Db 460 - Fiori Group

Transcript

TRANSLATION FROM ORIGINAL LANGUAGE en_UK DB 460 SELF LOADING CONCRETE MIXER USE AND MAINTENANCE MANUAL PERKINS ENGINE Stage III B Tier 4 Interim RIF. 9301445206 ed. 00 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 DB 460 460 REV. REV. 00 02 27/07/2015 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 460 REV. 00 27/07/2015 CONTENTS 0 INTRODUCTION 1 TECHNICAL FEATURES 2 SAFETY PRECAUTIONS 3 OPERATION AND USE 4 MAINTENANCE 5 OPTIONAL EQUIPMENT 6 TECHNICAL ANNEXES id.: DB 460 REV. 00 27/07/2015 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. 3.1.18. 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 DANGEROUS WORKING CONDITIONS ....................................................................................... 32 7 id.: DB 460 REV. 00 27/07/2015 CONTENTS 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. 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. 4.2.1. CONTROLS AND GAUGES ........................................................................................................... 62 DRIVER’S SEAT .............................................................................................................................. 62 DB 460 REV. 00 MEANING OF THE WARNING AND SAFETY LABELS .................................................................... 49 8 27/07/2015 id.: CONTENTS 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.i 4.2.1.j 4.2.1.k 4.2.1.l 4.2.1.m 4.2.1.n 4.2.1.o 4.2.1.p 4.2.1.q 4.2.1.r 4.2.1.s 4.2.1.t 4.2.1.u 4.2.1.v 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 4.2.2.o 4.2.2.p 4.2.3. 4.2.3.a 4.2.3.b 4.2.3.c 4.2.3.d 4.2.4. 4.2.5. 4.2.6. Steering wheel ................................................................................................................................ 62 Height- and depth-djustable driver’s seat with seatbelt ................................................................. 62 Service and emergency brake pedal .............................................................................................. 63 Accelerator pedal ........................................................................................................................... 63 Parking brake button ...................................................................................................................... 63 Steering type selecting lever ........................................................................................................... 63 Pivoting driving post locking lever .................................................................................................. 64 Windscreen washer switch.............................................................................................................. 64 Regeneration switch disabled ......................................................................................................... 64 Regeneration switch forced............................................................................................................. 64 Power socket................................................................................................................................... 64 Heating/defrosting fan adjuster ....................................................................................................... 64 Windscreen water switch ................................................................................................................ 64 Rotating light switch ........................................................................................................................ 64 Short Manual ................................................................................................................................... 65 Hand accelerator lever .................................................................................................................... 65 Rear windscreen wiper.................................................................................................................... 65 Cabin light ....................................................................................................................................... 65 Windscreen washer fluid tank ........................................................................................................ 65 Fuses and Relays ........................................................................................................................... 65 Electronic engine parameter control monitor .................................................................................. 66 DRIVING POST INSTRUMENT PANEL .......................................................................................... 67 Electronic control panel .................................................................................................................... 67 Water Liter counter........................................................................................................................... 68 Hour counter .................................................................................................................................... 68 Maintenance schedule .................................................................................................................... 69 Forward/reverse gear selector ......................................................................................................... 69 Slow / fast gear selector .................................................................................................................. 69 Mechanical gear selector ................................................................................................................ 70 Drum rotation switch ........................................................................................................................ 70 Reset button ..................................................................................................................................... 70 Water pumps control switch ............................................................................................................ 71 Hazard light toggle switch ............................................................................................................... 71 Working light switch ........................................................................................................................ 71 Red warning light engine fault indicator .......................................................................................... 71 Engine starter and stopping switch ................................................................................................. 72 Rotary switch with horn push button direction indicators toggle switch ........................................... 73 OPERATING CONTROL PANEL..................................................................................................... 74 Drum traverse swinging lever .......................................................................................................... 74 Drum raising lever ............................................................................................................................ 74 Unloading chute control lever........................................................................................................... 75 Joystick for arm raising and bucket/loader rotation .......................................................................... 75 WATER FEEDING AND DISTRIBUTION CONTROLS .................................................................. 76 GROUND CONTROL PANEL (MIX CONTROL) ............................................................................ 77 OPERATION OF THE ELECTRONIC LITRE COUNTER AND MIX CONTROL PROGRAMMING .................................................................................................. 78 9 id.: DB 460 REV. 00 27/07/2015 CONTENTS 4.3. 4.3.1. 4.3.2. 4.3.3. 4.3.4. 4.3.5. 4.3.6. 4.3.7. 4.3.8. 4.3.9. 4.3.10. 4.3.11. 4.3.12. 4.3.13. 4.3.14. 4.3.15. INSTRUCTIONS FOR USE ............................................................................................................. 79 REFUELLING................................................................................................................................... 79 LEVEL CHECK ................................................................................................................................ 80 FILLING THE WATER TRANSFER PUMP BODY .......................................................................... 80 ADJUSTING THE SEAT................................................................................................................... 81 ADJUSTING THE REAR-VIEW MIRROR........................................................................................ 81 DRIVING POST PIVOTING ............................................................................................................. 82 STARTING THE ENGINE ................................................................................................................ 83 ENGINE OPERATION AT LOW RPM ..............................................................................................84 ADJUSTING WHEEL ALIGNMENT ..................................................................................................84 TESTING THE PARKING BRAKE ....................................................................................................84 STARTING AND DRIVING THE VEHICLE .......................................................................................85 FIELD OF INDIRECT VISIBILITY OF THE REAR OF THE VEHICLE ............................................86 STOPPING THE VEHICLE ...............................................................................................................87 STOPPING THE ENGINE ................................................................................................................87 PARKING THE VEHICLE ..................................................................................................................87 4.4. 4.4.1. TRANSPORTING THE VEHICLE .....................................................................................................88 LIFTING THE VEHICLE WITH A CRANE ........................................................................................89 4.5. 4.5.1 TOWING AND RECOVERY ..............................................................................................................90 4.5.2 RELEASING THE PARKING BRAKE IN THE EVENT OF A BRAKE SUPPLY SYSTEM FAULT ......91 GEARSHIFTING TO NEUTRAL .......................................................................................................91 4.6. DRIVING ON PUBLIC ROADS .........................................................................................................92 4.7. HOMOLOGATION FOR ROAD USE (ITALY) ...................................................................................93 4.8. 4.8.1 PRECAUTIONS FOR USE IN COLD CLIMATE CONDITIONS........................................................93 SUMMER/WINTER HEATING SYSTEM .........................................................................................94 4.9. PRECAUTIONS IN THE EVENT OF LONG PERIODS OF INACTIVITY ........................................95 4.10. WORKING PHASES .........................................................................................................................95 4.10.1. CORRECT USE OF THE VEHICLE .................................................................................................96 4.10.2. BEFORE GETTING ON THE VEHICLE (CHECKS AND WARNINGS) ............................................96 4.10.3. CORRECT USE ON SLOPES ..........................................................................................................96 4.10.4. CONCRETE COMPOSITION AND BATCHING TABLE....................................................................98 4.10.5. FIRST FILLING WITH MIXING WATER............................................................................................99 4.10.5.a Filling the tanks with mixing water ....................................................................................................99 4.10.5.b First filling with mixing water ...........................................................................................................100 4.10.5.c Activating the water transfer pump..................................................................................................100 4.10.6. CEMENT LOADING ........................................................................................................................101 4.10.6.a Cement in bags ...............................................................................................................................101 4.10.6.b Cement in silos................................................................................................................................102 4.10.7. AGGREGATE LOADING ................................................................................................................102 4.10.7.a Heaped aggregate .........................................................................................................................102 4.10.8. MIXING AND SECOND FILLING WITH WATER ............................................................................103 4.10.9. CONCRETE UNLOADING..............................................................................................................104 4.10.9.a Concrete unloading from chute .......................................................................................................104 4.10.9.b Front unloading from chute..............................................................................................................105 4.10.9.c Unloading in formworks in traverse swinging mode ........................................................................106 10 DB 460 REV. 00 27/07/2015 id.: CONTENTS 4.10.9.d Direct unloading from hopper ..........................................................................................................107 4.10.9.e Concrete unloading from drum emergency door.............................................................................108 4.10.10. BUCKET, DRUM AND CHUTE WASHING ....................................................................................109 4.10.11. INTERNAL CLEANING OF THE MIXING DRUM .......................................................................... 110 4.10.12. EXTRAORDINARY DRUM CLEANING OR BLADE REPLACEMENT .......................................... 110 5 MAINTENANCE 5.1. FOREWORD ..................................................................................................................................... 111 5.1.1. VISUAL EXTERNAL INSPECTION ................................................................................................... 112 5.1.2. CLEANING THE VEHICLE .............................................................................................................. 112 5.1.3. CHECKING FOR DAMAGES ............................................................................................................ 113 5.1.4. ACCESS TO THE MAIN DEVICES ................................................................................................... 113 5.1.4.1. PARTS CONTAINED IN THE TOOL KIT ........................................................................................... 113 5.1.4.2. ROUTINE MAINTENANCE AND CHECKS....................................................................................... 114 5.2. MAINTENANCE SCHEDULE............................................................................................................ 115 5.3. RUNNING-IN AND SERVICE ........................................................................................................... 115 5.4. SCHEDULED MAINTENANCE TABLE ............................................................................................. 116 5.5. ENGINE MAINTENANCE SCHEDULE ............................................................................................. 117 5.6. RECOMMENDED LUBRICANTS AND FLUIDS TABLE ................................................................... 118 5.6.1. DIESEL FUEL REQUIREMENTS ..................................................................................................... 118 5.7. GENERAL INSPECTIONS ................................................................................................................121 5.7.1. GREASE ...........................................................................................................................................121 5.7.2. CLEANING AND DRAINING THE FUEL TANK ................................................................................122 5.7.3. FIFTH WHEEL LUBRICATION..........................................................................................................122 5.7.4. SCRAPER BLADE AND LOADING BUCKET HATCH BELLOWS ....................................................123 5.8. AXLE AND WHEELS ........................................................................................................................124 5.8.1. CLEANING THE AXLE AND DIFFERENTIAL BLEEDERS ...............................................................124 5.8.2. CHECKING AND TOPPING UP THE OIL LEVEL IN THE FRONT AND REAR AXLES ...................124 5.8.3. REPLACING THE OIL IN THE FRONT AND REAR AXLES .............................................................125 5.8.4. CHECKING AND ADJUSTING THE TYRE PRESURE .....................................................................126 5.8.5. REPLACING THE WHEELS .............................................................................................................127 5.9. 5.9.1. 5.9.2. 5.9.3. 5.9.4. 5.9.5. BRAKES ............................................................................................................................................130 CHECKING AND TOPPING UP THE BRAKE FLUID LEVEL ..........................................................130 CLEANING THE BRAKE FLUID TANK BLEEDERS ........................................................................130 REPLACING THE BRAKING SYSTEM FLUID .................................................................................131 EFFICIENCY OF THE HAND BRAKE ..............................................................................................132 CHECKING THE WEAR CONDITION OF THE BRAKING SYSTEM ...............................................132 5.10. 5.10.1. 5.10.2. 5.10.3. 5.10.4. 5.10.5. 5.10.6. HYDRAULIC SYSTEM .....................................................................................................................133 CHECKING THE HYDRAULIC OIL...................................................................................................133 REPLACING THE HYDRAULIC OIL TANK BLEEDER ....................................................................133 CHANGE THE HYDRAULIC OIL FILTER CARTRIDGE...................................................................134 REPLACING THE HYDRAULIC OIL .................................................................................................135 CHECKING AND TOPPING UP THE DRUM REDUCTION GEAR OIL LEVEL ...............................136 DRUM REDUCTION GEAR OIL CHANGE .......................................................................................136 11 id.: DB 460 REV. 01 00 05/11/2015 27/07/2015 CONTENTS 5.10.7. REPLACING THE DRUM REDUCTION GEAR OIL .........................................................................137 5.11. ENGINE ............................................................................................................................................138 5.11.1. CLEANING THE ENGINE AIR FILTER SEPARATOR .....................................................................138 5.11.2. CLEANING OR REPLACING THE ENGINE AIR FILTER CARTRDIGE...........................................138 5.11.3. CHECKING AND TOPPING UP THE COOLANT LEVEL ................................................................139 5.11.4. REPLACING THE ENGINE COOLANT ...........................................................................................140 5.11.5. CHECKING AND ADJUSTING THE ALTERNATOR BELT TENSIONING ........................................141 5.11.6. FUEL SEDIMENT BOWL .................................................................................................................141 5.11.7. AIR BLEEDING IN THE ENGINE FUEL SUPPLY SYSTEM ............................................................142 5.11.8. REPLACING THE ENGINE FUEL SUPPLY PRE-FILTER AND FILTER ...........................................142 5.11.9.CHECKING AND TOPPING UP THE ENGINE OIL LEVEL ...............................................................143 5.11.10. REPLACING THE ENGINE OIL FILTER .........................................................................................144 5.11.11. REPLACING THE ENGINE OIL ......................................................................................................144 5.11.12. DIESEL PARTICULATE FILTER REGENERATION .......................................................................144 5.11.12.1 Regeneration Indicators ...............................................................................................................145 5.11.12.2 Modes of Regeneration .................................................................................................................145 5.11.12.3 Indicator Operation ........................................................................................................................146 5.11.12.4 Regeneration Operation ................................................................................................................146 5.11.13. ENGINE DIAGNOSTICS ................................................................................................................147 5.11.14. DISPLAYING ENGINE FAULT CODES ON THE PARAMETER CONTROL MONITOR................147 5.12. ELECTRIC COMPONENTS ................................................................................................................148 5.12.1. FUSES AND RELAYS .......................................................................................................................148 5.12.2. ELECTRONIC DASHBOARD WARNING LIGHTS ...........................................................................151 5.12.3. REPLACING THE LIGHT BULBS .....................................................................................................152 5.12.4. CHECKING AND TOPPING UP THE BATTERY ELECTROLYTE LEVEL ......................................153 5.12.5. BATTERY PINS CONTACT ..............................................................................................................154 5.12.6. BATTERY REPLACE ........................................................................................................................154 5.13. WATER SYSTEM ...............................................................................................................................155 5.13.1. CHECKING AND MAINTAINING THE LITRE COUNTER .................................................................155 5.13.2. CHECKING THE WATER TRANSFER PUMP EFFICIENCY ............................................................155 5.13.3. WATER PUMP EMERGENCY ACTIVATION ...................................................................................156 5.13.4. CLEANING PRE-FILTER OF THE WATER PUMP ..........................................................................156 6 OPTIONAL EQUIPMENT .............................................................................................................157 157 TECHNICAL ANNEXES ...............................................................................................................................167 USE AND MAINTENANCE MANUAL ENGINE PARAMETER CONTROL MONITOR ENGINE USE AND MAINTENANCE MANUAL 12 DB DB 460 460 REV. REV. 00 01 27/07/2015 05/11/2015 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 Dealer or the Manufacturer immediately for a new copy. The machine must be used for its intended purpose only. Any other use is to be considered improper and consequently dangerous. Thorough and ongoing observance of the instructions contained herein will help ensure a longer service life and reduction of maintenance and stop time. In addition, this will help you to avoid the most common accidents 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 460 REV. 00 27/07/2015 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 REAR FRONT 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 460 REV. 00 27/07/2015 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 460 REV. 00 27/07/2015 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 460 REV. 00 27/07/2015 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 460 REV. 00 27/07/2015 1 INTRODUCTION F 2 C E 1 A *BF08HB0900* 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 460 REV. 00 27/07/2015 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 460 / BF08H SERIAL NUMBER ...............................................................................................................•BF08H B 0900• YEAR ............................................................................................................................................................ C - ENGINE DATA PLATE The engine data plate is positioned on the power take-off side. Write down your vehicle numbers in the space below for quick and easy reference: MODEL No. ............................................................................................................................ 854E-E34TA SERIAL NUMBER ....................................................................................................................................... D - AXLE DATA PLATE The axle type and serial numbers are printed on the plate found on the axle central case. Write down the information in the space below for quick reference: FRONT AXLE TYPE ....................................................................................................... • 000 - 212 - 670 • SERIAL NUMBER ....................................................................................................................... K ITA...... REAR AXLE TYPE .......................................................................................................... • 357 - 212 - 320 • SERIAL NUMBER ....................................................................................................................... K ITA...... 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 .................................................................................................................. • A4VG56 • SERIAL NUMBER .................................................................................................................................. 2 - ENGINE MODEL ................................................................................................................ • A6VM80 • 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 460 REV. 00 27/07/2015 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 - EU STAGE III B / EPA Tier 4 Interim CABIN - ROPS UNI 11023 - FOPS LEVEL I ISO 3449 - FOPS LEVEL II ISO 3449 (optional) QUALITY STANDARD FIORI GROUP S.p.A. is a certified company: - ISO 9001 - 2008 “Quality” - ISO 14001 - 2004 “Environment” - BS OHSAS 18001 – 2007 “Safety” 20 DB 460 REV. 00 27/07/2015 id.: INTRODUCTION 1 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 - DB460 BF08H *BF08HB0000* FIORI GROUP S.p.A. 2015 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. 106 108 4 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 FIORI GROUP S.p.A. Finale Emilia, lì 21 id.: DB 460 REV. 00 27/07/2015 TECHNICAL FEATURES 2 2.1 DIMENSIONS - Minimum transfer length .................................................................................................................. 5,585 mm - Maximum length with loader on the ground .................................................................................... 6,440 mm - Maximum width ............................................................................................................................... 2,430 mm - Minimum height with loader on the ground ..................................................................................... 3,105 mm - Maximum road transfer height ......................................................................................................... 4,030 mm - Maximum hopper unloading height .................................................................................................. 2,130 mm - Maximum chute unloading height..................................................................................................... 1,765 mm - Minimum chute unloading height...................................................................................................... 1,635 mm - Front angle of attack ...................................................................................................................................41° - Rear angle of attack ...................................................................................................................................56° - Ground clearance under the differentials ........................................................................................... 390 mm - Minimum wheel radius...................................................................................................................... 2,030 mm - Minimum outside wheel radius ......................................................................................................... 4,580 mm 23 id.: DB 460 REV. 00 27/07/2015 2 TECHNICAL FEATURES 2.2 TECHNICAL DATA DIESEL ENGINE : E.U. Stage III B / EPA Tier 4 Interim Model : .................................................................................................................. PERKINS series 854 E turbo Total displacement, no Cylinders : .............................................................................3,400cc - 4 in line + DPF Injection : ................................................................................................ Electronic control with direct injection Cooling : .................................................................................................................. air water fi lter, dry air fi lter Max. power : ............................................................................................................................. 83 kW (113 Hp) Adj. power. :......................................................................................................................... 83 kW (2,200 rpm) Max. torque :...................................................................................................................... 450 Nm a 1,400 rpm ELECTRIC SYSTEM Alternator: .........................................................................................................................................12 V - 80 A Battery: .............................................................................................................................12 V - 132 Ah (600 A) Road light system, rear working lights. 4X4 FOUR-WHEEL DRIVE Hydrostatic “automotive” transmission with variable displacement pump and variable displacement hydraulic motor with electro-hydraulic control, and reverse gear control on the steering wheel. Electro-hydraulically controlled mechanical gearbox for “working speed” and “road transfer” speed. SPEED 4 forward gears Ist 0 - 3.0 Km/h IInd 0 - 7.2 Km/h IIIrd 0 - 10.0 Km/h IVth 0 - 25.0 Km/h Traction / weight ratio 2 reverse gears 0 - 3.0 Km/h 0 - 3.0 Km/h 0 - 10.0 Km/h 0 - 10.0 Km/h ................................................................................................................................. 48% AXLES AND WHEELS Front, oscillating (± 6°) and steering with planetary reduction gears on the wheel hubs. Rear and steering with planetary reduction gears on the wheel hubs and flanged gearbox. Tyres .......................................................................................................................................... 18 -19.5 14PR BRAKES Internal oil-bath disc service and emergency brakes acting on the 4 wheels, activation with miniservo pump on independent dual circuit. Negative type parking brake, with internal oil-bath discs on the rear axle and electro-hydraulically controlled release. STEERING Assisted by means of load-sensing power steering with double displacement on 4 steering wheels; steering selection device for: 2 steering wheels, 4 steering wheels - crab steering. 24 DB 460 REV. 00 27/07/2015 id.: TECHNICAL FEATURES 2 EQUIPMENT HYDRAULIC SYSTEM Gear pump Max. flow rate: ............................................................................................................................... 45 litres/min. Maximum pressure: ............................................................................................................................... 180 bar 5-element distributor servo-controlled with multi-function joystick. Chute lever distributor. Aluminium heat exchanger for hydraulic oil cooling. Pressurised closed-circuit intake with oil filter replaceable from the outside. MIXING AND UNLOADING Double-cone drum with double-spiral mixing screws and convex bottom. Geometrical drum volume: ............................................................................................................... 5,050 litres Drum rotation speed: ............................................................................................................................. 24 rpm. Class S1 concrete produced as : ..........................................................................................................4.0 cu m Counterframe mounted on “heavy-duty” ball fifth wheel, with 245° hydraulic rotation and automatic locking by means of negative brake. 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. Unloading chute with hydraulic tilting by means of a double-acting jack and 180° rotation, independent from the mixing drum inclination. Removable chute, for direct unloading from hopper. 2 unloading chute extensions provided as standard equipment. WATER SYSTEM “Self-priming” volumetric water pump with quick-suction. Max. capacity: .............................................................................................................................. 250 litres/min. Maximum head: ......................................................................................................................................... 4 bar Two connected tanks positioned opposite each other made of polyethylene with a total capacity of ..870 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 LOADER Loading arms with self-compensated kinematic mechanism, double-acting loader lifting and return cylinders, electro-hydraulically controlled hatch with standard Tip-Off function. Volumetric capacity: ............................................................................................................................ 