movement or activation of the working equipment and hence dangerous conditions. - Place all objects not needed for driving in the storage compartments provided. - Do not carry objects in your pockets that may fall into the open compartments of the vehicle. - Always keep the driver’s seat clear of foreign objects, especially if not secured. - Do not leave components or tools scattered around the cabin. - Do not use mobile phones in the cabin while driving or operating the vehicle. - Never take dangerous objects into the cabin, for example, flammable or explosive objects. 3.1.10 DRIVER’S CAB / OPERATOR’S PROTECTIVE STRUCTURE - DO NOT modify, repair or remove the operator protective structure. Should it be structurally damaged or modified (e.g. by welding or drilling) the protection provided by the cabin/roof would be compromised, creating a risk which may cause death or serious injury. - After an accident, carefully inspect the protective structure, the driver’s seat, the seatbelt and all the pillars. - Replace all the parts that show any sign of damage. Original spare parts must be used as indicated in the Spare Parts Catalogue and can be ordered from FIORI. 3.1.11 ROPS (ROLL OVER PROTECTIVE STRUCTURE) - The ROPS structure serves to protect the operator and cushion the impact in the event that the vehicle overturns. - The ROPS structure is an integral part of the cabin. Do not operate the vehicle without this protection system. - The ROPS structure is in compliance with the safety regulations for the vehicle type. If it is damaged, repaired or modified without authorisation, its deformability may change. In this case, it will no longer be able to correctly perform its protective function and must be replaced. - If the structure has been involved in an accident, do not use the vehicle until the structure has been replaced or inspected by qualified personnel. - The ROPS structure guarantees protection if the seatbelt is properly fastened. For this reason, always keep the seatbelt fastened while the vehicle is moving. 29 id.: DB 180 REV. 00 02/01/2012 3 SAFETY PRECAUTIONS 3.1.12 FOPS (FALLING OBJECT PROTECTIVE STRUCTURE) - The FOPS structure is installed to protect the operator from objects falling from heights. - If the structure is damaged or modified without the Manufacturer’s permission, its stability will be reduced. In this case, it will no longer be able to correctly perform its protective function and must be replaced. - If the structure has been involved in an accident, do not use the vehicle until the structure has been replaced or inspected by qualified personnel. The FOPS structure cannot be installed on the vehicle as a standard part, as it is only required for certain types of work. 3.1.13 SEATBELTS - Check that the seatbelts do not show any sign of fraying or cuts and that they have not been subjected to heavy strain (overturning) in which case they need to be replaced. - Keep the seatbelts correctly positioned on the seat, do not let them get twisted and do not alter or modify them in any way. Always keep them clean. - Choose the most comfortable driving position in relation to your build. - Adjust the seat position. Check functioning of the adjuster, the buckle and the winders (where fitted) and the method that allows checking that the seatbelts are locked. Adjust the seatbelt tension so that it holds you in place at the level of the hips leaving your abdomen completely free. - Do not start work before having checked these safety conditions. 3.1.14 CHECKS BEFORE STARTING THE VEHICLE - It is prohibited to start or operate the vehicle IF IT IS NOT IN PERFECT WORKING CONDITIONS (e.g. faulty or malfunctioning). - 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 critical manoeuvre. - Check that the steering controls and the brakes function perfectly. In case of malfunctions, notify the maintenance manager and stop the vehicle. - Check that all the guards and safety devices are in the right position and in such a condition that they can be operated. - Check proper functioning of all the safety devices on the vehicle and in the working area. - Should there be any problems, immediately inform your manager and do not start work if the necessary safety conditions are not present. - Do not make any botched repairs just for the sake of starting work. - Do not deactivate the safety equipment. 3.1.15 STARTING THE VEHICLE - Before starting the vehicle, check and adjust the seat position for optimal driving comfort and so that you can easily reach the controls, and always fasten the seatbelts. - Adjust the mirrors so that you can clearly see the area behind the vehicle from the driver’s seat. - Check that the warning lights work properly and check the angle of the headlights and the working lights. - Do not drive the vehicle unless you are properly seated on the driver’s seat. - Never attempt to start the engine by short-circuiting the starter motor. This may cause fire or serious injury. - Keep your head, body and limbs inside the driver’s cabin, to prevent injury from hitting objects outside the cabin. - Do not allow anyone other than yourself to get on the vehicle. - Do not try to start the engine by rolling the vehicle down a slope. - Check that no one is standing within the range of action of the vehicle before starting it and using the equipment. - Never leave the machine with the engine on. 30 DB DB 180 180 00 REV. 02 02/01/2012 15/06/2016 id.: SAFETY PRECAUTIONS 3 3.1.16 PRECAUTIONS WHILE DRIVING - Before moving the vehicle, check that there is no one in the vicinity. - Use the horn and observe the signs, banners and signals. - Always make sure that you can clearly see the entire working or manoeuvring area. If the cabin has windows, they must always be kept clean and intact. - Always lock the cabin door in closed position. Lock the cabin windows in open or closed position. - Always check that the brakes function properly and do not use the vehicle if there are any malfunctions or irregularities. - Never turn the ignition switch key to neutral while the vehicle is moving. - Hold the vehicle at such a speed that 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 visibility. - Avoid driving over obstacles, where possible. If you need to drive over an obstacle, drive at low speed. Never drive over obstacles that will cause the vehicle to lean too far to one side. - Pay attention to ground unevenness, poor visibility, and other vehicles in the vicinity. - If the engine slows down and stops under load or runs at idle speed, inform the maintenance manager and do not use the vehicle until it has been checked. - When driving on public roads, observe the road regulations and before setting off consult with the competent authorities and follow their instructions. This vehicle travels at a speed lower than that of normal motor vehicles, therefore, keep to the edge of the road leaving the centre free for other vehicles to pass. - If working in the dark, carefully check the working area, turn on all the lights available and do not work in areas where visibility is poor. - Do not make quick movements (e.g. continuously steering right and left) which may cause the vehicle to overturn. - Overtake only when absolutely necessary. - When crossing bridges or similar structures, first check that the structure is strong enough to support the weight of the vehicle and its load. 3.1.17 PRECAUTIONS WHILE DRIVING IN REVERSE - Reversing at high speed can cause accidents; do not reverse at top speed and always drive at a safe speed suited to the working conditions. - When reversing always look in the direction the vehicle is moving. Watch out for people in the area and immediately stop if anyone comes into the range of action of the vehicle and into the working area. - If you cannot clearly see the entire working area, ask someone to guide you with hand signals. This person must stand outside the working area and you must be able to see him or her clearly. 31 id.: DB 180 REV. 00 02/01/2012 3 SAFETY PRECAUTIONS 3.1.18 DANGEROUS WORKING CONDITIONS Before starting any operation, check that there are no dangerous working conditions in the surrounding area. - Areas where there are slopes, humps, trees, demolished constructions, escarpments, gorges, tilled soil, ditches, excavations, heavy traffic, crowded parking and service areas and closed places are classified as risk areas. - Check that there are no obstacles such as piping, cables, bottlenecks or loading limitations on the grounds, bridges, pavements or access ramps. - Establish the due safety measures to prevent danger on public roads in collaboration with the owners, users and competent authorities. - In places where there are underground water or gas pipes or high-voltage cable ducts, contact the public utilities to find out their exact position. Ensure that these structures are not damaged. - Take particular precautions when working near ditches, escarpments or close to open excavations. - To carry out operations in water or when crossing sand banks, check the conditions of the bed and the depth and speed of water flow. - Always move slowly on very uneven ground and ridges, in the vicinity of slopes or gorges, and on icy or slippery ground. Remember that the ground is wet and soft after heavy rains. If the ground starts to cave in, the vehicle could tip over, sink in or overturn, causing serious injuries. - If you work with the vehicle in tight spaces or have to pass through narrow doors or structures, manoeuvre very carefully. - Avoid crossing or going over obstacles such as rocks, felled trunks, steps, ditches and tracks. - Always ensure good visibility. Check that there are no people or obstacles in the area around the vehicle. - Check the conditions of the working area to ensure that you can operate and move safely. 3.1.19 WORKING AREA The WORKING AREA is defined as the area in proximity of the vehicle where only persons that know its operating capabilities may work. The driver may operate only and exclusively when there is no one within the range of action. The driver must warn anyone in the vicinity of the vehicle of the danger they are in by voice or sounding the horn. If there is scaffolding or unstable structures near where you are working, keep at a safe distance so that you do not risk touching these structures should you accidentally make an incorrect manoeuvre. 3.1.20 VISIBILITY OF THE WORKING AREA - - Always check that there is no one in the vicinity of the vehicle before starting work. Before getting on the vehicle, walk around it once and check that everything is in order. Dust, smoke, fog, etc. may reduce your vision and cause accidents. Always stop or slow down until the impediment has been removed and you have perfect visibility of the working area. If you cannot clearly see the entire working area, ask someone to guide you with hand signals and delimit an area of over 12 metres for forward movement. This person must stand outside the working area and you must be able to see him or her clearly. If working in the dark, carefully check the working area, turn on all the lights available and do not work in areas where visibility is poor. Always make sure that you can clearly see the entire working or manoeuvring area. If the cabin has windows, they must always be kept clean and intact. 32 DB 180 REV. 00 02/01/2012 id.: SAFETY PRECAUTIONS 3 3.1.21 SITE CONDITIONS - Before starting work, analyse and ask for the topography and geological characteristics of the area, so that the appropriate measures can be taken to prevent landslides and the vehicle from overturning. Holes, obstructions, rubble and other risks connected with the working areas may cause physical injury or death. - Always carefully inspect the site to identify any of these risk elements before using the vehicle. - Be aware of all the conditions on the site and always look in the direction you are driving before starting any manoeuvre. - Find out about the movements of persons and vehicles on the site. Follow the indications given by signals and signs. - Do not start work until you have ascertained all the safety conditions. 3.1.22 PRECAUTIONS DURING OPERATIONS - Before and during operations do not drink alcohol, take medicines or other substances that may alter your capability of working with machine tools. If you are very tired or not feeling well, do not use the vehicle, and in any case pay the utmost attention at the beginning and end of your shift. - Contact the site manager for the safety regulations to be applied according to the laws in force. - Watch out for people in the area and immediately stop if anyone comes into the range of action of the vehicle and into the working area. - During work keep an eye on the instruments and immediately stop the vehicle if any malfunctions are indicated. Pay attention to any unusual noise from the engine, the hydraulic device, the transmission components, the working equipment, etc. If you hear any suspicious noise, immediately stop the vehicle and check what causes it. - If you need to continuously work in very noisy conditions, wear a protective headset in accordance with the regulations in force. - If working in the dark, carefully check the working area, turn on all the lights available and do not work in areas where visibility is poor. - If you cannot clearly see the entire working area, ask someone to guide you with hand signals and delimit an area of over 12 metres for forward movement. This person must stand outside the working area and you must be able to see him or her clearly. While carrying out manoeuvres do not give signals or instructions at the same time as other persons. Signals must be given by one person only. Always pay attention to the instructions given by the persons in charge. - Always operate the hydraulic equipment seated in the driver’s seat, check that no one is within the range of action of the vehicle and signal with the horn when you are about to make a manoeuvre. - To prevent accidents due to collision with other objects, always operate at a safe speed when carrying out manoeuvres, especially if you are in tight spaces and in places where there are other vehicles. - Do not call out or give someone who is working a fright without good reason, and do not throw objects, not even as a joke. - Whenever you take a break, carefully check that all the controls are in NEUTRAL position and that the safety devices are locked. 33 id.: DB 180 REV. 00 02/01/2012 3 SAFETY PRECAUTIONS 3.1.23 WORKING ON SLOPES - Moving or working on steep slopes, hills, river or lake embankments can be dangerous. Always drive up and down slopes at low speed and pay attention. Obstacles or changes in the gradient may cause you to lose control of the vehicle and consequently it might overturn. - Before starting work, check the working area for any signs of holes, landslips, gravel or tilled soil that could affect the working conditions and the stability of the vehicle. - Always move in a straight line when going up or down a slope. - Do not turn around on slopes or move across them. - Never move sharply sideways, or even worse, with the vehicle axis turned 90º with respect to the direction of the slope. WARNING: Do not work on slopes with a gradient over the limit as this may cause the vehicle to overturn. - Do not drive downhill with the gear in neutral or excessively using the brakes. Select and engage the most suitable gear that will allow maintaining the speed necessary to prevent losing control of the vehicle. - If you need to drive down very steep slopes do not overrun the engine; select the most suitable gear before setting off downhill. - NEVER park or leave the vehicle unattended on a slope. - Drive slowly over grass, fallen leaves or wet steel sheet. - 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 yourself and to anyone standing downstream of the vehicle. - The limit gradient must be assessed based on the type of ground, the load, the vehicle conditions and speed and visibility. - Driving on public roads: for gradients of more than 5% use the lowest gear. 3.1.24 DRIVING ON ICY OR SNOW-COVERED SURFACES - If you need to work on icy or snow-covered surfaces, reduce the speed and avoid making sudden movements, as the vehicle is much more sensitive and can easily slip sideways. - When a lot of snow has fallen, pay the utmost attention as it is difficult to see the edges of the road. 3.1.25 ELECTRICAL LINES - Working in proximity of electrical lines can be extremely dangerous and it is therefore essential that you take the necessary precautions to eliminate the potential risks. - Any job where parts of the vehicle are raised to a height that may reach the minimum safety distance laid down in the national safety regulations is considered working in proximity of electrical lines. - Do not work at a distance of less than 5 metres from overhead electrical lines, unless having notified the electricity board and having provided for adequate protection to prevent accidental contact or coming dangerously close to the line conductors. - In order to work without any risk, keep as far away as possible from the electrical line and never violate the minimum safety distance. Even only passing near high-voltage cables may cause electric shock and hence burns or even death. - Be prepared for any possible emergency situation and wear rubber shoes and gloves. Place a rubber mat on the driver’s seat and be careful not to touch any part of the chassis with uncovered parts of your body. Ask someone to warn you if the vehicle comes too close to electrical cables. - During operations near high-voltage cables, do not allow anyone to approach the vehicle. - Should you make contact with an electrical line, absolutely do not leave the vehicle touching the live metal structures but wait until you have received confirmation that the power has been cut. In addition, do not allow anyone to approach the vehicle. 34 DB 180 REV. 00 02/01/2012 id.: SAFETY PRECAUTIONS 3 3.1.26 CLOSED ENVIRONMENTS When you need to work in a tunnel or closed places (factory buildings, car parks etc.) it is advisable to check before starting that there is sufficient air exchange and good ventilation to prevent build-up of toxic exhaust gas or dust. In any event, it is always advisable to convey the engine exhaust gas to the outside using a flexible hose. Open doors and windows to facilitate ventilation and wear an appropriate protective mask. 3.1.27 STOPPING THE VEHICLE Do not leave the vehicle unattended with the engine running for any reason whatsoever. If you want to stop the vehicle for any reason, follow the instructions given in the chapter STOPPING THE VEHICLE and TURNING OFF THE ENGINE. Always turn off the engine whenever you leave the vehicle. Before leaving the vehicle, do the following: - Make sure that there is no one near the vehicle. - Slowly lower the equipment. - Set all the controls to neutral position. - Shift the gear lever to NEUTRAL and engage the control locking lever. Engage the parking brake. - Remove the key from the ignition block. 