560 litres Number of loaderfuls per load: ....................................................................................................... around 9 /10 25 id.: DB 460 REV. 00 27/07/2015 2 TECHNICAL FEATURES CABIN Closed cabin with heating system, designed in accordance with ROPS & FOPS 1st Level standards . Sliding side window 180° pivoting driving post. Anatomic seat with flexible suspension and height adjustment, seat belts. SERVICE REFILL CAPACITIES Fuel tank in polyethylene, ...................................................................................................................... 95 litres Total hydraulic system capacity: .......................................................................................................... 125 litres Engine oil: ...............................................................................................................................................6.75 kg WEIGHTS Operating weight .................................................................................................................................. 7,300 kg Max gross weight: ...............................................................................................................................16,500 kg load-carring capacity: ...........................................................................................................................9,200 kg 26 DB 460 REV. 00 27/07/2015 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 .........................................................................................................106 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 460 REV. 00 27/07/2015 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 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 ................................................2.3 m/sec² This value is to be understood as RMS, weighted using the “broadband” method in compliance with ISO 26311 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. - Do not use the bucket for lifting loads not concerned with the machine’s work cycle. - Do not use the movements of the bucket or its arms for control inside the drum. 28 DB 460 REV. 00 27/07/2015 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 460 REV. 00 27/07/2015 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 460 REV. 00 27/07/2015 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. - If required, check that the camera display is on, in order to ensure maximum visibility of the area behind the machine. - 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 460 REV. 00 27/07/2015 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 460 REV. 00 27/07/2015 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 460 REV. 00 27/07/2015 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 460 REV. 00 27/07/2015 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 460 REV. 00 27/07/2015 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 460 REV. 00 27/07/2015 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 460 REV. 00 27/07/2015 3 SAFETY PRECAUTIONS 3.2.5 OVERTURNING - The operator must be fully knowledgeable with the performance, weight and the maximum load the vehicle can transport in relation to the ground conditions (flat, compact, uneven, sloping). - Before starting to work, always check that the area on which the vehicle 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 vehicle and its stability. - Analyse and record the topography and geological characteristics of the site in order to take the appropriate preventive measures against the vehicle overturning, landslides or landslips. - Consider the characteristics of the ground complementary to those of the vehicle; 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 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. - 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 vehicle may be used on sloping ground only within the limits indicated by the manufacturer. Where the ground is particularly steep and inaccessible, it is advisable to have only experienced operators use the vehicle. - The vehicle may also overturn because of uneven ground, the ground caving in (especially when working near the 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 vehicle 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 vehicle. - The vehicle is equipped with a ROPS safety cabin. Nevertheless, in the event of the vehicle overturning, if you do not have the seatbelt fastened, you will be thrown out with the risk of getting crushed by the vehicle. IN THE EVENT OF OVERTURNING The protective structure makes the driver’s seat the only safe place to be should the vehicle overturn. DURING OVERTURNING Never leave the vehicle but remain seated firmly, gripping the seat or the steering wheel. AFTER OVERTURNING Make sure that the vehicle is stable and that it will not continue turning over, unfasten the seatbelt, quickly leave the vehicle trying to get off at the top to avoid being crushed by the vehicle should it continue overturning. 38 DB 460 REV. 00 27/07/2015 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 460 REV. 00 27/07/2015 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 460 REV. 00 27/07/2015 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 460 REV. 00 27/07/2015 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 460 REV. 00 27/07/2015 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 460 REV. 00 27/07/2015 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 460 REV. 00 27/07/2015 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 460 REV. 00 27/07/2015 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 460 REV. 00 27/07/2015 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 460 REV. 00 27/07/2015 3 SAFETY PRECAUTIONS VEHICLE EXTERIOR 48 DB 460 REV. 00 27/07/2015 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: Vehicle with crab steering When the driving post is facing the drum, steering is inverted with respect to steering wheel rotation; in this case, it is prohibited to use this function as it is very easy to make a mistake. 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 460 REV. 00 27/07/2015 3 SAFETY PRECAUTIONS DANGER: This symbol indicates that the safety stop on the lifting cylinder must be engaged before accessing the area underneath the mixing drum. 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. 50 DB 460 REV. 00 27/07/2015 id.: SAFETY PRECAUTIONS 3 WARNING: After completing the operations permitted by the control engage the safety stop. 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 460 REV. 00 27/07/2015 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 F A G D E B 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. B - 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. C - PARKING BRAKE BUTTON (fig.1) It lets you engage the parking brake with the engine running. The vehicle is automatically braked when the engine is off with the key in the “0” position. D - MECHANICAL ROTATION LOCK FOR PIVOTING DRIVING POST (fig.1) Allows locking the driving post in the two driving positions. 52 DB 460 REV. 00 27/07/2015 id.: SAFETY PRECAUTIONS 3 E- HAND ACCELERATOR (fig.1) If the hand accelerator lever is not in the initial position, it is impossible to move the vehicle. F - DEACTIVATION BUTTON FOR ARM DESCENT LOCKING VALVE (fig.1) If the button is not pressed, the arm will not lower even if operating the joystick. G - JOYSTICK LOCK KNOB (fig.1) When it is in locked position, it prevents movement of the joystick, helping to ensure protection against accidental manoeuvres. L H M N I 2 G - GROUND CONTROL EMERGENCY STOP BUTTON (fig.2) Positioned on the rear right-hand side of the vehicle, pressing it will automatically turn off the diesel engine. H - BATTERY MASTER SWITCH KEY (fig.2) 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. L - ROTATING BEACON (fig.2) Fixed on the cabin roof, it signals the presence of the vehicle. M - OPERATOR’S PROTECTION / CABIN WITH “FOPS - ROPS” STRUCTURE (fig.2) Designed and constructed to safeguard the operator in the event of the vehicle overturning and objects falling from heights. N - REAR VIEW MIRROR (fig.2) The rearview mirror is essential for visibility of the rear left-hand side of the vehicle. Correctly position the mirror before starting. 53 id.: DB 460 REV. 00 27/07/2015 3 SAFETY PRECAUTIONS V R U 1 S T Q P O 3 O - DRUM FALL STOP DEVICE (fig.3) 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. P - DRUM COUNTERFRAME ROTATION STOP DEVICE (fig.3) When it is engaged, the drum counterframe cannot rotate; it is automatically engaged when the drum is lowered parallel to the driving direction. Keep it engaged during road transfers and when loading from a heap. Q - DIESEL TANK CAP WITH KEY (fig.3) It is fitted with an anti-drip valve in the event of the vehicle overturning. R - ARM LOCKING CABLE (fig.3) When the bucket arm is raised, it prevents accidental lowering of the arm during transfer and transport. S - REAR SIDE HORN (fig.3) Acoustically warns that the engine is starting and that the reverse gear is engaged. It also indicates when the drum counterframe rotates. T - ARM DESCENT SWITCH (fig.3) Once the drum has rotated beyond 180° towards the front, the loading arms cannot be lowered. CAUTION: During front unloading, always check that the arm is raised. During front unloading never touch the arm control lever. It is advisable to engage the CONTROL LOCK (C). 54 DB 460 REV. 00 27/07/2015 id.: SAFETY PRECAUTIONS 3 U - CAMERA (Standard only for specific countries) (fig.3) It enables a complete view of the rear of the machine and of the area not directly visible to the operator, by means of the display (1) placed at the back inside the cabin. 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. D A D1 B C 4 A - STEERING SELECTOR (fig.4) CAUTION: THE STEERING SELECTOR MUST BE POSITIONED ON 2 STEERING WHEELS Perform this operation after aligning the front and rear wheels in relation to the longitudinal axis of the machine. B - DRIVER’S SEAT (fig.4) Turned forward (concrete mixer behind) in preferential driving direction and locked with the latch (2). C - HAND ACCELERATOR (fig.4) If the hand accelerator lever is not in the initial position, it is impossible to move the vehicle. D - JOYSTICK (fig.4) Lock the joystick by inserting the locking rod D1. 55 id.: DB 460 REV. 00 27/07/2015 3 SAFETY PRECAUTIONS L E I F 2 1 H 1 2 G 5 E - FLASHING LIGHT (fig.5) It is mandatory to have an approved flashing light device and it must always be in perfect working order. F - DRUM FIFTH WHEEL (fig.5) The drum and its counterframe must be horizontal to the vehicle and locked with the special pin. G - NUMBER PLATE (fig.5) Check that the number plate is clean before driving on the road. H - CONCRETE UNLOADING CHUTE (fig.5) The unloading chute (1) must be turned crosswise and locked with the special screw pin (2). I - LOADING ARM (fig.5) The arm (1) must be locked in a vertical position with the special steel wire (2). L - DOORS (fig.5) Keep the doors closed while travelling. 56 DB 460 REV. 00 27/07/2015 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 460 REV. 00 27/07/2015 4 OPERATION AND USE E O H G F Q A P B C R N I M L D 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 Q R - 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 Rotary frame Hydraulic bucket hatch Mix Control 58 DB 460 REV. 00 27/07/2015 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. 59 id.: DB 460 REV. 01 00 05/11/2015 27/07/2015 4 OPERATION AND USE Indicates the functions to run to directly fill the drum or the tanks with water, with the warning to open the cap to avoid the tank from swelling. Indicates the 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 the joystick positions for arm raising, bucket rotation and hydraulic hatch closing/opening. 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 three types of steering. Indicates the lever positions for chute tilting. 60 DB 460 REV. 00 27/07/2015 id.: OPERATION AND USE 4 Indicates the lever positions for the rotation direction of the drum fifth wheel. Indicates the lever positions for drum raising. Indicates the switch to reset the litre counter and other reset functions. 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 that, when turning the drum counterframe towards “front unloading”, you need to check that the arms are fully raised so that they do not interfere with or touch the engine compartment lid. Indicates functioning of the litre counter and the water pump. It stands for the exact position of the intake filter above 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. 61 id.: DB 460 REV. 00 27/07/2015 4 OPERATION AND USE 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 E O F J K N L M A I P C D B Q H 2 62 DB 460 REV. 00 27/07/2015 id.: OPERATION AND USE 4 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. 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 engine speed and the automotive system controls the vehicle speed when a gear is engaged. 4.2.1.e - E - Parking brake button (fig. 2). Allows the operator to lock the vehicle during breaks, keeping the engine on. Press the button to lock. Press the button to unlock. When the engine is off, the vehicle is automatically braked. The warning light indicates that the parking brake is engaged when the electric panel is active. The warning light indicates a malfunction in the parking brake circuit. 4.2.1.f -F - Steering type selecting lever (fig. 2). This lever allows you to select the type of steering according to the situation you are in. 2 RS CRAB 4 RS Two front steering wheels. Crab steering, i.e. with the same steering angle on the front and the rear wheels. Four steering wheels with the rear wheels in the opposite direction to the front ones. CAUTION: Before any road transfers, check that the four wheels are properly aligned (see the procedure described in Chapter 4.3.9). It is prohibited to use CRAB STEERING if the driving post is facing the drum. In this position steering is inverted with respect to steering wheel rotation. 63 id.: DB 460 REV. 00 27/07/2015 4 OPERATION AND USE 4.2.1.h - H - 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. If the driving post is not securely locked in the positions A or B, dedicated microswitches will not allow vehicle movement. 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.i - I - Windscreen washer switch (fig. 2). Snap switch to turn on the front wiper. 4.2.1.j - J - Regeneration switch disabled (fig. 2). Press to disable the regeneration of the engine’s diesel particulate filter. 4.2.1.k - K - Regeneration switch forced (fig. 2). Press to activate the regeneration of the engine’s diesel particulate filter. 4.2.1.l - L - Power socket (fig. 2). It draws current from the 12V battery by means of a bayonet coupling. 4.2.1.m - M - Heating/defrosting fan adjuster (fig. 2). Turns on the fan for defrosting the windows or heating the closed cabin. 4.2.1 n - N - Windscreen water switch (fig. 2). Allows you to pump the windscreen washer fluid. 4.2.1.o - O - Rotating light switch (fig. 2). Snap switch to turn on the rotating beacon on the cabin roof. 64 DB 460 REV. 00 27/07/2015 id.: OPERATION AND USE 4 4.2.1.p - P - Short Manual (fig. 2). Quick manual for the main starting and driving functions and maintenance of the vehicle. 4.2.1.q - Q - Hand accelerator lever (fig. 2). 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. S V R T U 3 4.2.1.r - R - Rear windscreen wiper (fig. 3). Act on the snap switch to turn on the rear wiper. 4.2.1.s - S - Cabin light (fig. 3). Act on the lever to turn on the cabin light. 4.2.1.t - T - Windscreen washer fluid tank (fig. 3). The water tank is positioned on the inside of the control panel; to access the tank for filling open the rear cover by undoing the retaining screws. 4.2.1.u - U - Fuses and Relays (fig. 3). The fuses and relays are positioned inside the driving post. Using the key provided, open the door to access the fuses and the relays. 65 id.: DB 460 REV. 00 27/07/2015 4 OPERATION AND USE 4.2.1.v - V - Electronic engine parameter control monitor (fig. 3). 2 3 1 4 5 6 7 Faceplate Features: 1 - Display. 2 - Amber LED on: caution, reports an engine fault. 3 - Red LED on: serious danger, the error code displays on the monitor. 4 - Menù: Enter or exit menu screens. 5 - Left Arrow: Scroll the screen or move the parameter selection to the left or upward. 6 - Right Arrow: Scroll the screen and move the parameter selection to the right or downward. 7 - Enter Key: Select a menu or parameter or hide/view an active fault code. When the leds turn on, the yellow engine fault led also turns on (par. 4.2.2 pos.9) together with the amber LED, the engine fault indicator (par. 4.2.2.n-I) together with the red LED. CAUTION: Refer to the user manual for further information about the instrument’s functions; the user manual is supplied separately from this document. Where necessary, ask an Authorised FIORI Service Centre for assistance. 66 DB 460 REV. 00 27/07/2015 id.: OPERATION AND USE 4.2.2 4 DRIVING POST INSTRUMENT PANEL 5 6 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: indicates a fault in the parking brake circuit. 4 - Red warning light: indicates that the parking brake is engaged. 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: indicates an engine fault, the amber led on the monitor also lights up. 10 - Yellow warning light: indicates that there is water in the fuel sediment bowl. 11 - Red warning light: indicates that the hydraulic oil filter is clogged. 67 id.: DB 460 REV. 00 27/07/2015 4 OPERATION AND USE 12 - Red warning light: indicates that the hydraulic oil level is low. 13 - Yellow warning light: function not available. 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 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 (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. 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. 68 DB 460 REV. 00 27/07/2015 id.: OPERATION AND USE 4 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. B I E H G C F D 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. 69 id.: DB 460 REV. 00 27/07/2015 4 OPERATION AND USE 4.2.2.g - C- Mechanical gear selector (fig. 6). 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. The gear selector allows you to select two basic speeds: 1st gear - low or loading/unloading speed 2nd gear - high or road transfer speed To shift mechanical gear follow these instructions: - Stop the vehicle on a stable surface. - Set the selector (A) to neutral. - Depress the service brake pedal (C, Fig. 2) and simultaneously set the selector (B) to the desired gear. - If you are unable to engage the desired gear, re-engage the previously selected gear. 4.2.2.h - D - 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.i - E - 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. 70 DB 460 REV. 00 27/07/2015 id.: OPERATION AND USE 4 4.2.1.k - F - 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.l - G - Hazard light toggle switch (fig. 6). Snap switch to turn on the four hazard warning lights. 4.2.1.m - H - Working light switch (fig. 6). Snap switch to turn on the rear working lights. 4.2.2.n - I - Red warning light engine fault indicator (fig. 6). Lights up in the presence of an engine fault; the red led on the monitor also lights up. 71 id.: DB 460 REV. 00 27/07/2015 4 OPERATION AND USE 5 6 10 0 1 1 2 3 18 7 4.2.2.o 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. During this phase the engine will not start, 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), while the warning light that indicates that there is water in the fuel sediment bowl (10) will emit only a test flash. Subsequently, at the bottom of the numerical display (18) will be displayed, simultaneously and for 5 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. When the ignition key is released from the positions 2 and 3 it automatically returns to this position. 2 Position not activated 3 Starting position Activates the starter motor that turns the engine. As soon as the engine starts, the engine rpm is displayed on the parameter control monitor. 72 DB 460 REV. 00 27/07/2015 id.: OPERATION AND USE 4 3 1 2 8 4.2.2.p 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. 73 id.: DB 460 REV. 00 27/07/2015 4 OPERATION AND USE 4.2.3 OPERATING CONTROL PANEL D C A B 9 4.2.3 a - A - Drum traverse swinging lever (fig. 9). The lever controls rotation of the fifth wheel of the drum. Before turning the drum, lift it from its seat by releasing the safety stop (see chapter 3.5 Fig. 3 O) Position 1 - Clockwise drum traverse swinging. Position N - Neutral. Position 2 - Anticlockwise drum traverse swinging. 4.2.3 b - B - Drum raising lever (fig. 9). The lever controls drum raising. Follow the instructions below: Position 1 - Drum raising. Position N - Neutral. Position 2 - Drum lowering. 74 DB 460 REV. 00 27/07/2015 id.: OPERATION AND USE 4 4.2.1.c - C - Unloading chute control lever (fig. 9). This lever allows tilting the unloading chute using a jack. This operation can be carried out from the driver’s seat. Shifting the lever to the right, the chute is tilted downward and to the left upward. 4.2.3 d - D - Joystick for arm raising and bucket/loader rotation (fig. 9 - 10). F 3 F N 1 D 2 E F 1 4 3 E 4 2 10 The joystick controls arm raising and loader rotation. Arms / hydraulic hatch: Position “1” - Arm lowering: only with button E pressed to prevent accidental manoeuvres. Position “2” - Arm raising: without pressing button E. Bucket / loader Position “3” - Downward loader rotation. Press button F to close the hydraulic loader hatch. Position “4” - Upward loader rotation. Press button F to open the hydraulic loader hatch. Position “N” - Neutral. 75 id.: DB 460 REV. 00 27/07/2015 4 OPERATION AND USE 4.2.4 WATER FEEDING AND DISTRIBUTION CONTROLS (fig. 11). B 1 2 F H D E C A 11 The following parts control feed and distribution of the mixing and washing water: A – Suction coupling - Water suction from external water sources (tanks, ditches, etc.) by means of a flexible suction hose E. - Water suction from the vehicle tank. B – Delivery switching valve Position 1 - Water delivery to the drum from an external source or from the vehicle tank. Position 2 - Water delivery to the tank from an external source. C – Litre counter Totals the amount of water pumped into the drum and shows it on the driving post and the Mix Control display. D – Water suction pump Self-priming volumetric pump with bronze impeller. E – Flexible suction hose with suction filter F To be positioned in the water source involved: reservoir, ditch, external tank, etc. G – Washing nozzle Used to wash the bucket, drum and chute and is positioned at the rear of the vehicle. To be connected to the union H of the switching valve B turning the lever to position 2. 76 DB 460 REV. 00 27/07/2015 id.: 4 OPERATION AND USE 4.2.5 GROUND CONTROL PANEL (MIX CONTROL) (OPTIONAL) (fig. 12). A E D C B 12 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 4.2.6. 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. 77 id.: DB 460 REV. 00 27/07/2015 4 OPERATION AND USE 4.2.6 OPERATION OF THE ELECTRONIC LITRE COUNTER AND MIX CONTROL PROGRAMMING Note: if the FIORI BATCH CONTROLLER is installed on the machine, value 0000 must be set to disable the 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. 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. 78 DB 460 REV. 00 27/07/2015 id.: OPERATION AND USE 4 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 13 4.3.1 REFUELLING (fig. 13) - 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. 79 id.: DB 460 REV. 00 27/07/2015 4 OPERATION AND USE 2 4 3 1 5 14 4.3.2 LEVEL CHECK (fig. 14) 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. B 1 A 2 C D 15 4.3.3 FILLING THE WATER TRANSFER PUMP BODY (fig.15). For proper operation of the self-priming pump, this must contain water. Remove the closing cap C and take out the pre-filter D. Check that it contains water through the suction pipe union A. If there is no water, refit the pre-filter D, fill the pump body with water through the suction union A holding the 80 DB 460 REV. 00 27/07/2015 id.: OPERATION AND USE 4 delivery switching valve B in position 1 or 2 but not in the central position. Finally, refit the closing cap C. 3 2 1 16 4.3.4 ADJUSTING THE SEAT (fig. 16) 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. . 1 17 4.3.5 ADJUSTING THE REAR-VIEW MIRROR (fig. 17) CAUTION: Operation to be carried out before starting the vehicle. To adjust the field of vision of the sideview mirror (1), turn it so that you can see the rear left-hand side of the vehicle as shown in the figure. 81 id.: DB 460 REV. 00 27/07/2015 4 OPERATION AND USE B A 1 2 2 18 4.3.6 DRIVING POST PIVOTING (fig. 18) 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. 82 DB 460 REV. 00 27/07/2015 id.: OPERATION AND USE 4 1 2 3 4 19 4.3.7 STARTING THE ENGINE (fig. 19) 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. 83 id.: DB 460 REV. 00 27/07/2015 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 ADJUSTING WHEEL ALIGNMENT CAUTION: The steering must be selected with the machine stationary. Whenever you drive on the road or for long stretches, it is essential to check proper alignment of the four wheels to prevent running into translation problems. To align the four wheels, operate as follows: Turn the steering wheel to move the rear wheels into a straight line with the vehicle. Shift the selection lever to the “2 RS” position and use the steering wheel to align the front wheels with the rear ones (visually check). Select the type of steering based on the type of translation to be performed with the vehicle. After this procedure the steering will be synchronized. During translation with “2 RS” the rear wheels remain in fixed position thanks to a check valve. 4.3.10 PARKING BRAKE (fig. 19) CAUTION: When the engine is turned on, the parking brake automatically disengages if the button (1) is released. The next time the vehicle is turned off the parking brake automatically engages because the residual pressure is cancelled out. DANGER: Do not use the parking brake to slow down the vehicle, except in emergencies, as the vehicle would stop suddenly reducing the efficiency of the brake. To disengage it, turn the button (1) and release it. For temporary stops on slopes or where necessary engage the parking brake by pressing the button (1). To release the brake in the event of a braking system failure, see chapter 4.5.1. 84 DB 460 REV. 00 27/07/2015 id.: OPERATION AND USE 4 4.3.11 STARTING AND DRIVING THE VEHICLE (fig. 20) A E C B F D 20 CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out as set out in Chapter 3. - Start the engine following the procedure described above. - Keep the engine running for the time required to warm up the hydraulic system oil. - Disengage the parking brake. - Check that the hand accelerator (D) is set to “0” and the selector (A) is in neutral position. If the hand accelerator (D) is set to “1”, the machine does not move when the selector (A) is moved to the desired driving direction. - Depress the service brake pedal (B) and simultaneously set the selector (C) to the desired gear while at the same time turning the steering wheel to the right and left so as to facilitate the meshing of the gear, with lever (E) in position “4RS”. - If you are unable to engage the desired gear, re-engage the previously selected gear. - Set the gear selector to low gear for driving on steep slopes or to high gear for flat stretches. CAUTION: Mechanical gears must only be selected with the vehicle stationary and stable. - Set the gear selector (A) to the desired driving direction. - Check that you can safely move forward, then start depressing the accelerator pedal (F) to move the machine. DANGER: Steer maintaining an adequate speed and act gradually on the steering wheel, especially when you are on a slope. 85 id.: DB 460 REV. 00 27/07/2015 4 OPERATION AND USE 4.3.12 FIELD OF INDIRECT VISIBILITY OF THE REAR OF THE VEHICLE (Standard only for specific countries) (fig. 21) CAMERA: FAR FILED OF VIEW CAMERA: NEAR FIELD OF VIEW 1mt. 1 3 2 21 Looking at the images on the display (2) transmitted by the camera (1) and using the rearview mirror (3), you have a wide view of the area behind the vehicle. This allows you to safely reverse from and approach the unloading area. CAUTION: For the display (2) operation, refer to its user manual that comes with the vehicle. DANGER: Check that the display (2) is properly set for direct visibility (NO MIRROR). 86 DB 460 REV. 00 27/07/2015 id.: OPERATION AND USE 4 4.3.13 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. 4.3.14 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. 4.3.15 PARKING THE VEHICLE CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out as set out in Chapter 3. CAUTION: 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. 87 id.: DB 460 REV. 00 27/07/2015 4 OPERATION AND USE 4.4 TRANSPORTING THE VEHICLE (fig. 22) 6440 2975 > 4000 900 10-15% 22 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. 88 DB 460 REV. 00 27/07/2015 id.: OPERATION AND USE 4 4.4.1 LIFTING THE VEHICLE WITH A CRANE (fig. 23) 3100 1650 1 10° 10° DRY WEIGHT 7.300 KG 1700 23 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. 89 id.: DB 460 REV. 00 27/07/2015 4 OPERATION AND USE 4.5 TOWING AND RECOVERY (fig. 24) 1 24 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 until reaching a trailer and recovery vehicle. 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. Shift the gearbox lever to neutral Disengage the parking brake (see procedure 4.5.1). Connect a suitable tow bar to the front lifting couplings (1). Turn on the emergency lights and the revolving lamp. An operator must be on board the vehicle, properly seated in the driver’s seat with the seat belt fastened and the driving turret facing the preferential direction of travel, with the steering lever on 2RS, in order to control and stop it. If the vehicle has to be steered, make sure you understand the actions of the person driving the towing vehicle. Follow his instructions and comply with all the relative regulations. Bear in mind that the steering wheel is harder to turn if the engine is off. - Use a vehicle that is capable of towing a weight of more than 16,500 kg with full load and 7,300 kg when empty. - When you have finished the towing operations, restore the parking brake and the gearbox. CAUTION: Take the machine to an AUTHORISED FIORI SERVICE CENTRE to have the safety valve calibration checked and corrected as required. 90 DB 460 REV. 00 27/07/2015 id.: OPERATION AND USE 4 4.5.1 RELEASING THE PARKING BRAKE IN THE EVENT OF A BRAKE SUPPLY SYSTEM FAULT (fig. 25) 1 1 1 1 25 Carry out this operation on a flat surface after blocking the wheels with wedges. - Tighten the four screws (1) of the axles using a no. 14 wrench tightening them by one turn each one after another in sequence until they are at the end of travel mechanically releasing the brake. - To resume the brake original conditions, follow the above procedures in reverse order. 4.5.2 GEARSHIFTING TO NEUTRAL (fig. 26) 3 4 2 26 - Loosen the two hydraulic pipings (2). - Loosen the plug (3) using a no. 22 socket wrench (not reinforced) and move the shaft (4) until it offers no resistance, meaning that the gear is disengaged. - To resume the gearbox original conditions, follow the procedures described above in reverse order. 91 id.: DB 460 REV. 00 27/07/2015 4 OPERATION AND USE 4.6 DRIVING ON PUBLIC ROADS (fig. 27) 1 4 2 3 27 CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out as set out in Chapter 3. CAUTION: THE STEERING SELECTOR MUST BE POSITIONED ON 2 STEERING WHEELS - Direct the driving post in the preferential driving direction. Activate all the safety devices as indicated in chapter 3.6. 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. With the vehicle stationary, shift the gear lever to 2nd gear for transfers on flat surfaces or moderate slopes, or to 1st gear for medium to steep slopes. - Keep an eye on the instruments and check that they function properly. - Strictly observe the road regulations. If traffic slows down, move onto the hard shoulder to allow faster vehicles to pass. CAUTION: If you need to change a tyre, make sure that the type and tread are those 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. 92 DB 460 REV. 00 27/07/2015 id.: OPERATION AND USE 4 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 2 1 28 At the end of each work shift, empty the plastic water tanks to prevent them from swelling and bursting. Unscrew the caps (1) as shown in the figure, positioned underneath the two tanks 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). 93 id.: DB 460 REV. 00 27/07/2015 4 OPERATION AND USE 4.8.1 SUMMER/WINTER HEATING SYSTEM (fig. 29) D B OPEN CLOSED C A 29 During the summer, or when temperatures are higher than 20°C, it is best to shut off the heating circuit, especially if you intend to use the A/C (optional). Slacken off nut A, unscrew nut B and rotate scale C; cock D is located on the chassis under the cab, turn the lever 90° CW to close the circuit. During the winter, or when temperatures are low, open the circuit by turning the valve lever 90° CCW. 94 DB 460 REV. 00 27/07/2015 id.: OPERATION AND USE 4 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. - Do not leave biodesel (where used) inside the engine supply circuit. - To keep the engine lubricated, let it run for at least 20 minutes no less than once a week. 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. 95 id.: DB 460 REV. 00 27/07/2015 4 OPERATION AND USE 4.10.1 CORRECT USE OF THE VEHICLE During transfer the operator should keep the driving post turned toward the front of the machine. When driving on public roads follow the specific safety rules of chapter 3. Working in worksite the operator should proceed with the machine in transfer lay out. If it is necessary to proceed with the turret rotated working phase (e.g. unloading operations for foundations, inability to maneuver, etc.), ask for a person to stand on the ground who can give useful info with manual signals for delimiting an advancement area of more than 12 m. 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).................................... 23° (41.6%) Maximum permissible gradient on steep roads during transfer: front .................................................................................................................................................... 14° (25%) Side ..................................................................................................................................................... 4.6° (8%) 96 DB 460 REV. 00 27/07/2015 id.: OPERATION AND USE 4 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. 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. 97 id.: DB 460 REV. 00 27/07/2015 4 OPERATION AND USE 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 98 DB 460 REV. 00 27/07/2015 id.: OPERATION AND USE 4 4.10.5 FIRST FILLING WITH MIXING WATER 4.10.5.a Filling the tanks with mixing water (fig. 33) L 2 1 B E H F A C 33 CAUTION: In the event of pump failure, check that there is water in the pump body (see chapter 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 L. You can fill from both water tanks positioned opposite each other as they are connected. - Filling with water using the transfer pump CAUTION: Check that the pre-filter is fitted inside the filler neck A of the pump, and always use the filter F during suction from water sources, since the pump may take in small parts that could damage the pump propeller. - Remove the closing cap C checking that the pre-filter is fitted, insert the flexible suction hose E into the suction pipe filler neck A of the pump. - Insert the tube leading to the tank into the delivery filler neck H. - Move the valve B to the correct position (with delivery to tank 2). - Position the flexible suction hose E in the relative water source (reservoir, external tank, ditch etc.). - Open both covers L to prevent the water tank from swelling. - Check that the suction filter F is completely immersed (the maximum difference in height from the union A 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 L. CAUTION: The pump automatically stops when the water tanks are full. 99 id.: DB 460 REV. 00 27/07/2015 4 OPERATION AND USE 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. - Filling with water from an external water source - Position the flexible suction hose E in the relative water source. Check that the hose coupling is connected to the suction pump union A and that the suction filter F is intact. - Set the switching valve B to position “1” and then continue directly filling the drum with mixing water. - Filling with water from the vehicle tank - When the tank is full, set the switching valve B to position “1” checking that the coupling of the hose leading from the vehicle tank is connected to the suction pipe union A of the pump. B A 34 4.10.5.c Activating the water transfer pump (fig. 34) - Check that all the control levers are in neutral position. - Start the engine. - Rotate the drum. - Increase 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 in the cabin 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. 100 DB 460 REV. 00 27/07/2015 id.: OPERATION AND USE 4 4.10.6 CEMENT LOADING DANGER: It is strictly prohibited to climb onto the vehicle, whether it is in the mixing phase or stationary. 35 4.10.6.a Cement in bags (fig. 35) 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. - Calculate the quantity of cement to be loaded referring to the CONCRETE COMPOSITION AND BATCHING TABLE in chapter 4.10.4. - Manually fill the bucket with cement, tearing open the bags on the serrated blade of the bucket. - Remove the paper bags. - Raise the arm to its maximum height. - Open the unloading hatch and wait until the cement has poured into the drum through the hopper, helping it along by vigorously shaking the bucket with the arm. 101 id.: DB 460 REV. 00 27/07/2015 4030 4 OPERATION AND USE 36 4.10.6.b Cement in silos (fig. 36) - Keep the drum rotating at top speed. Raise the bucket arm to its maximum height (4030 mm) Move to underneath the unloading point of the silo. Calculate the quantity of cement to be loaded referring to the CONCRETE COMPOSITION AND BATCHING TABLE in chapter 4.10.4. - Open the unloading hatch and fill the drum using the silo dosage system. 4.10.7 AGGREGATE LOADING 37 4.10.7.a Heaped aggregate (fig. 37) - 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 102 DB 460 REV. 00 27/07/2015 id.: OPERATION AND USE 4 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. 4.10.8. MIXING AND SECOND FILLING WITH WATER (fig. 38) 38 - 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. 103 id.: DB 460 REV. 00 27/07/2015 4 OPERATION AND USE 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. CAUTION: The use of drum side unloading is only permitted with the machine stationary and placed on compact ground, with slopes not exceeding 5%. E B D C A 39 4.10.9.a Concrete unloading from chute (fig. 39) - - Keep the drum rotating in the mixing direction (clockwise). Approach the unloading area. Stop the vehicle. Loosen the lever A that locks the chute B. Move the chute B directing it to the correct unloading position. Operate the lever E positioned in the driving post to adjust the chute height. This control acts on the chute tilting cylinder C. Arrange any extensions D and lock the chuteB 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 regular concrete unloading. 104 DB 460 REV. 00 27/07/2015 id.: OPERATION AND USE - 4 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). Approach and position in the new unloading area and follow all the instructions given above. B A 40 4.10.9.b Front unloading from chute (fig. 40) CAUTION: During front unloading, never lower the loader arm. The new version of the FIORI concrete mixer allows front unloading from the left-hand side, directly visible by the operator in the cabin. To make use of this new feature, some preliminary operations must be carried out to prevent damage to the engine casing and the skid unit. Proceed as follows: - Check that the engine casing is closed and at a standstill. - Lower the front left light unit A CAUTION: Move the chute back into place after unloading, as this is essential for road transfer. - Turn and lock the chute B with the mouth facing the outside of the vehicle, and secure it with a setscrew. - Raise the loader arm to its maximum height, then turn the counterframe to the desired position making sure that the arms are completely raised so as not to interfere with the engine compartment lid. - Then continue with the normal unloading operations. 105 id.: DB 460 REV. 00 27/07/2015 4 OPERATION AND USE B 24 0° FRONT DISCHARGE A SIDE DISCHARGE 41 4.10.9.c Unloading in formworks in traverse swinging mode (fig. 41) CAUTION: The unbalance due to the weight variations of the vehicle may alter the stability conditions. Therefore, be extremely careful when rotating the drum. To unload concrete into form works or foundations using the side unloading hatch operate as follows: - Keep the drum rotating in the mixing direction (clockwise). - Approach the unloading area with the forward movement line parallel to the unloading line. Stop the vehicle. - Arrange any extensions in the unloading chute. - Bring the engine rpm up to a medium speed. - Direct the rotary frame by operating the lever B that drives fifth wheel rotation. Move the chute A directing it to the correct unloading position. - Invert the drum rotation direction for unloading by acting on the selector in the cabin. - Accelerate the engine and 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. - Visually inspect regular concrete unloading. - Drive slowly in the working direction, avoiding sudden braking or acceleration. 106 DB 460 REV. 00 27/07/2015 id.: OPERATION AND USE 4 4.10.9.d Direct unloading from hopper (fig. 42 - 43) A B C 42 The concrete can be unloaded directly from the hopper by removing the unloading chute A. In this way, you can use a maximum height of 2,130 mm. - Remove the 2 screws B from the relative supports. - Remove the chute A with its mount. - Remove the chute tilting cylinder C. - Keep the drum rotating in the mixing direction. - Approach the unloading area. - Stop the vehicle. 2130 2130 43 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. - For side unloading, orient the rotary frame in the most appropriate position. - 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. 107 id.: DB 460 REV. 00 27/07/2015 4 - OPERATION AND USE Raise the drum but not necessarily to its maximum height. Visually inspect regular concrete unloading. 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). Approach and position in the new unloading area and follow all the instructions given above. 4.10.9.e Concrete unloading from drum emergency door DANGER: This operation must be performed by Authorised FIORI Workshops qualified personnel. 108 DB 460 REV. 00 27/07/2015 id.: OPERATION AND USE 4 4.10.10. BUCKET, DRUM AND CHUTE WASHING (fig. 44) B G 2 44 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. - Connect the washing nozzle G to the pump delivery. Set the switching valve B to position “2” - Externally wash the bucket, drum and chute as well as all the parts normally soiled with concrete. - Raise the drum. - Change drum rotation from clockwise to anticlockwise. - Drain 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. 109 id.: DB 460 REV. 00 27/07/2015 4 OPERATION AND USE 4.10.11. INTERNAL CLEANING OF THE MIXING DRUM (fig. 45) 45 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 4.10.10, 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. 110 DB 460 REV. 00 27/07/2015 id.: 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. 111 id.: DB 460 REV. 00 27/07/2015 5 MAINTENANCE 5.1.1 VISUAL EXTERNAL INSPECTION (fig. 1) C A G B D E 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- Transmission G- Jacks and pins 5.1.2 CLEANING THE VEHICLE Clean the vehicle with water. Pay particular attention to the bottom of the vehicle. Do not let mud to deposit under the engine and the transmission. Check that the radiator grille is not clogged. 112 DB 460 REV. 00 27/07/2015 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 M30 T-wrench 6 - no.1 flat-blade/cross-slotted screwdriver 7 - no.1 manual grease pump 113 id.: DB 460 REV. 00 27/07/2015 5 MAINTENANCE 5.1.4.2 ROUTINE MAINTENANCE AND CHECKS (fig. 2) B A C 2 CAUTION: Never open the various access doors if the machine is not parked on a flat surface with the engine off and the parking brake engaged. - Driving post To access the use and maintenance manual and the fuses and relays, open the driving post door (A) with the key provided. To access the windscreen washer water tank, undo the screws of the panel (B). - Engine compartment lid Unlock the lid (C) with the key provided and raise it to access the following parts: - Engine oil cap, level gauge and filter - Engine accelerator cables - Starter motor and alternator - Hydraulic oil tank cap - Radiator - Engine air filter - Hydraulic oil filter. 114 DB 460 REV. 00 27/07/2015 id.: MAINTENANCE 5 5.2 MAINTENANCE SCHEDULE - Service - 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. Service includes a series of operations to be carried out on the vehicle after the first 100 hours of operation: - Axle oil change - 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. 115 id.: DB 460 REV. 00 27/07/2015 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 FIFTH WHEEL 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 NEGATIVE PARKING BRAKE PARKING BRAKE TEST BRAKING SYSTEM FLUID HYDRAULIC SYSTEM OPERATION OF THE HYRAULIC SERVICE DEVICES HYDRAULIC SYSTEM OIL HOSE RUBBING AND DAMAGE HYDRAULIC OIL TANK CAP BLEEDER HYDRAULIC OIL FILTER 116 DB 460 REV. 00 27/07/2015 id.: EVERY 500 HOURS OR 12 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 500 HOURS OR 12 MONTHS EVERY 1000 HOURS OR 24 MONTHS EVERY 2000 HOURS OR 48 MONTHS DRUM REDUCTION GEAR OIL SLEVING RING REDUCTION GEAR OIL LIGHT INDICATORS AND ACOUSTIC ALARMS ELECTRIC COMPONENTS ELECTRIC EQUIPMENT OPERATION INSTRUMENT PANEL BATTERY ELECTROLYTE LEVEL PARKING BRAKE BUTTON BATTERY PINS HAND ACCELERATOR MICROSWITCH WATER SYSTEM PIVOTING POST MICRO SWITCHES LITER COUNTER WATER TRANSFER PUMP PRE-FILTER WATER TRANSFER PUMP 5.5 ENGINE MAINTENANCE SCHEDULE CAUTION: For maintenance, refer to the table on page 86 of the engine user manual, enclosed with this document. 117 id.: DB 460 REV. 00 27/07/2015 5 MAINTENANCE 5.6 RECOMMENDED LUBRICANTS AND FLUIDS TABLE DEVICE TO BE REFILLED COOLING SYSTEM ENGINE AXLES FRONT Q.TY RECOMMENDED LUBRICANT AMBIENT TEMPERATURE IN ° C VISCOSITY INTERNATIONAL CLASSIFICATION ETHYLENE GLYCOL B.S. 6580.92 20 l ENI ANTIFREEZE EXTRA 50% ETHYLENE GLYCOL 50% WATER -35° ÷ +50° 6,75 kg TITAN CARGO 5W 40 82,7 mm2/s (40°) 14,3 mm2/s (100°) -25° ÷ +50° ACEA E9 - E7 API GJ-4 CAT ECF-2/ECF-3 ENI MULTI-THT/SL80W 72 CTS 80W -25° ÷ +50° API GL 4 141 mm2/s (40°C) -21° ÷ +200° ISO-L-CKD DIN 51517 TEIL 3 CLP ANSI / AGMA 9005 - 94 CAS 101316 - 72 - 7 CAS 64741 - 95 - 3 ASTM D 3306 ASTM D 4985 ASTM D 1384 CUNA NC 956-16 7 kg AXLES REAR 6.75 kg 4 HUBS 2.85 kg GEARBOX 1.45 kg DRUM REDUCTION GEAR 2.5 kg ENI BLASIA 150 FIFTH WHEEL REDUCTION GEAR 1 kg Q8 GOYA 150 150 mm2/s (40°C) -27° ÷ +240° ENI ARNICA 22 22 -27° ÷ +25° ARNICA 46 46 -10° ÷ +35° ARNICA 68 68 -3° ÷ +45° 20 CTS -40° ÷ +50° PSA-B-712710 ISO 7308 -40° ÷ +50° GREASE NLGI 1 HYDRAULIC SYSTEM 125 l BRAKING SYSTEM 0.75 l ENI LHM SUPER VARIOUS GREASING PRODUCTS 0.5 kg ENI GR LP1 FUEL TANK DIN51524 PARTE 3HVLP CETOP RP 91H HV ISO L-HV DENISON HF0-HF2 DIESEL ASTM N2 95 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. 5.6.1 DIESEL FUEL REQUIREMENTS The Engine manufacturer is not in a position to continuously evaluate and monitor all worldwide distillate diesel fuel specifications that are published by governments and technological societies. The Specification for Distillate Diesel Fuel provides a known reliable baseline in order to judge the expected performance of distillate diesel fuels that are derived from conventional sources. Satisfactory engine performance is dependent on the use of a good quality fuel. The use of a good quality fuel will give the following results: long engine life and acceptable exhaust emissions levels . The fuel must meet the minimum requirements that are stated in the table. 118 DB DB 460 460 REV. REV. 00 01 27/07/2015 05/11/2015 id.: MAINTENANCE 5 Note: The footnotes are of the key part Specification for Distillate Diesel Fuel Table. Read ALL of the footnotes. SPECIFICATION FOR DISTILLATE DIESEL FUEL (1) Property UNITS Requirements ASTMTest ISOTest Aromatics %Volume 35% maximum D1319 I SO3837 Ash %Weight 0,01% maximum D482 ISO6245 Carbon Residue on 10% Bottoms %Weight 0,35% maximum D524 ISO4262 Cetane Number(2) Cloud Point 40 minimum °C Copper Strip Corrosion D613/D6890 ISO5165 The cloud point must D2500 not exceed the lowest expected ambient temperature. N. 3 maximum D130 ISO3015 ISO2160 Density at 15 °C (59 °F)(3) Kg/m3 801 minimum and 876 maximum No equivalent test ISO 3675ISO 12185 Distillation °C 10% at 282 °C (539.6 °F) maximum 90% at 360 °C (680 °F) maximum D86 ISO3405 Flash Point °C legal limit D93 ISO2719 Thermal Stability Minimum of 80% re- D6468 flectance after aging for 180 minutes at 150 °C (302 °F) No equivalent test Pour Point °C 6 °C (42.8 °F) minimum below ambient temperature D97 ISO3016 Sulfur(1) % mass 0,0015 D5453/D26222 ISO 20846ISO 20884 Kinematic Viscosity(4) mm2/s (cSt) The viscosity of the fuel that is delivered to the fuel injection pump. “1.4 minimum/ 4.5 maximum” D445 ISO3405 Water and sediment %Weight 0,1% maximum D1796 ISO3734 Water %Weight 0,1% maximum D1744 Sediment %Weight 0,05% maximum D473 D473 Gums and Resins (5) mg/100mL 10 mg per 100 mL maximum D381 ISO6246 Lubricity corrected wear scar diameter at 60 °C (140 °F).(6) mm 0,52 maximum D6079 ISO12156-1 No equivalent test 119 id.: DB DB 460 460 REV. REV. 01 00 05/11/2015 27/07/2015 5 MAINTENANCE (1) This specification includes the requirements for Ultra Low Sulfur Diesel (ULSD). ULSD fuel will have ≤ 15 ppm (0.0015%) sulfur. Refer to ASTM D5453, ASTM D2622, or ISO 20846, ISO 20884 test methods. (2) A fuel with a higher cetane number is recommended in order to operate at a higher altitude or in cold weather. (3) “Via standards tables, the equivalent API gravity for the minimum density of 801 kg / m3 (kilograms per cubic meter) is 45 and for the maximum density of 876 kg / m3 is 30”. (4) The values of the fuel viscosity are the values as the fuel is delivered to the fuel injection pumps. Fuel should also meet the minimum viscosity requirement and the fuel should meet the maximum viscosity requirements at 40 °C (104 °F) of either the ASTM D445 test method or the ISO 3104 test method. If a fuel with a low viscosity is used, cooling of the fuel may be required to maintain “1.4 cSt”or greater viscosity at the fuel injection pump. Fuels with a high viscosity might require fuel heaters in order to lower the viscosity to “1.4 cSt” at the fuel injection pump. (5) Follow the test conditions and procedures for gasoline (motor). (6) The lubricity of a fuel is a concern with ultra low sulfur fuel. To determine the lubricity of the fuel, use the ISO 12156-1 or ASTM D6079 High Frequency Reciprocating Rig (HFRR) test. If the lubricity of a fuel does not meet the minimum requirements, consult your fuel supplier. Do not treat the fuel without consulting the fuel supplier. Some additives are not compatible. These additives can cause problems in the fuel system. Engines that are certified with the fuel that is prescribed by the United States Environmental Protection Agency. Engines that are manufactured are certified with the fuel that is prescribed by the European Certification. The Engine manufacturer does not certify diesel engines on any other fuel. Note: The owner and the operator of the engine has the responsibility of using the fuel that is prescribed by the EPA and other appropriate regulatory agencies. CAUTION: Operating with fuels that do not meet the Engine manufacturer recommendations can cause the following effects: Starting difficulty, reduced fuel filter service life, poor combustion, deposits in the fuel injectors, significantly reduce service life of the fuel system, deposits in the combustion chamber and reduced service life of the engine. CAUTION: The diesel engine must be operated using Ultra Low Sulfur Diesel. The sulphur content of this fuel must be lower than 15 PPM. This fuel complies with the emissions regulations that are prescribed by the Environmental Protection Agency of the United States. The fuel specifications that are listed in the table are released as acceptable to use on engine. Acceptable Fuel Specification for the 854 Engines (1) Fuel Specification Comments EN590 European Automotive Diesel Fuel (DERV) ASTM D975 GRADE 1D S15 “North American Light Distillate Diesel fuel with less than 15 PPM sulfur level” ASTM D975 GRADE 2D S15 “North American Middle Distillate general purpose Diesel fuel with less than 15 PPM sulfur level” JIS K2204 “Japanese Diesel Fuel” Must meet the requirements that are stated in the section “Lubricity”. BS 2869: 2010 CLASS A2 or EU equivalent “EU Off Road Diesel fuel. Acceptable from 2011 MUST have less than 10 PPM sulfur level” (1) All the fuels must comply with the specification in the table Specification Distillate Diesel Fuel. 120 DB 460 460 DB REV. 01 00 REV. 27/07/2015 05/11/2015 id.: MAINTENANCE 5 5.7 GENERAL INSPECTIONS 5.7.1 GREASE (fig. 3) A 9 12 9 1 8 10 12 7 13 6 5 11 7 8 2 4 3 2 3 4 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. 1 WORKING AREA PIVOTING DRIVING POST Q. EVERY 40 HOURS OF EVERY 160 HOURS OF EVERY 8 HOURS OPERATION OR WEEKLY OPERATION OR MONTHLY OR DAILY 1 X 2 AXLE HUBS 4+4 X 3 TRANSMISSION SHAFT 3 X 4 OSCILLATING CHASSIS 2 5 MIXER ROTATION SAFETY STOP DEVICE 1 6 DRUM LIFTING CYLINDERS 2+2 X X X 7 ARM LIFTING CYLINDERS 2+2 X 8 LOADER CONNECTING ROD AND TIE-ROD 3+3 X 9 LOADER CYLINDERS 2+2 X 10 MIXER ROLLERS 1+1 X 1 X 2+2 X 11 UNLOADING CHUTE 12 LIFTING ARM 13 MIXER ROTATION FIFTHWHEEL 2 X 121 id.: DB 460 REV. 00 27/07/2015 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 FIFTH WHEEL LUBRICATION (fig. 5) A C B 5 - Park the vehicle on flat ground and make sure the drum is empty. - After the drum has been raised, engage the drum descent stop lock by turning the two handles A of the lifting cylinder cocks, lastly turn it so the rack can be accessed easily. - Turn the engine off, take the ignition key out and make certain the parking brake is on. - Lubricate pinion C with grease using a hard bristle brush. - Grease the internal rack B with the nipples. 122 DB 460 REV. 00 27/07/2015 id.: MAINTENANCE 5 5.7.4 SCRAPER BLADE AND LOADING BUCKET HATCH BELLOWS (fig. 6) B A 6 - Check the wear and tear of the scraper blade A on the loading bucket and replace it if damaged. - Check that bellows B protecting the cylinder rods are in proper working order and replace them if damaged. 123 id.: DB 460 REV. 00 27/07/2015 5 MAINTENANCE 5.8 AXLE AND WHEELS 5.8.1 CLEANING THE AXLE AND DIFFERENTIAL BLEEDERS (fig. 7) 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 bleeders (1) located on both the axles and the differentials. 5.8.2 CHECKING AND TOPPING UP THE OIL LEVEL IN THE FRONT AND REAR AXLES (fig. 7) 1 2 1 A 2 3 B 3 2 4 3 7 CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out as set out in Chapter 3. CAUTION: The gearbox housing A is connected to the axle B, therefore the optimal oil level of the axle corresponds to that of the gearbox housing. - 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 (2) and the level gauge caps (3) - (4) (in horizontal position). - If oil trickles from the level gauge caps (3) - (4) , it is not necessary to top up; if not, top up using a funnel adding oil through the filler cap (2) and the level gauge cap (4) until reaching the optimal level. - Screw all the caps back on after topping up. 124 DB 460 REV. 00 27/07/2015 id.: MAINTENANCE 5 5.8.3 REPLACING THE OIL IN THE FRONT AND REAR AXLES (fig. 8) 4 4 1 3 3 1 4 2 1 3 8 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. - Turn the engine off and apply the parking brake. - Loosen drain plugs (1) and (2). Plug (2) is to be set in lower position through the planetary reduction gear rotation. - Loosen the oil level cap (3). - Let oil flow out completely. - Move the planetary reduction gear with cap (2) back into position as shown in the figure. - Loosen the filling up plug (4). - With a funnel put the recommended type of oil in through the filling up cap (4) until it starts dripping from the level hole (3) and (2). 125 id.: DB 460 REV. 00 27/07/2015 5 MAINTENANCE 5.8.4 CHECKING AND ADJUSTING THE TYRE PRESURE (fig. 9) 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 18 - 19,5 14PR PRESSURE WHEEL NUT TIGHTENING TORQUE 5,4 bar 630 Nm 9 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. 126 DB 460 REV. 00 27/07/2015 id.: MAINTENANCE 5 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 10 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. 11 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. 127 id.: DB 460 REV. 00 27/07/2015 5 MAINTENANCE B C B A 12 CAUTION: Jack up the vehicle ONLY when the drum is empty and in rest position. Ensure that there are always 3 wheels resting on level and solid ground. DANGER: The front axle is oscillating and, during lifting, there is a risk of crushing your limbs between the axle and the chassis. Incorrectly jacking up may moreover cause the vehicle to overturn posing a grave risk to anyone working in the vicinity. CAUTION: Pay attention to the support area underneath the jack; this area must be capable of supporting the entire weight of the vehicle. Fit the jack A under the central body B of the front axle. To replace the rear tyres, fit the jack A under the screwed-on plate C of the axle shaft or, in the case of a roundsection axle shaft, fit an adapter (fork) in the jack. Slowly jack up the vehicle until the arch rests on the chassis, then continue jacking up slowly until the deflated tyre lifts off the ground and then proceed with repairing it. 128 DB 460 REV. 00 27/07/2015 id.: MAINTENANCE 5 D 13 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. 14 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. 129 id.: DB 460 REV. 00 27/07/2015 5 MAINTENANCE 5.9 BRAKES 5.9.1 CHECKING AND TOPPING UP THE BRAKE FLUID LEVEL (fig. 15) A 15 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. 15) 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. 130 DB 460 REV. 00 27/07/2015 id.: MAINTENANCE 5 5.9.3 REPLACING THE BRAKING SYSTEM FLUID (fig. 16) A B 16 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. - 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. 131 id.: DB 460 REV. 00 27/07/2015 5 MAINTENANCE 5.9.4 TESTING THE HAND BRAKE (fig. 17) 1 17 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. The efficiency of the hand brake helps ensure that the machine will remain still under full load on a gradient of 25%. - Ensure that the parking brake button (1) is fully pressed down. - If you notice that the vehicle moves, contact an AUTHORISED FIORI SERVICE CENTRE. CAUTION: Do not use the vehicle if the parking brake is not fully efficient. 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. 132 DB 460 REV. 00 27/07/2015 id.: MAINTENANCE 5 5.10 HYDRAULIC SYSTEM 5.10.1 CHECKING THE HYDRAULIC OIL (fig. 18) MAX MIN A 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. - 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. Open the engine compartment lid. Check the hydraulic oil level with the dipstick A. If it needs topping up, add oil through the filler neck. 5.10.2 REPLACING THE HYDRAULIC OIL TANK BLEEDER (fig. 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. - 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. 133 id.: DB 460 REV. 00 27/07/2015 5 MAINTENANCE 5.10.3 CHANGE THE HYDRAULIC OIL FILTER CARTRIDGE (fig. 19) C A 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 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. - Raise the engine compartment lid. Remove the level gauge and filler cap. A and the filter cover C. Remove the cartridge D. Manually refit the new cartridge D taking care to correctly position the seals. Clean and refit the filter cover C, taking care to correctly position the seal. Check the level in the tank with the dipstick A and if topping up is required, fill with the specified oil until reaching the indicated level, then screw the filler cap A back on. - 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. 134 DB 460 REV. 00 27/07/2015 id.: MAINTENANCE 5 5.10.4 REPLACING THE HYDRAULIC OIL (fig. 20) MAX MIN A B E 20 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. - Raise the engine compartment lid. Remove the bleeder and filler cap A. Unscrew the drain cap B and drain all the oil from the tank into a container. When the tank is empty, screw the drain cap B back in and fill the tank with the recommended oil until reaching the required level, checking with the dipstick A. - 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. - Bleed any air that may have formed in the system by loosening the bleeder pipe E. 135 id.: DB 460 REV. 00 27/07/2015 5 MAINTENANCE 5.10.5 CHECKING AND TOPPING UP THE DRUM REDUCTION GEAR OIL LEVEL (fig. 21) B C A 21 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. - If you need to top up, unscrew the cap B and add oil until reaching the optimal level. CAUTION: Do not add oil through the air valve C. 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 and the filler cap B then drain out all the oil into a prearranged container. Screw the level gauge cap back on and then turn the drum so that the level gauge hole A is in horizontal position and the filler cap hole B positioned at the top. - Fill with the recommended oil using a syringe. - Screw the filler cap B back on. 136 DB 460 REV. 00 27/07/2015 id.: MAINTENANCE 5 5.10.7 REPLACING THE DRUM REDUCTION GEAR OIL (fig. 22) B 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 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. - Work from underneath the vehicle to access the reduction gear. Unscrew the drain cap A and drain out all the oil into a prearranged container. Add the specified oil through the filler cap B using a syringe. Screw the caps A and B back on. 137 id.: DB 460 REV. 00 27/07/2015 5 MAINTENANCE 5.11 ENGINE 5.11.1 CLEANING THE ENGINE AIR FILTER SEPARATOR (fig. 23) A 23 - 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. 24) B A C E D 24 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. 138 DB 460 REV. 00 27/07/2015 id.: MAINTENANCE - 5 Open the engine compartment lid and check the air filter. Release the two hooks D and remove the cover A. Remove the cartridge B and replace it with a new one if necessary. Remove cartridges B and C, clean cartridge B by tapping its front E gently several times onto a flat surface; do not use compressed air. 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. If cartridge C is soiled, do not attempt to clean the cartridges, replace them both. Before refitting the cartridge, clean the inside of the filter body and the separator. Refit the cartridge and make sure that it is properly in place. Close the cover A. It is essential to keep a stock of spare cartridges B 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. 25) A MIN 25 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. - Check the fluid level in the tank. - If the level is low, wait until the fluid has reached ambient temperature, slowly unscrew the cap A and top up until reaching the optimal level. 139 id.: DB 460 REV. 00 27/07/2015 5 MAINTENANCE 5.11.4 REPLACING THE ENGINE COOLANT (fig. 26) A B MAX C D 26 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: 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. 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. 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 fluid reaches the ambient temperature. - Slowly unscrew cap A of the introduction tray B. - To drain all the fluid out, slacken off screw C to vent any air, place a container under the radiator and remove cap D to drain it. - Screw cap D andthe screw C back in, then slowly add the recommended fluid in the tank B up to the maximum level. - Screw the cap A back on. - Close the engine compartment lid. - Start the engine and let it run for a few minutes. - Let the engine cool down. - Check the fluid level in the tank B and top up if necessary. 140 DB 460 REV. 00 27/07/2015 id.: MAINTENANCE 5 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 FUEL SEDIMENT BOWL (fig. 27) 27 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. 141 id.: DB 460 REV. 00 27/07/2015 5 MAINTENANCE - Move the vehicle onto flat ground, engage the parking brake, turn off the engine and remove the ignition key. - Open the engine compartment lid; the bowl is positioned on the left-hand side of the engine. - It does not require particular care, only check that there is fuel in the injection circuit. - Periodically check if the sediment bowl is clogged or contains water. - Always bleed the air from the system after cleaning the bowl. 5.11.7 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. 5.11.8 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. 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. 142 DB 460 REV. 00 27/07/2015 id.: MAINTENANCE 5 5.11.9 CHECKING AND TOPPING UP THE ENGINE OIL LEVEL (fig. 28) B A 28 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. 143 id.: DB 460 REV. 00 27/07/2015 5 MAINTENANCE 5.11.10 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. 5.11.11 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. 5.11.12 DIESEL PARTICULATE FILTER REGENERATION The DPF (Diesel Particulate Filter) uses passive regeneration in order to remove the soot from the DPF. Passive regeneration is a chemical reaction within the system. Normal operation of the engine creates enough heat for a chemical reaction in order to regenerate the DPF. The regeneration occurs automatically during normal engine operation. This system uses an amount of active regeneration in order to ensure that soot cannot exit the DPF. The DPF will not require manual cleaning. 144 DB 460 REV. 00 27/07/2015 id.: MAINTENANCE 5 5.11.12.1 Regeneration Indicators Five indicators can be affected by the DPF regeneration. these indicators are, Regeneration Active (A), DPF (B), Disable Regeneration (C) (Electronic engine parameter control monitor), Amber, or Yellow Warning Indicator (D) (Electronic control panel) and Red Stop Indicator. (E) (Driving post instrument panel). A - Regeneration Active: This indicator will illuminate during active regeneration. The indicator shows that elevated exhaust temperatures are possible. The indicator will be turned off when regeneration is complete. B - DPF: This indicator provides a general indication of the soot load. The indicator is off when the soot load is normal. C - Disable Regeneration: This indicator is illuminated whenever the disable switch is activated. D D E E 29 5.11.12.2 Modes of Regeneration Automatic regeneration - Automatic regeneration will occur when the level of soot reaches the trigger point that is set in the ECM. The engine can operate normally during an automatic regeneration. Manual - This operation must be carried out with the engine off and the parking brake engaged. A manual regeneration is initiated by pressing the regeneration switch (F). A forced regeneration can only be performed after the soot load has illuminated the DPF indicator . A forced regeneration will only be required if the automatic regeneration has not been completed. This situation can be due to either the disable switch (G) being operated or the duty cycle of the engine. F - Force Regeneration: Press the switch for 2 seconds in order to begin regeneration. G F G - Disable Regeneration: Press the switch for 2 seconds in order to disable regeneration. Note: You may return to normal operation at any point during a regeneration. 145 id.: DB 460 REV. 00 27/07/2015 5 MAINTENANCE 5.11.12.3 Indicator Operation Aftertreatment Aftertreatment Warning Indicator Indicator State Indicator Warning Indicator State Regeneration Active indicator (A) Description Action Required Regeneration is activated. The indicator will stay illuminated during regeneration. DPF Indicator (B) On Solid DPF Indicator (B) On Solid DPF Indicator (B) On Solid The indicator provides a general indication of the soot load. The indicator is off when the soot load isnormal. Lock the joystick by inserting the locking rod. Amber indicator Flashing (D) The indicator indicates that the soot load has increased. The engine will derate. A manual regeneration is required. Perform a manual regeneration, or a service regeneration will be required. Amber indicator Flashing (D) The flashing warning indicator and red stop indicator indicates that the engine has continued to be operated while a regeneration is required. The engine will be derated and the engine should be shut down immediately. Once the engine enters into shutdown mode, you must contact your Perkins distributor or your Perkins dealer. Your dealer or distributor will need to perform a service level regeneration. The DFP may need to be replaced. Red indicator (STOP) (E) On Solid 5.11.12.4 Regeneration Operation Regeneration will require the following conditions: - Automatic Regeneration In order for an automatic regeneration to take place the engine must be at operating temperature. Turning the keyswitch to the OFF position during a regeneration will stop the regeneration. An interrupted regeneration will not remove the soot from the DPF and will waste fuel. - Manual Regeneration The DPF indicator must be illuminated. Where applicable, safety interlock for your application must be engaged before a manual regeneration can occur, refer to your OEM for more information. No throttle inputs are required, the ECM will control the engine RPM. Press the force regeneration switch for 2 seconds. Do not operate the application during the manual regeneration. The regeneration time varies according to the extent of clogging of the DPF. The operation is completed when the DPF warning light (B) switches off. - Service Regeneration CAUTION: The electronic service tool will be required in order to perform a force regeneration. Contact your Perkins distributor or your Perkins dealer. 