3.1.28 PARKING THE VEHICLE - - - 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 slope without first having blocked the vehicle with wedges or similar to prevent accidental movement. To park on steep slopes, position the vehicle crosswise to the slope, check that there is no risk of it slipping, engage the parking brake and wedge the wheels. Do not park with the wheels facing downhill. Lock the equipment controls. Always remove the key from the ignition block when you need to leave the vehicle parked to prevent accidental or unauthorised starting. Secure and lock the vehicle when you have finished work and whenever you temporarily leave the vehicle. Hand the keys to the person in charge. Check that all the manoeuvres provided in this manual have been observed. If you expect to work in low temperatures, check that the cooling system is filled with the right percentage of antifreeze. 35 id.: DB 180 DB 260 SL REV. 00 05 02/01/2012 01/10/2009 3 SAFETY PRECAUTIONS 3.1.29 TOWING AND RECOVERY CAUTION: The vehicle is not designed to tow other vehicles. - If towing the vehicle (permitted for short distances only), use the warning signs according to the regulations in force and follow the instructions given in this manual. - Always wear protective gloves when handling the towing devices. - DO NOT use cables or chains for towing. - To tow the vehicle, exclusively use the couplings specified and adequate towing devices. - Hook the vehicle with extreme care and make sure that the devices used are securely fastened before towing. - Never tow a vehicle on a slope. - Do not allow anyone to stand in the vicinity of the vehicle being towed. - Keep eye contact with the operators. - Follow all the instructions given in the relative chapter. 3.1.30 TRANSPORT - To load or unload the vehicle from the means of transport find a level area that offers a solid support for the wheels of the transport vehicle. - Ensure that the means of transport is of adequate capacity to carry the vehicle (see weights and dimensions in the chapter “Technical Data”). The weight, transport height and overall length of the vehicle vary depending on the working equipment, therefore, check the dimensions. Check that the overall dimensions are permitted by the Road Regulations. - Use robust access ramps of adequate height and angle. - Ensure that the ramp surface is clean and free of any traces of grease, oil, ice or other material residues. Remove any dirt from the vehicle’s wheels. In the event of rain, the surface of the ramps may become slippery: be extremely careful. Check that the platform of the means of transport is well cleaned. - Let the engine run at low speed and proceed slowly. The weight must be transferred gradually from the loading ramp to the transport vehicle. - Never steer on the ramps to correct the vehicle’s position. If necessary, drive off the ramps, correct the direction and then drive back up. The vehicle must be positioned in such a way that the loads on the axles are as specified for the transport vehicle and that it is not unbalanced. Securely tie the vehicle to the platform with chains or cables and block the wheels with wedges. - Ensure that the engine is off and that the windows and door (if any) are closed. 36 DB 180 REV. 00 02/01/2012 id.: SAFETY PRECAUTIONS 3 3.2 PRECAUTIONS AGAINST RESIDUAL RISKS 3.2.1 SLIPPING - The driver’s seat, the steps and the handholds must always be kept clean and free of any foreign object or traces of grease, oil, mud or water in order to reduce the risk of slipping. - Pay attention to possible slippery steps and slippery ground around the vehicle. - Always clean your shoes before getting on to prevent slipping or stumbling. 3.2.2 MOVING PARTS - DO NOT come close to the moving parts of the vehicle with your limbs or other parts of your body. This may cause serious injury or death by crushing or amputation. - Keep objects away from the moving fan blades. The fan blades may project or cut objects. - Turn off the engine and wait until all the moving parts have stopped before carrying out maintenance or any other operation on the vehicle. 3.2.3 SHEARING OR TRAPPING - It is advisable to keep at a safe distance from moving parts. - Do not hang your legs or arms out of the vehicle as you might get seriously injured if you knock them against obstacles. - In some parts of the vehicle there are devices that may cause serious injury to your limbs. It is strictly prohibited to insert any parts of your body in these devices when the engine is running. - Wear suitable clothing that cannot get caught up in the moving parts of the vehicle. - Never climb into or insert your hands, arms or other parts of your body in the moving parts between the working equipment and the vehicle or between the cylinder and the working equipment. If someone inadvertently activates the control levers, the play of the working equipment is altered with the risk of serious injury to the body, 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. 3.2.4 CRUSHING The machine is a vehicle to all intents and purposes, therefore, be extremely careful when handling it and watch out for persons, animals or objects around the working area. - Check the efficiency of the controls and in particular the braking devices. Make sure that you can clearly see the entire working area from the driver’s seat, also with the aid of the mirrors, video devices, lighting equipment for night-time work, and keep them efficient and in working order. - Before carrying out any operation with the vehicle, always check that you have sufficient room to work safely. Ask someone on the ground to help you when carrying out operations in tight spaces or with poor visibility. - Adjust the speed to the limits established for the various areas on the site, never exceed 15 km/h and drive at walking speed in the vicinity of workstations. - During manoeuvres, do not allow anyone to access the working area by posting appropriate signs and cordoning off the area. The operator (or the person in charge) must ensure that this rule is observed, even suspending work if necessary. - If the driver needs to be contacted while he is working, approach the cabin from a point visible to the driver and only after he has given his consent. - The conditions of the ground must be such as to allow quickly stopping the vehicle. - It is prohibited to stand underneath the working equipment. 37 id.: DB 180 REV. 00 02/01/2012 3 SAFETY PRECAUTIONS 3.2.5 OVERTURNING - The operator must be fully knowledgeable with the performance, weight and the maximum load the machine can transport in relation to the ground conditions (flat, compact, uneven, sloping). - Before starting to work, always check that the area on which the machine wheels stand is sufficiently solid and capable of supporting its weight and, consequently, keep at a safe distance from the edge of the excavation. - Check that the site paths are adequate and that the working areas are clear and suitable for transit of the machine and its stability. - Analyse and record the topography and geological characteristics of the site in order to take the appropriate preventive measures against the machine overturning, landslides or landslips. - Consider the characteristics of the ground complementary to those of the machine; variables controlled by the operator such as speed, angle of attack on slopes, gradient of the ground, load distribution etc., are essential to minimise the risk of overturning. - Follow the rules given in the chapter on driving on slopes. CAUTION: Observing the recommended gradient limits does not mean that you can manoeuvre the machine in total freedom in all load, ground or manoeuvring conditions on a slope. In any event, it is advisable to halve the gradient values on wet or uneven ground. - In the case of a machine with central articulation, always keep it with the two frames aligned on the same axis to avoid possible overturning. - Avoid reaching the limit conditions and generally act with 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 machine 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 machine. - The machine may also overturn because of uneven ground, the ground caving in (especially when working near the edge of the road or the manoeuvring surface), slipping on wet or muddy surfaces or making incorrect or careless manoeuvres (sudden acceleration or steering, unbalanced load, excessive speed, etc.). - Do not steer sharply at high speed. - The machine centre of gravity may shift in relation to the size and position of the load, the gradient of the ground and the movement of the machine. - The machine is equipped with a ROPS safety cabin. Nevertheless, in the event of the machine overturning, if you do not have the seatbelt fastened, you will be thrown out with the risk of getting crushed by the machine. IN THE EVENT OF OVERTURNING The protective structure makes the driver’s seat the only safe place to be should the machine overturn. DURING OVERTURNING Never leave the machine but remain seated firmly, gripping the seat or the steering wheel. AFTER OVERTURNING Make sure that the machine is stable and that it will not continue turning over, unfasten the seatbelt, quickly leave the machine trying to get off at the top to avoid being crushed by the machine should it continue overturning. 38 DB 00 05 DB180 260 SL REV. REV. 02/01/2012 01/10/2009 id.: SAFETY PRECAUTIONS 3 3.2.6 TYRE BURSTING If the tyres or rims are incorrectly used, there is a risk of the tyres bursting or getting damaged. Tyre maintenance, removal, repair and refitting require special tools and techniques, therefore, always have these operations carried out by an AUTHORISED SERVICE CENTRE OR AUTHORISED PERSONS. - Check that the wheel nuts are properly fastened before starting work. If necessary tighten the nuts. - Always check that the tyre inflation pressure is as specified by the manufacturer and check that the tyres are in good condition. If the tyre pressure is too low, the tyre could overheat and burst. Also if the tyre pressure is too high, there is a risk of the tyres bursting. - Check the tyre pressure when the tyres are still cold. Do not release the pressure when it increases in a hot tyre. - Keep at a safe distance or stand next to the tyre when inflating it. - Keep the working area clear of sharp objects that could damage the tyres. Deflate the tyres before removing any foreign bodies that may have lodged in the tread. - Never use overhauled rims, since improperly carried out welding or heat treatments might weaken them. - Do not cut or weld the rims when the tyres are fitted and inflated. - Never inflate the tyres with a gas different from compressed air. - The tyre pressure values and permitted speed specified in this manual correspond to the values specified by the manufacturer (see the pressures and loads table). For more information, contact FIORI or the tyre manufacturer. 3.2.7 ELECTRICAL RISKS 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; if so, immediately contact your local FIORI dealer. In the event of an electrical fault, do not attempt to start the vehicle by running it downhill. 3.2.8 RISK OF SHORT-CIRCUIT Do not under any circumstances start the engine by short-circuiting the starter motor terminal or the battery. 3.2.9 BATTERY The battery electrolyte contains sulphuric acid and batteries generate flammable hydrogen gas which could explode. Improper use may cause serious injury or fire. - Do not use or charge the battery when the electrolyte level is below the minimum level mark. Check the electrolyte level at regular intervals and add distilled water to bring it up to maximum level. - ALWAYS wear protective goggles and rubber gloves when working with batteries. - Do not smoke or use open flames near the battery. - If the acid comes into contact with your clothes or skin, immediately rinse with abundant water. If the acid comes into contact with your eyes, immediately rinse with abundant water and seek medical advice. - The battery must never be tilted more than 45° in any direction, as this may cause the acid to leak out of the battery. - Do not connect a flat battery in series to a charged battery. Risk of explosion! 39 id.: DB 180 REV. 00 02/01/2012 3 SAFETY PRECAUTIONS 3.2.10 HOT AND PRESSURISED FLUIDS The hydraulic system is pressurised when the engine is running and may remain under pressure even after the engine has been turned off. Hot hydraulic oil causes serious burns. - Wait for the oil to cool down before disconnecting the pipes. Pressurised fluid leaks may be invisible. - DO NOT use your hands to check for leaks. Fluid leakage even from a very small hole may have sufficient force to penetrate the skin. If you need to check for leaks, use a piece of cardboard or wood. Wear gloves to protect your hands from any oil splashes. DO NOT attempt to repair or tighten flexible hoses or hydraulic unions when the hydraulic system of the vehicle is under pressure. - TURN OFF the engine, discharge all the cylinders and release the pressure. - Keep your face and hands away from loosened unions while you are checking the efficiency of the hydraulic system. Wear protective goggles as the jet of pressurised hydraulic oil may penetrate your skin and cause permanent injury to your eyes. - If any fluid or oil leaks are found, immediately stop the vehicle and make the necessary repairs. - Turn off the engine and check that all the hydraulic controls are in neutral position before removing covers, unions, pipes, caps, etc. 3.2.11 RISK OF BURNS - In order to prevent burns caused by boiling water or steam escaping while checking or draining the coolant, wait for the water to cool down to a temperature such that you can touch the radiator cap without burning your hand. Even when the coolant has cooled down, loosen the cap gradually to allow the pressure in the radiator to drop before removing the cap completely. - In order to prevent burns while checking or draining the oil, wait for the oil to cool down to a temperature such that you can touch the drain cap without burning your hand. Even when the oil has cooled down, loosen the drain cap gradually to allow the internal pressure to drop before removing the plug completely. - Do not touch the silencer immediately after turning off the engine, as it is extremely hot and may cause serious injury. 3.2.12 VENTILATION Do not work with the vehicle in closed places unless equipped with a suitable combustion gas suction and exhaust system. Good ventilation is very important for vehicle operation. Carbon monoxide emission from the engine’s exhaust may moreover cause suffocation in closed areas. 3.2.13 INTOXICATION - Engine combustion smoke can be very dangerous and/or lethal for the human body if directly and continuously inhaled. - If you need to work in closed environments, take all possible precautions to ensure circulation of fresh air and protect the airways by wearing a suitable 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. 40 DB 180 REV. 00 02/01/2012 id.: SAFETY PRECAUTIONS 3 3.2.14 FIRE PREVENTION Fire caused by fuel or oil Fuel and oil are highly flammable and dangerous. Always take the following precautions to prevent fires: - Do not refuel with the engine on and in the presence of smoking materials and open flames. Do not use matches, lighters or torches to illuminate the refuelling area. - Do not smoke, use open flames or create sparks in the vicinity of the vehicle while refuelling or changing the oil. - The fuel nozzle must always remain in contact with the filler neck. Hold the fuel nozzle in contact throughout refuelling to prevent sparks from being created due to build-up of static electricity. - Do not leave the vehicle unattended while refuelling or topping up the oil. Clean off any spillage after refuelling or topping up with oil. Do not spill fuel on hot surfaces or on parts of the electric system. - Store oil and fuel in a special room and do not allow access to unauthorised persons. - Before carrying out any grinding or welding on the chassis, move any flammable material to a safe place. - Do not weld or use a cutting torch to cut ducts or pipes that contain flammable liquids. Use a non-flammable 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 FLAMMABLE MATERIAL - Remove dry leaves, stone splinters, pieces of paper, dust or other flammable materials that have accumulated or attached to the engine, the exhaust manifold, the silencer, the battery or in the internal guards. FIRE IN THE ELECTRIC SYSTEM - Short-circuits in the electric system may cause a fire. - Check that there are no loose or damaged parts in the system. Tighten any loose connectors or wiring terminals. If any cables or connections are corroded and/or damaged, immediately contact your local FIORI dealer. - 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. - Do not smoke and avoid sparks or flames in the recharging area to prevent the outbreak of fire. - Recharge the battery only in adequately ventilated places to prevent accidental explosions due to gas buildup. 41 id.: DB 180 REV. 00 02/01/2012 3 SAFETY PRECAUTIONS 3.3 PRECAUTIONS DURING MAINTENANCE OPERATIONS CAUTION: Do not tamper with the setting of the devices for control of the hydraulic and electrical circuits. 3.3.1 CORRECT MAINTENANCE Before using or carrying out any operation on the vehicle always do the following: - Carefully read all the instructions contained in this manual. - Always read the labels and the instructions on the vehicle and in the manual before starting any operation on the vehicle. The instructions contain important information (see the chapter “Safety Labels”). - Repairs and maintenance on the vehicle may only be carried out by authorised persons. Do not allow unauthorised persons to access the area. If necessary, have someone stand guard in the area. - Before carrying out any operation, apply all the special safety devices. - First of all, check that the maintenance operations have meticulously been carried out at the intervals established. - Always wear suitable protective clothing and any other protection required for the operation to be carried out. - Do not leave hammers or other tools lying around in the working area. Remove any traces of grease, oil or other substances that might cause someone to slip. Always keep the workplace clean and tidy so that you can carry out all the operations in complete safety. If the workplace is dirty and untidy, there is a risk of tripping, slipping, falling and being injured. - Check that all the tools provided are in good condition. Do not under any circumstances use tools with upset heads and always wear protective goggles. - Always keep the vehicle clean to prevent the formation of dirt and oil encrustations. This also reduces the risk of fire and makes it easier to identify damaged components and detached parts. - Do not lubricate or repair the vehicle when the engine is running, except where expressly indicated in this manual. - Do not allow anyone to tamper with the danger signs or make them illegible. - Do not use parts of the vehicle, such as handholds or supports, to carry out the operations. - Absolutely do not use matches, lighters, torches or open flames to illuminate dark areas. - Use lights or lamps (vehicle and auxiliary lights) positioning them in such a way that other persons working in the area are not blinded. ROUTINE MAINTENANCE - Always lower the equipment to the ground and release the hydraulic pressure from all the circuits before starting to carry out maintenance on the vehicle. - Connect all the safety devices on the vehicle and remove the ignition key. - Depending on the type of maintenance to be carried out, disconnect the battery master switch and hang a sign on the driver’s seat saying that maintenance is in progress. EXTRAORDINARY MAINTENANCE - Do not keep the engine running in closed spaces without adequate ventilation. - Keep your head, body, limbs and hands away from moving and/or raised equipment. - Do not remove any safety devices, lids, covers or guards if not for maintenance reasons. If they need to be removed, be extremely careful and refit them before using the vehicle. - If during maintenance you need to move the equipment using the hydraulic control, operate as follows: - Before starting the engine, warn everyone in the vicinity to move away from the vehicle. - Operate seated on the driver’s seat and never use the controls if not seated on the driver’s seat. - Engage the parking brake. - Signal when you are about to make a manoeuvre by voice and sounding the horn - Manoeuvre slowly - Always lock the arms or the parts that need to remain raised during the operation using external devices. 