146 DB 460 REV. 00 27/07/2015 id.: MAINTENANCE 5 5.11.13 ENGINE DIAGNOSTICS (fig. 30) B A 30 CAUTION: Engine diagnostics must be run by an authorised FIORI technician. - Make sure that the vehicle is on flat ground and the parking brake engaged. - Remove the LH ABS protection cover A on the side dashboard, remove the cap B of the diagnostics socket and then insert the diagnostics connector. Now run the engine diagnostics procedure. 5.11.14 DISPLAYING ENGINE FAULT CODES ON THE PARAMETER CONTROL MONITOR (fig. 31) START SCREEN SCREEN WITH FAULT CODE 31 When the parameter control monitor receives a fault code from the engine, it displays a message with the fault code for the cause of the engine fault itself. For the meanings of the fault codes, refer to the STANDARD LIST OF ENGINE DIAGNOSTICS MESSAGES in the paragraph TECHNICAL ENCLOSURES. 147 id.: DB 460 REV. 00 27/07/2015 5 MAINTENANCE 5.12 ELECTRIC COMPONENTS 5.12.1 FUSES AND RELAYS - Driver’s seat fuses (fig. 32) 22 5 16 15 14 13 12 11 4 3 2 1 23 10 9 21 20 19 18 17 8 7 6 24 25 POS. AMPERAGE COLOUR POS. AMPERAGE COLOUR 1 15A blue 14 7,5A brown 2 7,5A brown 15 15A blue 3 10A red 16 3A violet 4 5A beige 17 3A violet 5 15A blue 18 15A blue 6 7,5A brown 19 15A blue 7 15A blue 20 15A blue 8 10A red 21 15A blue 9 10A red 22 5A beige 10 5A beige 23 10A red 11 5A beige 24 5A beige 12 3A violet 25 5A beige 13 7,5A brown 148 DB 460 32 REV. 02 00 REV. 27/07/2015 20/12/2016 id.: MAINTENANCE 5 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 parking brake control, neutral enable on forward drive control, relay (K103), neutral relay. 08 - (F108) - Power supply for acoustic indicator and rear camera (optional). 09 - (F109) - Power supply for direction indicators and stop light bulb. 10 - (F110) - Power supply for drum rotation control, frame rotation pressure gauge. 11 - (F111) - Power supply for water in the fuel, LCD instrument, 1st and 2nd gear warning lights, relay coil (K107), relay coil (K108), relay coil (K111). 12 - (F112) - Front LH and rear RH position light, power supply for rear working lights. 13 - (F113) - RH low beam headlight. 14 - (F114) - LH low beam headlight. 15 - (F115) - Power supply for additive pumps (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. 24 - Engine sensor power supply. 25 - ECM control unit power supply. 149 id.: DB 460 REV. 00 27/07/2015 5 MAINTENANCE - Fuses above the engine power takeoff (fig. 33) 28 26 29 A 30 27 33 26 - 30A - green - power supply for leisure device relay. 27 - 40A - yellow – power supply for starter motor relay and fuse/relay printed circuit board. 28 - 50A - red - start switch power supply. 29 - 60A - blue - spark plug control unit power supply (A). 30 - 30A - Maxi fuse - ECM control unit 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. - Driver’s seat relays (fig. 34) 10 9 14 8 15 7 11 6 12 5 4 13 3 2 1 34 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 - Available. 150 DB460 460 DB REV. 00 02 REV. 20/12/2016 27/07/2015 id.: MAINTENANCE 5 07 - K107 - Engine off micro relay. 08 - K108 - Micro relay for start enable without water in the fuel. 09 - K109 - A/C compressor micro relay (optional). 10 - K110 - Micro relay for rear working lights. 11 - K111 - Micro relay for machine operating acoustic indicator control. 12 - K112 - Diode module for neutral and gearshift enable. 13 - K113 - Flashing hazard lights/direction indicators 14 - K114 - Available. 15 - K115 - Available. - Relays above the engine power takeoff (fig. 35) A 16 17 35 16 - Relay for engine electronic power supply enable (main relay) 17 - Starter motor relay A - Engine spark plug control unit ATTENZIONE: Se un fusibile o un relè si brucia, trovare la causa prima di sostituirlo con uno nuovo. 5.12.2 ELECTRONIC DASHBOARD WARNING LIGHTS (fig. 36) 36 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. 151 id.: DB 460 460 REV. REV. 02 00 20/12/2016 27/07/2015 5 MAINTENANCE 5.12.3 REPLACING THE LIGHT BULBS (fig. 37) 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 C-D-G B A B 37 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 ............................................................................................................... 12V - 886 50W 152 DB 460 REV. 00 27/07/2015 id.: MAINTENANCE 5 5.12.4 CHECKING AND TOPPING UP THE BATTERY ELECTROLYTE LEVEL (fig. 38) E B D C A 38 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 vehicle. 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 D to cut the power to the system. - To access the battery loosen the nut A, unscrew the nut B and turn the ladder C. - To top up the electrolyte level, remove the caps E 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. 153 id.: DB 460 REV. 00 27/07/2015 5 MAINTENANCE 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. 154 DB 460 REV. 00 27/07/2015 id.: MAINTENANCE 5 5.13 WATER SYSTEM 5.13.1 CHECKING AND MAINTAINING THE LITRE COUNTER (fig. 39) HORIZONTAL INSTALLATION 39 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. 5.13.2 CHECKING THE WATER TRANSFER PUMP EFFICIENCY (fig. 40) B F H A C M - 40 Keep the engine running at 2000 rpm. Activate the transfer pump M. Check by means of the flow meter C that the water flow rate is higher than 250 litres/min. Also check for leaks from the valve unions B and from the suction pipe unions A and H. Check that the suction filter F is in proper working order. 155 id.: DB 460 REV. 00 27/07/2015 5 MAINTENANCE 41) A 41 To activate a pump that has stopped because of an electrical fault, remove the cap A on the control panel and, using a screwdriver, act on the distributor button to activate the pump manually. 5.13.4 CLEANING PRE-FILTER OF THE WATER PUMP (fig. 42) C D 42 Before starting the daily work shift, you must clean the pre-filter of the water pump. Remove the closing cap C from the pump, take out the pre-filter D and check whether it is dirty inside. To remove it, use a jet of clean water or compressed air. Finally, reposition it inside the filler neck and refit the closing cap C. CAUTION: Check that there is water inside th pump (see chapter 4.3.3 for the related procedure). 156 DB 460 REV. 00 27/07/2015 id.: OPTIONAL EQUIPMENT 6 6 CONTENTS 6.1 6.1.1. DRUM CLOSING HATCH.............................................................................................................. 158 OPERATION .................................................................................................................................. 158 6.2 6.2.1. 6.2.2. 6.2.3. 6.2.4. 6.2.5. 6.2.6. 6.2.7. POWER JET CLEANER .................................................................................................................. 159 TECHNICAL DATA ....................................................................................................................... 159 INSTRUCTION LABELS ON THE MACHINE ................................................................................ 159 REFERENCES AND DESCRIPTIONS OF THE MAIN DEVICES ................................................ 160 USING THE POWER JET CLEANER............................................................................................ 161 PRECAUTIONS FOR USE IN COLD CLIMATE CONDITIONS .................................................... 162 SCHEDULED MAINTENANCE TABLE .......................................................................................... 162 CLEANING OR REPLACING THE FILTER CARTRIDGE ............................................................. 163 6.3 6.3.1. 6.3.2. 6.3.3. 6.3.4. AIR-CONDITIONER....................................................................................................................... 164 OPERATION .................................................................................................................................. 164 MAINTENANCE ............................................................................................................................. 165 TECHNICAL DATA ....................................................................................................................... 166 SCHEDULED MAINTENANCE TABLE .......................................................................................... 166 157 id.: DB DB 460 460 REV. REV. 00 01 27/07/2015 05/11/2015 6 OPTIONAL EQUIPMENT 6.1 DRUM CLOSING HATCH The hatch closes the drum opening, thus avoiding concrete spillage, specially when the machine is driven on uphill stretches. B 1 6.1.1. OPERATION The hatch opens automatically when the counterframe is lifted using the lever B in the cabin (as described in chapter 4.2.3.b). The hatch is closed automatically when the counterframe is lowered by means of lever B. DANGER: Do not climb on the machine, do not place your limbs or parts of your body in the drum opening: risk of crushing if the hatch is closed inadvertently! Do not use the arms as lifting device. 158 DB 460 REV. 00 27/07/2015 id.: OPTIONAL EQUIPMENT 6 6.2 POWER JET CLEANER The high-pressure power jet cleaner allows thorough cleaning of the machine parts or other objects. 6.2.1. TECHNICAL DATA - Hydraulically-driven water cleaner pump. - Maximum oil flow rate ......................................................................................................................... 25 l/min. - Maximum water output flow rate ..................................................................................................... 16.8 l/min. - Maximum oil input pressure ................................................................................................................ 190 bar - Maximum water output pressure .......................................................................................................... 228 bar 6.2.2. INSTRUCTION LABELS ON THE MACHINE Indicates that the water filter of the power jet cleaner system must periodically be cleaned. Indicates the positions of the lever for use of the power jet cleaner or the water suction pump. 1 159 id.: DB 460 REV. 00 27/07/2015 6 OPTIONAL EQUIPMENT 6.2.3. REFERENCES AND DESCRIPTIONS OF THE MAIN DEVICES (fig. 2). C D E 2 1 L H I B F G A 2 The following parts control water feed and distribution through the power jet cleaner: A - Power jet cleaner. Positioned behind the cabin under the water suction pump. B - Low-pressure nozzle. C - High-pressure nozzle. D – Pressure regulating valve. Turning the valve clockwise releases the pressure and anticlockwise increases the pressure. E - Switch Position “1” - Water suction pump activation. Position “2”- Power jet cleaner pump activation. F - High-pressure hose. Connects the pump to the power jet cleaner. G - Water pressure gauge. Shows the pressure of the water flowing from the pump. H - Water pump. Positioned at the rear of the chassis in the tool compartment. I - Switch Turn switch lever E to position “2” to trigger the switch that enables water sensor L. If the sensor detects that there is no water flow due to the empty tank, pump H automatically stops. 160 DB 460 REV. 00 27/07/2015 id.: OPTIONAL EQUIPMENT 6 6.2.4 USING THE POWER JET CLEANER (fig. 3) C D 2 1 S H E B F G A 3 DANGER: The high energy of the pressurised jet may be extremely dangerous. Keep away from persons, animals and any delicate object when the pump is operating. Never direct the pressurised jet at persons, animals, electrical equipment and fragile parts in general. Never put your hands in the pressurised jet (RISK OF INJURY). Never leave the hose F under pressure. This may cause damage to persons or things should you involuntarily pull the trigger of the power jet cleaner. CAUTION: Wear protective goggles and clothing during use of the power jet cleaner. Always hold the power jet cleaner with both hands when it is operating. - Start the engine and engage the parking brake. - Press the switch S on the dashboard in the cabin to activate the water pump circuit. - Turn the lever of the switch Eto position (2) to activate the power jet cleaner pump H. - Open the catches and extract the power jet cleaner A , unwind the high-pressure hose F from its reel and screw it onto the power jet cleaner. - Turn the valve D on the power jet cleaner until the low-pressure nozzle B is completely open. - Hold the trigger of the power jet cleaner pulled and let the pump run until all the air has been expelled from the tubes and the water flows uniformly and continuously from the nozzles B and C . - Gradually close the valve D on the power jet cleaner until the pointer of the water pressure gauge G indicates that the operating pressure has been reached (150 bar). - Close and open the power jet cleaner two or three times to check proper functioning. Releasing the trigger, the pump must stop and restart as soon as the trigger is pulled again; the pressure gauge reading must drop by 10-15 bar to return to the set value. - When you have finished work, fully open the low-pressure nozzle B of the power jet cleaner. - Turn the lever of the switch E to position (1) to close the oil inlet to the pump H. 161 id.: DB 460 REV. 00 27/07/2015 6 OPTIONAL EQUIPMENT - Pull the trigger of the power jet cleaner to discharge all the residual pressure in the tubes to ground. CAUTION: If during use you notice that the pump becomes noisier and the jet discontinuous, it means that it is taking in air. Immediately open the low-pressure nozzle B and correct the fault. CAUTION: Use only nozzles with a fan-pattern jet to clean delicate surfaces, holding the nozzle 75cm away from the surface to be cleaned. CAUTION: In the event of malfunctioning, immediately contact the nearest AUTHORISED FIORI WORKSHOP. 6.2.5. PRECAUTIONS FOR USE IN COLD CLIMATE CONDITIONS If you have to work in ambient temperatures close to 0°C, the pump has to be operated without pressure for one minute with the power jet cleaner open so that any ice that has formed can melt. CAUTION: If the pump has frozen, do not operate it until the entire system has defrosted. - Clean the pump with water mixed with a solution of antifreeze for radiators or an oily lubricating and antioxidant solution. - Do not operate the pump with cold oil. - If the hoses have frozen, let them defrost before starting work. - When you have finished work, disconnect the water inlet tube and fully discharge the pressure by holding the regulating valve on the power jet cleaner open. Use the breather valve to drain out the residual water in the pump cover. 6.2.6. 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 POWER JET CLEANER PUMP POWER JET CLEANER FILTER 162 DB 460 REV. 00 27/07/2015 id.: EVERY 500 HOURS OR 12 MONTHS EVERY 1000 HOURS OR 24 MONTHS EVERY 2000 HOURS OR 48 MONTHS OPTIONAL EQUIPMENT 6 6.2.7. CLEANING OR REPLACING THE FILTER CARTRIDGE (fig. 4) B A 4 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. - Move the vehicle onto flat ground, engage the parking brake, turn off the engine and remove the ignition key. - The filter is positioned between the water tank and the rear wheel on the left-hand side of the machine. Remove the cover A. Remove the cartridge B and replace it with a new one if necessary. Remove the cartridge B and clean it with a blast of dry compressed air from the inside to the outside. After cleaning the cartridge, check that there is no internal damage using a torch to illuminate the inside. If light filters through to the outside the cartridge must be replaced. Also replace the cartridge when the rubber seal is damaged. Before refitting the cartridge clean the inside of the filter body and the separator. Refit the cartridge and make sure that it is properly in place. Close the cover A. It is essential to keep a stock of spare cartridges B, which can be ordered from the AUTHORISED FIORI SERVICE CENTRES or directly from FIORI SPARE PARTS DEPARTMENT. 163 id.: DB 460 REV. 00 27/07/2015 6 OPTIONAL EQUIPMENT 6.3 AIR-CONDITIONER The air conditioner allows air cooling inside the driver’s cabin. During the summer, or when temperatures are higher than 20°C, it is best to shut off the heating circuit, especially if you intend to use the A/C (optional). Slacken off nut A, unscrew nut B and rotate scale C; cock D is located on the chassis under the cab, turn the lever 90° CW to close the circuit. D B CLOSED C A 1 6.3.1. OPERATION (fig. 2) A B C C 2 - Start the engine. - Adjust the fan speed as desired using the knob on the switch A. Note: the air conditioner is only activated if the fan speed is set at least to the first level. 164 DB 460 REV. 00 27/07/2015 id.: OPTIONAL EQUIPMENT 6 - Adjust the temperature as desired using the knob on the thermostat B. - Direct the air flow through the adjustable air vents C. - Do not set and hold the thermostat B to the highest value and the fan switch A to the first speed, to avoid freezing the evaporator battery inside the air conditioner. - If the machine is parked in the sun for long periods of time, move the fan control (switch A and the thermostat B) to the highest level; aerate the cabin thoroughly, driving for several minutes with the windows open. - Should the system performance decrease, please contact an Authorised FIORI Service Centre or Workshop to check the quantity of refrigerant. CAUTION: The recommended temperature is 5 or 6°C. This is below the outside temperature. 6.3.2. MAINTENANCE DANGER: For specific maintenance operations on the air-conditioning system (e.g. cleaning of the condenser, radiator, air filter, and refrigerant refilling), please contact an Authorised FIORI Service Centre or Workshop. Failure to observe this instruction may lead to serious damages. DANGER: The refrigerant in the-air conditioning system is extremely dangerous. If it is sprayed into the eyes or comes in contact with the skin, immediately wash the affected parts with abundant running water and seek medical advice. In addition, to prevent explosions, do not create sparks nor use open flames in the vicinity of the system. 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: 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. CAUTION: To discharge the gas from the air-conditioning system and clean the filter A of the radiator, contact an authorized Fiori Service Centre or a workshop specialised in air-conditioning system maintenance. A 165 id.: DB 460 REV. 00 27/07/2015 6 OPTIONAL EQUIPMENT 6.3.3. TECHNICAL DATA - Gas type................................................................................................................................................ R134A - Quantity................................................................................................................................................ 0.85 kg - Recharging pressure.........................................................................................................................9 - 12 bar 6.3.4. SCHEDULED MAINTENANCE TABLE Description of the symbols used in the table: = Check and repair = Replace = Clean = Grease or lubricate REGULAR MAINTENANCE INTERVALS WORKING AREA EVERY 250 HOURS AIR-CONDITIONER GAS AIR-CONDITIONER GAS FILTER 166 DB 460 REV. 00 27/07/2015 id.: EVERY 500 HOURS EVERY 1200 HOURS EVERY 2000 HOURS 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] 167 id.: DB 460 REV. 00 27/07/2015 TECHNICAL ANNEXES HYDRAULIC DIAGRAM 168 DB 460 REV. 00 27/07/2015 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 17 18 19 20 21 22 23 24 25 26 27 28 29 31 DRUM SUPPORT ROTATION MOTOR COUNTERFRAME LIFTING JACKS SERVICE DISTRIBUTOR LOADER OPENING/CLOSING JACK ARM LIFTING JACK LOADER HATCH CLOSING JACK CHUTE LIFTING JACK CHUTE CONTROL BLOCK NEGATIVE BRAKE CONTROL UNIT - GEARBOX NEGATIVE BRAKE MECHANICAL GEARBOX SOLENOID VALVE FOR ARM LOWERING ENABLE BUCKET CONTROL SELECTOR - HATCH SAFETY VALVES WATER PUMP MOTOR FRONT AXLE REAR AXLE CHECK VALVE STEERING SELECTION DISTRIBUTOR FLOW INVERTER HYDRAULIC STEERING PRIORITY VALVE RETURN OIL COLLECTION BLOCK HEAT EXCHANGER HYDROSTATIC TRACTION MOTOR DRUM ROTATION MOTOR DRUM ROTATION PUMP HYDROSTATIC TRACTION PUMP HEAT ENGINE PRESSURISED FILTER 169 id.: DB 460 REV. 00 27/07/2015 TECHNICAL ANNEXES STANDARD LIST OF DIAGNOSTICS DESCRIPTION PARAMETER SPN Override Control Mode Requested Speed Control conditions Override Control Mode Priorit Requested Speed / speed Limit Requested Torque / Torque Limit 695 696 897 898 518 Barometric pressure Ambient air temperature 108 171 Torque Speed control Ambient Conditions Aftertreatment 1 lntermediate Gas Aftertreatment 1 Diesel Particulate Filter Differential Pressure 3251 Auxiliar l/0 Status 2 AUX l/0 #20 AUX l/0 #19 3843 3842 Make Model Serial Number 586 587 588 Requested Percent Fan DPF Regen lnhibit Switch DPF Regen Force Switch 986 3695 3696 Protect Lamp Stop Lamp Warning Lamp Flash Warning Lamp Flash Protect SPN FMl 0ccurrence SPN conversion 987 623 624 3040 3041 1214 1215 1216 1706 SPN FMl 0ccurrence SPN conversion 1214 1215 1216 1706 Clear Codes Req PGN DPF Lamp Command DPF Active Regen Status DPF Status DPF Active Regen lnhibit Switch Exhaust High Temp Lamp Command 3697 3700 3701 3703 3698 Engine Aux Shutdown 970 Component ldentification Cab Message 1 Diagnostic Message 1 Diagnostic Message 2 Diagnostic Message 3 Diesel Particulate Filter Electronic Brake Controller 171 id.: DB 460 REV. 00 27/07/2015 TECHNICAL ANNEXES Engine Configuration Engine speed at idle point 1 Percent torque at idle point 1 Engine speed at point 2 Percent torque at point 2 Engine speed at point 3 Percent torque at point 3 Engine speed at point 4 Percent torque at point 4 Engine speed at point 5 Percent torque at point 5 Engine speed at high idle, point 6 Engine Reference Torque Maximum Momentar Override Time Requested Speed Control Range Lower Limit Requested Speed Control Upper Limit Requested Torque Control Lower Limit Range Requested Torque Control Range Upper Limit Engine Default Torque Limit 188 539 528 540 529 541 530 542 531 543 532 544 534 535 536 537 538 1846 Oil Qualit Engine 0il State Prop Prop Engine Torque Mode Actual Engine - Percent Torque (HR) Drivers Demand Engine Percent Torque Actual Engine Percent Torque Engine Speed SA Controlling Engine Starter Mode Engine Demand - Percent Torque 899 4154 512 513 190 1483 1675 2432 Throttle 1 lVS Throttle 2 lVS Throttle 1 Position Percent Load at current speed Throttle 2 Position Actual Maximum Available Engine Torque 558 2970 91 92 29 3357 Nominal Friction Torque Engine Desired Engines Operating Speed As mmetr Adjust 514 515 519 Engine Rated Power Engine Rated Speed 166 189 Engine oil pressure 100 Engine coolant temperature Fuel Temperature 1 110 174 Total Engine Hours Total Engine Revolutions 247 249 Proprietar Message Electronic Engine Controller Electronic Engine Controller 2 Electronic Engine Controller 3 Electronic Engine Controller 4 Engine Fluid Level / Pressure Engine Temperature Engine Hours/Revolutions 172 DB 460 REV. 00 27/07/2015 id.: TECHNICAL ANNEXES High Resolution Liquid Fuel Consumption HR Engine Trip Fuel HR Engine Total Fuel Used 5053 5054 lnlet / Exhaust Conditions Boost pressure lntake manifold temperature Exhaust Gas Temperature 102 105 173 Trip Fuel Total Fuel Used 182 250 Fuel rate lnstantaneous Fuel Econom 183 184 Fuel Consumption Fuel Econom 0ff Highwa Engine Control Selection State Engine Alternate Rating Select State 2888 0ff Highwa Engine Control Selection Engine Alternate Rating Select 2882 (Proprietar Message) Engine Oil Life Reset Demand Forced Regeneration lnterlock Prop Prop ldle shutdown has shutdown engine ldle shutdown driver alert ldle shutdown timer state wait to start lamp Engine protection has shutdown engine 593 594 590 1081 1110 Electrical Potential Batter Potential Switched 168 158 No. of lD fields Software lD 965 234 Water ln Fuel lndicator 97 Shutdown Vehicle Electrical Power Software ldentification Water in Fuel lnformation 173 id.: DB 460 REV. 00 27/07/2015 PowerView¥ ¥ Model PV101-C User’s Guide Version 3.2 2013-04-08 00-02-0796 Catalog Section 78 Table of Contents Introduction ............................................................................... 1 Engine and Transmission Parameters .................................................................... 2 Faceplate Features ................................................................................................. 3 Navigation and Keypad Functions .......................................................................... 4 First Time Start Up ................................................................... 8 Main Menu Options ................................................................11 Go to 1-Up Display/Go to 4-Up Display ................................................................ 11 DPF Regen* .......................................................................................................... 11 Selecting a Language ........................................................................................... 13 Stored Codes ........................................................................................................ 14 Engine Configuration ............................................................................................. 14 Setup 1-Up Display ............................................................................................... 14 Setup 4-Up Display ............................................................................................... 17 Service Reminders ................................................................................................ 20 Select Units ........................................................................................................... 22 Backlight Adjustment ............................................................................................. 22 Contrast Adjustment .............................................................................................. 22 Utilities Menu ..........................................................................23 Gage Data ............................................................................................................. 23 Remove All Gages ................................................................................................ 23 Software Version ................................................................................................... 23 Fault Conversion ................................................................................................... 24 Analog Input .......................................................................................................... 25 Engine Speed Control ........................................................................................... 25 OEM Menu ...............................................................................27 MODBUS£ Setup ................................................................................................. 27 CANBUS Data Rate .............................................................................................. 28 Select Engine ECU ............................................................................................... 29 Set Source Address .............................................................................................. 30 Restore All Defaults .............................................................................................. 30 Clear Machine Hours ............................................................................................ 30 Set Machine Hours ................................................................................................ 30 Fuel Setpoints ....................................................................................................... 31 DPF Regen Menu ON/OFF ................................................................................... 31 ENG SPD CTRL Menu ON/OFF ........................................................................... 32 Faults and Warnings..............................................................33 Auxiliary Gage Fault .............................................................................................. 34 Active Fault Codes ................................................................................................ 34 Derate / Shutdown Codes ..................................................................................... 35 Acknowledging Fault Codes ................................................................................. 36 Troubleshooting .....................................................................37 Additional Contact Information ...........................................42 In order to consistently bring you the highest quality, full featured products, we reserve the right to change our specifications and designs at any time. The latest version of this manual can be found at www.fwmurphy.com. Warranty - A limited warranty on materials and workmanship is given with this Enovation Controls product. A copy of the warranty may be viewed or printed by going to www.fwmurphy.com/warranty BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT: x Disconnect all electrical power to the machine. x Make sure the machine cannot operate during installation. x Follow all safety warnings of the machine manufacturer. x Read and follow all installation instructions. Introduction Congratulations on purchasing your PowerView display, a multifunction tool that provides a window into the many parameters and service codes of modern electronic engines and transmissions. This guide is intended to help you set up your PowerView display and identify navigation basics and product features. The display’s simple navigation and powerful features allow you to quickly master the product. Additional information can be found on our website at www.fwmurphy.com/pv101/. 00-02-0796 -1- 2013-04-08 Engine and Transmission Parameters The following are some of the engine and transmission parameters which can be displayed in standard or metric units as well as in English, Spanish, French, Italian or German languages (when applicable, consult engine or transmission manufacturer for SAE J1939 supported parameters): x x x x x x x x x x Engine RPM Engine hours System voltage Percent engine load at current RPM Coolant temperature Oil pressure Fuel economy Throttle position Engine manifold air temperature Current fuel consumption 00-02-0796 -2- x x x x x x Transmission oil pressure Transmission oil temperature Transmission gear position Engine configuration parameters Active fault codes Stored fault codes 2013-04-08 Faceplate Features 00-02-0796 -3- 2013-04-08 Navigation and Keypad Functions The keypad on the PowerView display is a capacitive touch sensing system. There are no mechanical switches to wear or stick. The keys on the keypad perform the following functions: Menu – Enter or exit menu screens. Left Arrow – Scroll the screen or move the parameter selection to the left or upward. Right Arrow – Scroll the screen and move the parameter selection to the right or downward. Enter Key – Select a menu or parameter or hide/view an active fault code. 00-02-0796 -4- 2013-04-08 Basic Navigation 1. When Menu is pressed, the Main menu items display. 2. Press the Arrow Keys to move the selection bar to other menu items. 00-02-0796 -5- 2013-04-08 3. Certain menus have multiple pages. Scrolling to the top or bottom item on the current page reveals other menu items on additional pages. 00-02-0796 -6- 2013-04-08 4. When the desired item is highlighted by the cursor, pressing Enter selects that item and displays the corresponding screen. 00-02-0796 -7- 2013-04-08 1. First Time Start Up When power is first applied to the display, the Murphy logo is displayed. NOTE: Expect a 20-minute warm up for the display at temperatures of -29oC/-20oF. 00-02-0796 -8- 2013-04-08 2. If the Engine ECU is broadcasting a ‘Wait to Start' message, this screen will be shown. Engine manufacturers typically recommend against starting the engine while this message is broadcasted from the ECU. Once the ECU stops broadcasting this message, this screen will no longer be displayed. 00-02-0796 -9- 2013-04-08 3. Once the engine has started, the single engine parameter is displayed with the engine RPM. Touching the Right Arrow Key displays the coolant temperature. The screen can be changed to other parameters by touching Menu. 00-02-0796 - 10 - 2013-04-08 Main Menu Options This section describes the features listed on the Main menu of the PowerView. These menu options display whenever you touch Menu. The Arrow Keys allow you to scroll through items. Enter selects the highlighted option. Go to 1-Up Display/Go to 4-Up Display If you want to go to a different display, touch Enter. The alternate view is displayed. DPF Regen* *Murphy products are compliant with requirements for U.S. EPA Emission Standard ௅ Tier 4 Interim and EU Emissions Standard ௅ Stage IIIB for diesel engines. These engines when fitted with a DPF (Diesel Particulate Filter) can self-clean the filter of particulates. This self-cleaning is known as Regeneration. PowerView offers 3-CAN options when DPF REGEN is enabled and available in the engine ECU. For more information, find document # 1110836 on the Murphy Web site (www.fwmurphy.com). Unless selected in the OEM Menu, DPF REGEN does not display in the Main Menu. When available, the following options are presented: 00-02-0796 - 11 - 2013-04-08 1. AUTO DPF REGEN – This is the factory default. Select and PowerView sends a CAN message to the ECU to perform DPF Regeneration (regen) automatically whenever needed. 2. REQUEST DPF REGEN – Select this and a second screen, REQUEST DIESEL PARTICULATE FILTER REGEN, displays. Use this to force a regen when autoregen is not due or is inhibited by PowerView. Touch YES (Enter) and PowerView sends a request for a regen every second for 10 seconds. If the engine does not respond, PowerView defaults back to Auto DPF Regen. You may send the request again or exit without sending a request by touching CANCEL (Menu). You return to the Main menu. 3. INHIBIT DPF REGEN – In cases where regen cannot be performed due to restrictions, select this to eliminate the possibility of a regen occurring. The inhibit lamp displays when the engine ECU responds to this inhibit request from PowerView. Once this option is selected, it remains in place through power cycles. When inhibit is no longer needed, you can select a different option. 00-02-0796 - 12 - 2013-04-08 The following ISO symbols indicate regen status. In each case, the symbol displays when the parameter’s lamp status is broadcast from the ECU back to the PowerView. DPF Regen ISO Symbols Icon PGN SPN Description 64892 3697 High Exhaust Temperature (HEST) lamp indicates regeneration in process. 64892 3703 DPF Particulate Filter Restricted lamp indicates a Regen is needed. 64892 3698 DPF Inhibit lamp indicates an inhibited Regen status. Selecting a Language From LANGUAGES, you may select ENGLISH, ESPANOL, FRANCAIS, ITALIANO, or DEUTSCH. An asterisk to the right of the language indicates it is selected. 