42 DB DB180 180 00 REV. 02 02/01/2012 15/06/2016 id.: SAFETY PRECAUTIONS 3 - To lift and transport heavy parts use cranes or hoists of adequate capacity. Sling the material as best you can. Use eyebolts where required. Always check that no one is in the vicinity. - If you need to remove or fit units on the vehicle that need to be supported by hydraulic or pneumatic lifting devices, check that they are of adequate capacity to support and handle the load. Do not allow anyone to pass in the vicinity of the vehicle and absolutely do not allow anyone to stand underneath the raised equipment even when you are certain that it is locked. - Do not work on or under the vehicle if it is only supported by hydraulic or pneumatic lifting devices without locking valves. Do not work under or near a tool, a vehicle or parts of it that have been removed if they are not adequately supported. - If you need to make repairs at the top of the vehicle, use ladders or platforms compliant to the safety regulations in force and always pay the utmost attention. - Loads lifted with jacks is always dangerous. Before operating on parts lifted with jacks, it is obligatory to position adequate supports to ensure that they are securely supported. - If there is a risk of being hit by metal splinters (grinding) always wear safety goggles. After maintenance or repairs never leave tools, cloths or any other material in compartments containing moving parts. BATTERY - Before carrying out any operation on the electric system, always disconnect the battery by removing the key from the battery master switch. - If you need to replace the battery, first disconnect the negative and then the positive cable. To reconnect the battery, first connect the positive and then the negative cable and then reinsert the key in the battery master switch. - To recharge the battery, 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. ENGINE - Do not operate on the vehicle with the engine on. - Do not turn on the engine while the lid is raised. - Do not check or even less adjust the alternator belt tension with the engine on. - Do not adjust the fuel pump with the engine on. - When handling flammable materials, keep at a certain distance from the exhaust manifold, the silencer or hot points of the engine. GREASING AND LUBRICATION - Use only the products recommended by the manufacturer as indicated in the lubricants table. - Lubricate and grease the vehicle at the intervals given in the scheduled maintenance table in this manual in order to keep the vehicle in efficient and safe operating conditions. - Wear clothing suited to the operations to be carried out. - Position the vehicle on level ground, engage the parking brake and turn off the engine. - If the lubrication and greasing points require the equipment to be raised, use the special safety devices provided. IT IS DANGEROUS TO WORK UNDERNEATH THE EQUIPMENT WITHOUT THE SAFETY DEVICES. 43 id.: DB 180 REV. 00 02/01/2012 3 SAFETY PRECAUTIONS TYRES - The tyres are very heavy. Handle them carefully and when stored make sure that they cannot fall out of their storage space and cause injury. - Never attempt to repair a tyre on public roads. - When a tyre needs to be changed, the first thing to do is engage the parking brake, shift the gear lever to neutral, turn off the engine and remove the ignition key. This operation must be carried out on level and solid ground. Position a wedge under the wheel diametrically opposite the one to be replaced. - Always stand the jack on a solid and flat surface. - Check that the jack has sufficient lifting capacity for the vehicle. - Use stands or other suitable supports to support the weight of the vehicle while you repair the tyres. - Never lie under the vehicle, not even partially, or start the engine when the vehicle is lifted with a jack. - Never hit the tyre or rim with a hammer. - Check that the rim is clean and without rust or other damage. Do not weld, braze or repair a rim in any way nor use a damaged rim. - Do not inflate a tyre if the rim is not fitted on the vehicle and well fastened so that it cannot move in the event that the tyre or the rim suddenly break. - When fitting a new or repaired tyre, use a pressure gauge with a flexible hose connected to the valve so that you can stand far away from the tyre during inflation. If possible, also use a safety cage. - When checking the tyre pressure, also inspect the treads and the sides for any damage. Neglected damage may lead to premature tyre breakage. - The inflation pressure also determines the weight a tyre can support. Identify the tyre sizes 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 the permitted value with the bead not perfectly adjusted, there is a risk of the bead or the rim breaking with an explosive force that could cause serious injury. - Do not inflate a tyre that has been used deflated or at very low pressure, but first have it examined by a qualified person. - During inflation stand in a protected area with respect to the side of the tyre. Never inflate using flammable gases or compressed air from systems with alcohol injectors. - After refitting the wheel, tighten the wheel fastening nuts on the axle to the specified torque. Check the torque of the nuts every day until it has stabilised. REFUELLING - Use only the products recommended by the manufacturer as indicated in the lubricants table. - Refuel and top up at the intervals indicated in the scheduled maintenance table in this manual in order to keep the vehicle in efficient and safe operating conditions. - Wear clothing suited to the operations to be carried out. - Any fluid top-ups must be carried out with the engine off and cold. - Before checking or refuelling, make sure that there are no open flames or smoking materials in the area and do not use matches, lighters or torches as light source. - Unscrew the caps very slowly to release the pressure from the system before removing them completely. - Be careful during refuelling and topping up as splashes of fuel and oil may cause slipping and injury. Immediately and thoroughly clean off any soiled areas. 44 DB 180 REV. 00 02/01/2012 id.: SAFETY PRECAUTIONS 3 3.3.2 PRECAUTIONS DURING WELDING OPERATIONS - Welding operations must always be carried out by a qualified welder and in a place equipped with adequate tools. - If you are involved in welding operations, wear dark-glassed goggles or a mask, a hardhat, overalls, and safety gloves and shoes. Never look at the welding arc without wearing all the specific personal protection devices. Eye protection must also be worn by anyone standing in the vicinity even if not directly involved in the welding operations. - Have a fire extinguisher at hand in the area where the welding operations are carried out. - Remove the key from the battery master switch before carrying out any welding operations 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. 3.3.3 FAULTS AND UNAUTHORISED MODIFICATIONS - If faults are found during vehicle operation or maintenance (noise, vibration, unusual smells, fault signalling, oil leaks, etc.) report to the person in charge so that the appropriate action can be taken. Do not start the vehicle until the fault has been repaired. - No modifications may be made to the vehicle without prior authorisation from FIORI, as modifications may create risks. - Before making any modification, consult with FIORI. FIORI is not responsible for any injury or damage caused by unauthorised modifications. 3.3.4 CLEANING THE VEHICLE - Parts soiled with oil or grease, broken tools or parts left lying around are dangerous as they may cause slipping and falling. Always keep the vehicle and the workplace clean and tidy. Thoroughly clean the floor, handrails, instruments, plates, lights and windows of the cabin. - When using compressed air to clean parts, wear protective goggles, limit the pressure to maximum 2 bar and adhere to the safety regulations in force. - Accidental infiltration of water into the electric system may cause functional and operational problems. Do not use pressurised water or steam to clean the electric system (sensors, connectors). - Do not use petrol, solvents or other flammable liquids to clean parts; use approved non-flammable and nontoxic commercial solvents. - If inspection and maintenance are carried out when the vehicle is still soiled with oil or mud, you run the risk of slipping and falling, or that the mud and dirt comes into contact with your eyes. Always keep the vehicle clean. 45 id.: DB 180 REV. 00 02/01/2012 3 SAFETY PRECAUTIONS 3.3.5 WASTE FLUID/MATERIAL DISPOSAL - Incorrect disposal of waste fluids can seriously harm the environment. Before disposing of waste fluids, contact the competent local authorities 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. 46 DB 180 REV. 00 02/01/2012 id.: SAFETY PRECAUTIONS 3 3.4 WARNING AND SAFETY LABELS (RESIDUAL RISKS) The warning and safety labels are found on your vehicle as shown in the figures below and serve as a guide for your own safety and those that work with you. A label is positioned at each part of the vehicle that may be a source of residual risk. Therefore, walk around the vehicle with this manual in hand and familiarise yourself with where the various labels are positioned and read them. Point them out to all the vehicle operators and always keep them legible; if they become illegible, order a set from the FIORI Spare Parts Service Department. Always keep the labels clean. Use detergent and water to clean the labels. Do not use organic solvents or petrol as they may damage the labels. 1 - Clean the labels with soap and water and dry them with a soft cloth. 2 - Replace the damaged or missing labels with original FIORI labels. 3 - If you need to replace a component bearing a safety or warning label, make sure that the new component has the same labels. 4 - When replacing labels make sure that the surface on which they are applied is clean, dry and without oil or grease. WARNING: The manufacturer declines all responsibility for personal injury or property damage if the rules of conduct indicated on the labels are not observed or the labels are not kept in perfect conditions. 3.4.1 LOCATION OF THE WARNING AND SAFETY LABELS CABIN INTERIOR 47 id.: DB DB 180 180 REV. 02 00 REV. 02/01/2012 15/06/2016 3 SAFETY PRECAUTIONS VEHICLE EXTERIOR 48 DB 180 REV. 00 02/01/2012 id.: SAFETY PRECAUTIONS 3 3.4.2 MEANING OF THE WARNING AND SAFETY LABELS DANGER: It is prohibited to approach and lean on the drum when it is rotating as there is a risk of getting crushed or dragged. DANGER: Do not climb onto the vehicle for inspections or to hitch a ride as you may easily slip and fall. DANGER: In the event of the vehicle overturning, do not leave the vehicle but remain seated firmly gripping the steering wheel. 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: With the vehicle in motion do not allow anyone to enter the central working area, as there is the danger of crushing. DANGER: When the vehicle is moving do not stand or allow anyone to stand in the range of action of the vehicle, especially in the arm movement areas. 49 id.: DB 180 REV. 00 02/01/2012 3 SAFETY PRECAUTIONS DANGER: The acoustic signal indicates that the vehicle or parts of it are moving, therefore, stand well away from the vehicle and do not allow anyone to come into its range of action. WARNING: The engine compartment contains moving components (fan, belts) that may cause serious injury. Before opening the lid to carry out maintenance operations in the engine compartment, it is absolutely essential that you turn off the engine. WARNING: This symbol indicates an area that emanates strong heat; to prevent burning yourself, approach it carefully and wait for it to cool down before carrying out any maintenance operation. WARNING: The battery contains an acid solution and must be handled with care wearing protective goggles to prevent possible splashing into your eyes. The vehicle is equipped with a device that allows disconnecting the negative ground cable. WARNING: Many parts of the vehicle are a source of danger (heat, rotating devices, etc.) and can hence cause serious injury. Before leaving the vehicle for inspections, refuelling or maintenance, it is absolutely essential that you turn off the engine, remove the key from the dashboard and consult this manual. 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. WARNING: After completing the operations permitted by the control engage the safety stop. 50 DB 180 REV. 00 02/01/2012 id.: SAFETY PRECAUTIONS 3 WARNING: Do not stand or allow anyone to stand underneath raised equipment if the special safety device has not been installed. MANDATORY RULE: This symbol indicates the location 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 average exposure to noise is over 85 Lpa. Use adequate anti-noise protection in relation to your daily exposure to noise. 51 id.: DB 180 REV. 00 02/01/2012 3 SAFETY PRECAUTIONS 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 MAINTENANCE TABLE The vehicle is equipped with safety devices whose specific functions are described in the legend below: C A D 1 A - REVERSING MICRO-SWITCHES (fig.1) When the driving post is in the loading or transfer position it determines the FORWARD AND REVERSE movement according to the driving position of the operator in that precise moment. When the pivoting driving post is turned in the working direction, high gear cannot be engaged even if the SLOW/FAST switch is set to fast. Moreover, the vehicle can only operate when the driving post is correctly positioned in the driving direction. C - SEAT BELTS (fig.1) Always fasten the seatbelt when operating the vehicle. The seatbelt is essential as it holds you anchored on the seat in the event of the vehicle overturning. Periodically check the integrity, cleanliness and fastening of the structure. D- MECHANICAL ROTATION LOCK FOR PIVOTING DRIVING POST (fig.1) Allows locking the driving post in the two driving positions. 52 DB DB180 180 00 REV. 02 02/01/2012 15/06/2016 id.: SAFETY PRECAUTIONS 3 E H F I G 2 3 E - CONTROL LOCKING LEVER (fig.2) In block position it prevents the motion of the bucket control lever, which ensure protection against any accidental maneuver. F - DEACTIVATION BUTTON FOR ARM DESCENT LOCKING VALVE (fig.2) If this push button is not pressed the arm cannot be lowered despite flipping the lever. G- HAND ACCELERATOR MICROSWITCH (fig.2) If the hand accelerator lever is not in the initial position, it is impossible to move the vehicle. H - BATTERY MASTER SWITCH KEY (fig.3) When the key is removed, the negative cable of the battery is disconnected and hence the power to the electric system. It prevents unintentional starting of the engine during maintenance. It allows welding operations to be performed without having 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. I - JOINT LOCK (fig.3) If it is engaged, the machine steering is not possible. It must be engaded during maintenance operations and during transport with motor vehicles. 53 id.: DB DB180 180 REV. REV. 00 02 02/01/2012 15/06/2016 3 SAFETY PRECAUTIONS N L O M P 4 5 L - OPERATOR’S PROTECTION / CABIN WITH “FOPS - ROPS” STRUCTURE (fig.4) Designed and constructed to safeguard the operator in the event of the vehicle overturning and objects falling from heights. M- SUPPLEMENTARY MIRROR AT BACK LEFT-HAND SIDE OF CAB (fig.4) When the machine is running in working direction (turret turned towards the tank), it allows a good visual when reversing. N - ROTATING BEACON (fig.4) Fixed on the cabin roof, it signals the presence of the vehicle. O - REAR VIEW MIRROR (fig.4) The rearview mirror is essential for visibility of the rear left-hand side of the vehicle. Correctly position the mirror before starting. P - GROUND CONTROL EMERGENCY STOP BUTTON (fig.5) S R Q 7 6 54 DB 180 REV. 02 00 REV. 02/01/2012 15/06/2016 id.: SAFETY PRECAUTIONS 3 Q - REAR SIDE HORN (fig.6) An acoustic signal is emitted when reverse gear is engaged. It also indicates when the drum counterframe rotates. R - DRUM FALL STOP DEVICE (fig.7) When the drum is raised and the valve handle is turned, the cylinders hydraulically lock even when the engine is off, preventing accidental lowering during maintenance operations. S - ARM LOCKING CABLE (fig.7) When the bucket arm is raised, it prevents accidental lowering of the arm during transfer and transport. 3.6 SAFETY DEVICES FOR ROAD USE CAUTION: For road circulation in Italy and other countries, it is mandatory to adopt various safety devices and ensure their correct application. Always ensure that the vehicle complies with the local regulations concerning the equipment of these vehicles when travelling on public roads. Check that the signalling and light devices function properly. A 2 B 1 2 8 A - DRIVER’S SEAT (fig.8) Turned forward (concrete mixer behind) in preferential driving direction and locked with the latch (2). B - EQUIPMENT CONTROL LEVER (fig.8) The shovel and arm control lever (1) must mechanically be locked through the suitable forked pin (2). 55 id.: DB DB 180 180 REV. 02 00 REV. 02/01/2012 15/06/2016 3 SAFETY PRECAUTIONS D C E 1 2 1 2 G F 9 C - FLASHING LIGHT (fig.9) It is mandatory to have an approved flashing light device and it must always be in perfect working order. D - LOADING ARM (fig.9) The arm (1) must be locked in a vertical position with the special steel wire (2). E - CONCRETE UNLOADING CHUTE (fig.9) The unloading chute (1) must be turned crosswise and locked with the special screw pin (2). F - NUMBER PLATE (fig.9) Check that the number plate is clean before driving on the road. G - DOORS (OPTIONAL) (fig.9) Keep the doors closed while travelling. 