00-02-0796 - 13 - 2013-04-08 Stored Codes Select this and PowerView requests and displays stored fault codes from the engine ECU. If the engine does not support this function, a “Timeout ECU Not Responding” message displays. Engine Configuration This allows you to scroll through and view the engine’s configuration data. If the engine does not support this function, a “No Engine Configuration Data” message displays. Setup 1-Up Display Press Menu and use the Arrow Keys to highlight SETUP 1-UP DISPLAY, then press Enter. Three options are available for modification of the 1-Up display: 1. Use Defaults – This option contains a set of engine parameters: Engine Hours, Engine RPM, System Voltage, Battery Voltage, % Engine Load at Current RPM, Coolant Temperature, and Oil Pressure. 00-02-0796 - 14 - 2013-04-08 To select USE DEFAULTS, highlight the option and press Enter. A message indicating “RESTORED TO DEFAULTS” is displayed. 2. Custom Setup – In this option, select the parameters and order in which they will be displayed. The list is long; continue to scroll until you have seen all available parameters. To select Custom Setup, highlight and press Enter. A list of engine parameters displays. NOTE: The PV101 must see the parameter being broadcast over J1939 in order to select the parameter from the list. To select a parameter, use the Arrow Keys to scroll and highlight the parameter, then press Enter. Selected parameters are indicated by a number to the right of it. The numbers represent the order in which the parameters will be displayed. To deselect a parameter and remove it from the list of displayed parameters, highlight the parameter and touch Enter. 00-02-0796 - 15 - 2013-04-08 Continue to scroll and select additional parameters for the CUSTOM 1-UP DISPLAY. Touch Menu at any time to return to the CUSTOM SETUP menu. 3. Automatic Scan – (Default is OFF) Selecting the AUTOMATIC SCAN ON function will cause the 1-up display to scroll through the selected set of parameters one at a time. Once the Use Defaults, Custom Setup and Automatic Scan functions have been set, touch Menu once to return to the Main menu, or twice to display the 1-up display screen. 00-02-0796 - 16 - 2013-04-08 Setup 4-Up Display There are two 4-up display screens available. Each option can place parameter data into one of four areas on the screen known as quadrants. ƒ Factory defaults for the first 4-up display include coolant temperature, engine speed, oil pressure, and battery voltage. ƒ Factory defaults for the second 4-up display include DEF (diesel exhaust fluid) Level, DPF (diesel particulate filter) active regen status, exhaust filter inlet temperature, and exhaust filter outlet temperature. You can customize each 4-up display with the parameter you define for each quadrant. 1. Touch Menu and use the Arrow Keys to highlight SETUP 4-UP DISPLAY, and touch Enter. 2. To select USE DEFAULTS, highlight the option and press Enter. A message indicating “RESTORED TO DEFAULTS” is displayed. 3. To select CUSTOM SETUP, highlight the option and press Enter. The 4-up display appears. 00-02-0796 - 17 - 2013-04-08 4. Use the Arrow Keys to switch between the two 4-up displays. 5. To edit a 4-up display, touch Enter while that 4-up displays on screen. 6. Use the Arrow Keys to select which quadrant to edit. 7. Once you select a quadrant, press Enter and you move to a list of parameters. NOTE: The PowerView must see the parameter being broadcast over J1939 in order to select the parameter from the list. 8. The parameter highlighted is the selected parameter for the screen. The number to the right of the parameter indicates in which quadrant it displays. 00-02-0796 - 18 - 2013-04-08 1 = upper left quadrant 3 = upper right quadrant 2 = lower left quadrant 4 = lower right quadrant 9. Use the Arrow Keys to highlight the new parameter to be placed in the selected quadrant. Touch Enter. 10. Press Menu to return to the SETUP 4-UP CUSTOM SETUP screen. 11. The parameter in the selected quadrant has changed to the parameter selected in the previous screen. 12. Repeat the parameter selection process until you fill all quadrants. 00-02-0796 - 19 - 2013-04-08 Service Reminders SERVICE REMINDERS permit you to RESET REMINDERS or MODIFY REMINDERS for changing engine oil, air filters, and hydraulic oil or for servicing the engine and/or machine. NOTE: Service Reminders are internal reminders within PowerView. Once a Service Reminder is active, warnings will show SPN 916 and FMI 17. Check PowerView Service Reminders prior to calling Technical Support. 1. Use the Arrow Keys to highlight Service Reminders and touch Enter. 2. The Service Reminders options display. Use the Arrow Keys to select either Reset Reminders or Modify Reminders, and then touch Enter. 3. If you select Reset Reminders, use the Arrow Keys to highlight the Reminder you wish to edit. Touch Enter. 4. The Reminder name appears at the top of the screen. The action (ON or OFF) displays mid-screen, and two choices display at screen bottom. Touch Menu to Cancel the action. Touch Enter to choose Reset. 00-02-0796 - 20 - 2013-04-08 5. If you select Modify Reminders, use the Arrow Keys to highlight the Reminder to modify and touch Enter. 6. The Reminder name appears at top screen. The hour value displays mid-screen and allows you to set the number of hours to elapse before a Reminder prompts. Bottom screen shows Cancel and Save. Touch Cancel to discard changes and return to Reminders list. 7. Use the right Arrow Key to increment the highlighted number. Use the left Arrow Key to move to the next number space. 8. Touch Save. The Modify Service Reminder screen displays. Touch YES to save or NO to return to the Reminders list. 9. A modified Reminder displays a (+) at right of Reminder name when successfully completed. Follow the above steps to modify other Reminders. When finished, touch Menu to return to the Main Menu. 00-02-0796 - 21 - 2013-04-08 Select Units From SELECT UNITS, you may select how information is displayed: ƒ ENGLISH for Imperial units (PSI, qF) ƒMETRIC KPA ƒ METRIC BAR for IS units (kPa, Bar, qC). Backlight Adjustment ADJUST BACKLIGHT – Use the Arrow Keys to brighten or darken the backlight intensity. Contrast Adjustment ADJUST CONTRAST – Use the Arrow Keys to lighten or darken the text and graphics. 00-02-0796 - 22 - 2013-04-08 Utilities Menu UTILITIES is the last item on the Main Menu. The Utilities menu provides troubleshooting features and other information about the PowerView configuration. Gage Data View data for optional connected PVA gages. When Slave Active is enabled, gage data is not available. Remove All Gages Reset the gage memory on the PowerView. When Slave Active is enabled, this function is not available. Software Version This screen lists Configuration, Firmware, Languages, and Bootloader versions for this PowerView unit. You may need this information if requesting assistance from Technical Support. 00-02-0796 - 23 - 2013-04-08 Fault Conversion View/Edit the J1939 fault code version. Use the Arrow Keys to move between Versions, and then touch Enter to select a version. NOTE: There are four methods for converting fault codes. The PowerView always looks for J1939-Version 4. However, PowerView can be set to read one of three other J1939 versions, if Version 4 is not used/unavailable. Most ECU’s use Version 4, so adjustment of this menu option is rarely required. Upon receiving an unrecognizable fault, change to a different J1939 Version in the list. If the fault SPN does not change when the version is changed, the ECU generating the fault is using Fault Conversion Method 4. If the SPN number does change, but is still unrecognizable, try changing to another unused J1939 Version and continue to check the SPN number. 00-02-0796 - 24 - 2013-04-08 Analog Input With Analog Input highlighted, press Enter. You can select between two settings: 1) BACKLIGHT DIMMER, this is in factory default upon first use. The unit accepts an optional backlighting dimmer (0-1k Ÿ potentiometer). 2) FUEL LEVEL, touch Enter to reach SET LOW FUEL LEVEL screen. Then, touch Enter to reach LOW FUEL % screen. Use the right Arrow Key to increase, and left Arrow Key to decrease the percentage of remaining fuel at which to send a warning. The default is 20%. NOTE: The PowerView accepts optional Murphy fuel sender (recommend Model ES2F) for fuel level information. A custom setup for a non-Murphy fuel sender is available. For more information, see FUEL SETPOINTS, page 31 (OEM Menu). Engine Speed Control This option must be ON in the OEM Menu for functionality to be available from the Utilities Menu. 00-02-0796 - 25 - 2013-04-08 1) From the Engine Speed Control screen, touch Enter to reach the Speed Control screen. 2) To change the setting of the engine speed via TSC1; use the right Arrow Key to increase or left Arrow key to decrease the throttle setting. 3) Once the target speed is reached, select ENABLE (Enter) to turn ON the TSC1 throttling control. (Use Disable to turn throttling control OFF and discard changes). NOTE: Once enabled Engine Speed Control will stay enabled even through power cycles. To turn OFF, you must disable the feature from the SPEED CTRL screen. 00-02-0796 - 26 - 2013-04-08 OEM Menu The OEM menu is the last item on the Utilities menu. You must have a password to access the OEM menu. Once in the OEM Menu, select an item by highlighting it and touch Enter to reach additional screens. ENTER PASSWORD screen – Enter 3482 in the numeric spaces provided. Start at the furthest left numeric value and use the Left Arrow Key to increment the number and the Right Arrow Key to move to the next numeric position. If the Murphy standard key does not work, contact the OEM from whom the engine or machine was purchased. If you have access, the password is user changeable via the PV101-C Config Tool application. The following items are in the OEM Menu. MODBUS£ £ Setup To set the MODBUS, highlight MODBUS SETUP and touch Enter. 00-02-0796 - 27 - 2013-04-08 1) There are four selections: Use Factory Defaults, Serial Port Setup, Slave Address Setup, and Master Active/Slave Active. You can toggle between Slave Active (which is SCADA/remote Modbus master) and Master Active (which is Auxiliary gages). Highlight your selection and touch Enter. 2) If in Slave Active, select SERIAL PORT SETUP and touch Enter. 3) Scroll through the Serial Port Setup list and make selections for BAUD RATE, PARITY, DATA BITS, and STOP BITS to configure the serial port parameters for your Modbus slave application. CANBUS Data Rate Touch Enter to reach the six CANBUS data rates. Use the Arrow Keys to highlight your choice and touch Enter to make the selection. 00-02-0796 - 28 - 2013-04-08 Select Engine ECU Highlight Select Engine ECU and touch Enter. 1) The message “LISTEN TO ECU: ALL” displays as the default setting. This message indicates the PV101 is listening to all devices on the network. 2) To change the setting to a specific address, press the Arrow Keys to scroll through the selections (0253, and ALL). 3) Once the target address displays, press Enter. 4) A confirmation screen displays; selecting NO (Menu) returns to the SELECT ENGINE ECU screen. Selecting YES (Enter) stores the selected address and returns to the OEM menu. 00-02-0796 - 29 - 2013-04-08 Set Source Address Allows setting the source claim address for the PowerView on the CAN Network. Options are Auto Claim or 0 to 253. Restore All Defaults PowerView automatically resets after the restore defaults is complete. RESTORING ALL FACTORY DEFAULTS displays when this is selected. Clear Machine Hours Use this to clear machine hours internal to PowerView outside of ECU hours. Set Machine Hours Machine hours calculate internally when the RPM is greater than 50 and the engine is not broadcasting hours. Use this if you want to track hours for just the machine. 00-02-0796 - 30 - 2013-04-08 Fuel Setpoints Highlight and press Enter to select Fuel Setpoints. 1) Press Enter to turn Fuel Setpoints ON or OFF. 2) Choose Set Empty Setpoint, Set Fuel Setpoint, Show Fuel Setpoints, Clear Fuel Setpoints, or choose to set ¼, ½ and ¾ fuel points. Fuel Setpoints must be ON to work with a non-Murphy fuel sender. Modifying fuel setpoints is a complex process. To configure for a Murphy Fuel Sender or program for a nonMurphy Sender, find document #1110833, PowerView – Model PV101-C V3.2 Fuel Sender Calibration on the FW Murphy Web site at www.fwmurphy.com/pv101. DPF Regen Menu ON/OFF Highlight and touch Enter to turn this option ON or OFF. Turn this option ON to have it available in the Main menu or OFF for no availability in the Main menu. 00-02-0796 - 31 - 2013-04-08 ENG SPD CTRL Menu ON/OFF This option must be ON in the OEM Menu for functionality to be available in the Utilities Menu. Highlight and touch Enter. The Speed Control can be Enabled (ON) or Disabled (OFF). 00-02-0796 - 32 - 2013-04-08 Faults and Warnings The PowerView provides two means for detecting faults and warnings: visual LEDs on the casing (Amber in the upper left corner, and Red in the upper right corner) and fault indicators on the display. Visual Indication x Amber LED (Warning) x Red LED (Derate / Shutdown) Fault Indicators 00-02-0796 - 33 - 2013-04-08 Auxiliary Gage Fault Murphy PVA Gages can be attached to the PowerView. If an auxiliary gage should fail, the 1-up or 4-up display will be replaced with a fault message: GAGE NOT RESPONDING. NOTE: A fault can only be cleared by correcting the cause of the condition (See Troubleshooting in this document). Active Fault Codes When the PowerView receives a fault code from an engine, the 1-up or 4-up display is replaced with the active fault codes message. See following fault example: 00-02-0796 - 34 - 2013-04-08 Example: Active Fault Code screen Derate / Shutdown Codes When the PowerView receives a severe fault code from an engine control unit the 1-up or 4-up display is replaced with the SHUTDOWN message. 00-02-0796 - 35 - 2013-04-08 Acknowledging Fault Codes 1. To acknowledge and hide the fault and return to the 1-up or 4-up display, touch Enter. The display will return to the 1-up or 4-up display, but the display will contain the warning or shutdown icon. 2. Touch Enter to redisplay the hidden fault. Touch Enter once again hides the fault and returns the screen to the 1-up or 4-up display. 00-02-0796 - 36 - 2013-04-08 Troubleshooting ¾ WAIT TO START PREHEATING is displayed The ECU is broadcasting a 'Wait to Start' message. Engine manufacturers typically recommend against starting the engine while the ECU is broadcasting this message. Once the ECU stops broadcasting this message, this screen will no longer be displayed on the PowerView. ¾ CANBUS FAILURE is displayed The PowerView has not received any valid J1939 CAN messages for at least 30 seconds. Check wiring, CANBUS, termination resistors, and Engine ECU address in the OEM Menu. ¾ TIMEOUT ECU NOT RESPONDING is displayed The PowerView sent a request to the ECU for Stored Fault Code (DM2) information, and the ECU did not respond to the request. This message on the PowerView indicates the ECU may not support Stored Fault Code (DM2) functionality over J1939. 00-02-0796 - 37 - 2013-04-08 ¾ NO STORED CODES is displayed The PowerView sent a request to the ECU for Stored Fault Code (DM2) information. The ECU responded: There are zero stored codes. ¾ NO GAGE DATA is displayed The PowerView has no record of gages connected to the RS485 bus. ¾ NO DATA is displayed in place of a parameter value The PowerView has not received data for the selected parameter for at least 5 seconds. ¾ NOT SUPPORTED is displayed in place of a parameter value This means the data received for this parameter is not valid or not supported. 00-02-0796 - 38 - 2013-04-08 ¾ DATA ERROR is displayed in place of a parameter value The ECU is sending a message that there is a data error with this parameter. Alternatively, (PV101 only) FUEL LEVEL has been selected for display, ANALOG INPUT has been set to FUEL LEVEL, but no Murphy Fuel Sender has been connected to the analog input. ¾ One of the 4-UP quadrants is empty No parameter has been selected for display in this quadrant. ¾ Display is not readable, either very dim or very dark The LCD contrast may have been over or under adjusted. Press and hold the MENU key for approximately 5 seconds. This will reset the LCD contrast setting to factory default. ¾ PVA Gages not working When PVA Gages are connected and do not seem to work, go to the Utilities menu and select Remove all Gages. 00-02-0796 - 39 - 2013-04-08 IMPORTANT! Before returning your PV101 for Warranty, please call our Technical Support team to further troubleshoot any issues. +1 (918) 317-4100 00-02-0796 - 40 - 2013-04-08 NOTES 00-02-0796 - 41 - 2013-04-08 NOTES NOTES Murphy, the Murphy logo, and PowerView are registered and/or common law trademarks of Enovation Controls, LLC. This document, including textual matter and illustrations, is copyright protected by Enovation Controls, with all rights reserved. © 2013 Enovation Controls, LLC. Other third party product or trade names referenced herein are the property of their respective owners and are used for identification purposes only. Additional Contact Information ENOVATION CONTROLS – CORPORATE HQ nd 5311 S. 122 East Ave. Tulsa, OK 74146 USA Phone: +1 918 317 4100 FAX: +1 918 317 4266 [email protected] Web: www.fwmurphy.com FW MURPHY, LTD. Church Rd Laverstock Salisbury SP1 1QZ UK Phone: +44 1722 410055 FAX: +44 1722 410088 [email protected] Web: www.fwmurphy.co.uk ENOVATION CONTROLS – SAN ANTONIO OFFICE 5757 Farinon Drive San Antonio, TX 78249 USA Phone: +1 210 495 9772 FAX: +1 210 495 9791 [email protected] Web: www.econtrols.com MURPHY ECONTROLS TECHNOLOGIES (HANGZHOU) CO, LTD. 77 23RD Street Hangzhou Economic & Technological Development Area Hangzhou, Zhejiang 310018 China Phone: +86 571 8788 6060 FAX: +86 571 8684 8878 [email protected] Web: www.fwmurphy.com/company_ch INDIA SALES AND SUPPORT Phone: +91 91581 37633 [email protected] Web: www.fwmurphy.com MURPHY INDUSTRIAL PANEL DIVISION 5311 S. 122nd East Ave. Tulsa, OK 74146 USA Phone:+1 918 317 4100 FAX: +1 918 317 4124 [email protected] Web: www.fwmurphy.com LATIN AMERICA & CARIBBEAN SALES AND SUPPORT Phone: +1 918 317 2500 [email protected] Web: www.fwmurphy.com www.fwmurphy.com/PV101 SEBU8726-02 July 2013 Operation and Maintenance Manual 854E-E34TA and 854F-E34T Industrial Engines JR (Engine) JS (Engine) JT (Engine) Important Safety Information Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly. Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below. The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved. The message that appears under the warning explains the hazard and can be either written or pictorially presented. Operations that may cause product damage are identified by “NOTICE” labels on the product and in this publication. Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method or operating technique that is not specifically recommended by Perkins is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose. The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Perkins dealers or Perkins distributors have the most current information available. When replacement parts are required for this product Perkins recommends using Perkins replacement parts. Failure to heed this warning can lead to premature failures, product damage, personal injury or death. SEBU8726 3 Table of Contents Table of Contents Maintenance Section Foreword.............................. ............................. 4 Refill Capacities....................... ....................... 66 Safety Section Safety Messages....................... ....................... 5 Maintenance Recommendations.......... .......... 80 Maintenance Interval Schedule ........... ........... 83 General Hazard Information ............... .............. 6 Warranty Section Burn Prevention........................ ........................ 9 Warranty Information .................. ...................112 Fire Prevention and Explosion Prevention ... .. 10 Reference Information Section Crushing Prevention and Cutting Prevention . 12 Reference Materials ................... ...................113 Mounting and Dismounting............... .............. 12 Index Section High Pressure Fuel Lines ................ ............... 12 Index............................... ...............................114 Before Starting Engine ................. .................. 14 Engine Starting ........................ ....................... 14 Engine Stopping ....................... ...................... 14 Electrical System ...................... ...................... 14 Engine Electronics..................... ..................... 16 Product Information Section General Information.................... .................... 17 Product Identification Information.......... ......... 25 Operation Section Lifting and Storage..................... ..................... 30 Features and Controls .................. .................. 32 Engine Diagnostics..................... .................... 49 Engine Starting ........................ ....................... 53 Engine Operation...................... ...................... 56 Cold Weather Operation................. ................ 60 Engine Stopping ....................... ...................... 64 4 SEBU8726 Foreword Foreword Literature Information This manual contains safety, operation instructions, lubrication and maintenance information. This manual should be stored in or near the engine area in a literature holder or literature storage area. Read, study and keep it with the literature and engine information. English is the primary language for all Perkins publications. The English used facilitates translation and consistency. Some photographs or illustrations in this manual show details or attachments that may be different from your engine. Guards and covers may have been removed for illustrative purposes. Continuing improvement and advancement of product design may have caused changes to your engine which are not included in this manual. Whenever a question arises regarding your engine, or this manual, please consult with your Perkins dealer or your Perkins distributor for the latest available information. Safety This safety section lists basic safety precautions. In addition, this section identifies hazardous, warning situations. Read and understand the basic precautions listed in the safety section before operating or performing lubrication, maintenance and repair on this product. Operation Operating techniques outlined in this manual are basic. They assist with developing the skills and techniques required to operate the engine more efficiently and economically. Skill and techniques develop as the operator gains knowledge of the engine and its capabilities. The operation section is a reference for operators. Photographs and illustrations guide the operator through procedures of inspecting, starting, operating and stopping the engine. This section also includes a discussion of electronic diagnostic information. Maintenance The maintenance section is a guide to engine care. The illustrated, step-by-step instructions are grouped by service hours and/or calendar time maintenance intervals. Items in the maintenance schedule are referenced to detailed instructions that follow. Recommended service should be performed at the appropriate intervals as indicated in the Maintenance Interval Schedule. The actual operating environment of the engine also governs the Maintenance Interval Schedule. Therefore, under extremely severe, dusty, wet or freezing cold operating conditions, more frequent lubrication and maintenance than is specified in the Maintenance Interval Schedule may be necessary. The maintenance schedule items are organized for a preventive maintenance management program. If the preventive maintenance program is followed, a periodic tune-up is not required. The implementation of a preventive maintenance management program should minimize operating costs through cost avoidances resulting from reductions in unscheduled downtime and failures. Maintenance Intervals Perform maintenance on items at multiples of the original requirement. We recommend that the maintenance schedules be reproduced and displayed near the engine as a convenient reminder. We also recommend that a maintenance record be maintained as part of the engine's permanent record. Your authorized Perkins dealer or your Perkins distributor can assist you in adjusting your maintenance schedule to meet the needs of your operating environment. Overhaul Major engine overhaul details are not covered in the Operation and Maintenance Manual except for the interval and the maintenance items in that interval. Major repairs should only be carried out by Perkins authorized personnel. Your Perkins dealer or your Perkins distributor offers a variety of options regarding overhaul programs. If you experience a major engine failure, there are also numerous after failure overhaul options available. Consult with your Perkins dealer or your Perkins distributor for information regarding these options. California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling. 5 SEBU8726 Safety Section Safety Messages Safety Section i04112132 Safety Messages There may be several specific warning signs on your engine. The exact location and a description of the warning signs are reviewed in this section. Please become familiar with all warning signs. Ensure that all of the warning signs are legible. Clean the warning signs or replace the warning signs if the words cannot be read or if the illustrations are not visible. Use a cloth, water, and soap to clean the warning signs. Do not use solvents, gasoline, or other harsh chemicals. Solvents, gasoline, or harsh chemicals could loosen the adhesive that secures the warning signs. The warning signs that are loosened could drop off the engine. Replace any warning sign that is damaged or missing. If a warning sign is attached to a part of the engine that is replaced, install a new warning sign on the replacement part. Your Perkins distributor can provide new warning signs. Universal Warning Do not operate or work on this equipment unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in serious injury or death. Illustration 1 g01154807 Typical example The Universal Warning label (1) is located on the top of the engine, on the engine interface connector cover. 6 SEBU8726 Safety Section General Hazard Information Illustration 2 g02582556 Typical example i03566024 General Hazard Information • Tampering with the engine installation or tampering with the OEM supplied wiring can be dangerous. Personal injury, death and/or engine damage could result. • Vent the engine exhaust to the outside when the engine is operated in an enclosed area. • If the engine is not running, do not release the secondary brake or the parking brake systems unless the vehicle is blocked or unless the vehicle is restrained. • Wear a hard hat, protective glasses, and other protective equipment, as required. • When work is performed around an engine that is operating, wear protective devices for ears in order to help prevent damage to hearing. Illustration 3 g00104545 Attach a “Do Not Operate” warning tag or a similar warning tag to the start switch or to the controls before the engine is serviced or before the engine is repaired. Attach the warning tags to the engine and to each operator control station. When it is appropriate, disconnect the starting controls. Do not allow unauthorized personnel on the engine, or around the engine when the engine is being serviced. • Do not wear loose clothing or jewelry that can snag on controls or on other parts of the engine. • Ensure that all protective guards and all covers are secured in place on the engine. • Never put maintenance fluids into glass containers. Glass containers can break. • Use all cleaning solutions with care. • Report all necessary repairs. Unless other instructions are provided, perform the maintenance under the following conditions: 7 SEBU8726 Safety Section General Hazard Information • The engine is stopped. Ensure that the engine can not be started. • The protective locks or the controls are in the applied position. Use caution when cover plates are removed. Gradually loosen, but do not remove the last two bolts or nuts that are located at opposite ends of the cover plate or the device. Before removing the last two bolts or nuts, pry the cover loose in order to relieve any spring pressure or other pressure. • Engage the secondary brakes or parking brakes. • Block the vehicle or restrain the vehicle before maintenance or repairs are performed. • Disconnect the batteries when maintenance is performed or when the electrical system is serviced. Disconnect the battery ground leads. Tape the leads in order to help prevent sparks. • Disconnect the connector for the unit injector that is located on the valve cover base. This will help prevent personal injury from the high voltage to the unit injectors. Do not come in contact with the unit injector terminals while the engine is operating. • Do not attempt any repairs or any adjustments to the engine while the engine is operating. • Do not attempt any repairs that are not understood. Use the proper tools. Replace any equipment that is damaged or repair the equipment. • For initial start-up of a new engine or for starting an engine that has been serviced, make provisions to stop the engine if an overspeed occurs. This may be accomplished by shutting off the fuel supply and/or the air supply to the engine. • Start the engine from the operator's station (cab). Never short across the starting motor terminals or the batteries. This could bypass the engine neutral start system and/or the electrical system could be damaged. Engine exhaust contains products of combustion which may be harmful to your health. Always start the engine and operate the engine in a well ventilated area. If the engine is in an enclosed area, vent the engine exhaust to the outside. Cautiously remove the following parts. To help prevent spraying or splashing of pressurized fluids, hold a rag over the part that is being removed. • Filler caps • Grease fittings Illustration 4 g00702020 • Wear a hard hat, protective glasses, and other protective equipment, as required. • When work is performed around an engine that is operating, wear protective devices for ears in order to help prevent damage to hearing. • Do not wear loose clothing or jewelry that can snag on controls or on other parts of the engine. • Ensure that all protective guards and all covers are secured in place on the engine. • Never put maintenance fluids into glass containers. Glass containers can break. • Use all cleaning solutions with care. • Report all necessary repairs. Unless other instructions are provided, perform the maintenance under the following conditions: • The engine is stopped. Ensure that the engine cannot be started. • Disconnect the batteries when maintenance is performed or when the electrical system is serviced. Disconnect the battery ground leads. Tape the leads in order to help prevent sparks. • Breathers • Do not attempt any repairs that are not understood. Use the proper tools. Replace any equipment that is damaged or repair the equipment. • Drain plugs Pressurized Air and Water • Pressure taps Pressurized air and/or water can cause debris and/or hot water to be blown out. This could result in personal injury. 8 SEBU8726 Safety Section General Hazard Information When pressurized air and/or pressurized water is used for cleaning, wear protective clothing, protective shoes, and eye protection. Eye protection includes goggles or a protective face shield. Asbestos Information The maximum air pressure for cleaning purposes must be below 205 kPa (30 psi). The maximum water pressure for cleaning purposes must be below 275 kPa (40 psi). Fluid Penetration Pressure can be trapped in the hydraulic circuit long after the engine has been stopped. The pressure can cause hydraulic fluid or items such as pipe plugs to escape rapidly if the pressure is not relieved correctly. Do not remove any hydraulic components or parts until pressure has been relieved or personal injury may occur. Do not disassemble any hydraulic components or parts until pressure has been relieved or personal injury may occur. Refer to the OEM information for any procedures that are required to relieve the hydraulic pressure. Illustration 6 g00702022 Perkins replacement parts that are shipped from Perkins are asbestos free. Perkins recommends the use of only genuine Perkins replacement parts. Use the following guidelines when you handle any replacement parts that contain asbestos or when you handle asbestos debris. Use caution. Avoid inhaling dust that might be generated when you handle components that contain asbestos fibers. Inhaling this dust can be hazardous to your health. The components that may contain asbestos fibers are brake pads, brake bands, lining material, clutch plates, and some gaskets. The asbestos that is used in these components is usually bound in a resin or sealed in some way. Normal handling is not hazardous unless airborne dust that contains asbestos is generated. If dust that may contain asbestos is present, there are several guidelines that should be followed: Illustration 5 g00687600 Always use a board or cardboard when you check for a leak. Leaking fluid that is under pressure can penetrate body tissue. Fluid penetration can cause serious injury and possible death. A pin hole leak can cause severe injury. If fluid is injected into your skin, you must get treatment immediately. Seek treatment from a doctor that is familiar with this type of injury. Containing Fluid Spillage NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates. SEBU8726 9 Safety Section Burn Prevention • Never use compressed air for cleaning. i04289958 • Avoid brushing materials that contain asbestos. Burn Prevention • Avoid grinding materials that contain asbestos. • Use a wet method in order to clean up asbestos materials. • A vacuum cleaner that is equipped with a high efficiency particulate air filter (HEPA) can also be used. • Use exhaust ventilation on permanent machining jobs. • Wear an approved respirator if there is no other way to control the dust. • Comply with applicable rules and regulations for the work place. In the United States , use Occupational Safety and Health Administration (OSHA) requirements. These OSHA requirements can be found in 29 CFR 1910.1001. • Obey environmental regulations for the disposal of asbestos. • Stay away from areas that might have asbestos particles in the air. Dispose of Waste Properly Do not touch any part of an operating engine system. The engine, the exhaust, and the engine aftertreatment system can reach temperatures as high as 650 °C (1202 °F) under normal operating conditions. At idle engine speed and/or zero vehicle speed, an operator can request a manual regeneration. Under this condition, the exhaust gas temperature can reach 650 °C (1202 °F). Otherwise automatic regeneration can produce exhaust gas temperatures as high as 650 °C (1202 °F). Allow the engine system to cool before any maintenance is performed. Relieve all pressure in the following systems, hydraulic system, lubrication system, fuel system, and the cooling system before related items are disconnected. Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death. After the engine has stopped, you must wait for 10 minutes in order to allow the fuel pressure to be purged from the high-pressure fuel lines before any service or repair is performed on the engine fuel lines. Induction System Sulfuric Acid Burn Hazard may cause serious personal injury or death. Illustration 7 g00706404 Improperly disposing of waste can threaten the environment. Potentially harmful fluids should be disposed of according to local regulations. Always use leakproof containers when you drain fluids. Do not pour waste onto the ground, down a drain, or into any source of water. The exhaust gas cooler may contain a small amount of sulfuric acid. The use of fuel with sulfur levels greater than 15 ppm may increase the amount of sulfuric acid formed. The sulfuric acid may spill from the cooler during service of the engine. The sulfuric acid will burn the eyes, skin and clothing on contact. Always wear the appropriate personal protective equipment (PPE) that is noted on a material safety data sheet (MSDS) for sulfuric acid. Always follow the directions for first aid that are noted on a material safety data sheet (MSDS) for sulfuric acid. 10 SEBU8726 Safety Section Fire Prevention and Explosion Prevention Coolant When the engine is at operating temperature, the engine coolant is hot. The coolant is also under pressure. The radiator and all lines to the heaters or to the engine contain hot coolant. i04303237 Fire Prevention and Explosion Prevention Any contact with hot coolant or with steam can cause severe burns. Allow cooling system components to cool before the cooling system is drained. Check the coolant level after the engine has stopped and the engine has been allowed to cool. Ensure that the filler cap is cool before removing the filler cap. The filler cap must be cool enough to touch with a bare hand. Remove the filler cap slowly in order to relieve pressure. Cooling system conditioner contains alkali. Alkali can cause personal injury. Do not allow alkali to contact the skin, the eyes, or the mouth. Oils Hot oil and hot lubricating components can cause personal injury. Do not allow hot oil to contact the skin. Also, do not allow hot components to contact the skin. Batteries Electrolyte is an acid. Electrolyte can cause personal injury. Do not allow electrolyte to contact the skin or the eyes. Always wear protective glasses for servicing batteries. Wash hands after touching the batteries and connectors. Use of gloves is recommended. Illustration 8 g00704000 All fuels, most lubricants, and some coolant mixtures are flammable. Flammable fluids that are leaking or spilled onto hot surfaces or onto electrical components can cause a fire. Fire may cause personal injury and property damage. After the emergency stop button is operated, ensure that you allow 15 minutes, before the engine covers are removed. Determine whether the engine will be operated in an environment that allows combustible gases to be drawn into the air inlet system. These gases could cause the engine to overspeed. Personal injury, property damage, or engine damage could result. If the application involves the presence of combustible gases, consult your Perkins dealer and/ or your Perkins distributor for additional information about suitable protection devices. Remove all flammable combustible materials or conductive materials such as fuel, oil, and debris from the engine. Do not allow any flammable combustible materials or conductive materials to accumulate on the engine. Store fuels and lubricants in correctly marked containers away from unauthorized persons. Store oily rags and any flammable materials in protective containers. Do not smoke in areas that are used for storing flammable materials. Do not expose the engine to any flame. Exhaust shields (if equipped) protect hot exhaust components from oil or fuel spray in a line, a tube, or a seal failure. Exhaust shields must be installed correctly. SEBU8726 11 Safety Section Fire Prevention and Explosion Prevention Do not weld on lines or tanks that contain flammable fluids. Do not flame cut lines or tanks that contain flammable fluid. Clean any such lines or tanks thoroughly with a nonflammable solvent prior to welding or flame cutting. Wiring must be kept in good condition. All electrical wires must be correctly routed and securely attached. Check all electrical wires daily. Repair any wires that are loose or frayed before you operate the engine. Clean all electrical connections and tighten all electrical connections. Eliminate all wiring that is unattached or unnecessary. Do not use any wires or cables that are smaller than the recommended gauge. Do not bypass any fuses and/or circuit breakers. Arcing or sparking could cause a fire. Secure connections, recommended wiring, and correctly maintained battery cables will help to prevent arcing or sparking. Illustration 9 Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death. g00704059 Use caution when you are refueling an engine. Do not smoke while you are refueling an engine. Do not refuel an engine near open flames or sparks. Always stop the engine before refueling. After the engine has stopped, you must wait for 10 minutes in order to allow the fuel pressure to be purged from the high-pressure fuel lines before any service or repair is performed on the engine fuel lines. Ensure that the engine is stopped. Inspect all lines and hoses for wear or for deterioration. The hoses must be correctly routed. The lines and hoses must have adequate support and secure clamps. Ensure that Oil filters and fuel filters are correctly installed. The filter housings must be tightened to the correct torque. Refer to the Disassembly and Assembly manual for more information. Illustration 10 g00704135 Gases from a battery can explode. Keep any open flames or sparks away from the top of a battery. Do not smoke in battery charging areas. Never check the battery charge by placing a metal object across the terminal posts. Use a voltmeter or a hydrometer. Incorrect jumper cable connections can cause an explosion that can result in injury. Refer to the Operation Section of this manual for specific instructions. 12 SEBU8726 Safety Section Crushing Prevention and Cutting Prevention Do not charge a frozen battery. Charging a frozen battery may cause an explosion. The batteries must be kept clean. The covers (if equipped) must be kept on the cells. Use the recommended cables, connections, and battery box covers when the engine is operated. Fire Extinguisher Make sure that a fire extinguisher is available. Be familiar with the operation of the fire extinguisher. Inspect the fire extinguisher and service the fire extinguisher regularly. Obey the recommendations on the instruction plate. Lines, Tubes, and Hoses Do not bend high-pressure lines. Do not strike highpressure lines. Do not install any lines that are damaged. Leaks can cause fires. Consult your Perkins dealer or your Perkins distributor for replacement parts. Replace the parts if any of the following conditions are present: • High-pressure fuel line or lines are removed. Unless other maintenance instructions are provided, never attempt adjustments while the engine is running. Stay clear of all rotating parts and of all moving parts. Leave the guards in place until maintenance is performed. After the maintenance is performed, reinstall the guards. Keep objects away from moving fan blades. The fan blades will throw objects or cut objects. When objects are struck, wear protective glasses in order to avoid injury to the eyes. Chips or other debris may fly off objects when objects are struck. Before objects are struck, ensure that no one will be injured by flying debris. i04016709 Mounting and Dismounting Do not climb on the engine or the engine aftertreatment. The engine and aftertreatment have not been designed with mounting or dismounting locations. Refer to the OEM for the location of foot and hand holds for your specific application. • End fittings are damaged or leaking. • Outer coverings are chafed or cut. i04112191 • Wires are exposed. High Pressure Fuel Lines • Outer coverings are ballooning. • Flexible parts of the hoses are kinked. • Outer covers have embedded armoring. • End fittings are displaced. Make sure that all clamps, guards, and heat shields are installed correctly. During engine operation, this check will help to prevent vibration, rubbing against other parts, and excessive heat. Regeneration The exhaust gas temperature during regeneration will be elevated. Follow proper fire prevention instructions and use the disable switch function when appropriate. i02143194 Crushing Prevention and Cutting Prevention Support the component correctly when work beneath the component is performed. Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death. SEBU8726 13 Safety Section High Pressure Fuel Lines Illustration 11 (1) High-pressure line (2) High-pressure line g02315653 (3) High-pressure line (4) High-pressure line The high-pressure fuel lines are the fuel lines that are between the high-pressure fuel pump and the highpressure fuel manifold and the fuel lines that are between the fuel manifold and cylinder head. These fuel lines are different from fuel lines on other fuel systems. These differences are because of the following items: • The high-pressure fuel lines are constantly charged with high pressure. • The internal pressures of the high-pressure fuel lines are higher than other types of fuel system. • The high-pressure fuel lines are formed to shape and then strengthened by a special process. Do not step on the high-pressure fuel lines. Do not deflect the high-pressure fuel lines. Do not bend or strike the high-pressure fuel lines. Deformation or damage of the high-pressure fuel lines may cause a point of weakness and potential failure. Do not check the high-pressure fuel lines with the engine or the starting motor in operation. After the engine has stopped wait for 10 minutes in order to allow the fuel pressure to be purged from the highpressure fuel lines before any service or repair is performed. Do not loosen the high-pressure fuel lines in order to remove air from the fuel system. This procedure is not required. Visually inspect the high-pressure fuel lines before the engine is started. This inspection should be each day. (5) High-pressure fuel manifold (rail) (6) Fuel transfer line that is high pressure If you inspect the engine in operation, always use the proper inspection procedure in order to avoid a fluid penetration hazard. Refer to Operation and Maintenance Manual, “General hazard Information”. • Inspect the high-pressure fuel lines for damage, deformation, a nick, a cut, a crease, or a dent. • Do not operate the engine with a fuel leak. If there is a leak, do not tighten the connection in order to stop the leak. The connection must only be tightened to the recommended torque. Refer to Disassembly and Assembly, “Fuel injection lines Remove and Fuel injection lines - Install”. • If the high-pressure fuel lines are torqued correctly, and the high-pressure fuel lines are leaking the high-pressure fuel lines must be replaced. • Ensure that all clips on the high-pressure fuel lines are in place. Do not operate the engine with clips that are damaged, missing, or loose. • Do not attach any other item to the high-pressure fuel lines. • Loosened high-pressure fuel lines must be replaced. Also removed high-pressure fuel lines must be replaced. Refer to Disassembly and Assembly, “Fuel Injection Lines - Install”. 14 SEBU8726 Safety Section Before Starting Engine i02813489 Before Starting Engine Before the initial start-up of an engine that is new, serviced or repaired, make provision to shut the engine off, in order to stop an overspeed. This may be accomplished by shutting off the air and/or fuel supply to the engine. Overspeed shutdown should occur automatically for engines that are controlled electronically. If automatic shutdown does not occur, press the emergency stop button in order to cut the fuel and/or air to the engine. Inspect the engine for potential hazards. Start the engine from the operators compartment or from the engine start switch. Always start the engine according to the procedure that is described in the Operation and Maintenance Manual, “Engine Starting” topic in the Operation Section. Knowing that the correct procedure will help to prevent major damage to the engine components. Knowing that the procedure will also help to prevent personal injury. To ensure that the jacket water heater (if equipped) and/or the lube oil heater (if equipped) is working correctly, check the water temperature gauge. Also, check the oil temperature gauge during the heater operation. Before starting the engine, ensure that no one is on, underneath, or close to the engine. Ensure that the area is free of personnel. Engine exhaust contains products of combustion which can be harmful to your health. Always start the engine and operate the engine in a well ventilated area. If the engine is started in an enclosed area, vent the engine exhaust to the outside. If equipped, ensure that the lighting system for the engine is suitable for the conditions. Ensure that all lights work correctly, if equipped. Note: These engines are equipped with a glow plug starting aid in each cylinder that heats the intake air in order to improve starting. All protective guards and all protective covers must be installed if the engine must be started in order to perform service procedures. To help prevent an accident that is caused by parts in rotation, work around the parts carefully. Do not bypass the automatic shutoff circuits. Do not disable the automatic shutoff circuits. The circuits are provided in order to help prevent personal injury. The circuits are also provided in order to help prevent engine damage. See the Service Manual for repairs and for adjustments. i04478934 Engine Starting i02234873 Engine Stopping Stop the engine according to the procedure in the Operation and Maintenance Manual, “Engine Stopping (Operation Section)” in order to avoid overheating of the engine and accelerated wear of the engine components. Use the Emergency Stop Button (if equipped) ONLY in an emergency situation. Do not use the Emergency Stop Button for normal engine stopping. After an emergency stop, DO NOT start the engine until the problem that caused the emergency stop has been corrected. Stop the engine if an overspeed condition occurs during the initial start-up of a new engine or an engine that has been overhauled. Do not use aerosol types of starting aids such as ether. Such use could result in an explosion and personal injury. To stop an electronically controlled engine, cut the power to the engine and/or shutting off the air supply to the engine. i04112409 If a warning tag is attached to the engine start switch, or to the controls DO NOT start the engine or move the controls. Consult with the person that attached the warning tag before the engine is started. All protective guards and all protective covers must be installed if the engine must be started in order to perform service procedures. To help prevent an accident that is caused by parts in rotation, work around the parts carefully. Electrical System Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operating. A spark can cause the combustible gases that are produced by some batteries to ignite. SEBU8726 15 Safety Section Electrical System To help prevent sparks from igniting combustible gases that are produced by some batteries, the negative “−” cable should be connected last from the external power source to the negative “−” terminal of the starting motor. If the starting motor is not equipped with a negative “−” terminal, connect the cable to the engine block. Check the electrical wires daily for wires that are loose or frayed. Tighten all loose electrical connections before the engine is started. Repair all frayed electrical wires before the engine is started. See the Operation and Maintenance Manual for specific starting instructions. Grounding Practices Illustration 13 g02315900 Typical example (5) Ground to battery (6) Ground to engine block (7) Primary position for grounding Correct grounding for the engine electrical system is necessary for optimum engine performance and reliability. Incorrect grounding will result in uncontrolled electrical circuit paths and in unreliable electrical circuit paths. Uncontrolled electrical circuit paths can result in damage to engine components. Illustration 12 Typical example (1) Ground to battery (2) Primary position for grounding (3) Ground to engine block (4) Ground to starting motor g02315896 Engines that are installed without engine-to-frame ground straps can be damaged by electrical discharge. To ensure the engine and the engine electrical systems function correctly, an engine-to-frame ground strap with a direct path to the battery must be used. This path may be provided by way of a direct engine ground to the frame. The connections for the grounds should be tight and free of corrosion. The engine alternator must be grounded to the negative “-” battery terminal with a wire adequate to handle the full charging current of the alternator. The power supply connections and the ground connections for the engine electronics should always be from the isolator to the battery. 16 SEBU8726 Safety Section Engine Electronics i04346349 Engine Electronics Tampering with the electronic system installation or the OEM wiring installation can be dangerous and could result in personal injury or death and/or engine damage. Electrical Shock Hazard. The electronic unit injectors use DC voltage. The ECM sends this voltage to the electronic unit injectors. Do not come in contact with the harness connector for the electronic unit injectors while the engine is operating. Failure to follow this instruction could result in personal injury or death. This engine has a comprehensive, programmable Engine Monitoring System. The Electronic Control Module (ECM) has the ability to monitor the engine operating conditions. If any of the engine parameters extend outside an allowable range, the ECM will initiate an immediate action. The following actions are available for engine monitoring control: • Warning • Derate • Shutdown The following monitored engine operating conditions and components have the ability to limit engine speed and/or the engine power : • Engine Coolant Temperature • Engine Oil Pressure • Engine Speed • Intake Manifold Air Temperature • Engine Intake Throttle Valve Fault • Wastegate Regulator • Supply Voltage to Sensors • Fuel Pressure in Manifold (Rail) • NOxReduction System • Engine Aftertreatment System The Engine Monitoring package can vary for different engine models and different engine applications. However, the monitoring system and the engine monitoring control will be similar for all engines. SEBU8726 17 Product Information Section Model View Illustrations Product Information Section General Information i05297867 Model View Illustrations The following model views show typical features of the engine. Due to individual applications, your engine may appear different from the illustrations. Engine and Aftertreatment Illustration 14 g03367500 Typical example (1) Engine aftertreatment system (2) NOx control valve (3) Air outlet connection from turbocharger (4) Alternator (5) Air intake from air filter (6) Coolant intake connection (7) Turbocharger (8) Solenoid for stating motor (9) Starting motor (10) Oil drain plug (11) Flywheel housing (12) Flywheel 18 SEBU8726 General Information Model View Illustrations Illustration 15 g03367502 Typical example (13) Secondary fuel filter (14) Oil filter (15) Oil level gauge (Dipstick) (16) High-pressure fuel pump (17) Valve mechanism cover SEBU8726 19 General Information Model View Illustrations Illustration 16 (18) Rear lifting eyes (19) Front lifting eye (20) Crankcase breather g03367547 (21) Oil filler cap (22) Belt (23) Coolant pump The oil filler cap (21) can be located on the valve mechanism cover. (24) Coolant outlet connection (25) Air inlet connection 20 SEBU8726 General Information Model View Illustrations Off Engine Parts Illustration 17 (26) Fuel priming pump (27) Primary fuel filter g03367521 (28) Differential pressure sensor (29) Electronic control module (30) Relay for glow plugs SEBU8726 21 General Information Model View Illustrations Engine View with Wall Flow Diesel Particulate Filter Illustration 18 Typical example The wall flow Diesel Particulate Filter (DPF) will require a service, refer to this Operation and Maintenance Manual, “Maintenance Interval Schedule” for the service period. g03367096 22 SEBU8726 General Information Product Description Engine View with Through Flow Diesel Particulate Filter Illustration 19 g03367094 Typical example The through-flow type of DPF will not require a service interval. • In-line 4 cylinder • Two valves in each cylinder i05326347 Product Description • Four stroke cycle • Turbocharged • Turbocharged charge cooled The Perkins 854F-E34T and the 854E-E34TA industrial engines has the following characteristics. • Wall Flow Diesel Particulate Filter or Through-Flow Diesel Particulate Filter Engine Specifications Note: The front end of the engine is opposite the flywheel end of the engine. The left and the right sides of the engine are determined from the flywheel end. The number 1 cylinder is the front cylinder. SEBU8726 23 General Information Product Description Electronic Engine Features The engine operating conditions are monitored. The Electronic Control Module (ECM) controls the response of the engine to these conditions and to the demands of the operator. These conditions and operator demands determine the precise control of fuel injection by the ECM. The electronic engine control system provides the following features: • Engine monitoring • Engine speed governing • Control of the injection pressure Illustration 20 g02317934 Cylinder and valve location • Cold start strategy • Automatic air/fuel ratio control (A) Exhaust valves (B) Inlet valves • Torque rise shaping Table 1 • Injection timing control 854F-E34T and 854E-E34TA Engine Specifications Operating Range (rpm) Number of Cylinders 4 In-Line Bore 99 mm (3.89763 inch) Stroke 110 mm (4.33070 inch) Power 854F 45 to 55.4 kW (60.345 to 74.3 hp) 854E 62 to 86 kW (83.142 to 115.326 hp) Aspiration Compression Ratio Displacement Firing Order Rotation (flywheel end) (1) • System diagnostics 800 to 2500(1) 854F Turbocharged 854E Turbocharged charge cooled 17: 1 3.4 L (207.48 cubic inch) 1-3-4-2 Counterclockwise The operating rpm is dependent on the engine rating, the application, and the configuration of the throttle. Engine Type and Aftertreatment Type There are three different engine types and two different types of aftertreatment. The 854E-E34TA is turbocharged, charge cooled engine, with a wall flow Diesel Particulate Filter (DPF). The letters JR will be on the identification plate. The 854F-E34T is divided into two different engine types. The engine with JS on the identification plate will have a wall flow DPF. The engine with the letters JT on the identification plate will have a through-flow DPF. The through-flow DPF will not require a service period. • Aftertreatment Regeneration For more information on electronic engine features, refer to the Operation and Maintenance Manual, “Features and Controls” topic (Operation Section). Engine Diagnostics The engine has built-in diagnostics in order to ensure that the engine systems are functioning correctly. The operator will be alerted to the condition by a “Stop or Warning” lamp. Under certain conditions, the engine horsepower and the vehicle speed may be limited. The electronic service tool may be used to display the diagnostic codes. There are three types of diagnostic codes: active, logged and event. Most of the diagnostic codes are logged and stored in the ECM. For additional information, refer to the Operation and Maintenance Manual, “Engine Diagnostics” topic (Operation Section). The ECM provides an electronic governor that controls the injector output in order to maintain the desired engine rpm. Engine Cooling and Lubrication The cooling system and lubrication system consists of the following components: 24 General Information Product Description • Belt driven centrifugal water pump • Water temperature regulator which regulates the engine coolant temperature • Gear-driven rotor type oil pump • Multi plate oil cooler The engine lubricating oil is cooled and the engine lubricating oil is filtered. Engine Service Life Engine efficiency and maximum utilization of engine performance depend on the adherence to proper operation and maintenance recommendations. In addition, use recommended fuels, coolants, and lubricants. Use the Operation and Maintenance Manual as a guide for required engine maintenance. Aftermarket Products and Perkins Engines Perkins does not warrant the quality or performance of non-Perkins fluids and filters. When auxiliary devices, accessories, or consumables (filters, additives, catalysts,) which are made by other manufacturers are used on Perkins products, the Perkins warranty is not affected simply because of such use. However, failures that result from the installation or use of other manufacturers devices, accessories, or consumables are NOT Perkins defects. Therefore, the defects are NOT covered under the Perkins warranty. Aftertreatment System The aftertreatment system is approved for use by Perkins . In order to be emission-compliant only the approved Perkins aftertreatment system must be used on a Perkins engine. SEBU8726 SEBU8726 25 Product Identification Information Plate Locations and Film Locations Product Identification Information Serial Number location i04725109 Plate Locations and Film Locations (Engine) Perkins engines are identified by an engine serial number. An example of an engine number is JR*****L000001V. ***** JR L 000001 V The list number for the engine The type of engine Built in the Italy Engine Serial Number Year of Manufacture Perkins dealers or Perkins distributors need all of these numbers in order to determine the components that were included with the engine. This information permits accurate identification of replacement part numbers. The numbers for fuel setting information for electronic engines are stored within the flash file. These numbers can be read by using the electronic service tool. Illustration 21 g02474416 Typical example of a non-stressed cylinder block The engine serial number can be installed in three different positions. All engines will have the serial number install in location (1) on the front face of the engine. On a non-stressed cylinder block the serial number is located in position (2). On the left-hand side on the cylinder block. 26 SEBU8726 Product Identification Information Plate Locations and Film Locations Illustration 22 g02826736 Typical example On a stressed cylinder block the serial number is located in position (3). The engine serial number is stamped on the emissions plate. SEBU8726 27 Product Identification Information Plate Locations and Film Locations i05328112 Plate Locations and Film Locations (Aftertreatment) Wall Flow Diesel Particulate Filter (DPF) Illustration 23 Typical example The serial number for identifying the aftertreatment will be in two locations. On the DPF in position (1) and in position (2). On the end cover of the inlet to the DPF. g02475495 28 SEBU8726 Product Identification Information Plate Locations and Film Locations Illustration 24 (1) Serial numbers on main body g02723697 (2) Serial numbers on inlet end cover Ensure that all numbers on the aftertreatment are recorded. Your Perkins distributor or your dealer will require all the numbers in order to identify the components for your aftertreatment. i05328174 Plate Locations and Film Locations (Aftertreatment) Through-Flow Diesel Particulate Filter (DPF) A serial number label for identifying the through-flow DPF will be located on the main body of the DPF. i04460799 Emissions Certification Film The emission label will be installed on the left side of the non-stressed cylinder block. SEBU8726 29 Product Identification Information Reference Information Illustration 25 g02646428 Typical example i05324886 Reference Information Engine Aftertreatment System Part Number Serial Number Information for the following items may be needed to order parts. Locate the information for your engine. Record the information in the appropriate space. Make a copy of this list for a record. Keep the information for future reference. Record for Reference Engine Model Engine Serial Number Engine Low Idle Revolutions Per Minute (RPM) Engine Full Load RPM Primary Fuel Filter Secondary Fuel Filter Element Lubrication Oil Filter Element Auxiliary Oil Filter Element Total Lubrication System Capacity Total Cooling System Capacity Air Cleaner Element Drive Belt 30 SEBU8726 Operation Section Product Lifting Operation Section Some removals require lifting the fixtures in order to obtain correct balance and safety. Lifting and Storage To remove the engine ONLY, use the lifting eyes that are on the engine. i04315227 Product Lifting Lifting eyes are designed and installed for specific engine arrangements. Alterations to the lifting eyes and/or the engine make the lifting eyes and the lifting fixtures obsolete. If alterations are made, ensure that correct lifting devices are provided. Consult your Perkins dealer or your Perkins distributor for information regarding fixtures for correct engine lifting. Note: The engine is equipped with three lifting eyes. All the lifting eyes must be used in order to lift the engine. i04084189 Product Storage (Engine and Aftertreatment) Perkins are not responsible for damage which may occur when an engine is in storage after a period in service. Your Perkins dealer or your Perkins distributor can assist in preparing the engine for extended storage periods. Condition for Storage The engine must be stored in a water proof building. The building must be kept at a constant temperature. Engines that are filled with Perkins ELC will have coolant protection to an ambient temperature of −36° C (−32.8° F). The engine must not be subjected to extreme variations in temperature and humidity. Illustration 26 g02475658 Typical example NOTICE Never bend the eyebolts and the brackets. Only load the eyebolts and the brackets under tension. Remember that the capacity of an eyebolt is less as the angle between the supporting members and the object becomes less than 90 degrees. When it is necessary to remove a component at an angle, only use a link bracket that is properly rated for the weight. Storage Period An engine can be stored for up to 6 months provided all the recommendation are adhered to. Storage Procedure Keep a record of the procedure that has been completed on the engine. Note: Do not store an engine that has biodiesel in the fuel system. 1. Ensure that the engine is clean and dry. Use a hoist to remove heavy components. Use an adjustable lifting beam to lift the engine. All supporting members (chains and cables) should be parallel to each other. The chains and cables should be perpendicular to the top of the object that is being lifted. a. If the engine has been operated using biodiesel, the system must be drained and new filters installed. The fuel tank will require flushing. SEBU8726 31 Lifting and Storage Product Storage b. Fill the fuel system with an ultra low sulfur fuel. For more information on acceptable fuels refer to this Operation and Maintenance Manual, “Fluid recommendations”. Operate the engine for 15 minutes in order to remove all biodiesel from the system. 2. Drain any water from the primary filter water separator. Ensure that the fuel tank is full. 3. The engine oil will not need to be drained in order to store the engine. Provided the correct specification of engine oil is used the engine can be stored for up to 6 months. For the correct specification of engine oil refer to this Operation and Maintenance Manual, “Fluid recommendations”. 4. Remove the drive belt from the engine. Sealed Coolant System Ensure that the cooling system is filled with Perkins ELC, or an antifreeze that meets ASTM D6210 specification. Open Cooling System Ensure that all cooling drain plugs have been opened. Allow the coolant to drain. Install the drain plugs. Place a vapor phase inhibitor into the system. The coolant system must be sealed once the vapor phase inhibitor has been introduced. The effect of the vapor phase inhibitor will be lost if the cooling system is open to the atmosphere. For maintenance procedures ref to this Operation and Maintenance Manual. Aftertreatment No special procedures are required. The exhaust outlet of the aftertreatment should be capped. Before storing, the engine and the aftertreatment must be enclosed in a cover. Monthly Checks The crankshaft must be rotated in order to change the spring loading on the valve train. Rotate the crankshaft more than 180 degrees. Visibly check for damage or corrosion to the engine and aftertreatment. Ensure that the engine and aftertreatment are covered completely before storage. Log the procedure in the record for the engine. 32 SEBU8726 Features and Controls Alarms and Shutoffs Features and Controls i05324913 Alarms and Shutoffs The alarm is a warning to the operator that an abnormal operating condition has occurred. The shutoffs are set in order to protect the engine from damage. A shutoff can be triggered by pressure, temperature, engine speed, and electronic fault. The operator should become familiar with the warning lamps and shutdown lamps on the installed control panel before operating the application. For more information refer to this Operation and Maintenance Manual, “Monitoring System (Table for the Indicator lamps)”. Jacket Water Coolant Temperature – Typical temperature range is 79° to 94°C (174° to 201 °F). This temperature range will vary according to engine load and the ambient temperature. A 100 kPa (14.5 psi) radiator cap must be installed on the cooling system. The maximum temperature for the cooling system will depend on engine power. For engines that are 75kW and lower the maximin cooling temperature is 110° C (230° F). For engines that are above 75kW the maximin temperature is 108° C (226.4° F). The engine coolant temperature is regulated by the engine sensors and the engine ECM. This programming cannot be altered. An engine derate can occur if the maximum engine coolant temperature is exceeded. If the engine is operating above the normal range, reduce the engine load. If high coolant temperatures are a frequent event, perform the following procedures: i04316262 Gauges and Indicators Your engine may not have the same gauges or all of the gauges that are described. For more information about the gauge package, see the OEM information. Gauges provide indications of engine performance. Ensure that the gauges are in good working order. Determine the normal operating range by observing the gauges over a period. Noticeable changes in gauge readings indicate potential gauge or engine problems. Problems may also be indicated by gauge readings that change even if the readings are within specifications. Determine and correct the cause of any significant change in the readings. Consult your Perkins distributor for assistance. Some engine applications are equipped with Indicator Lamps. Indicator lamps can be used as a diagnostic aid. There are two lamps. One lamp has an orange lens and the other lamp has a red lens. These indicator lamps can be used in two ways: • The indicator lamps can be used to identify the current operational status of the engine. The indicator lamps can also indicate that the engine has a fault. This system is automatically operated via the ignition switch. • The indicator lamps can be used to identify active diagnostic codes. This system is activated by pressing the Flash Code button. Refer to the Troubleshooting Guide, “Indicator Lamps” for further information. 