56 DB 180 180 DB REV. REV. 02 00 15/06/2016 02/01/2012 id.: OPERATION AND USE 4 4.0. INTRODUCTION This chapter is intended to help you learn how to manoeuvre with the vehicle. Read it carefully from start to finish. When you have finished reading this chapter, you should have good knowledge of the vehicle and its functioning. Pay particular attention to the safety labels. They are positioned to help you recognise the possible residual risks. Don’t just read them, but think about what they really mean. Be aware of the risks and how to prevent them. Once you have learned where the controls are and what they do, practice using them. Practice by using 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 roughly on the controls, but use them carefully until you fully understand the effect they have on the vehicle. Finally, do not rush to learn to manoeuvre the vehicle. Take your time and do things calmly and safely. CAUTION: Before starting to use 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. 57 id.: DB 180 REV. 00 02/01/2012 4 OPERATION AND USE F H E O A L G P M N I D B C 1 4.1. REFERENCES AND DESCRIPTIONS OF THE MAIN DEVICES (fig. 1) The references and descriptions of the main devices of the vehicle are given here so that you can quickly get to know and understand them when mentioned further on in this manual. Therefore, it is important that you very carefully read the legend below. A B C D E F G H I L M N O P - Pivoting driving post Fuel tank Front axle Rear axle / two-speed gearbox Mixing drum Loading bucket Unloading hopper Unloading chute Water tank Engine assembly / hydraulic pumps Hydraulic oil tank Water system ROPS/ FOPS protection Mix control 58 DB 180 REV. REV.02 00 15/06/2016 02/01/2012 id.: OPERATION AND USE 4 4.1.1. INSTRUCTION LABELS 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 has the same labels. 4 - When replacing labels make sure that the surface on which they are applied is clean, dry and without oil or grease. WARNING: The manufacturer declines all responsibility for personal injury or property damage if the rules of conduct indicated on the labels are not observed or the labels are not kept in perfect conditions. Indicates the diesel fuel tank; for refuelling, see the instructions in this manual. Indicates the hydraulic oil tank; to top up the oil, see the instructions in this manual. Indicates the brake fluid tank; to top up the oil, see the instructions in this manual. exclusively use mineral oil. For lifting, tying and towing the vehicle, use only the special couplings marked with this symbol. Indicates the engine coolant tank. To fill the tank, see the instructions in this manual. It stands for the exact position of the intake filter above the inlet joint, when the suction pipe is placed on the rotating framework to prevent it from breaking during the rotation of the same framework. 59 id.: DB 180 REV. 00 02/01/2012 4 OPERATION AND USE Indicates the selection for the drum rotation direction. With the pivoting post turned towards the drum: if the drum turns anticlockwise, the concrete is unloaded; if it turns clockwise the concrete is mixed. Indicates an area with live electrical contacts. Act extremely carefully and do not to use too powerful jets of water, which might compromise functioning of the electric system. Indicates the position of the hand accelerator that allows you to adjust the engine rpm when the vehicle is stationary. The vehicle can only be moved when the lever is in the initial position (0). Indicates the movements of the arm - bucket and drum raising. Indicates the functions to be performed to load the water directly into the drum. Indicates the functions to be performed to fill the water tanks. Indicates functioning of the litre counter and the water pump. 60 DB180 180 DB REV.02 00 REV. 02/01/2012 15/06/2016 id.: OPERATION AND USE 4 4.2. CONTROLS AND GAUGES Your safety and that of others in the vicinity depends on your good judgement and care in using the vehicle. Therefore, you should know exactly where all the controls are positioned and what their function is. Every vehicle has its limits: before using it, familiarise yourself with its speed, braking, steering, stability and load capabilities. This chapter provides all the useful information you need to quickly get to know and safely use the vehicle 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 SEAT A H F B E C D J 2 4.2.1.a - A - Steering wheel (fig. 2). Turn the steering wheel in the desired driving direction. Using the knob you can steer with just one hand during loading operations. 4.2.1.b - B - Height- and depth-djustable driver’s seat with seatbelt (fig. 2). Always fasten the seatbelt when you are driving the vehicle. 61 id.: DB DB180 180 REV. 00 02 02/01/2012 15/06/2016 4 OPERATION AND USE 4.2.1.c - C - Service and emergency brake pedal (fig. 2). Push the service brake pedal to slow down or stop the vehicle; use the brakes to avoid picking up speed when you are going downhill. CAUTION: If driving down steep slopes never use only the brake pedal, but also engage the lowest gear and depress the brake pedal intermittently so as not to overheat the brakes. The stop lights must come on when the brakes are engaged. Only use the vehicle if both stop lights are functioning properly. 4.2.1.d - D - Accelerator pedal (fig. 2). The pedal controls the revolutions number of the engine; by releasing the pedal the transmission is electrically disconnected and the machine slows down until it stops. 4.2.1.e - E - Pivoting driving post locking lever (fig. 2). The lever allows the operator to lock the driving post in the transfer A and loading B positions. CAUTION: The driving post must be turned in the direction as shown in Fig. A for road transfers and in Fig. B for the drum loading phases. Turn the driving post with 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 4.2.1.f - F - Parking brake lever (fig. 2). Allows the operator to lock the vehicle during breaks, keeping the engine on. Pull the lever hard upwards to lock. Press the button and release the lever to unlock. 4.2.1.h - H - (Mechanical) gearshift control lever (fig. 2). The gear lever allows you to select two basic speeds: Position I - Low or working speed Position O - NEUTRAL Position II - High or road transfer speed CAUTION: Select the speed when the vehicle is stationary and stable. Before driving uphill or downhill on steep slopes, always select the lowest gear with the vehicle stationary and stable. 62 DB 180 REV. REV. 02 00 15/06/2016 02/01/2012 id.: OPERATION AND USE 4 4.2.1.j - J - Fuses and Relays (fig. 2). The fuses and relays are positioned inside the driving post. Using the key provided, open the door to access the fuses and the relays. I I L M 3 4.2.1.i - I - Windscreen wiper (fig. 3). Turn the windscreen wiper on with the snap-action switch. 4.2.1.l - L - Cabin light (fig. 3). Act on the lever to turn on the cabin light. 4.2.1.m - M - Windscreen washer fluid tank (fig. 3). The water tank is installed behind the operating control panel. 63 id.: DB DB 180 180 REV. REV. 00 REV.02 01 15/06/2016 02/01/2012 01/04/2013 4 OPERATION AND USE 4.2.2 DRIVING POST INSTRUMENT PANEL 6 5 7 8 4 9 3 2 10 1 11 17 16 15 12 14 13 4 4.2.2.a Electronic control panel (fig. 4) 1 - Yellow warning light: indicates when the next service is due. 2 - Yellow warning light: indicates that the fuel tank is in reserve. 3 - Red warning light: function not available. 4 - Red warning light: function not available. 5 - Red 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: function not available. 11 - Red warning light: indicates that the hydraulic oil filter is clogged. 64 DB 180 REV. REV.02 00 15/06/2016 02/01/2012 id.: OPERATION AND USE 4 12 - Red warning light: indicates that the hydraulic oil level is low. 13 - Red warning light: indicates the preheating phase of the engine spark plugs. 14 - Green warning light: indicates that the position lights or low beams are on. 15 - Green warning light: indicates that the direction indicators are on. 16 - Illuminated tortoise: indicates that low gear is engaged. 17 - Display: displays the hours of operation, fuel level, engine rpm and litre counter. Note: if the FIORI BATCH CONTROLLER is installed on the machine, all functions of the litre counter located on the electronic dashboard are not active, as the functions are displayed on the operating panel. 17 E 1 18 5 4.2.2.b Water liter counter (fig. 5) The three digits at the top of the display (17) indicate the total litres of water in the tank. The litre counter can be reset by pressing and holding down the reset button E for at least 3 seconds with the ignition key turned to the first click (on position) or with the engine on. 4.2.2.c Hour 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 immediately followed by the actual total hours of vehicle operation, again shown for 5 seconds, after which the engine rpm are shown. The operating hour counter (18) cannot be reset. The hours of operation are totalled correctly only if the engine is running at a speed of more than 200 rpm. Counting does not depend on the number of engine revolutions, but only on the time that has actually elapsed. 65 id.: DB 180 REV. REV. 02 00 15/06/2016 02/01/2012 4 OPERATION AND USE 4.2.2.d Maintenance schedule (fig. 5) In case the warning light (1) stays on, it means that it is almost time to do maintenance to the machine (the warning light indicates this event about 20 hours before the deadline set by FIORI). The preset service interval is every 500 hours. Therefore, the warning light will flash after 500, 1000, 1500, 2000, ... hours. Once the vehicle has been serviced, the flashing warning light can be reset and the counter reset to start the countdown to the next service. To reset flashing, hold the reset button (E) on the driving post instrument panel pressed down for 20 seconds. After 20 seconds the word “RESET” will appear on the display and the warning light (1) will come on. To reset the counter, release the button and press it again for another 2 seconds. After 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. D B G F E C A 6 4.2.2.e - A - Forward/reverse gear selector (fig. 6). Push the selector forward to engage forward gear. Always return the selector to neutral position when the vehicle is stationary and parked. Push the selector backward to engage reverse gear. 4.2.2.f - B - Slow movement switch (fig. 6). Flick the switch forward to use the normal driving functions. This function is enabled only with the selector (A) forward to engage forward gear. Flick the switch backward (tortoise) to maintain a constant low speed, useful to carry out dangerous manoeuvres, precision manoeuvres in tight spaces and to drive downhill using the engine brake. 66 DB 180 REV. REV. 02 00 15/06/2016 02/01/2012 id.: OPERATION AND USE 4 4.2.2.g - C - Drum rotation switch (fig. 6). This selector is used to control drum rotation. Turn the driving post towards the drum (secondary driving direction) and follow the instructions below: Clockwise drum rotation during concrete loading and mixing. 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 selector. 4.2.2.h - D - Reset button (fig. 6). This button is used to reset the litre counter and the hours to the next service due. This button is used to reset the litre counter simultaneously on the instrument panel and on the MIX CONTROL keeping the two displays in phase. (for litre counter programming see chapter 4.2.6). CAUTION: The water pump and the litres of water pumped into the drum can also be controlled from the rear of the vehicle by means of the MIX CONTROL (see chapter 4.2.6). Note: if the FIORI BATCH CONTROLLER is installed on the machine, all functions of the litre counter located on the electronic dashboard are not active, as the functions are displayed on the operating panel. 4.2.1.i - E - Water pumps control 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). 4.2.1.k - F - Hazard light toggle switch (fig. 6). Snap switch to turn on the four hazard warning lights. 4.2.1.l - G - Working light switch (OPTIONAL) (fig. 6). Snap switch to turn on the rear working lights. 67 id.: DB 180 REV.02 00 REV. 02/01/2012 15/06/2016 4 OPERATION AND USE 5 0 6 1 1 2 3 18 13 7 4.2.2.m Engine starter and stopping switch (fig.7) It is activated with the ignition key and can be set to four different positions. The key can only be removed if the switch is in the off position. 0 Off position/engine stop Engine stopping position. 1 On position In this position the switch connects the battery to all the electrical circuits, except the lights and hazard-light circuits. (The hazard warning light circuit is permanently powered). The instrument runs a short test by turning on all the segments of the display. The instrument panel warning lights will signal the vehicle status by means of the generator warning light (6) and the engine oil warning light (5). Subsequently, at the bottom of the numerical display (18) will be displayed, simultaneously and for 5 seconds, the hours remaining until the next service is due and the maintenance warning light (1), immediately followed by 5 seconds in which the actual total hours of vehicle operation will be displayed. At the end, the engine rpm will be displayed. When the ignition key is released from the positions 2 and 3 it automatically returns to this position. 2 Pre-heating position When starting the engine in cold climates, hold the key in pre-heating position until the spark plug preheating warning light (13) goes off. 3 Starting position Activates the starter motor that turns the engine. As soon as the engine starts, the dashboard lights up and the engine rpm is displayed. 68 DB 180 REV. REV.02 00 15/06/2016 02/01/2012 id.: OPERATION AND USE 4 3 1 2 8 4.2.2.n Rotary switch with horn push button direction indicators toggle switch (fig.8). The rotary switch and direction indicators’ toggle switch allow activating the following functions: - Direction indicators Shift the direction indicators’ toggle switch (1) forward to indicate a left turn. Shift the direction indicators’ toggle switch (1) backward to indicate a right turn - Horn Press on the rotary switch (2) to activate the horn - Light switch The lights come on only if the ignition key is inserted - Position lights: turn the rotary switch (3) forward by one click - Low beams: turn the rotary switch (3) forward by 2 clicks. 69 id.: DB180 180 DB 02 REV. 00 15/06/2016 02/01/2012 4 OPERATION AND USE 4.2.3 OPERATING CONTROL PANEL A C D 1 N B F 3 G 4 2 E 9 4.2.3 a - A - Control lever of bucket and drum lifting (fig. 9). The control lever controls the movements of bucket arm and drum lifting; please observe the following instructions: DRUM: Position “1” - Lifting. Position “2” - Lowering. BUCKET: Position “3” - Lifting. Position “4” - Lowering. Position “N” - Neutral position to apply block lever (safety). 4.2.3 b - B - Safety push-button (fig. 9). It enables the bucket lowering function with joystick A in position 4. 4.2.3 c - C - Safety lever for joystick locking (fig. 9). It permits the mechanical lock of joystick C whenever necessary due to safety reasons. CAUTION: Always engage the lever when the equipment is not used continuously. 4.2.3 d - D - Power socket (fig. 9). It draws current from the 12V battery by means of a bayonet coupling. 4.2.1.e - E - Hand accelerator lever (fig. 9). Allows the operator to adjust the engine RPM when the vehicle is stationary; use only during concrete mixing and unloading and to operate the water transfer pump. Before activating it, check that the electrical gear selector lever is in neutral position. CAUTION: Always shift the lever back to “0”, otherwise the vehicle will not move forward since the forward/reverse selector is disabled. 70 DB 180 REV. REV. 02 00 15/06/2016 02/01/2012 id.: OPERATION AND USE 4 4.2.3.f - F - Rotating light switch (fig. 9). Snap switch to turn on the rotating beacon on the cabin roof. 4.2.3.g - G - Windscreen water switch (fig. 9). Allows you to pump the windscreen washer fluid. 71 id.: DB 180 180 DB REV. REV. 02 00 15/06/2016 02/01/2012 4 OPERATION AND USE 4.2.4 GROUND CONTROL PANEL (MIX CONTROL) (fig. 11). A E D C B 11 Some operations controlled from the cabin can also be carried out from the rear right-hand side (driving direction) of the vehicle, more precisely: Emergency engine stop, drum rotation, water pump activation, check of litres of water pumped into the drum and, on request, chute raising. A - Emergency engine stop from the ground (safety) - Press the button in the event of danger. - Turn the button to the right and release it to turn the engine back on after eliminating the risk. B - Drum rotation switch - Up for clockwise rotation (mixing). - Down for anticlockwise rotation (unloading). 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 decreases the value set each time it is pressed. When the set amount of water has been pumped in, the water pump automatically turns off. For programming, see chapter 4.2.5. E - Liquid crystal display - Displays the litres pumped into the drum CAUTION: Before approaching the MIX CONTROL warn the operator in the cabin of your presence. Collaboration and eye contact between the various operators around the vehicle is essential for your own and others’ safety. 72 DB 180 REV. 00 02/01/2012 id.: OPERATION AND USE 4 4.2.5 OPERATION OF THE ELECTRONIC LITRE COUNTER AND MIX CONTROL PROGRAMMING - The litre counter indicates the litres of water pumped into the mixing drum. - The reset key D is used to reset the progressive litre counter. Programming You can program the number of litres to be pumped into the drum (only with MIX CONTROL) so that the pump automatically stops when the preset value is reached. CAUTION: When the preset value is reached, it is no longer possible to start the pump directly unless the litre counter is reset. If the value set is 0 (zero), the pump can only be operated manually and must be stopped by the operator. CAUTION: If the water runs out, the litre counter does not work and hence, because the pump does not stop, the rubber impeller can easily burn. Setting 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: E D 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 downwards to obtain a decrease in steps of ten (0, 9990, 9980, 9970, etc.) D- Release the lever when the display indicates the desired value. The number will turn to 0 (zero) within 5 seconds and setting is complete. 73 id.: DB 180 REV. 00 02/01/2012 4 OPERATION AND USE 4.2.6 WATER SUPPLY AND DISTRIBUTION CONTROLS Water supply and distribution for mixing and washing operations are governed by the following elements: A 1 2 13 A- Diverting suction valve (fig.13) Position “1” - Water suction from machine tank. Position “2” - Water suction from outer water sources (tanks, ditches, etc.). B 3 4 14 B- Delivery diverting valve (fig.14) Position “3” - Water delivery to drum from an outer source or from machine tank. Position “4” - Water delivery to tank from an outer source. C- Liter-counter (fig.15) It totals the water quantity introduced into the drum (see par. 4.2.2.b) C 15 74 DB 180 REV. 00 02/01/2012 id.: OPERATION AND USE D- Washing nozzle diverting valve (fig.16) It permits divert water flow towards washing nozzle E. Position “1” - Water delivery to drum. Position “2” - Water delivery to nozzle. 4 2 D 1 E 16 4.2.7 CHUTE CYLINDER MANUAL HYDRAULIC CONTROL (OPTIONAL) (fig.17). D A C B E 17 To perform the hydraulic lifting of the chute A, manually use pump B located on the rear left-hand mudguard. To lift the chute, use lever C of the pump (oil delivery to cylinder E) until the desired position is reached. To lower the chute, turn the knob D anti-clockwise (oil unloading from cylinder E) and lower the chute manually. Finally, turn the knob D clockwise to close the oil circuit. 