1. Reduce the load and the engine rpm. 2. Determine if the engine must be shut down immediately or if the engine can be cooled by reducing the load. 3. Inspect the cooling system for leaks. If necessary, consult your Perkins distributor for assistance. Tachometer – This gauge indicates engine speed (rpm). When the throttle control lever is moved to the full throttle position without load, the engine is running at high idle. The engine is running at the full load rpm when the throttle control lever is at the full throttle position with maximum rated load. NOTICE To help prevent engine damage, never exceed the high idle rpm. Overspeeding can result in serious damage to the engine. Operation at speeds exceeding high idle rpm should be kept to a minimum. Ammeter – This gauge indicates the amount of charge or discharge in the battery charging circuit. Operation of the indicator should be to the “ +”” side of “ 0”” (zero). Fuel Level – This gauge indicates the fuel level in the fuel tank. The fuel level gauge operates when the “ START/ STOP”” switch is in the “ on”” position. Service Hour Meter – The gauge indicates total operating hours of the engine. SEBU8726 33 Features and Controls Monitoring System Indicator Lamps • Shutdown lamp • Warning lamp • Wait to start lamp • Low oil pressure lamp (On solid) and engine oil reset lamp (Flashing) For information, refer to this manual, “Monitoring System (Table for the Indicator Lamps)” for the sequence of operation of the shutdown lamp and the warning lamp. The function of the wait to start lamp is automatically controlled at engine start-up. The low oil pressure lamp has two functions. • The low oil pressure lamp is controlled by the engine ECM. If low oil pressure is detected, the lamp will be illuminated on solid. The reason for the illumination of the low-pressure lamp should be investigated immediately. • Low oil pressure lamp flashing, an engine oil change is required. The lamp must be reset, refer to this Operation and Maintenance Manual, “Engine Oil and Filter - Change” for more information. All lamps will illuminate for 2 seconds in order to check that the lamps are functioning when the keyswitch is turned to the ON position. If any of the lamps stay illuminated, the reason for illumination should be investigated immediately. Aftertreatment Lamps For information on the aftertreatment lamp, refer to this Operation and Maintenance Manual, “Diesel Particulate Filter Regeneration”. i04710837 Monitoring System (Table for the Indicator lamps) When in operation the amber warning indicator has three states, on solid, flashing and fast flashing. The sequence is to give a visual indication of the importance of the warning. Some application can have an audible warning installed. 34 SEBU8726 Features and Controls Monitoring System Table 2 Warning Indicator Shutdown Indicator On On Lamp State Description of the Indication Engine Status Indicator Check When the keyswitch is moved to the The keyswitch is in the ON ON position, the lamps will illumiposition but the engine has nate for 2 seconds and the lamps not yet been cranked. will then go off. During indicator check, the aftertreatment indicators will also be checked. Off Off No Faults With the engine in operation, there are no active warnings, diagnostic codes, or event codes. Operator Action If any of the indicators will not illuminate during indicator check, the fault must be investigated immediately. If any Indicators stay illuminated or flash, the fault must be investigated immediately. The engine is operating with no detected faults. None Level 1 On Solid Off Warning The engine is operating nor- As soon as possible the mally but there is one or more fault should be faults with the electronic man- investigated. agement system for the engine. Level 1 warning Level 2 Flashing Off Warning Level 2 warning The engine continues to be Stop the engine. operated, but there are active Investigate the code. diagnostic, or event codes active. Derate to engine power may be applied. Level 3 Flashing On solid Warning Level 3 warning If both the warning lamp and the shutdown lamp are in operation, this issue indicates one of the following conditions. The engine continues to be Stop the engine operated, but the level of im- immediately. portance of the warning has Investigate the fault increased. The engine will automatically shut down. 1. One or more of the shutdown val- If shut down is not enabled, ues for the engine protection strat- the engine could be damaged if continued to be operated. egy has been exceeded. 2. A serious active diagnostic code has been detected. 3. After a short time period, the engine may shut down. SEBU8726 35 Features and Controls Monitoring System i04317185 Monitoring System If the Shutdown mode has been selected and the warning indicator activates, engine shutdown may take as little as 20 seconds from the time the warning indicator is activated. Depending on the application, special precautions should be taken to avoid personal injury. The engine can be restarted following shutdown for emergency maneuvers, if necessary. NOTICE The Engine Monitoring System is not a guarantee against catastrophic failures. Programmed delays and derate schedules are designed to minimize false alarms and provide time for the operator to stop the engine. The following parameters are monitored: • Coolant temperature • Intake manifold air temperature • Intake manifold air pressure • Oil pressure • Pressure in the fuel rail Programmable Options and Systems Operation If the Warning/Derate/Shutdown mode has been selected and the warning indicator activates, bring the engine to a stop whenever possible. Depending on the application, special precautions should be taken to avoid personal injury. The engine can be programmed to the following modes: “ Warning”” The orange “Warning” lamp will turn “ON” and the warning signal is activated continuously in order to alert the operator that one or more of the engine parameters is not within normal operating range. “ Derate”” The orange “Warning” lamp will turn “ON” and the red shutdown lamp will be flashing. After the warning, the engine power will be derated. The warning lamp will begin to flash when the derating occurs. The engine will be derated if the engine exceeds preset operational limits. The engine derate is achieved by restricting the amount of fuel that is available for each injection. The amount of this reduction of fuel is dependent on the severity of the fault that has caused the engine derate, typically up to a limit of 50%. This reduction in fuel results in a predetermined reduction in engine power. • Engine speed/timing • Fuel temperature • Atmospheric pressure (Barometric pressure) • Water in fuel switch • Inlet temperature of the diesel oxidation catalyst • Inlet temperature of the diesel particulate filter • Differential pressure in the diesel particulate filter • The amount of soot in the diesel particulate filter “ Shutdown”” The orange warning will turn “ON” and the red shutdown lamp will also turn “ON” . After the warning, the engine power will be derated. The engine will continue at the rpm of the set derate until a shutdown of the engine occurs. The engine can be restarted after a shutdown for use in an emergency. A shutdown of the engine may occur in as little as 20 seconds. The engine can be restarted after a shutdown for use in an emergency. However, the cause of the initial shutdown may still exist. The engine may shut down again in as little as 20 seconds. If there is a signal for high coolant temperature, there will be a 2 second delay in order to verify the condition. If there is a signal for low oil pressure, there will be a 2 second delay in order to verify the condition. 36 SEBU8726 Features and Controls Overspeed For information on the operation of the warning lamps and the shutdown lamp, refer to this Operation and Maintenance Manual, “Monitoring System (Table for Indicator Lamps)”. For each of the programmed modes, refer to Troubleshooting Guide, “Indicator Lamps” for more information on Indicator Lamps. For more information or assistance for repairs, consult your Perkins distributor or your Perkins dealer. i04348489 Overspeed • ECM Electronic Control Module • RPM Revolutions Per Minute An overspeed is detected by the speed/timing sensors. The default overspeed is set at 2800. The ECM will cut the power to the electronic unit injectors, until the rpm drops below the overspeed setting. A diagnostic fault code will be logged into the ECM memory and a warning lamp will indicate a diagnostic fault code. Some application may have a display panel in order to alert the operator. SEBU8726 37 Features and Controls Sensors and Electrical Components i05325438 Sensors and Electrical Components Full Engine Views Illustration 27 g03373765 Typical example (1) 10 Pin and 62 pin connector (2) Fuel temperature sensor (3) Oil pressure switch (4) Primary speed/timing sensor (crankshaft position sensor) (5) Water in fuel switch (6) Fuel metering valve 38 SEBU8726 Features and Controls Sensors and Electrical Components Illustration 28 g02477200 Typical example (7) Fuel manifold (rail) pressure sensor (8) Electronic control module (9) Secondary speed/timing sensor (camshaft position sensor) (10) Alternator (11) Coolant temperature sensor (12) Intake throttle valve SEBU8726 39 Features and Controls Sensors and Electrical Components Illustration 29 g02529496 Typical example (13) Inlet manifold pressure and temperature sensor. (14) Exhaust temperature sensor connection (15) Exhaust pressure sensor (16) Waste gate regulator (17) Starting motor Note: Item (13), lower powered engines have separate inlet manifold pressure sensors and inlet manifold temperature sensors. (18) Oxygen sensor (19) Control valve for the NOx reduction system 40 SEBU8726 Features and Controls Sensors and Electrical Components Engine View Low Power with Separate Inlet Pressure and Inlet Temperature Illustration 30 g03373789 Typical example (13 A) Inlet pressure sensor (13 B) Inlet temperature sensor SEBU8726 41 Features and Controls Sensors and Electrical Components Location Views Illustration 31 g03373767 Typical example (1) 10 Pin and 62 pin connector (2) Fuel temperature sensor (3) Oil pressure switch (4) Primary speed/timing sensor (crankshaft position sensor) (5) Water in fuel switch (6) Fuel metering valve 42 SEBU8726 Features and Controls Sensors and Electrical Components Illustration 32 g02529820 Typical example (7) Fuel manifold (rail) pressure sensor (8) Electronic control module (9) Secondary speed/timing sensor (camshaft position sensor) (10) Alternator Note: The location of item (8) the engine electronic control module will depend on the application. (11) Coolant temperature sensor (12) Intake throttle valve SEBU8726 43 Features and Controls Sensors and Electrical Components Illustration 33 g02529821 Typical example (13) Inlet manifold pressure and temperature sensor. (14) Exhaust temperature sensor connection (A) Exhaust temperature sensor (15) Exhaust pressure sensor (16) Waste gate regulator 44 SEBU8726 Features and Controls Sensors and Electrical Components Illustration 34 g02530397 Typical example (17) Starting motor (18) Position for oxygen sensor Note: Some engines can have the air intake temperature sensor and the glow plug control unit supplied loose. (19) NOx reduction control valve 45 SEBU8726 Features and Controls Sensors and Electrical Components Separate Inlet Pressure and Inlet Temperature Views Illustration 35 g03373791 Typical example (13 A) Intake manifold pressure sensor (13 B) Intake manifold temperature sensor 46 SEBU8726 Features and Controls Sensors and Electrical Components Engine Option or Parts that are Supplied Loose Illustration 36 g02821639 Typical example (20) Glow plug control unit (21) Inlet air temperature sensor Some engines can have a breather heater (22) for the crankcase breather installed. i05325624 Sensors and Electrical Components (Aftertreatment) There are two types of aftertreatment that can be installed. The engine power will determine the type of aftertreatment that is installed. (22) Breather heater 47 SEBU8726 Features and Controls Sensors and Electrical Components Wall Flow Aftertreatment Illustration 37 g03373851 Typical example (1) Diesel oxidation catalyst temperature sensor (2) Diesel particulate filter (DPF) temperature sensor (3) Inlet connection for the differential pressure sensor (4) Outlet connection for the differential pressure sensor (5) Oxygen sensor 48 SEBU8726 Features and Controls Sensors and Electrical Components Through Flow Aftertreatment Illustration 38 g03373872 Typical example (1) Diesel oxidation catalyst (DOC) temperature sensor (2) Temperature sensor after DOC Differential Pressure sensor Illustration 39 g02477086 Typical example (1) Differential pressure sensor The location of the differential pressure sensor will depend on the application. The differential pressure is installed on the wall flow DPF. The through-flow DPF does not always require the sensor to be installed. (3) Oxygen sensor SEBU8726 49 Engine Diagnostics Self-Diagnostics Engine Diagnostics i04348749 i02651093 Self-Diagnostics Perkins electronic engines have the capability to perform a self-diagnostics test. When the system detects an active problem, a diagnostic lamp is activated. Diagnostic codes will be stored in permanent memory in the Electronic Control Module (ECM). The diagnostic codes can be retrieved by using the electronic service tool. Refer to Troubleshooting, “Electronic Service Tools” for further information. Some installations have electronic displays that provide direct readouts of the engine diagnostic codes. Refer to the manual that is provided by the OEM for more information on retrieving engine diagnostic codes. Alternatively refer to Troubleshooting, “Indicator Lamps” for further information. Active codes represent problems that currently exist. These problems should be investigated first. Logged codes represent the following items: • Intermittent problems • Recorded events • Performance history The problems may have been repaired since the logging of the code. These codes do not indicate that a repair is needed. The codes are guides or signals when a situation exists. Codes may be helpful to troubleshoot problems. When the problems have been corrected, the corresponding logged fault codes should be cleared. i02651107 Diagnostic Lamp Fault Logging The system provides the capability of Fault Logging. When the Electronic Control Module (ECM) generates an active diagnostic code, the code will be logged in the memory of the ECM. The codes that have been logged by the ECM can be identified by the electronic service tool. The active codes that have been logged will be cleared when the fault has been rectified or the fault is no longer active. i03554534 Engine Operation with Active Diagnostic Codes If a diagnostic lamp illuminates during normal engine operation, the system has identified a situation that is not within the specification. Use electronic service tools to check the active diagnostic codes. Note: If the customer has selected “DERATE” and if there is a low oil pressure condition, the Electronic Control Module (ECM) will limit the engine power until the problem is corrected. If the oil pressure is within the normal range, the engine may be operated at the rated speed and load. However, maintenance should be performed as soon as possible. The active diagnostic code should be investigated. The cause of the problem should be corrected as soon as possible. If the cause of the active diagnostic code is repaired and there is only one active diagnostic code, the diagnostic lamp will turn off. Operation of the engine and performance of the engine can be limited as a result of the active diagnostic code that is generated. Acceleration rates may be significantly slower. Refer to the Troubleshooting Guide for more information on the relationship between these active diagnostic codes and engine performance. i01902995 A diagnostic lamp is used to indicate the existence of an active fault. Refer to Troubleshooting, “Indicator Lamps” for more information. A fault diagnostic code will remain active until the problem is repaired. The diagnostic code may be retrieved by using the electronic service tool. Refer to Troubleshooting, “Electronic Service Tools” for more information. Engine Operation with Intermittent Diagnostic Codes If a diagnostic lamp illuminates during normal engine operation and the diagnostic lamp shuts off, an intermittent fault may have occurred. If a fault has occurred, the fault will be logged into the memory of the Electronic Control Module (ECM). 50 Engine Diagnostics Configuration Parameters SEBU8726 In most cases, it is not necessary to stop the engine because of an intermittent code. However, the operator should retrieve the logged fault codes and the operator should reference the appropriate information in order to identify the nature of the event. The operator should log any observation that could have caused the lamp to light. • Low power • Limits of the engine speed • Excessive smoke, etc This information can be useful to help troubleshoot the situation. The information can also be used for future reference. For more information on diagnostic codes, refer to the Troubleshooting Guide for this engine. i04349071 Configuration Parameters The engine electronic control module (ECM) has two types of configuration parameters. The system configuration parameters and the customer specified parameters. The electronic service tool is required in order to alter the configuration parameters. System Configuration Parameters System configuration parameters affect the emissions of the engine or the power of the engine. System configuration parameters are programmed at the factory. Normally, system configuration parameters would never require changing through the life of the engine. System configuration parameters must be reprogrammed if an ECM is replaced. Customer Specified Parameters Customer specified parameters allow the engine to be configured to the exact needs of the application. The electronic service tool is required in order to alter the customer configuration parameters. Customer parameters may be changed repeatedly as operational requirements change. Table 3 Customer Specified Parameters Specified Parameters Record Low Idle Speed Throttle Position 1 Engine Speed (continued) SEBU8726 51 Engine Diagnostics Configuration Parameters (Table 3, contd) Throttle Position 2 Engine Speed Throttle Position 3 Engine Speed Throttle Position 4 Engine Speed Engine Idle Shutdown Enable Status Engine Idle Shutdown Delay Status Throttle Lock Feature Installation Status Multi State Input Switch Enable Status Multi State Input Switch Control Purpose Multi Position Throttle Switch Initialization Enable Status Throttle Lock Engine Set Speed #1 Throttle Lock Increment Speed Ramp Rate Throttle Lock Decrement Speed Ramp Rate Throttle Lock Engine Set Speed Increment Monitoring Mode Shutdowns Limp Home Desired Engine Speed Engine Acceleration Rate Engine Location High Exhaust System Temperature Indicator Installation Status DPF Regeneration Inhibit Indicator Installation Status DPF Soot Loading Indicator Installation Status Oil Pressure Lamp Installation Status Wait to Start Lamp Installation Status Warning Lamp Installation Status Shutdown Lamp Installation Status Starter Relay Installation Status Low Pressure Fuel Pump Installation Status Remote Torque Speed Control Enable Status Throttle Arbitration Method Manual Throttle Arbitration Precondition Check Throttle Enable Status Throttle #1 Initial Lower Position Throttle #1 Initial Upper Position Throttle #1Idle Validation Switch Enable Status Throttle #1Idle Validation Minimum Off Threshold Throttle #1 Idle Validation Maximum On Threshold Throttle #1 Lower Diagnostic Limit Throttle #1 Upper Diagnostic Limit (continued) 52 Engine Diagnostics Configuration Parameters (Table 3, contd) Throttle #2 Initial Lower Position Throttle #2 Initial Upper Position Throttle #2 Idle Validation Switch Enable Status Throttle #2 Idle Validation Minimum Off Threshold Throttle #2 Idle Validation Maximum On Threshold Throttle #2 Lower Diagnostic Limit Throttle #2 Upper Diagnostic Limit Engine Operation Mode #1 High Idle Speed Engine Operation Mode #1 High Idle Droop Percentage Engine Operation Mode #1 Throttle #1 Droop Percentage Engine Operation Mode #2 Throttle #1 Droop Percentage Engine Operation Mode #1 TSC1 Droop Percentage Engine Operation Mode #2 High Idle Speed Engine Operation Mode #2 High Idle Droop Percentage Engine Operation Mode #2 Throttle #1 Droop Percentage Engine Operation Mode #2 Throttle #2 Droop Percentage Engine Operation Mode #2 TSC1 Droop Percentage Engine Operation Mode #3 High Idle Droop Percentage Engine Operation Mode #3 High Idle Droop Percentage Engine Operation Mode #3 Throttle #1 Droop Percentage Engine Operation Mode #3 Throttle #2 Droop Percentage Engine Operation Mode #3 TSC1 Droop Percentage Engine Operation Mode #4 High Idle Speed Engine Operation Mode #4 High Idle Droop Percentage Engine Operation Mode #4 Throttle #1 Droop Percentage Engine Operation Mode #4 Throttle #2 Droop Percentage Engine Operation Mode #4 TSC1 Droop Percentage SEBU8726 SEBU8726 53 Engine Starting Before Starting Engine Engine Starting i05365825 i03648917 Cold Weather Starting Before Starting Engine ce and other periodic maintenance before the engine is started. Inspect the engine compartment. This inspection can help prevent major repairs at a later date. Refer to the Operation and Maintenance Manual, “Maintenance Interval Schedule” for more information. • Ensure that the engine has an adequate fuel supply. • Open the fuel supply valve (if equipped). NOTICE All valves in the fuel return line must be open and fuel supply lines must be open. Damage to the fuel system can occure if fuel lines are closed with the engine in operation. If the engine has not been started for several weeks, fuel may have drained from the fuel system. Air may have entered the filter housing. Also, when fuel filters have been changed, some air pockets will be trapped in the engine. In these instances, prime the fuel system. Refer to the Operation and Maintenance Manual, “Fuel System - Prime” for more information on priming the fuel system. Also, check that the fuel specification is correct and that the fuel condition is correct. Refer to the Operation and Maintenance Manual, “Fuel Recommendations”. Engine exhaust contains products of combustion which may be harmful to your health. Always start and operate the engine in a well ventilated area and, if in an enclosed area, vent the exhaust to the outside. Do not use aerosol types of starting aids such as ether. Such use could result in an explosion and personal injury. The ability to start the engine will be improved at temperatures below −18 °C (0 °F) from the use of a jacket water heater or extra battery capacity. When Group 2 diesel fuel is used, the following items provide a means of minimizing starting problems and fuel problems in cold weather: Engine oil pan heaters, jacket water heaters, fuel heaters and fuel line insulation. Use the procedure that follows for cold weather starting. Note: Do not adjust the engine speed control during start-up. The electronic control module (ECM) will control the engine speed during start-up. 1. Disengage any driven equipment. Note: During key ON, the indicator lamps will be illuminated for 2 seconds in order to check the lamp operation. If any of the indicator lamps do not illuminate check the bulb. If any indicator lamps stay illuminated or flash, refer to Troubleshooting, “Indicator Lamp Circuit - Test”. 2. Turn the keyswitch to the RUN position. Leave the keyswitch in the RUN position until the warning light for the glow plugs is extinguished. 3. When the warning light for the glow plugs is extinguished, turn the keyswitch to the START position in order to engage the electric starting motor and crank the engine. • Do not start the engine or move any of the controls if there is a “DO NOT OPERATE” warning tag or similar warning tag attached to the start switch or to the controls. Note: The operating period of the warning light for the glow plugs will change due to the ambient air temperature. • Reset all of the shutoffs or alarm components. NOTICE Do not engage the starting motor when flywheel is turning. Do not start the engine under load. • Ensure that any driven equipment has been disengaged. Minimize electrical loads or remove any electrical loads. If the engine fails to start within 30 seconds, release the starter switch or button and wait two minutes to allow the starting motor to cool before attempting to start the engine again. 54 SEBU8726 Engine Starting Starting the Engine 4. Allow the keyswitch to return to the RUN position after the engine starts. 5. Repeat step 2 through step 4 if the engine fails to start. Note: After starting, the engine will be held at low speed. The time held at low speed will depend on ambient temperature and time since last run. The procedure is in order to allow the engine systems to stabilize. The engine should not be “raced” in order to speed up the warm-up process. 6. Allow the engine to idle for 3 to 5 minutes, or allow the engine to idle until the water temperature indicator begins to rise. When idling after the engine has started in cold weather, increase the engine rpm from 1000 to 1200 rpm. This operation will warm up the engine more quickly. Maintaining an elevated low idle speed for extended periods will be easier with the installation of a hand throttle. Allow the white smoke to disperse before proceeding with normal operation. 7. Operate the engine at low load until all systems reach operating temperature. Check the gauges during the warm-up period. i05365826 Starting the Engine Note: Do not adjust the engine speed control during start-up. The electronic control module (ECM) will control the engine speed during start-up. Starting the Engine 1. Disengage any equipment that is driven by the engine. 2. Turn the keyswitch to the first position power on. Check that the low oil pressure lamp is on solid. If the lamp is on solid, the engine start sequence can continue. If the lamp is flashing, and engine oil change is required. Refer to this Operation and Maintenance Manual, “Engine Oil and Filter Change” for more information. 3. Turn the keyswitch to the RUN position. Leave the keyswitch in the RUN position until the warning light for the glow plugs is extinguished. Note: During the key on, the indicator lamps will be illuminated for 2 seconds in order to check lamp operation. If any of the lamps do not illuminate, check the bulb. If the fault remains refer to Troubleshooting, “Indicator Lamp Circuit - Test”. 4. When the warning light for the glow plugs is extinguished, turn the keyswitch to the START position in order to engage the electric starting motor and crank the engine. Note: The operating period of the warning light for the glow plugs will change due to the temperature of the engine. NOTICE Do not engage the starting motor when flywheel is turning. Do not start the engine under load. If the engine fails to start within 30 seconds, release the starter switch or button and wait two minutes to allow the starting motor to cool before attempting to start the engine again. 5. Allow the keyswitch to return to the RUN position after the engine starts. Ensure that all warning lamps are off. 6. Repeat step 2 through step 5 if the engine fails to start. 7. After starting, the engine will be held at low speed. The time held at low speed will depend on ambient temperature and time since last run. The procedure is in order to allow the engine systems to stabilize. 8. If the engine will not start, refer to Troubleshooting, “Engine Cranks but Does Not Start” i03663103 Starting with Jump Start Cables Improper jump start cable connections can cause an explosion resulting in personal injury. Prevent sparks near the batteries. Sparks could cause vapors to explode. Do not allow jump start cable ends to contact each other or the engine. 55 SEBU8726 Engine Starting After Starting Engine Note: If it is possible, first diagnose the reason for the starting failure. Refer to Troubleshooting, “Engine Will Not Crank and Engine Cranks But Will Not Start” for further information. Make any necessary repairs. If the engine will not start only due to the condition of the battery, either charge the battery, or start the engine by using another battery with jump start cables. The condition of the battery can be rechecked after the engine has been switched OFF. NOTICE Using a battery source with the same voltage as the electric starting motor. Use ONLY equal voltage for jump starting. The use of higher voltage will damage the electrical system. Do not reverse the battery cables. The alternator can be damaged. Attach ground cable last and remove first. Turn all electrical accessories OFF before attaching the jump start cables. Ensure that the main power switch is in the OFF position before attaching the jump start cables to the engine being started. 1. Turn the start switch on the stalled engine to the OFF position. Turn off all the engine's accessories. 2. Connect one positive end of the jump start cable to the positive cable terminal of the discharged battery. Connect the other positive end of the jump start cable to the positive cable terminal of the electrical source. 3. Connect one negative end of the jump start cable to the negative cable terminal of the electrical source. Connect the other negative end of the jump start cable to the engine block or to the chassis ground. This procedure helps to prevent potential sparks from igniting the combustible gases that are produced by some batteries. Note: The engine ECM must be powered before the starting motor is operated or damage can occur. 4. Start the engine in the normal operating procedure. Refer to this Operation and Maintenance Manual, “Starting the Engine”. 5. Immediately after the engine is started, disconnect the jump start cables in reverse order. After jump starting, the alternator may not be able to fully recharge batteries that are severely discharged. The batteries must be replaced or charged to the proper voltage with a battery charger after the engine is stopped. Many batteries which are considered unusable are still rechargeable. Refer to Operation and Maintenance Manual, “Battery - Replace” and Testing and Adjusting Manual, “Battery - Test”. i05397433 After Starting Engine After starting, the engine will be held at low speed. The time held at low speed will depend on ambient temperature and time since last run. The procedure is in order to allow the engine systems to stabilize. Note: In ambient temperatures from 0 to 60°C (32 to 140°F), the warm-up time is approximately 3 minutes. In temperatures below 0°C (32°F), additional warm-up time may be required. When the engine idles during warm-up, observe the following conditions: Do not check the high-pressure fuel lines with the engine or the starting motor in operation. If you inspect the engine in operation, always use the proper inspection procedure in order to avoid a fluid penetration hazard. Refer to Operation and Maintenance Manual, “General hazard Information”. • Check for any fluid or for any air leaks at idle rpm and at one-half full rpm (no load on the engine) before operating the engine under load. • Allow the engine to idle for 3 to 5 minutes, or allow the engine to idle until the water temperature indicator begins to rise. Check all gauges during the warm-up period. Note: Gauge readings should be observed and the data should be recorded frequently while the engine is operating. Comparing the data over time will help to determine normal readings for each gauge. Comparing data over time will also help detect abnormal operating developments. Significant changes in the readings should be investigated. 56 SEBU8726 Engine Operation Engine Operation Engine Operation i04690175 i04653132 Engine Operation Proper operation and maintenance are key factors in obtaining the maximum life and economy of the engine. If the directions in the Operation and Maintenance Manual are followed, costs can be minimized and engine service life can be maximized. The time that is needed for the engine to reach normal operating temperature can be less than the time taken for a walk-around inspection. The engine can be operated at the rated rpm after the engine is started and after the engine reaches operating temperature. The engine will reach normal operating temperature sooner during a low engine speed (rpm) and during a low-power demand. This procedure is more effective than idling the engine at no load. The engine should reach operating temperature in a few minutes. Avoid excess idling. Excessive idling causes carbon buildup, engine slobber and soot loading of the Diesel Particulate Filter (DPF). Excess idling can be harmful to the engine. Gauge readings should be observed and the data should be recorded frequently while the engine is operating. Comparing the data over time will help to determine normal readings for each gauge. Comparing data over time will also help detect abnormal operating developments. Significant changes in the readings should be investigated. System Check During normal engine operation the Electronic Control Module (ECM) will elevate the fuel pressure to the injectors. This check will be at scheduled intervals of approximately 100 hours depending on the duty cycle of the engine. The check will be carried out automatically without the need of any input from the operator. During the time of elevated fuel pressure, the operator may notice a change in the tone of the engine. The ECM will operate the check at low idle for approximately 5 minutes. Diesel Particulate Filter Regeneration Regeneration Regeneration is the removal of soot from the Diesel Particulate Filter (DPF). There are two different types of DPF that can be installed The through flow DPF and the wall flow DPF. Engines with a power output of 56kW and above will have the wall flow DPF installed. Engines with a power output below 56kW have the option to use both types of DPF. In table 4 titled Indicator Operation the operator will find information on the regeneration indicators. The table informs the operator why an indicator is illuminated and what action should be taken. Through Flow DPF The through flow DPF uses passive regeneration in order to remove the soot from the DPF. Passive regeneration is a chemical reaction within the system. Normal operation of the engine creates enough heat for a chemical reaction in order to regenerate the DPF. The regeneration occurs automatically during normal engine operation. This system uses an amount of active regeneration in order to ensure that soot cannot exit the DPF. The through flow DPF will not require manual cleaning. For a typical view of the through flow DPF, refer to this Operation and Maintenance Manual, “Sensors and Electrical Components (Aftertreatment)” Wall Flow DPF The wall flow DPF uses passive regeneration and active regeneration in order to remove the soot from the DPF. The ash is trapped within the DPF and must be removed by a manual cleaning process. Refer to Operation and Maintenance Manual, “Diesel Particulate Filter- Clean”. For a typical view of the wall flow DPF, refer to this Operation and Maintenance Manual, “Sensors and Electrical Components (Aftertreatment)” Regeneration Indicators Five indicators can be affected by the DPF regeneration. these indicators are, Regeneration Active, DPF, Disable Regeneration, Amber, or Yellow Warning Indicator and Red Stop Indicator. 