75 id.: DB DB180 180 REV. 00 02 02/01/2012 15/06/2016 4 OPERATION AND USE 4.3 INSTRUCTIONS FOR USE 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 during road transfer so that you develop a good feeling for the controls and the equipment movement times. This chapter is intended as a valid guide for those that already know the vehicle well and can hence easily and quickly understand the instructions given. Checks before starting work - Check that the vehicle has been equipped with all the required equipment. - Check that all the maintenance operations set out in Chapter 5 of this manual have been carried out. - If repairs were made, check tightness of all the screws and nuts and the adjustments. CAUTION: Before starting to use 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. 1 18 4.3.1 REFUELLING (fig. 18) - Refuel the vehicle with purified diesel fuel without water residues. - Use a pump equipped with filter with a delivery nozzle that goes down into the filler neck after removing the cap (1). It is advisable to refuel at the end of the working day thus avoiding condensation during the night. CAUTION: Do not run out of fuel so emptying the tank (keep an eye on the fuel reserve warning light). Should this occur, you will need to bleed the air from the engine fuel supply system. DANGER: Before checking or filling the fuel tank, make sure that there are no open flames or smoking materials in the area. Do not refuel with the engine on. Do not use matches, lighters or torches as light source. 76 DB 180 REV. 00 02/01/2012 id.: OPERATION AND USE 4 2 1 4 5 3 19 4.3.2 LEVELS CHECK (fig. 19) Before starting the vehicle check the following: - Engine oil level (1) - Engine coolant level (2) - Hydraulic oil level (3) - Brake fluid level (4) - Clean the contacts of the reverse gear microswitches (5). The procedures are described in chapter 5 on maintenance. 4.3.3 FILLING THE WATER TRANSFER PUMP BODY It must contain water to allow the pump to function. Before starting work, pour at least 50 litres of water into the tank. As the pump is positioned below the tank, it is automatically filled when the water is poured into the tank. 3 2 1 20 4.3.4 ADJUSTING THE SEAT (fig. 20) CAUTION: Before starting the vehicle, adjust and lock the seat in the most suitable and comfortable position, so that you can easily reach all the controls, and fasten the seatbelt. Use the lever (1) to adjust the seat distance from the pedals and the lever (2) to adjust the springing hardness (according to your weight). Use the knob (3) to adjust the seat height. . 77 id.: DB 180 180 DB REV. 02 00 15/06/2016 02/01/2012 4 OPERATION AND USE 1 21 4.3.5 ADJUSTING THE REAR-VIEW MIRROR (fig. 21) 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. B A 1 2 2 22 4.3.6 DRIVING POST PIVOTING (fig. 22) CAUTION: Turn the driving post with the vehicle stationary and stable. This operation may be carried out while you are seated 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. 78 DB 180 180 DB REV. REV. 02 00 15/06/2016 02/01/2012 id.: OPERATION AND USE 4 4 2 1 3 23 4.3.7 STARTING THE ENGINE (fig. 23) DANGER: Before starting the engine, check that there is no one in the vicinity of the vehicle. Do not operate the vehicle in closed places without ventilation. - Check that the parking brake (1) is applied. - Check that the electrical forward/reverse gear selector (2) is in neutral position (otherwise the vehicle will not start). - Check that the emergency button at the rear of the vehicle is deactivated and that the hand accelerator (3) is in rest position. - Start the engine by turning the ignition key (4). - When the engine has started, release the 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 warm up and lubricate all the parts; this is essential in cold climates. CAUTION: STARTING AT LOW TEMPERATURES Turn the ignition key clockwise by one click, wait until the display is in operating mode and turn the ignition key to pos. 2 and wait until the spark plug pre-heating warning light goes off, then turn it to position 3 to turn on the engine. Do not hold the accelerator pedal depressed during the preheating phase. 79 id.: DB 180 180 DB REV. REV. 02 00 15/06/2016 02/01/2012 4 OPERATION AND USE 4.3.8 ENGINE OPERATION AT LOW RPM It is unadvisable to leave the engine running at idle speed for too long. Therefore, if you can foresee that the engine will be running at idle speed for a long period of time, always turn it off. Nonetheless, if you need to keep the engine running, make sure that the engine speed is sufficient to supply the necessary engine oil pressure, indicated by the relative warning light on the instrument panel turning off. 4.3.9 TESTING THE PARKING BRAKE (fig. 23) DANGER: Before testing the efficiency of the parking brake, check that there is no one near the vehicle. Test the brake on a flat and dry surface. - Make sure that the parking brake (1) is fully engaged. - Set the electrical gear selector (2) to forward gear, gradually depress the accelerator pedal and test the efficiency of the brake. - Do not overdo things during the test so as not to achieve the opposite effect. - Do not use a vehicle whose parking brake is not efficient (see chapter 5.9.4 to repair the parking brake efficiency). CAUTION: Do not use the parking brake to slow down the vehicle, except in emergencies, as this would reduce the efficiency of the brake. 80 DB 180 REV. 00 02/01/2012 id.: OPERATION AND USE 4 4.3.10 STARTING AND DRIVING THE VEHICLE (fig. 24) A B D C 24 CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out as set out in Chapter 3. - Lock the driving post in the road transfer position using the dedicated lever and check that it is firmly secured. Start the engine following the procedure described above. Keep the engine running for the period of time necessary to warm up the hydraulic system oil. Disengage the parking brake. Depress the service brake pedal (B) and shift the gear lever (C) to position “1” for driving on steep slopes or to position “2” for flat stretches. CAUTION: Mechanical gears must only be selected with the vehicle stationary and stable. - Set the gear selector (A) to the desired driving direction. This selection can also be performed while the vehicle is moving. - Check that you can safely move forward, then start depressing the accelerator pedal (D) to move the vehicle. Steer maintaining an adequate speed and act gradually on the steering wheel, DANGER: especially when you are on a slope. 81 id.: DB DB 180 180 REV. 02 00 REV. 02/01/2012 15/06/2016 4 OPERATION AND USE 4.3.11 STOPPING THE VEHICLE CAUTION: Whenever you interrupt work for any reason, always set the joystick safety switch to locked position. Before leaving the vehicle, set all the controls to neutral position. - Release the accelerator pedal. Gradually depress the brake pedal till the machine stops. Shift the gear selector to neutral position. Engage the parking brake. Lower the drum and bucket. CAUTION: Never perform reversing manoeuvres to stop the machine. 4.3.12 STOPPING THE ENGINE CAUTION: Never leave the vehicle with the engine on. - With the engine at idle speed, turn the key to “0” and remove it even if only temporarily leaving the vehicle. 4.3.13 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: Never stop or park on a slope without first blocking the vehicle to prevent it from moving. CAUTION: Always face the vehicle when getting on or off and check that your shoes and hands are clean and dry to prevent slipping and falling. Where possible, stop the vehicle on level and dry ground. Remove the ignition key before leaving the vehicle. - Deactivate all the unnecessary switches. Check that all the switches are deactivated before leaving the vehicle. If necessary, leave the hazard lights on. - Leaving and locking the vehicle Use the handles and steps to get off the vehicle. If you leave the vehicle, close and lock all the windows and the door (if present). Check that the fuel tank cap and the engine compartment lid are locked. 82 DB 180 REV. 00 02/01/2012 id.: OPERATION AND USE 4 4.4 TRANSPORTING THE VEHICLE (fig. 25) 4840 2600 3280 + 900 900 10-15% 25 CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out as set out in Chapter 3. CAUTION: Use transport vehicles of adequate capacity driven by qualified personnel. Before loading the vehicle onto the means of transport, check that it carries no other load. CAUTION: To secure the vehicle on the means of transport, use the special fastening points indicated with labels. CAUTION: Do not use the canopy ledges to anchor the vehicle during transport. Note: Before transporting the vehicle, ensure compliance with the regulations and laws of the areas you will be travelling through. Before loading the vehicle onto the means of transport, check that it does not interfere with the ramp angle of the trailer. See the section Specifications for the minimum height of the vehicle from the ground. Make sure that the transport vehicle is adequate. See the section “Specifications” for the vehicle weight and dimensions. - Have someone on the ground guide you in carrying out the manoeuvres. - 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 parking brake. When the bucket is raised or the rotating beacon is mounted on the cabin, the height exceeds 4 metres and transport is not permitted. - Secure the vehicle as described above. - Firmly anchor the vehicle on the platform and lock the wheels with wedges. - Check that the lid or other moving parts are properly closed. - Measure the maximum height of the vehicle from the ground. Inform the driver of the transport vehicle of the overall height before he sets off. 83 id.: DB 180 REV. 00 02/01/2012 4 OPERATION AND USE 4.4.1 LIFTING THE VEHICLE WITH A CRANE (fig. 26) 1500 2060 1 10° DRY WEIGHT 3700 KG 10° 260 881 1060 2000 26 CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out as set out in Chapter 3. CAUTION: Before lifting the vehicle, check that it does not carry any load and that the crane used is of adequate capacity to support the weight of the vehicle; see the section “Specifications” for the weights and dimensions. CAUTION: For lifting with a crane it is advisable to use adequate rocker arms in order not to damage parts of the vehicle when the chains tauten. Use only the lifting points marked on the vehicle. - 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. DANGER: 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. 84 DB 180 REV. 00 02/01/2012 id.: OPERATION AND USE 4 4.5 TOWING AND RECOVERY (fig. 27) 1 2 3 4 27 CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out as set out in Chapter 3. CAUTION: Remember that towing can further damage the vehicle. Tow the vehicle only as far as the breakdown truck. Drive very slowly and for short stretches (1,8 km/h) to prevent the hydraulic oil in the closed circuit from overheating. - Lower the drum and lift the arm locking it with the tie rod. - Stop the engine. - Open the engine compartment lid and release the hydraulic pump by undoing the screw (1). - Set the switch (2) to the neutral position. - Release the parking brake (3). - Attach a tow bar of adequate size to hook (4). - Switch on emergency lights and revolving lamp. - An operator must be on board the vehicle, sitting properly in the driver’s seat with the seat belt on and the driving post facing the preferential direction of trave, for driving and stopping it. If you need to steer make sure that you understand the actions of the driver of the towing vehicle. Follow his instructions and comply with all the relative regulations. Bear in mind that steering is harder when the engine is off. - Use a towing vehicle with a towing capacity of more than 8,400 Kg with full load and 3,700 kg when unladen. - After towing, screw back in the screw (1) of the hydraulic pump. 85 id.: DB DB180 180 REV. 00 02 02/01/2012 15/06/2016 4 OPERATION AND USE 4.6 DRIVING ON PUBLIC ROADS (fig. 28) 1 4 2 3 28 CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out as set out in Chapter 3. - Direct the driving post in the preferential driving direction. Lower the drum fully. Raise the bucket as far as it will go and tie it with the safety cable (1) so that the arm is locked. Direct the chute (2) into retracted position and lock it with the lever (3). Check that all the warning lights function properly. Turn on the rotating beacon (4) provided. 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: Make sure that the joystick for bucket control is in NEUTRAL position and locked by the safety lever in order to avoid any accidental maneuver. CAUTION: If you need to change a tyre, make sure that the type and tread are those specified by the MANUFACTURER. Not all tyres are homologated for road circulation with the required loads and speeds. CAUTION: The vehicle may circulate on the road with a full load and empty according to the carrying capacity indicated on the homologation plate. CAUTION: At regular intervals, check proper functioning of the lights and immediately replace any blown bulbs. 86 DB 180 REV. 00 02/01/2012 id.: 4 OPERATION AND USE 4.7 HOMOLOGATION FOR ROAD USE (ITALY) 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 circulating on the road. The danger signal, consisting in the simultaneous illumination of the direction indicators, must be activated when the vehicle is stationary on the road and in any situation where it is a hindrance to traffic. Anyone who circulates on the road with a vehicle that does not comply with or violates applicable legislation will be punished with a fine. The MANUFACTURER must provide the declaration of conformity for road circulation. The related documentation must be submitted by the Purchaser to the local Directorate-General for Road Traffic and Privately Operated Transport Vehicles, for obtaining the registration certificate (logbook) and number plate. CAUTION: The declaration of conformity alone is absolutely not sufficient for road circulation. It is mandatory to register the vehicle. The declaration of conformity must be submitted the Driver within 12 months from the date of issue; failure to do so may cause the Directorate-General for Road Traffic and Privately Operated Transport Vehicles to reject issuance of the registration certificate (logbook) and number plate. 4.8 PRECAUTIONS FOR USE IN COLD CLIMATE CONDITIONS 1 2 29 At the end of each work shift, empty the water tanks to prevent them from swelling and bursting. Unscrew the cap (1) as shown in the figure, positioned underneath the tank to let the water drain out. Empty the water transfer pump by undoing the screw (2) to let the water drain out. If you are forced to work in temperatures close to 0°C, check that the radiator is filled with an antifreeze mixture to prevent the water from freezing. - Check the quality of the antifreeze coolant at least once a year, for example, at the beginning of the cold season. The coolant must be changed every two years. - The antifreeze mixture must be made up of equal quantities of antifreeze and water. The corrosion inhibitor contained in the antifreeze must be diluted if using a solution with less than 50% antifreeze. Concentrations of more than 50% antifreeze may have a negative effect on coolant performance. - Use an antifreeze of the type and brand as indicated in the RECOMMENDED LUBRICANTS AND FLUIDS table and calculate the percentage water/antifreeze in relation to the ambient temperature using the table provided by the manufacturer. - After refilling/topping-up, run the engine for a few minutes to allow the water and antifreeze to mix well. CAUTION: To use the vehicle at low temperatures, you also need to change the lubricants and use types with an appropriate viscosity (see the RECOMMENDED LUBRICANTS AND FLUIDS TABLE). 87 id.: DB DB180 180 REV. 00 02 02/01/2012 15/06/2016 4 OPERATION AND USE 4.9 PRECAUTIONS IN THE EVENT OF LONG PERIODS OF INACTIVITY CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out as set out in Chapter 3. 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 time must be parked with the loader lowered; the rods can also be protected with external guards 1. If the vehicle is not to be used for a long period of time, follow the instructions below. - Clean the vehicle and lubricate it through the grease nipples. - Remove the battery, store it in a warm place and recharge it at least once a month. - Protect the jack rods with grease to prevent encrustations and corrosion. - Empty the water tanks and the transfer pump as described in the paragraph above. - Position the vehicle in a sheltered place and/or cover it with a waterproof sheet. CAUTION: For more information, contact an AUTHORISED FIORI WORKSHOP. 1 30 4.10 WORKING PHASES CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out as set out in Chapter 3. It is essential that the operator becomes familiar with all the controls and, for a first period of time, practices in a relatively isolated area where he will freely perform all the manoeuvres and operations, which will soon become routine operations by regularly using the vehicle. This chapter analyses all the working phases that should be carried out in sequence, in order to obtain optimal vehicle performance and comply with all the safety regulations. 1 2 3 4 5 6 7 8 - Before getting on the vehicle (checks and warnings). Correct use of the vehicle on slopes First filling with mixing water Cement loading Aggregate loading Mixing and second filling with mixing water Concrete unloading Bucket, drum and chute washing CAUTION: During road transfer, the driving post must face forward. CAUTION: Always fasten the seatbelts. 88 DB 180 REV. 00 02/01/2012 id.: OPERATION AND USE 4 4.10.1 CORRECT USE OF THE VEHICLE During road transfers keep the driving post facing the front of the vehicle. When driving on public roads, follow the specific safety regulations as set out in chapter 3. During work on a site, preferably drive the vehicle as you would during road transfer. If you need to drive with the driving post turned to working position (for example, unloading operations for foundations, or impossibility to make a manoeuvre, etc.) ask someone on the ground to guide you with hand signals and delimit an area of over 12 meters for forward movement. 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. Before using the vehicle, you must perform some safety checks. Some of these checks are aimed at verifying proper vehicle operation, others involve your own safety. Have any and all defects or malfunctions repaired by a mechanical engineer. Before performing all checks, make sure that the parking brake is applied. Cleanliness - Check that the light glass covers and the rearview mirrors are clean. NOTE: Check that the rearview mirrors are positioned so that you have the best possible visibility of the area behind the vehicle. - Remove grime and dirt from the cylinders, pins and the radiator. - Make sure that the steps and handhold are clean and dry. - Clean all the adhesive safety labels. Replace any illegible or missing labels. Damage - Check that there are no damaged or missing parts. - Check that all the articulation pins are properly in place and lubricated. - Check the windows for any cracks or damage. - Check that there are no oil, fuel or coolant leaks underneath the vehicle. Check all the devices as indicated in the scheduled maintenance table in chapter 5 and make any necessary repairs. 4.10.3 CORRECT USE ON SLOPES 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 working area for snow, small landslips, gravel and tilled soil which may suddenly change the working conditions and vehicle stability. Maximum surmountable gradient when loaded (ramps, obstacles, jerking).................................... 24,7° (46%) Maximum permissible gradient on steep roads during transfer: front ................................................................................................................................................. 21,8° (40%) Side ................................................................................................................................................. 10,2° (18%) 89 id.: DB 180 REV. 00 02/01/2012 4 OPERATION AND USE CAUTION: Observing the recommended gradient limits does not mean that you can manoeuvre the vehicle in total freedom in all load, ground or manoeuvring conditions on a slope. In any event, it is advisable to halve the gradient values on wet or uneven ground. 40% 18% 31 DANGER: Driving on slopes with a gradient above the prescribed one may cause the vehicle to lose stability and consequently overturn. RIGHT WRONG 32 - Do not change direction on slopes or move sideways, up or down the slope; if this is not possible, make several diagonal manoeuvres holding the vehicle axis as parallel as possible to the direction of the slope. - Never make sharp 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. 90 DB 180 REV. 00 02/01/2012 id.: OPERATION AND USE 4 4.10.4 CONCRETE COMPOSITION AND BATCHING TABLE The volumes and/or weights of the individual components vary in relation to the breaking load and the product characteristics, also considering practical experience. The table below gives approximate values. - Recommended operating cycle to produce workable concrete (A): 1) Pump in about 80-90% of the total quantity 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 AGGREGATE MIXTURE CEMENT kg GRAVEL m3 SAND m3 WATER lt STANDARD FOR FOUNDATIONS 150 200 0,80 0,80 0,40 0,40 100 120 (A) FOR OPERATIONS WITH FORMWORKS 200 250 300 0,80 0,80 0,80 0,40 0,40 0,40 120 140 150 (A) REINFORCED CONCRETE, IRON EXCLUDED 300 350 0,80 0,80 0,40 0,40 150 160 91 id.: DB 180 REV. 00 02/01/2012 4 OPERATION AND USE 4.10.5 FIRST FILLING WITH MIXING WATER 4.10.5.a Filling the tanks with mixing water (fig. 33) C A C B E D 33 CAUTION: Always refill the tank with water before starting to work, in order to prevent the pump from stopping due to lack of water (see section 4.3.3). - Fill with water through the water inlet pipe To fill the tank, use an external water source introducing water through the hole A. - Filling with water using the transfer pump CAUTION: Check that the pre-filter is fitted inside the filler neck C of the pump, and always use the filter B during suction from water sources, since the pump may take in small parts that could damage the pump propeller. - Remove the closing cap E checking that the pre-filter is fitted, insert the flexible suction hose D into the suction pipe filler neck C of the pump. - Position the flexible suction hose D in the relative water source (reservoir, external tank, ditch etc.). - Check that the suction filter B is completely immersed (the maximum difference in height from the filler neck C must be 4-5 m). - Start the engine. - Activate the transfer pump (engine rpm ideally about 2000). - Wait until the tank is full (when water starts flowing from the water inlet pipe and from the tank). - Stop the transfer pump and close the cover A. 92 DB 180 REV. REV. 02 00 15/06/2016 02/01/2012 id.: OPERATION AND USE 4 4.10.5.b First filling with mixing water (fig. 33) The mixing water is managed by two different systems: - External water source (tanks, reservoirs, ditches, etc.). - Vehicle tank The first system allows you to both fill the vehicle tank and directly fill the drum with mixing water. The second system only allows you to fill the drum with mixing water. E 1 2 G 4 F 3 34 REV. REV. 02 00 15/06/2016 02/01/2012 - Water loading from outer sources (fig.34) - Put the hose into the involved water source. - Move the diverting valve E to position “2”. - Move the diverting valve F to position “4”. - Make sure that the diverting valve G is positioned as described in the picture. - Water Loading from maschine tank (fig.34) - When the tank is full move the diverting valve E to position “1”. - Move the diverting valve F to position “3”. - Make sure that the diverting valve G is positioned as described in the picture. 93 id.: DB 180 180 DB 4 OPERATION AND USE 4.10.5.c Activating the water transfer pump (fig. 35) - Check that all the control levers are in neutral position. - Start the engine. - Rotate the drum. - Increase the rotation speed until reaching maximum speed. - Accelerate the engine by acting on the hand accelerator for 2/3 of its total travel (1800-2000 rpm). - Activate the transfer pump with the switch A of the operating control panel or using the Mix Control by means of switch B. - Check the quantity of water pumped in on the litre counter, which in this first phase should be 80-90% of the total quantity. - Refer to the CONCRETE COMPOSITION AND BATCHING table, chapter 4.10.4, to calculate the optimal quantity of water. A B 35 4.10.6. CEMENT LOADING DANGER: It is strictly prohibited to climb onto the vehicle, whether it is in the mixing phase or stationary. 36 4.10.6.a Cement in bags (fig. 36) CAUTION: Wear a protective mask. - Keep the drum rotating. - Raise the bucket about 0.5 metres and hold it in fully tilted position with the hatch closed. 94 DB 180 REV. REV. 02 00 15/06/2016 02/01/2012 id.: OPERATION AND USE 4 3280 - 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. - Wait until the cement has poured into the drum through the hopper, helping it along by vigorously shaking the bucket with the arm. 37 4.10.6.b Cement in silos (fig. 37) - Keep the drum rotating at top speed. Raise the bucket arm to its maximum height (3060 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 4.10.4. - Open the unloading hatch and fill the drum using the silo dosage system. 95 id.: DB 180 REV. 00 02/01/2012 4 OPERATION AND USE 4.10.7. AGGREGATE LOADING 38 4.10.7.a Heap Aggregate (fig. 38) - Keep the drum rotating at top speed. - Lower the arm after checking that the hatch has closed. - On the mechanical gearbox, select the 1st working speed (low). - Dig into the heap with the bucket and at the same time raise the arm, that way filling the bucket with a larger amount of material and reducing the arm raising time. - Raise the arm to its maximum height while moving backward. - Stop the vehicle. - Open the unloading hatch and wait until the cement has poured into the drum through the hopper helping it along by vigorously shaking the bucket with the 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. 96 DB 180 REV. 00 02/01/2012 id.: OPERATION AND USE 4 4.10.8 MIXING AND SECOND FILLING WITH WATER (fig. 39) 39 - Keep the drum rotating for about 2 minutes after the last aggregate loading phase. - Add the remaining amount of water, about 30% of the total, following the procedures described in chapter 4.10.5 to obtain the desired fluidity. 4.10.9. CONCRETE UNLOADING 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 carrying out the manoeuvres and keep eye contact at all times. CAUTION: Avoid sudden inversion of drum rotation when the drum is full or partially full and raised on uneven, bumpy or soft ground. CAUTION: When working on side slopes do not rotate the rotary frame with the unloading chute facing downhill. Avoid steep slopes when you need to traverse with the rotary frame. Keep the arms at the maximum height. CAUTION: Carefully rotate the drum to prevent unbalancing the wheels. 97 id.: DB 180 REV. 00 02/01/2012 4 OPERATION AND USE 4.10.9.a Concrete unloading from chute (fig. 40) OPTIONAL C E B D F - - A 40 Keep the drum rotating in the mixing direction (clockwise). Approach the unloading area. Stop the machine. Loosen the lever A that locks the chute B, set the height by adjusting the limits of mount F. Move the chute B directing it to the correct unloading position. (With hydraulic chute raising - OPTIONAL ch.4.2.7) Act on lever E of the hydraulic pump placed on the rear LH mudguard to adjust the chute height. This control acts on the chute tilting cylinder C. Arrange any extensions D and lock the chute B using the lever provided A. Bring the engine RPM up to a medium speed. Invert the drum rotation direction for unloading by 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. Raise the drum but not necessarily to its maximum height. Visually inspect that concrete unloading is correctly performed. To move on 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 rotation). Approach and position in the new unloading area and follow all the instructions given above. 98 DB 180 REV. REV. 02 00 15/06/2016 02/01/2012 id.: OPERATION AND USE 4 4.10.9.b Concrete unloading from drum emergency door (fig. 41) A C B 41 DANGER: During hatch opening, do not insert your arms or other parts of your body. Always check that the drum is blocked with wedges and that the engine is off. Should the rotation system fail, the drum will not rotate either clockwise or anticlockwise, and it needs to be emptied to prevent the concrete from solidifying. - For better fluidity of the concrete to be unloaded, add water using the transfer pump as described above. - If possible, raise the drum and lock it with the latch B positioning it on the lifting cylinder rod. - Rotate the drum. Depending on the fault, have an AUTHORISED WORKSHOP make the repair. - Move the inspection hatch A to the side, block the drum with wedges C to prevent it from accidentally turning and remove the hatch retaining screws. - Remove the hatch A. - Turn the drum further until the unloading opening is at the bottom from where the concrete will pour. - When unloading is complete, thoroughly wash the internal drum propellers through the main inlet. 99 id.: DB 180 REV. 00 02/01/2012 4 OPERATION AND USE 4.10.10. BUCKET, DRUM AND CHUTE WASHING (fig. 42) A 2 B 42 CAUTION: The washing operations can be carried out both with the nozzle provided (pressure of 4.5 bar) and with an optional nozzle operating at a pressure of around 150 bar. - Set the drum to rotate clockwise like for mixing. - Fill the drum with water and gravel following the procedures as described above (chapter 4.10.5) in a quantity sufficient to dilute and detach the concrete residues. - Move the switching valve A to position 2 to use the washing nozzle B provided. - Externally wash the bucket, drum and chute as well as all the parts normally soiled with concrete. - Raise the drum. - Change the drum rotation from clockwise to anticlockwise. - Drain out all the water in the drum and wash the chute and the extensions. - Remove the extensions. - Lower the bucket and wash it inside and out. CAUTION: during the machine general washing, pay attention to the front part of the engine compartment lid next to the grilles. As the pipe inlet connected to the air filter is placed inside the lid, right above the radiator, be careful not to let water in the pipe. 100 DB DB 180 180 REV. 02 00 REV. 02/01/2012 15/06/2016 id.: OPERATION AND USE 4 4.9.11. INTERNAL CLEANING OF THE MIXING DRUM (fig. 43) 43 DANGER: Do not climb 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. Therefore, in addition to washing the vehicle when you have finished work as described in chapter 4.9.10, it is advisable to wash the inside of the drum. Proceed as follows: - Lower the loader to the ground. - Fully raise the drum counterframe in order to bring the unloading hatch close to the ground. - Wash the inside of the drum as thoroughly as possible using the washing nozzle. - When done, turn the drum anticlockwise and drain out the water. 4.10.12. EXTRAORDINARY DRUM CLEANING OR BLADE REPLACEMENT DANGER: Do not climb into the drum while it is still mounted on the vehicle. Extensive use of the vehicle and not thoroughly washing the drum after mixing will wear out the blades or cause them to clog up with solidified concrete. Having to work inside the drum to solve these problems, it is obligatory to go to an equipped workshop and dismantle the drum from the vehicle so that these operations can be carried out on the ground in safe conditions. 101 id.: DB 180 REV. 00 02/01/2012 MAINTENANCE 5 5.1 FOREWORD This manual provides all the information necessary for routine maintenance on the FIORI vehicles. This chapter addresses the persons that will physically be carrying out routine maintenance and provides the rules to follow to achieve the end result, namely, repair when necessary and help ensure functionality of the FIORI vehicle over time. The service intervals given in this chapter refer to normal operating conditions. The service intervals may vary in the running-in period or in specific conditions. The main purpose of this chapter is to indicate all the operations to be carried out at the same service interval thus facilitating the procedures and reducing the vehicle stop time. CAUTION: All the operations described in detail in this chapter are considered routine maintenance. Given 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 WARNINGS FOR MAINTENANCE. Before and after the lubrication operations, clean the covers, grease nipples and caps to prevent dirt infiltrations. Lubrication is of primary importance in preventive maintenance, and the useful life of the vehicle depends on it. Therefore, it is absolutely essential that you follow the instructions given in this manual for the lubricants to use and the service intervals. CAUTION: Do not pollute the environment. In accordance with national and international laws, lubricants, fluids, coolants and impregnated filtering elements are classified as polluting and toxic waste. They must be stored and disposed of at special facilities. 103 id.: DB 180 REV. 00 02/01/2012 5 MAINTENANCE 5.1.1 VISUAL EXTERNAL INSPECTION (fig. 1) C D A G B E H F 1 Every day, before starting work or at the end of the day, it is advisable to quickly check the vehicle and take any necessary action, thus considerably reducing 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 - Axles and gearbox G - Jacks and pins H - Chassis articulated joint 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 radiator grille is not clogged. 104 DB 180 REV. REV. 02 00 15/06/2016 02/01/2012 id.: MAINTENANCE 5 5.1.3 CHECKING FOR DAMAGES - Check that all the pins are properly in place and well secured with the respective stops. - Check the light and signalling devices. - Check the tyres for sharp or cutting objects. - Check that all the adhesive safety labels are in place and undamaged. Replace them if necessary. Seatbelt CAUTION: Replace the seatbelt if worn or damaged following an accident. - Check that the seatbelt is not frayed or stretched. - Check that the buckles are intact and working. - Check that the fastening screws are properly fitted and tightened. ROPS & FOPS structures DANGER: Modified or improperly repaired ROPS/FOPS structures are dangerous. Do not repair them following an accident and do not use the vehicle until the structure has been checked and repaired by qualified personnel. The vehicle may not be used without the ROPS structure. - Check the structure for mechanical damage. - Check that the retaining screws are all in place, well fitted and properly tightened. 5.1.4 ACCESS TO THE MAIN DEVICES 5.1.4.1 PARTS CONTAINED IN THE TOOL KIT 5 7 2 1 3 4 6 1 - no.1 double fork wrench 10 - 13 2 - no.1 double fork wrench 17 - 19 3 - no.1 double fork wrench 24 - 27 4 - no.1 oil filter wrench 5 - no.1 M18 T-wrench 6 - no.1 flat-blade/cross-slotted screwdriver 7 - no.1 manual grease pump 105 id.: DB DB 180 180 REV. 02 00 REV. 02/01/2012 15/06/2016 5 MAINTENANCE 5.1.4.2 ROUTINE MAINTENANCE AND CHECKS (fig. 2) A B 2 CAUTION: Never open the various access doors if the vehicle is not parked on a flat surface with the engine off and the parking brake applied. - Driving post To access the use and maintenance manual and the fuses and relays, open the driving post door (A) with the key provided. - Engine compartment lid Unlock the lid (B) with the key provided and raise it to access the following parts: - Engine oil cap, level gauge and filter - Engine accelerator cables. - Starter motor and alternator - Hydraulic oil tank cap - Radiator - Engine air filter - Hydraulic oil filter. 106 DB 180 REV.02 00 REV. 02/01/2012 15/06/2016 id.: MAINTENANCE 5 5.2 MAINTENANCE SCHEDULE - Every 8 hours or daily - Every 500 hours or 12 months - Every 1000 hours or 24 months - Every 2000 hours or 48 months For engine maintenance, a copy of the maintenance schedule as indicated in the engine manufacturer’s instruction manual is annexed (Chapter 5.5). CAUTION: For all the operations on the engine, refer to the engine manufacturer’s instruction manual provided separately from this manual. 5.3 RUNNING-IN AND SERVICE The running-in period for this vehicle is at least 100 hours. Therefore it is recommended to observe the instructions mentioned below to avoid any possible trouble: - Let the engine run for a few minutes at medium RPM 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 operations (SERVICES) which subsequently will be required at longer intervals. Servicing includes a series of operations to be carried out on the vehicle: - Engine oil change - Hydraulic oil filter replacement - Air, oil and diesel filter replacement CAUTION: The instructions for engine maintenance and running-in are given by way of example. Follow the instructions given in the engine manufacturer’s instruction manual. 107 id.: DB 180 REV. 00 02/01/2012 5 MAINTENANCE 5.4 SCHEDULED MAINTENANCE TABLE Description of the symbols used in the table: = Check and repair = Replace = Clean = Grease or lubricate REGULAR MAINTENANCE INTERVALS EVERY 8 HOURS OR DAILY WORKING AREA COMPLETE VEHICLE SEAT BELT CONDITION AND FASTENING STEERING OPERATION GENERAL INSPECTIONS ACCELERATOR CABLES - PARKING BRAKE GREASE NIPPLES (SEE THE SPECIFIC TABLE) ACCELERATOR CABLES HYDRAULIC CYLINDER ROD CONDITIONS DRAINING THE FUEL TANK WASHER STUB AXLE PINS PROTECTIVE STRUCTURE AIR FILTER GASKETS AXLES AND WHEELS CLEANING THE AIR FILTER SEPARATOR TYRE / WHEEL TIGHTENING TORQUES AXLE AND DIFFERENTIAL BLEEDERS AXLE - GEARBOX OR DIFFERENTIAL OIL BRAKES BRAKING SYSTEM TANK CAP BLEEDER PARKING BRAKE TEST BRAKING SYSTEM FLUID HYDRAULIC SYSTEM NEGATIVE PARKING BRAKE OPERATION OF THE HYRAULIC SERVICE DEVICES HYDRAULIC SYSTEM OIL HOSE RUBBING AND DAMAGE HYDRAULIC OIL TANK CAP BLEEDER HYDRAULIC OIL FILTER 108 DB 180 REV. 00 02/01/2012 id.: EVERY 250 HOURS OR 6 MONTHS EVERY 1000 HOURS OR 24 MONTHS EVERY 2000 HOURS OR 48 MONTHS MAINTENANCE 5 REGULAR MAINTENANCE INTERVALS EVERY 8 HOURS OR DAILY REDUCTION GEARS WORKING AREA EVERY 250 HOURS OR 6 MONTHS EVERY 1000 HOURS OR 24 MONTHS EVERY 2000 HOURS OR 48 MONTHS DRUM REDUCTION GEAR OIL LIGHT INDICATORS AND ACOUSTIC ALARMS WATER SYSTEM ELECTRIC COMPONENTS ELECTRIC EQUIPMENT OPERATION INSTRUMENT PANEL BATTERY ELECTROLYTE LEVEL BATTERY PINS HAND ACCELERATOR MICROSWITCH PIVOTING POST MICRO SWITCHES LITER COUNTER WATER TRANSFER PUMP PRE-FILTER WATER TRANSFER PUMP 109 id.: DB 180 REV. 00 02/01/2012 5 MAINTENANCE 5.5 ENGINE MAINTENANCE SCHEDULE CAUTION: This table copy is purely indicative. For all maintenance operations, refer to the table in the engine manufacturer’s instruction manual provided separately from this manual. When necessary Battery .............................................................................................................. Battery or battery cable .................................................................................... Engine .............................................................................................................. Engine air filter (double) ................................................................................... Engine air filter (single) ..................................................................................... Fuel System...................................................................................................... Heavy duty........................................................................................................ Replace Disconnect Clean Clean - Replace Inspect - Replace Prime Check Daily Coolant level ..................................................................................................... Check Driven equipment ............................................................................................. Check Air filter ............................................................................................................clogging indicator Inspect Engine air prefilter .........................................................................................Check - Clean Engine oil level ................................................................................................. Check Primary fuel system filter/water separator ........................................................ Drain V-Belts ............................................................................................................. Inspect – Adjust - Replace Visual inspection 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 fuel system filter ............................................................................. Replace Hoses and clamps ............................................................................................ Inspect – Replace Radiator ............................................................................................................Clean Every 1000 hours of operation Engine valve clearance .................................................................................... Inspect - Adjust 110 DB 180 REV. 00 02/01/2012 id.: MAINTENANCE 5 Every 2000 hours of operation Aftercooler radiator core ................................................................................... Check Alternator .......................................................................................................... Inspect Engine 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 111 id.: DB 180 REV. 00 02/01/2012 5 MAINTENANCE 5.6 RECOMMENDED LUBRICANTS AND FLUIDS TABLE DEVICE TO BE REFILLED Q.TY RECOMMENDED LUBRICANT AMBIENT TEMPERATURE IN ° C VISCOSITY INTERNATIONAL CLASSIFICATION ETHYLENE GLYCOL B.S. 6580.92 10 l ENI ANTIFREEZE EXTRA 50% ETHYLENE GLYCOL 50% WATER -35° ÷ +50° ENGINE 7.07 kg ENI SIGMA TRUCK PLUS SAE 15W 40 110 mm2/s (40°) 15W 40 -10° ÷ +50° ACEA E7 - E5 - E3 - B3 API GL4 / API CE/SF (CCMC D4 - G4) MIL - L 2104 D AXLES FRONT 8.05 kg ENI MULTI-THT/SL80W 72 CTS 80W -25° ÷ +50° API GL 4 AXLES REAR 10.25 kg ISO-L-CKD DIN 51517 TEIL 3 CLP ANSI / AGMA 9005 - 94 CAS 101316 - 72 - 7 CAS 64741 - 95 - 3 COOLING SYSTEM 2 kg DRUM REDUCTION GEAR HYDRAULIC SYSTEM VARIOUS GREASING PRODUCTS FUEL TANK ENI BLASIA 150 141 mm2/s (40°C) -21° ÷ +200° ENI ARNICA 22 22 -27° ÷ +25° ARNICA 46 46 -10° ÷ +35° ARNICA 68 68 -3° ÷ +45° 0.5 l ENI LHM SUPER 20 CTS -40° ÷ +50° PSA-B-712710 ISO 7308 0.5 kg ENI GR LP1 -40° ÷ +50° GREASE NLGI 1 67 l BRAKING SYSTEM ASTM D 3306 ASTM D 4985 ASTM D 1384 CUNA NC 956-16 DIN51524 PARTE 3HVLP CETOP RP 91H HV ISO L-HV DENISON HF0-HF2 DIESEL ASTM N2 46 l D TYPE TT, HIGH QUALITY AND BRAND The oil quantities indicated are those needed for periodic oil changes, following the draining and filling procedures described in detail for each unit. 112 DB DB180 180 REV. 00 02 02/01/2012 15/06/2016 id.: MAINTENANCE 5 5.7 GENERAL INSPECTIONS 5.7.1 GREASE (fig. 3) A 8 1 5 7 6 9 7 2 3 4 4 3 3 CAUTION: For the greasing operations, park the vehicle on flat ground and lower the arm. Remove the ignition key and apply the parking brake. CAUTION: Daily grease the drum rollers to keep them free of concrete residues. Do not use graphite grease on the bearings. The vehicle must be greased regularly in order to keep it in efficient operating conditions. Grease using the pump A provided, and stop greasing as soon as fresh grease starts flowing out from the openings. POS. WORKING AREA 1 PIVOTING DRIVING POST 2 STEERING CYLINDER 3 TRANSMISSION SHAFT Q. EVERY 40 HOURS OF EVERY 160 HOURS OF EVERY 8 HOURS OPERATION OR WEEKLY OPERATION OR MONTHLY OR DAILY 1 X 2+2 X 3 X 4 OSCILLATING CHASSIS 5 LIFTING ARM 2+2 2 X 6 DRUM LIFTING CYLINDERS 2+2 7 ARM LIFTING CYLINDERS 2+2 X 8 MIXER ROLLERS 1+1 X 9 UNLOADING CHUTE 1 X X X 113 id.: DB 180 REV. 00 02/01/2012 5 MAINTENANCE 5.7.2 CLEANING AND DRAINING THE FUEL TANK (fig. 4) CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out as set out in Chapter 3. DANGER: Extinguish all smoking materials and open flames as there may be flammable vapours. With the engine off, position an adequatelysized container under the fuel tank. Unscrew the cap A and let the fuel flow out until it is clean and free of impurities that have remained at the bottom of the tank. A 4 5.7.3 ACCELERATOR AND PARKING BRAKE CABLE LUBRICATION (fig. 5) A B 5 Lubricate the cables of accelerator pedal A and parking brake B using the special greasing syringe. 114 DB DB 180 180 REV. REV.02 00 15/06/2016 02/01/2012 id.: MAINTENANCE 5 5.8 AXLE AND WHEELS 5.8.1 CLEANING THE AXLE AND DIFFERENTIAL BLEEDERS (fig. 6) CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out as set out in Chapter 3. DANGER: Never use petrol, solvents or flammable liquids in general for cleaning. Use only approved non-flammable and non-toxic commercial solvents. - Remove any dirt from the filler caps and bleeders (1), located on both axles and differentials. 5.8.2 CHECKING AND TOPPING UP THE OIL LEVEL IN THE FRONT AND REAR AXLES (fig. 6) 1 3 2 A 3 1 B 3 2 3 6 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. - Park the vehicle on level ground, turn off the engine, apply the parking brake, lower the arm and remove the ignition key. - Unscrew the filler cap (1) and the level gauge caps (2) - (3) (in horizontal position). - If oil trickles from the level gauge caps (2) - (3) , it is not necessary to top up; if not, top up using a funnel adding oil through the filler cap (1) and the level gauge cap (3) until reaching the optimal level. - Screw all the caps back on after topping up. 115 id.: DB 180 REV. 00 02/01/2012 5 MAINTENANCE 5.8.3 REPLACING THE OIL IN THE FRONT AND REAR AXLES (fig. 7) 4 4 3 3 1 1 2 7 CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out as set out in Chapter 3. - Park the vehicle on level ground, turn off the engine, apply the parking brake, lower the arm and remove the ignition key. - Position two pans under the front and rear axles. - Unscrew the draining caps (1) and (2). Position the cap (2) at the bottom by turning the planetary reduction gear. - Unscrew the level gauge cap (3). - Drain out all the oil. - Unscrew the filler cap (4). - Turn the planetary reduction gear so that the cap (2) is at the top and then use a funnel to add about 1.2 kg of gear oil. - Turn back the planetary reduction gear so that the plug (2) is in the position as shown in the figure. - Using a funnel, add the required type of oil through the filler cap (4) until oil trickles from the hole in the level gauges (2) and (3). 116 DB 180 REV. 00 02/01/2012 id.: MAINTENANCE 5 5.8.4 CHECKING AND ADJUSTING THE TYRE PRESURE (fig. 8) CAUTION: Tyre maintenance and inflation are potentially dangerous operations. If possible, it is advisable to have tyre maintenance and fitting carried out by a SPECIALISED CENTRE or SKILLED PERSONNEL. CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out as set out in Chapter 3. TYRES 12,0/75-18 12PR PRESSURE WHEEL NUT TIGHTENING TORQUE With washers: 270 Nm 4,0 bar Without washers: 330 Nm 8 Upon delivery of the vehicle, check the tyre inflation pressure and subsequently check it weekly. Make sure that the tyres are inflated to the pressure specified by the manufacturer. Check the tyre pressure when they are cold. The inflation 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 properly fitted. Only use air pumps fitted with a pressure regulator to be set to no more than 1 bar above the specified tyre inflation pressure. Make sure that the flexible air hose is properly connected to the tyre valve. CAUTION: Check and tighten the rim bolts before each work shift, alternately going from one bolt to the one diametrically opposite in the order shown in the figure. 117 id.: DB 180 REV. 00 02/01/2012 5 MAINTENANCE 5.8.5 REPLACING THE WHEELS CAUTION: Tyre maintenance and inflation are potentially dangerous operations. If possible, it is advisable to have tyre maintenance and fitting carried out by a SPECIALISED CENTRE or SKILLED PERSONNEL. CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out as set out in Chapter 3. 8 9 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. 10 DANGER: It is prohibited to change a tyre on a slope or near canals or ditches to prevent the vehicle from overturning and causing serious injury. This operation must be performed on a solid, flat surface. 118 DB 180 REV. 00 02/01/2012 id.: MAINTENANCE 5 C C E B A 11 CAUTION: Lift the machine ONLY when the mixer drum is empty and in the idle position. Make sure that 3 wheels are always resting on solid and level ground. DANGER: The front axle oscillates and during lifting there may be an area where there is a risk of limbs being crushed between the axle and the chassis. An incorrect lifting method may also cause the vehicle to tip, seriously endangering anyone working nearby. CAUTION: Pay attention to the support area underneath the jack. This area must be able to support the entire weight of the machine. Block the central joint with the relevant blocking device A. Insert the lifting jack B under the central body C of the front axle. To change the rear wheels, you can put the jack B under the screwed plate E of the axle shaft or insert an adapter (fork) in the jack if it is a round section axle shaft. Slowly lift until the arch rests on the chassis, then continue lifting slowly until the deflated wheel is clear of the ground it is resting on. Then proceed with repairing it. 119 id.: DB 180 REV. 00 02/01/2012 5 MAINTENANCE D 12 During tyre change or repair, always fit adequate stands or supports D capable of supporting the weight of the vehicle under the axles. After fitting the wheel, tighten the nuts in the order shown in the figure illustrating wheel nut tightening. 13 If you want to invert a wheel, operate as shown in the figure; you cannot interchange the tyres crosswise, because of the type of tread. Fit the wheels with the tyre tread facing in the direction shown in the figure. CAUTION: If present, always fit the flexible washer together with the nut. 120 DB 180 REV. 00 02/01/2012 id.: MAINTENANCE 5 5.9 BRAKES 5.9.1 CHECKING AND TOPPING UP THE BRAKE FLUID LEVEL (fig. 14) A 14 CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out as set out in Chapter 3. CAUTION: It is essential to use only the fluid indicated in the RECOMMENDED LUBRICANTS AND FLUIDS TABLE; using unsuitable fluids will damage the braking system. Regularly check good functioning of all the braking components. CAUTION: In the event of malfunctioning, immediately contact the nearest AUTHORISED FIORI WORKSHOP. The brake fluid tank is installed to the side of the revolving driving post. Always check the brake fluid level before you start using the vehicle. 5.9.2 CLEANING THE BRAKE FLUID TANK BLEEDERS (fig. 14) DANGER: Never use petrol, solvents or flammable liquids in general for cleaning. Use only non-flammable and non-toxic commercial solvents. Always wear protective goggles with side screens when working with compressed air. Limit the pressure 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. 121 id.: DB DB180 180 REV. 00 02 02/01/2012 15/06/2016 5 MAINTENANCE 5.9.3 REPLACING THE BRAKING SYSTEM FLUID (fig. 15) A B 15 CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out as set out in Chapter 3. CAUTION: Block all the wheels with wedges at the front and rear and always engage the parking brake before operating on the system lines. CAUTION: Air in the braking system will lead to poor braking performance. Always bleed the air after working on the braking system. If you are not sure that all the air has been bled from the system, have it checked by skilled technicians. CAUTION: Do not pollute the environment. Keep used 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. - Clean the external wheel hub areas. - Loosen the bleeder A and depress the brake pedal until all the fluid has drained into a pan positioned under the axle. - Tighten the bleeders A. - Top up 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 tank. 122 DB 180 REV.02 00 REV. 02/01/2012 15/06/2016 id.: MAINTENANCE 5 5.9.4 TESTING THE HAND BRAKE (fig. 16) 1 2 2 16 CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out as set out in Chapter 3. DANGER: Before testing the efficiency of the parking brake, check that there is no one near the vehicle. - Shift the lever (1) to released position. - Adjust the cable with the relative adjustment nuts (2). - Check correct cable tensioning by counting the number of clicks while pulling the lever; the correct tension is 6 clicks, which equal a force of 25 kg. 5.9.5 CHECKING THE WEAR CONDITION OF THE BRAKING SYSTEM This type of operation must be carried out by an AUTHORIZED FIORI SERVICE CENTRE. 123 id.: DB DB180 180 REV. 00 02 02/01/2012 15/06/2016 5 MAINTENANCE 5.10 HYDRAULIC SYSTEM 5.10.1 CHECKING THE HYDRAULIC OIL (fig. 17) A B 17 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. - Move the vehicle onto flat ground, engage the parking brake, turn off the engine and remove the ignition key. - Wait until oil has reached the ambient temperature. - Check if you can see the hydraulic oil half way up inspection glass B, as illustred. - If you neet to top-up with oil, pour it in through filling cap. A. 5.10.2 REPLACING THE HYDRAULIC OIL TANK BLEEDER (fig. 17) 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 disposable and hence does not need to be cleaned. - Replace it only if broken or clogged with an identical one in order to keep the system adequately pressurised. 124 DB 180 REV. REV.02 00 15/06/2016 02/01/2012 id.: 5 MAINTENANCE 5.10.3 CHANGE THE HYDRAULIC OIL FILTER CARTRIDGE (fig. 18) C A B D 18 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. CAUTION: Do not pollute the environment. Keep the filters in special containers and send them to companies specialised in storage and disposal of polluting and hazardous waste. CAUTION: If the filter clogged warning light is permanently illuminated even when the oil is hot (35°C), the suction filter needs to be replaced. - Move the vehicle onto flat ground, engage the parking brake, turn off the engine and remove the ignition key. - Remove the 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 through the sight glass B. If topping up is required, fill with the recommended oil until reaching the indicated level, then screw the filler cap A. - It is essential to keep a stock of spare cartridges D, which can be ordered from the AUTHORISED FIORI SERVICE CENTRES or directly from FIORI SPARE PARTS DEPARTMENT. 125 id.: DB 180 REV. 00 02/01/2012 5 MAINTENANCE 5.10.4 REPLACING THE HYDRAULIC OIL (fig. 19) C F A B E D 19 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. CAUTION: Do not pollute the environment. Keep used 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. - Loosen the filter cover C and remove the filler cap A. - Unscrew the drain cap E and drain all the oil from the tank into a container. - When the tank is empty, screw the filler cap E back on and fill the tank with recommended oil until the level indicated in B is reached. - Screw the cover C back on taking care to correctly position the seal and refit the filler cap A. - The pump frames F must be filled with oil in order to be greased for the first seconds when starting the diesel engine. To perform this operation use the draining pipes or the pump frames directly. - The engine must be started at first with successive activations of the starter motor without fully starting the engine. Once started, keep it at idle speed for a few minutes before checking proper operation of the hydraulic functions. 126 DB 180 REV. 00 02/01/2012 id.: MAINTENANCE 5 5.10.5 CHECKING AND TOPPING UP THE DRUM REDUCTION GEAR OIL LEVEL (fig. 20) A 20 CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out as set out in Chapter 3. - Raise the drum to horizontal position. - Turn the drum so that the level gauge A of the reduction gear is positioned in the horizontal lateral part. - Move the vehicle onto flat ground, engage the parking brake, turn off the engine and remove the ignition key. - The optimal level is in the middle of the sight glass of the level gauge. - In case of topping-up move the oil level gauge to the upper position by rotating the drum. - Unscrew the oil level gauge and add oil till optimum level is reached. 5.10.6 DRUM REDUCTION GEAR OIL CHANGE (fig. 20) CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out as set out in Chapter 3. CAUTION: Do not pollute the environment. Keep used 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 and engage the parking brake. - Turn the drum until the level gauge cap A is positioned at the bottom of the reduction gear. - Turn off the engine and remove the ignition key. - Unscrew the level gauge cap A 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 positioned at the top. - Fill with the recommended oil using a syringe. - Rotate drum to bring oil level gauge to check position. - If necessary top up the level. 127 id.: DB 180 REV. 00 02/01/2012 5 MAINTENANCE 5.11 ENGINE 5.11.1 CLEANING THE ENGINE AIR FILTER SEPARATOR (fig. 22) A 21 - Move the vehicle onto flat ground, engage the parking brake, turn off the engine and remove the ignition key. - Open the engine compartment lid to access the filter, squeeze the lower part of the separator A with your fingers to open it, letting the dust accumulated inside drop out. 5.11.2 CLEANING OR REPLACING THE ENGINE AIR FILTER CARTRDIGE (fig. 23) B C A 22 CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out as set out in Chapter 3. CAUTION: Do not pollute the environment. Keep the filters in special containers and send them to companies specialised in storage and disposal of polluting and hazardous waste. DANGER: 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. - Open the engine compartment lid and check the air filter. - Remove the cover A. 128 DB 180 REV. 00 02/01/2012 id.: MAINTENANCE - 5 In the event of replacement, remove the cartridges B and C and replace them with a new one. Clean the cartridges B and C by means of a blast of dry and clean compressed air, until all dust is removed. 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 and the separator. Refit the cartridges and make sure that they are properly in place. Close the cover A. It is essential to keep a stock of spare cartridges B and C, which can be ordered from the AUTHORISED FIORI SERVICE CENTRES or directly from FIORI SPARE PARTS DEPARTMENT. 5.11.3 CHECKING AND TOPPING UP THE COOLANT LEVEL (fig. 23) A 23 CAUTION: Use only coolant of the type and brand recommended by the manufacturer, as indicated in the Recommended Lubricants and Fluids table in the right WATER/ANTIFREEZE percentages. DANGER: Do not remove the cap when the engine is still hot. The fluid is under pressure, therefore, before removing the filler cap, turn it slowly to release the pressure. - Move the vehicle onto flat ground, engage the parking brake, turn off the engine and remove the ignition key. - Open the engine compartment lid. - Wait until the coolant has reached the ambient temperature. - Release slowly cap A and check that the liquid can be seen in the inlet tank, otherwise top up till optimum level is reached. 129 id.: DB 180 REV. 00 02/01/2012 5 MAINTENANCE 5.11.4 REPLACING THE ENGINE COOLANT (fig. 25) CAUTION: To replace the engine coolant contact your nearest Authorised Fiori Workshop. 5.11.5 CHECKING AND ADJUSTING THE ALTERNATOR BELT TENSIONING CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out as set out in Chapter 3. DANGER: 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 CENTRE or WORKSHOP for assistance. CAUTION: In addition to the operations described below, also refer to the engine manufacturer’s instruction manual. - Move the vehicle onto flat ground, engage the parking brake, turn off the engine and remove the ignition key. - Open the engine compartment lid and check the tension and wear of the alternator belt. - To work on the belt, refer to the engine manufacturer’s manual attached. 5.11.6 AIR BLEEDING IN THE ENGINE FUEL SUPPLY SYSTEM CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out as set out in Chapter 3. DANGER: 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 CENTRE or WORKSHOP for assistance. CAUTION: In addition to the operations described below, also refer to the engine manufacturer’s instruction manual. 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. 5.11.7 REPLACING THE ENGINE FUEL SUPPLY PRE-FILTER AND FILTER CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out as set out in Chapter 3. CAUTION: Do not pollute the environment. Keep the filters in special containers and send them to companies specialised in storage and disposal of polluting and hazardous waste. 130 DB 180 REV. 00 02/01/2012 id.: MAINTENANCE 5 DANGER: 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 CENTRE or WORKSHOP for assistance. - Move the vehicle onto flat ground, engage the parking brake, turn off the engine and remove the ignition key. - For the operations to be carried out, refer to the engine manufacturer’s manual attached. - It is essential to keep a stock of spare filters, which can be ordered from the AUTHORISED FIORI SERVICE CENTRES or directly from FIORI SPARE PARTS DEPARTMENT. 5.11.8 CHECKING AND TOPPING UP THE ENGINE OIL LEVEL (fig. 27) B A 24 CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out as set out in Chapter 3. DANGER: 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 CENTRE or WORKSHOP for assistance. CAUTION: In addition to the operations described below, also refer to the engine manufacturer’s instruction manual. - 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 between the two marks on the dipstick A - Screw the cap B back on put the dipstick A back into place. If the oil is at minimum level, add oil until the level is at the maximum mark on the dipstick. 131 id.: DB 180 REV. 00 02/01/2012 5 MAINTENANCE 5.11.9 REPLACING THE ENGINE OIL FILTER CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out as set out in Chapter 3. CAUTION: Do not pollute the environment. Keep the filters in special containers and send them to companies specialised in storage and disposal of polluting and hazardous waste. DANGER: 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 CENTRE or WORKSHOP for assistance. - Move the vehicle onto flat ground, engage the parking brake, turn off the engine and remove the ignition key. - For the operations to be carried out, refer to the engine manufacturer’s manual attached. - It is essential to keep a stock of spare filters, which can be ordered from the AUTHORISED FIORI SERVICE CENTRES or directly from FIORI SPARE PARTS DEPARTMENT. 5.11.10 REPLACING THE ENGINE OIL CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out as set out in Chapter 3. CAUTION: Do not pollute the environment. Keep used fluids in special containers and send them to companies specialised in storage and disposal of polluting and hazardous waste. DANGER: 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 CENTRE or WORKSHOP for assistance. CAUTION: In addition to the operations described below, also refer to the engine manufacturer’s instruction manual. - Move the vehicle onto flat ground, engage the parking brake, turn off the engine and remove the ignition key. - For the operations to be carried out, refer to the engine manufacturer’s manual attached. 132 DB 180 REV. 00 02/01/2012 id.: MAINTENANCE 5 5.12 ELECTRIC COMPONENTS 5.12.1 FUSES AND RELAYS - Driver’s seat fuses (fig. 25) 22 5 16 15 14 13 12 11 4 3 2 1 23 10 9 21 20 19 18 17 8 7 6 25 POS. AMPERAGE COLOUR POS. AMPERAGE COLOUR 1 15A blue 13 7,5A brown 2 7,5A brown 14 7,5A brown 3 10A red 15 15A blue 4 5A beige 16 3A violet 5 15A blue 17 3A violet 6 7,5A brown 18 15A blue 7 15A blue 19 15A blue 8 10A red 20 15A blue 9 10A red 21 15A blue 10 5A beige 22 5A beige 11 5A beige 23 10A red 12 3A violet 133 id.: DB DB180 180 REV. REV. 00 03 02/01/2012 20/12/2016 5 MAINTENANCE List of fuses 01 - (F101) - Courtesy light and socket power supply. 02 - (F102) - Power supply for arm lowering enable, relay (K101). 03 - (F103) - Power supply for front windscreen wipers, rear windscreen wipers and windscreen washer pump control. 04 - (F104) - Power supply for water pump control, litre counter sensor, relay (K102). 05 - (F105) - Power supply for heating fan control. 06 - (F106) - Relay power supply (K107). 07 - (F107) - Power supply for 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 LCD instrument, relay coil (K111), Mix Control emergency button, alternator. 12 - (F112) - Front LH and rear RH position light, power supply for rear working light control 13 - (F113) - RH low beam headlight. 14 - (F114) - LH low beam headlight. 15 - (F115) - (optional). 16 - (F116) - Front RH and rear LH position light, position light indicator. 17 - (F117) - Power supply for weighing central unit (optional). 18 - (F118) - Power supply for emergency lights, rotating beacon control. 19 - (F119) - Relay power supply (K109). 20 - (F120) – Relay power supply (K110). 21 - (SPARE 1) - Spare fuse. 22 - (SPARE 2) - Spare fuse. 23 - (SPARE 3) - Spare fuse. - Fuses above the engine power takeoff (fig. 26) 26 24 27 25 26 24 - 30A - green - power supply for start starter motor relay. 25 - 40A - yellow - power supply for printed circuit board and engine stop solenoid relay. 26 - 50A - red - start switch power supply. 27 - 60A - blue - engine preheating relay power supply. CAUTION: If a fuse blows or a relay burns, find the cause before replacing it with a new one. DANGER: Do not operate bypassing the fuse as there is a risk of short- circuit. 134 DB 180 REV. REV.02 00 15/06/2016 02/01/2012 id.: MAINTENANCE 5 - Relays driving station (fig. 27) 10 9 14 8 15 7 11 6 12 5 4 13 3 2 1 27 01 - K101 - Micro relay for arm lowering enable and Tip-Off control enable. 02 - K102 - Mini relay for water pump control. 03 - K103 - Micro relay for forward drive enable with accelerator lever on OFF. 04 - K104 - Micro relay for start enable with gear in neutral. 05 - K105 - Micro relay for forward drive enable. 06 - K106 - Micro relay available. 07 - K107 - Engine off micro relay. 08 - K108 - Micro relay available. 09 - K109 - Micro relay available. 10 - K110 - Micro relay for rear working lights. 11 - K111 - Micro relay for machine operating acoustic indicator control. 12 - K112 - Neutral enable diode module and machine operating acoustic indicator. 13 - K113 - Flashing hazard lights/direction indicators. 14 - K114 - Micro relay available. 15 - K115 - Micro relay available. - Relays above the engine power takeoff (fig. 28) 19 20 18 17 16 28 16 - Start enable relay 17 - Spark plug pre-heating relay 18 - Engine stop solenoid relay 19 - Spark plug pre-heating warning light timer 20 - Timer of the engine stop solenoid relay CAUTION: If a fuse blows or a relay burns, find the cause before replacing it with a new one. 135 id.: DB180 180 DB REV. 03 00 20/12/2016 02/01/2012 5 MAINTENANCE 5.12.2 ELECTRONIC DASHBOARD WARNING LIGHTS (fig. 29) 29 In the 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. 136 DB 180 REV. REV. 02 00 15/06/2016 02/01/2012 id.: MAINTENANCE 5 5.12.3 REPLACING THE LIGHT BULBS (fig. 30) DANGER: Modifications or repairs to the electric system made incorrectly or without taking the technical specifications of the system into account may cause malfunctions with a risk of fire. When a light is not working, check that the corresponding fuse is intact before replacing the bulb. Before replacing a burnt bulb, check that the contacts are not oxidised. Burnt bulbs must be replaced with new ones of the same type. Bulbs with insufficient power provide poor light, whereas too powerful bulbs absorb too much energy. After replacing a headlight bulb always check the orientation for safety reasons. E F D B-C-G A B B 30 A - low beam bulb...................................................................................................................12V - 55W H7 B - direction indicator bulb .....................................................................................................12V - P21W position light/side marker bulb ..........................................................................................12V - R5W C - Stop light/position light bulb .............................................................................................12V – P21/5W direction indicator light bulb ...............................................................................................12V - P21W D - number plate light bulb .....................................................................................................12V - W5W E - rotating beacon bulb ........................................................................................................12V - 55W H1 F - courtesy light bulb .............................................................................................................12V - C5W G - working light bulb (optional) ..............................................................................................12V - 886 50W 137 id.: DB DB180 180 REV. REV.00 02 02/01/2012 15/06/2016 5 MAINTENANCE 5.12.4 CHECKING AND TOPPING UP THE BATTERY ELECTROLYTE LEVEL (fig. 31) C B A 31 CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out as set out in Chapter 3. DANGER: Wear protective goggles when operating on the battery. The battery contains SULPHURIC ACID. If it comes into contact with your skin or eyes, immediately rinse with water for at least 15 minutes and immediately seek medical advice. DANGER: Wear protective gloves and clothing when handling the battery; do not tilt or turn the battery upside down as acid could leak from the bleeder holes. Extinguish open flames or smoking materials before checking or charging the battery. Batteries release FLAMMABLE VAPOURS. CAUTION: If the battery is partly discharged, replace it with an identical one or ask an electrical repair shop to recharge it, or emergency start the machine. CAUTION: Do not pollute the environment. The batteries are classified as polluting and hazardous waste according to the law. - The battery installed requires little maintenance, therefore, in normal conditions of use, the electrolyte does not need to be topped up. - Nevertheless, every 6 months check that the electrolyte level is between the MAX and MIN notches marked on the battery. - Before operating on the battery, remove the battery disconnection key A to cut the power to the system. - Remove the cover B in order to access the battery. - To top up the electrolyte level, remove the caps C and fill up with distilled water without exceeding the maximum level. For a longer battery life, it is advisable to follow these additional instructions: - Turn off the lights when the engine is off or in idle. - Do not turn off the engine for short stops because the battery uses a lot of power to start the engine. - Regularly check that the cable terminals are properly secured and lubricated with Vaseline. - Always keep the top of the battery clean. - Before working on the terminals, disconnect the end on the earth cable. 138 DB 180 REV. 00 02/01/2012 id.: MAINTENANCE 5 5.12.5 BATTERY PINS CONTACT CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out as set out in Chapter 3. - Disconnect the battery by removing the key from the battery master switch and proceed as described above to access the battery, remove the terminals and thoroughly clean their ends. - Refit the terminals and grease them with a layer of Vaseline grease. - Refit the battery into place and reconnect it by inserting the key in the battery master switch. 5.12.6 BATTERY REPLACE CAUTION: 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 and hazardous waste. - Disconnect the battery by removing the key from the battery master switch. - Proceed as described above to access the battery. - Remove the terminals. - Unscrew the retaining clip. - Remove the battery from its seat and replace it. - Refit the battery following the removal operations in reverse order, and remember to grease the terminals with Vaseline grease. 139 id.: DB 180 REV. 00 02/01/2012 5 MAINTENANCE 5.13 WATER SYSTEM 5.13.1 CHECKING AND MAINTAINING THE LITRE COUNTER (fig. 32) MONTAGGIO ORIZZONTALE 32 CAUTION: Do not use metal or abrasive objects to clean the duct. CAUTION: Do not use solvents, diesel or petrol to clean the external parts of the equipment or parts in its immediate vicinity. To keep the litre counter and the pump 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. 140 DB 180 REV. 00 02/01/2012 id.: MAINTENANCE 5 5.13.2 CHECKING THE WATER TRANSFER PUMP EFFICIENCY (fig. 33) B E A C - D 33 Keep the engine running at 2000 rpm. Activate the transfer pump A. Check by means of the flow meter B that the water flow rate is higher than 200 litres/min. Also check for leaks from the valve unions C and from the suction pipe unions D. Check that the suction filter E is in proper working order. 5.13.3 WATER PUMP EMERGENCY ACTIVATION (fig. 34) A 34 To activate a pump that has stopped because of an electrical fault, use a screwdriver and act on the distributor button A on the operating control panel to activate the pump manually. 141 id.: DB180 180 DB REV. 00 02 REV. 15/06/2016 02/01/2012 5 MAINTENANCE 5.13.4 CLEANING PRE-FILTER OF THE WATER PUMP (fig. 35) D C 35 Before starting the daily work shift, you must clean the pre-filter of the water pump. Remove the closing cap C from the filler neck, 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 there is water inside th pump (see chapter 4.3.3 for the related procedure). 142 DB 180 REV. 00 02/01/2012 id.: OPTIONAL EQUIPMENT 6 6 CONTENTS 6.1 6.1.1. 6.1.2. 6.1.3. LOADING GRAB BUCKET .......................................................................................................... 144 FOREWORD .................................................................................................................................. 144 JOYSTICK CONTROL BUCKET AND DRUM RAISING ............................................................... 144 LOADING OPERATIONS ............................................................................................................. 145 143 id.: DB 180 REV. 00 02/01/2012 6 OPTIONAL EQUIPMENT 6.1 LOADING GRAB BUCKET 6.1.1. FOREWORD This accessory allows loading extra material in the bucket during loading phases. The biting bucket can be moved by pressing a button placed on the joystick. 6.1.2. JOYSTICK CONTROL BUCKET AND DRUM RAISING The joystick controls the movements of the arm - bucket and drum raising. The instructions below should be followed: A 6 2 4 3 N N 8 5 7 1 B 1 A - Unpressed button (fig. 1) DRUM: Position 1 - Drum lowering. Position 2 - Drum raising. BUCKET: Position 3 - Locked. Position 4 - Arm raising Position N - Neutral for locking lever engagement (safety) B - Pressed button (fig. 1) BUCKET: Position 5 - Bucket closing. Position 6 - Bucket opening. Position 7 - Arm lowering. Position 8 - Arm raising. Position N - Neutral for locking lever engagement (safety) 144 DB DB 180 180 REV. 02 00 REV. 02/01/2012 15/06/2016 id.: OPTIONAL EQUIPMENT 6 6.1.3. LOADING OPERATIONS 6 7 2 CAUTION: Before starting any loading operations, check that there is no one in the vicinity. - Keep the drum rotating (fig. 2). - Lower the arm by holding the button down on the joystick 7. - Open the mixer bucket 6. - Select the slow working speed of the mechanical gearbox and the slow speed of the electric gearbox. - Dig into the heap with the bucket in open position. 145 id.: DB DB180 180 REV. REV. 00 02 02/01/2012 15/06/2016 6 OPTIONAL EQUIPMENT 8 5 7 3 - Close the bucket 5 (fig. 3). - Raise the arm 8. - Raise the arm to its maximum height while moving backward. - Stop the machine. - Wait until the cement has poured into the drum through the hopper, helping it along by vigorously shaking the bucket with the arm. - Approach the heap again while lowering the arm 7. - Repeat the operations described above at least 5-6 times. This is the bucket yield on average to obtain optimal drum loading. CAUTION: You can shift to reverse gear even if the machine has not completely stopped. 146 DB 180 REV.02 00 REV. 02/01/2012 15/06/2016 id.: TECHNICAL ANNEXES CAUTION For a better consultation you can ask for the vehicle’s wiring - hydraulic diagrams in PDF format at the FIORI email address: [email protected] 147 id.: DB 180 REV. 00 02/01/2012 TECHNICAL ANNEXES HYDRAULIC DIAGRAM 7 8 6 5 9 11 10 4 13 12 3 14 2 1 16 15 148 DB 180 REV. 00 02/01/2012 id.: TECHNICAL ANNEXES LIST OF COMPONENTS IN THE HYDRAULIC DIAGRAM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 ARM LIFTING JACKS FRAME LIFTING JACKS WATER PUMP ROTATION MOTOR PRIORITY VALVE HYDRAULIC STEERING FLOW INVERTER ARM JACK HYDROSTATIC TRACTION MOTOR DRUM ROTATION MOTOR DRUM ROTATION PUMP SERVICE PUMP + HYDRAULIC STEERING RETURN OIL COLLECTION BLOCK HEAT EXCHANGER PRESSURISED FILTER HEAT ENGINE HYDROSTATIC TRACTION PUMP 149 id.: DB 180 REV. 00 02/01/2012