57 SEBU8726 Engine Operation Diesel Particulate Filter Regeneration Regeneration Active – This indicator will illuminate during active regeneration. The indicator shows that elevated exhaust temperatures are possible. The indicator will be turned off when regeneration is complete. DPF – This indicator provides a general indication of the soot load. The indicator is off when the soot load is normal. Disable Regeneration – This indicator is illuminated whenever the disable switch is activated. Modes of Regeneration • Automatic regeneration • Manual regeneration Automatic regeneration – Automatic regeneration will occur when the level of soot reaches the trigger point that is set in the ECM. The engine can operate normally during an automatic regeneration. Manual – A manual regeneration is initiated by pressing the regeneration switch. A forced regeneration can only be performed after the soot load has illuminated the DPF indicator . A forced regeneration will only be required if the automatic regeneration has not been completed. This situation can be due to either the disable switch being operated or the duty cycle of the engine. Note: In some applications the engine safety interlocks will need to be in place before a forced regeneration can occur. Regeneration Switch Note: The regeneration switch is a three position switch. Some OEMs may use other means of activating a forced regeneration such as touch screen interfaces. Force Regeneration – Press in the top of the switch for 2 seconds in order to begin regeneration. Disable Regeneration – Press in the bottom of the switch for 2 seconds in order to disable regeneration. Note: The MIDDLE position of the regeneration switch is the default position for automatic regeneration. Note: You may return to normal operation at any point during a regeneration. Regeneration System Warning Indicators Some applications may also have an audible warning installed. 58 SEBU8726 Engine Operation Diesel Particulate Filter Regeneration Table 4 Indicator Operation During passive regeneration no indicator will be illuminated Aftertreatment Indicator Aftertreatment Indica- Warning Indicator tor State Warning Indicator Description State Regeneration Active indicator On Solid None None Action Required Regeneration is activated. None The indicator will stay illuminated during regeneration. DPF Indicator On Solid None None The indicator provides a general indication of the soot load. The indicator is off when the soot load is normal. A regeneration is required. In automatic mode the ECM will decide when to allow the active regeneration. If the DPF indicator stays illuminated allow a manual regeneration without interruption. An uninterrupted active regeneration will reset the DPF indicator. The indicator indicates that the soot load has increased. The engine will derate. A manual regeneration is required. Perform a manual regeneration, or a service regeneration will be required. The flashing warning indicator and red stop indicator indicates that the engine has continued to be operated while a regeneration is required. The engine will be derated and the engine should be shut down immediately. Once the engine enters into shutdown mode, you must contact your Perkins distributor or your Perkins dealer. Your dealer or distributor will need to perform a service level regeneration. The DFP may need to be replaced. DPF Indicator On Solid Amber indicator Flashing DPF Indicator On Solid Amber indicator Flashing - - Red indicator (STOP) On Solid Note: Amber or yellow warning indicator can be used as a diagnostic lamp. For more information refer to this Operation and Maintenance Manual, “Diagnostic Lamp”. Regeneration Operation Regeneration will require the following conditions: Automatic Regeneration In order for an automatic regeneration to take place the engine must be at operating temperature. Turning the keyswitch to the OFF position during a regeneration will stop the regeneration. An interrupted regeneration will not remove the soot from the DPF and will waste fuel. Wall Flow DPF Only The engine Revs Per Minute (RPM) must be above 1200 RPM for the regeneration to start. Normal operation can continue. During an automatic regeneration the minimum idle speed will be controlled to 950 RPM. Manual Regeneration The DPF indicator must be illuminated. Where applicable, safety interlock for your application must be engaged before a manual regeneration can occur, refer to your OEM for more information. No throttle inputs are required, the ECM will control the engine RPM. Press the force regeneration switch for 2 seconds. Do not operate the application during the manual regeneration. SEBU8726 59 Engine Operation Fuel Conservation Practices Service Regeneration The electronic service tool will be required in order to perform a force regeneration. Contact your Perkins distributor or your Perkins dealer. i04018232 Fuel Conservation Practices The efficiency of the engine can affect the fuel economy. Perkins design and technology in manufacturing provides maximum fuel efficiency in all applications. Follow the recommended procedures in order to attain optimum performance for the life of the engine. • Avoid spilling fuel. Fuel expands when the fuel is warmed up. The fuel may overflow from the fuel tank. Inspect fuel lines for leaks. Repair the fuel lines, as needed. • Be aware of the properties of the different fuels. Use only the recommended fuels. Refer to the Operations and Maintenance Manual, “Fuel Recommendations”for further information. • Avoid unnecessary idling. Shut off the engine rather than idle for long periods of time. • Observe the service indicator frequently. Keep the air cleaner elements clean. • Ensure that the turbocharger is operating correctly. For more information refer to this Operation and Maintenance Manual, “Turbocharger - Inspect” • Maintain a good electrical system. One faulty battery cell will overwork the alternator. This fault will consume excess power and excess fuel. • The belt should be in good condition. Refer to the Systems Operation, Testing and Adjusting, “V-Belt Test” for further information. • Ensure that all of the connections of the hoses are tight. The connections should not leak. • Ensure that the driven equipment is in good working order. • Cold engines consume excess fuel. Utilize heat from the jacket water system and the exhaust system, when possible. Keep cooling system components clean and keep cooling system components in good repair. Never operate the engine without water temperature regulators. All of these items will help maintain operating temperatures. 60 SEBU8726 Cold Weather Operation Cold Weather Operation Cold Weather Operation i05365832 Cold Weather Operation Perkins Diesel Engines can operate effectively in cold weather. During cold weather, the starting and the operation of the diesel engine is dependent on the following items: • The type of fuel that is used • The viscosity of the engine oil • The operation of the glow plugs Hints for Cold Weather Operation • If the engine will start, operate the engine until a minimum operating temperature of 80° C (176° F) is achieved. Achieving operating temperature will help prevent the intake valves and exhaust valves from sticking. • The cooling system and the lubrication system for the engine do not lose heat immediately upon shutdown. This means that an engine can be shut down for a period and the engine can still have the ability to start readily. • Install the correct specification of engine lubricant before the beginning of cold weather. • Check all rubber parts (hoses, fan drive belts,) weekly. • Optional Cold starting aid • Battery condition • Check all electrical wiring and connections for any fraying or damaged insulation. This section will cover the following information: • Keep all batteries fully charged and warm. • Potential problems that are caused by coldweather operation • Fill the fuel tank at the end of each shift. • Suggest steps which can be taken in order to minimize starting problems and operating problems when the ambient air temperature is between 0° to−40 °C (32° to 40 °F). The operation and maintenance of an engine in freezing temperatures is complex . This complexity is because of the following conditions: • Check the air cleaners and the air intake daily. Check the air intake more often when you operate in snow. • Ensure that the glow plugs are in working order. Refer to Troubleshooting, “Glow Plug Starting AidTest”. • Weather conditions • Engine applications Recommendations from your Perkins dealer or your Perkins distributor are based on past proven practices. The information that is contained in this section provides guidelines for cold-weather operation. Personal injury or property damage can result from alcohol or starting fluids. Alcohol or starting fluids are highly flammable and toxic and if improperly stored could result in injury or property damage. Do not use aerosol types of starting aids such as ether. Such use could result in an explosion and personal injury. • For jump starting with cables in cold weather, refer to the Operation and Maintenance Manual, “Starting with Jump Start Cables.” for instructions. SEBU8726 61 Cold Weather Operation Cold Weather Operation Viscosity of the Engine Lubrication Oil Recommendations for Coolant Warm Up Correct engine oil viscosity is essential. Oil viscosity affects the amount of torque that is needed to crank the engine. Refer to this Operation and Maintenance Manual, “Fluid Recommendations” for the recommended viscosity of oil. Warm up an engine that has cooled below normal operating temperatures due to inactivity. This warm -up should be performed before the engine is returned to full operation. During operation in very cold temperature conditions, damage to engine valve mechanisms can result from engine operation for short intervals. This damage can happen if the engine is started and the engine is stopped many times without being operated in order to warm up completely. Recommendations for the Coolant Provide cooling system protection for the lowest expected outside temperature. Refer to this Operation and Maintenance Manual, “Fluid Recommendations” for the recommended coolant mixture. In cold weather, check the coolant often for the correct glycol concentration in order to ensure adequate freeze protection. Engine Block Heaters Engine block heaters (if equipped) heat the engine jacket water that surrounds the combustion chambers. This heat provides the following functions: • Startability is improved. • Warm up time is reduced. An electric block heater can be activated once the engine is stopped. A block heater can be 110 V dc or 240 V dc. The output can be 750/1000W. Consult your Perkins dealer or your Perkins distributor for more information. Idling the Engine After starting the engine, the engine speed will be held at low speed. The time held at low speed will depend on ambient temperature and time since last run. The procedure is in order to allow the engine system to stabilize. When idling after the engine is started in cold weather, increase the engine rpm from 1000 to 1200 rpm. This idling will warm up the engine more quickly. Maintaining an elevated low idle speed for extended periods will be easier with the installation of a hand throttle. The engine should not be “raced” in order to speed up the warm-up process. While the engine is idling, the application of a light load (parasitic load) will assist in achieving the minimum operating temperature. The minimum operating temperature is 80° C (176° F). When the engine is operated below normal operating temperatures, fuel and oil are not completely burned in the combustion chamber. This fuel and oil causes soft carbon deposits to form on the valve stems. Generally, the deposits do not cause problems and the deposits are burned off during operation at normal engine operating temperatures. When starting and stopping an engine many times without being operated in order to warm up completely, the carbon deposits become thicker. This starting and stopping can cause the following problems: • Free operation of the valves is prevented. • Valves become stuck. • Pushrods may become bent. • Other damage to valve train components can result. For this reason, when the engine is started, the engine must be operated until the coolant temperature is 80° C (176° F) minimum. Carbon deposits on the valve stems will be kept at a minimum and the free operation of the valves and the valve components will be maintained. The engine must be thoroughly warmed in order to keep other engine parts in better condition. The service life of the engine will be generally extended. Lubrication will be improved. There will be less acid and less sludge in the oil. This condition will provide longer service life for the engine bearings, the piston rings, and other parts. However, limit unnecessary idle time to 10 minutes in order to reduce wear and unnecessary fuel consumption. 62 SEBU8726 Cold Weather Operation Fuel and the Effect from Cold Weather The Water Temperature Regulator and Insulated Heater Lines The engine is equipped with a water temperature regulator. When the engine coolant is below the correct operating temperature, jacket water circulates through the engine cylinder block and into the engine cylinder head. The coolant then returns to the cylinder block via an internal passage that bypasses the valve of the coolant temperature regulator. This return ensures that coolant flows around the engine under cold operating conditions. The water temperature regulator begins to open when the engine jacket water has reached the correct minimum operating temperature. As the jacket water coolant temperature rises above the minimum operating temperature, the water temperature regulator opens further allowing more coolant through the radiator to dissipate excess heat. The progressive opening of the water temperature regulator operates the progressive closing of the bypass passage between the cylinder block and head. This action ensures maximum coolant flow to the radiator in order to achieve maximum heat dissipation. Note: Do not restrict the air flow. Restriction of the air flow can damage the fuel system. Perkins discourages the use of all air flow restriction devices such as radiator shutters. Restriction of the air flow can result in the following: high exhaust temperatures, power loss, excessive fan usage and reduction in fuel economy. A cab heater is beneficial in very cold weather. The feed from the engine and the return lines from the cab should be insulated in order to reduce heat loss to the outside air. Recommendation for Crankcase Breather Protection Crankcase ventilation gases contain a large quantity of water vapor. This water vapor can freeze in cold ambient conditions and can plug or damage the crankcase ventilation system. If the engine is operated in temperatures below -15 °C (5 °F), measures must be taken to prevent freezing and plugging of the breather system. Insulated hoses and a heated assembly should be installed. Consult with your Perkins dealer or your Perkins distributer for the recommended breather components for operation from −15° to -40°C (5 ° to -72.°F). i02685960 Fuel and the Effect from Cold Weather Note: Only use grades of fuel that are recommended by Perkins . Refer to this Operation and Maintenance Manual, “Fluid Recommendations”. The following components provide a means of minimizing problems in cold weather: • Glow plugs (if equipped) • Engine coolant heaters, which may be an OEM option • Fuel heaters, which may be an OEM option • Fuel line insulation, which may be an OEM option The cloud point is a temperature that allows wax crystals to form in the fuel. These crystals can cause the fuel filters to plug. The pour point is the temperature when diesel fuel will thicken. The diesel fuel becomes more resistant to flow through fuel lines, fuel filters,and fuel pumps. Be aware of these facts when diesel fuel is purchased. Consider the average ambient air temperature for the engine's application. Engines that are fueled in one climate may not operate well if the engines are moved to another climate. Problems can result due to changes in temperature. Before troubleshooting for low power or for poor performance in the winter, check the fuel for waxing. Low temperature fuels may be available for engine operation at temperatures below 0 °C (32 °F). These fuels limit the formation of wax in the fuel at low temperatures. For more information on cold weather operation, refer to the Operation and Maintenance Manual, “Cold Weather Operation and Fuel Related Components in Cold Weather”. i02323237 Fuel Related Components in Cold Weather Fuel Tanks Condensation can form in partially filled fuel tanks. Top off the fuel tanks after you operate the engine. Fuel tanks should contain some provision for draining water and sediment from the bottom of the tanks. SEBU8726 63 Cold Weather Operation Fuel Related Components in Cold Weather Some fuel tanks use supply pipes that allow water and sediment to settle below the end of the fuel supply pipe. Some fuel tanks use supply lines that take fuel directly from the bottom of the tank. If the engine is equipped with this system, regular maintenance of the fuel system filter is important. Drain the water and sediment from any fuel storage tank at the following intervals: weekly, service intervals and refueling of the fuel tank. This will help prevent water and/or sediment from being pumped from the fuel storage tank and into the engine fuel tank. Fuel Filters A primary fuel filter is installed between the fuel tank and the engine fuel inlet. After you change the fuel filter, always prime the fuel system in order to remove air bubbles from the fuel system. Refer to the Operation and Maintenance Manual in the Maintenance Section for more information on priming the fuel system. The location of a primary fuel filter is important in cold weather operation. The primary fuel filter and the fuel supply line are the most common components that are affected by cold fuel. Fuel Heaters Note: The OEM may equip the application with fuel heaters. If this is the case, the temperature of the fuel must not exceed 73 °C (163 °F) at the fuel transfer pump. For more information about fuel heaters (if equipped), refer to the OEM information. 64 SEBU8726 Engine Stopping Stopping the Engine Engine Stopping i03648931 i04535875 Stopping the Engine After Stopping Engine Note: Before you check the engine oil, do not operate the engine for at least 10 minutes in order to allow the engine oil to return to the oil pan. NOTICE Stopping the engine immediately after it has been working under load, can result in overheating and accelerated wear of the engine components. Avoid accelerating the engine prior to shutting it down. Avoiding hot engine shutdowns will maximize turbocharger shaft and bearing life. Note: Individual applications will have different control systems. Ensure that the shutoff procedures are understood. Use the following general guidelines in order to stop the engine. 1. Remove the load from the engine. Reduce the engine speed (rpm) to low idle. Allow the engine to idle for 5 minutes in order to cool the engine. 2. Stop the engine after the cool down period according to the shutoff system on the engine and turn the ignition key switch to the OFF position. If necessary, refer to the instructions that are provided by the OEM. 3. Wait 60 seconds before the battery disconnect switch is turned off. The engine ECM required power after the keyswitch is turned off. i01903586 Emergency Stopping NOTICE Emergency shutoff controls are for EMERGENCY use ONLY. DO NOT use emergency shutoff devices or controls for normal stopping procedure. The OEM may have equipped the application with an emergency stop button. For more information about the emergency stop button, refer to the OEM information. Ensure that any components for the external system that support the engine operation are secured after the engine is stopped. Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death. • After the engine has stopped, you must wait for 10 minutes in order to allow the fuel pressure to be purged from the high pressure fuel lines before any service or repair is performed on the engine fuel lines. If necessary, perform minor adjustments. Repair any leaks from the low pressure fuel system and from the cooling, lubrication or air systems. Replace any high pressure fuel line that has leaked. Refer to Disassembly and assembly Manual, “Fuel Injection Lines - Install”. • Check the crankcase oil level. Maintain the oil level between the “MIN” mark and the “MAX” mark on the engine oil level gauge. • If the engine is equipped with a service hour meter, note the reading. Perform the maintenance that is in the Operation and Maintenance Manual, “Maintenance Interval Schedule”. • Fill the fuel tank in order to help prevent accumulation of moisture in the fuel. Do not overfill the fuel tank. NOTICE Only use antifreeze/coolant mixtures recommended in the Refill Capacities and Recommendations topic that is in this Operation and Maintenance Manual. Failure to do so can cause engine damage. Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure. SEBU8726 65 Engine Stopping After Stopping Engine • Allow the engine to cool. Check the coolant level. • Check the coolant for correct antifreeze protection and the correct corrosion protection. Add the correct coolant/water mixture, if necessary. • Perform all required periodic maintenance on all driven equipment. This maintenance is outlined in the instructions from the OEM. 66 SEBU8726 Maintenance Section Refill Capacities Maintenance Section • Glossary Refill Capacities • ISO International Standards Organization i04794766 • ASTM American Society for Testing and Materials • HFRR High Frequency Reciprocating Rig for Lubricity testing of diesel fuels Refill Capacities • FAME Fatty Acid Methyl Esters Lubrication System • CFR Co-ordinating Fuel Research The refill capacities for the engine crankcase reflect the approximate capacity of the crankcase or sump plus standard oil filters. Auxiliary oil filter systems will require additional oil. Refer to the OEM specifications for the capacity of the auxiliary oil filter. Refer to the Operation and Maintenance Manual, “Maintenance Section” for more information on Lubricant Specifications. • ULSD Ultra Low Sulfur Diesel Table 5 • PPM Parts Per Million Engine Refill Capacities Compartment or System Crankcase Oil Sump(1) (1) Minimum Maximum 6L (1.6 US gal) 8.5 L (2.2 US gal) Cooling System Refer to the OEM specifications for the External System capacity. This capacity information will be needed in order to determine the amount of coolant/ antifreeze that is required for the Total Cooling System. Table 6 • EPA Environmental Protection Agency of the United States General Information NOTICE Every attempt is made to provide accurate, up-to-date information. By use of this document you agree that Perkins Engines Company Limited is not responsible for errors or omissions. NOTICE These recommendations are subject to change without notice. Contact your local Perkins distributor for the most up-to-date recommendations. Diesel Fuel Requirements Perkins is not in a position to continuously evaluate and monitor all worldwide distillate diesel fuel specifications that are published by governments and technological societies. Engine Refill Capacities Compartment or System Liters 6 L (1.6 US gal) External System Per OEM(1) (1) • SME Soy Methyl Ester • DPF Diesel Particulate Filter These values are the approximate capacities for the crankcase oil sump (aluminum) which includes the standard factory installed oil filters. Engines with auxiliary oil filters will require additional oil. Refer to the OEM specifications for the capacity of the auxiliary oil filter. The design of the oil pan can change the oil capacity of the oil pan. Engine Only • RME Rape Methyl Ester The External System includes a radiator or an expansion tank with the following components: heat exchanger and piping. Refer to the OEM specifications. Enter the value for the capacity of the External System in this row. i05349395 Fluid Recommendations (Fuel Specification) The Perkins Specification for Distillate Diesel Fuel provides a known reliable baseline in order to judge the expected performance of distillate diesel fuels that are derived from conventional sources. Satisfactory engine performance is dependent on the use of a good quality fuel. The use of a good quality fuel will give the following results: long engine life and acceptable exhaust emissions levels . The fuel must meet the minimum requirements that are stated in the table 7 . SEBU8726 67 Refill Capacities Fluid Recommendations NOTICE The footnotes are of the key part Perkins Specification for Distillate Diesel Fuel Table. Read ALL of the footnotes. Table 7 Perkins Specification for Distillate Diesel Fuel(1) Property UNITS Requirements ASTMTest ISOTest Aromatics %Volume 35% maximum D1319 ISO3837 Ash %Weight 0.01% maximum D482 ISO6245 Carbon Residue on 10% Bottoms %Weight 0.35% maximum D524 ISO4262 Cetane Number (2) - 40 minimum D613/D6890 ISO5165 Cloud Point °C The cloud point must not ex- D2500 ceed the lowest expected ambient temperature. ISO3015 Copper Strip Corrosion - No. 3 maximum D130 ISO2160 801 minimum and 876 maximum No equivalent test ISO 3675ISO 12185 Density at 15 °C (59 °F)(3) Kg / M 3 Distillation °C 10% at 282 °C (539.6 °F) maximum 90% at 360 °C (680 °F) maximum D86 ISO3405 Flash Point °C legal limit D93 ISO2719 Thermal Stability - Minimum of 80% reflectance D6468 after aging for 180 minutes at 150 °C (302 °F) No equivalent test Pour Point °C 6 °C (42.8 °F) minimum be- D97 low ambient temperature ISO3016 Sulfur (1) %mass 0.0015 ISO 20846ISO 20884 Kinematic Viscosity (4) mm2/s (cSt) The viscosity of the fuel that D445 is delivered to the fuel injection pump. “1.4 minimum/ 4.5 maximum” ISO3405 Water and sediment % weight 0.1% maximum D1796 ISO3734 Water % weight 0.1% maximum D1744 No equivalent test Sediment % weight 0.05% maximum D473 ISO3735 Gums and Resins (5) mg/100mL 10 mg per 100 mL maximum D381 ISO6246 Lubricity corrected wear scar diameter at 60 °C (140 °F). (6) mm 0.52 maximum D6079 ISO12156-1 (1) (2) (3) D5453/D26222 This specification includes the requirements for Ultra Low Sulfur Diesel (ULSD). ULSD fuel will have ≤ 15 ppm (0.0015%) sulfur. Refer to ASTM D5453, ASTM D2622, or ISO 20846, ISO 20884 test methods. A fuel with a higher cetane number is recommended in order to operate at a higher altitude or in cold weather. “Via standards tables, the equivalent API gravity for the minimum density of 801 kg / m3 (kilograms per cubic meter) is 45 and for the maximum density of 876 kg / m3 is 30”. (continued) 68 SEBU8726 Refill Capacities Fluid Recommendations (Table 7, contd) (4) The values of the fuel viscosity are the values as the fuel is delivered to the fuel injection pumps. Fuel should also meet the minimum viscosity requirement and the fuel should meet the maximum viscosity requirements at 40 °C (104 °F) of either the ASTM D445 test method or the ISO 3104 test method. If a fuel with a low viscosity is used, cooling of the fuel may be required to maintain “1.4 cSt”or greater viscosity at the fuel injection pump. Fuels with a high viscosity might require fuel heaters in order to lower the viscosity to “1.4 cSt” at the fuel injection pump. (5) Follow the test conditions and procedures for gasoline (motor). (6) The lubricity of a fuel is a concern with ultra low sulfur fuel. To determine the lubricity of the fuel, use the ISO 12156-1 or ASTM D6079 High Frequency Reciprocating Rig (HFRR) test. If the lubricity of a fuel does not meet the minimum requirements, consult your fuel supplier. Do not treat the fuel without consulting the fuel supplier. Some additives are not compatible. These additives can cause problems in the fuel system. Engines that are manufactured by Perkins are certified with the fuel that is prescribed by the United States Environmental Protection Agency . Engines that are manufactured by Perkins are certified with the fuel that is prescribed by the European Certification. Perkins does not certify diesel engines on any other fuel. Note: The owner and the operator of the engine has the responsibility of using the fuel that is prescribed by the EPA and other appropriate regulatory agencies. NOTICE Operating with fuels that do not meet the Perkins recommendations can cause the following effects: Starting difficulty, reduced fuel filter service life, poor combustion, deposits in the fuel injectors, significantly reduce service life of the fuel system, deposits in the combustion chamber and reduced service life of the engine. NOTICE The Perkins 854 diesel engine must be operated using Ultra Low Sulfur Diesel. The sulphur content of this fuel must be lower than 15 PPM. This fuel complies with the emissions regulations that are prescribed by the Environmental Protection Agency of the United States. Illustration 40 g02157153 Illustration 40 is a representation of the label that will be installed next to the fuel filler cap on the fuel tank of the application. The fuel specifications that are listed in the table 8 are released as acceptable to use on 854 engine. SEBU8726 69 Refill Capacities Fluid Recommendations Table 8 Acceptable Fuel Specification for the 854 Engines(1) Fuel Specification Comments EN590 European Automotive Diesel Fuel (DERV) ASTM D975 GRADE 1D S15 “North American Light Distillate Diesel fuel with less than 15 PPM sulfur level” ASTM D975 GRADE 2D S15 “North American Middle Distillate general purpose Diesel fuel with less than 15 PPM sulfur level” JIS K2204 “Japanese Diesel Fuel” Must meet the requirements that are stated in the section “Lubricity”. BS 2869: 2010 CLASS A2 or EU equivalent “EU Off Road Diesel fuel. Acceptable from 2011 MUST have less than 10 PPM sulfur level” (1) All the fuels must comply with the specification in the table for the Perkins Specification Distillate Diesel Fuel . Diesel Fuel Characteristics Cetane Number Fuel that has a high cetane number will give a shorter ignition delay. A high cetane number will produce a better ignition quality. Cetane numbers are derived for fuels against proportions of cetane and heptamethylnonane in the standard CFR engine. Refer to ISO 5165 for the test method. Cetane numbers in excess of 45 are normally expected from current diesel fuel. However, a cetane number of 40 may be experienced in some territories. The United States of America is one of the territories that can have a low cetane value. A minimum cetane value of 40 is required during average starting conditions. A fuel with higher cetane number is recommended for operations at high altitudes or in cold-weather operations. Fuel with a low cetane number can be the root cause of problems during a cold start. The viscosity of the fuel is significant because fuel serves as a lubricant for the fuel system components. Fuel must have sufficient viscosity in order to lubricate the fuel system in both extremely cold temperatures and extremely hot temperatures . If the kinematic viscosity of the fuel is lower than “1.4 cSt” at the fuel injection pump, damage to the fuel injection pump can occur. This damage can be excessive scuffing and seizure. Low viscosity may lead to difficult hot restarting, stalling, and loss of performance. High viscosity may result in seizure of the pump. Perkins recommends kinematic viscosities of 1.4 and 4.5 mm2/sec that is delivered to the fuel injection pump. If a fuel with a low viscosity is used, cooling of the fuel may be required to maintain 1.4 cSt or greater viscosity at the fuel injection pump. Fuels with a high viscosity might require fuel heaters in order to lower the viscosity to 4.5 cSt at the fuel injection pump. Density Viscosity Viscosity is the property of a liquid of offering resistance to shear or flow. Viscosity decreases with increasing temperature. This decrease in viscosity follows a logarithmic relationship for normal fossil fuel. The common reference is to kinematic viscosity. Kinematic viscosity is the quotient of the dynamic viscosity that is divided by the density. The determination of kinematic viscosity is normally by readings from gravity flow viscometers at standard temperatures. Refer to ISO 3104 for the test method. Density is the mass of the fuel per unit volume at a specific temperature. This parameter has a direct influence on engine performance and a direct influence on emissions. This influence determines from a heat output given injected volume of fuel. This parameter is quoted in the following kg/m3 at 15 °C (59 °F). Perkins recommends a density of 841 kg/m 3 in order to obtain the correct power output. Lighter fuels are acceptable but these fuels will not produce the rated power. Sulfur The level of sulfur is governed by emissions legislations . Regional regulation, national regulations, or international regulations can require a fuel with a specific sulfur limit. The sulfur content of the fuel and the fuel quality must comply with all existing local regulations for emissions. 70 SEBU8726 Refill Capacities Fluid Recommendations Perkins 854 diesel engines have been designed to operate only with ULSD. By using the test methods ASTM D5453, ASTM D2622, or ISO 20846 ISO 20884, the content of sulfur in ULSD fuel must be below 15 PPM (mg/kg) or 0.0015% mass. NOTICE Use of diesel fuel with higher than 15 PPM sulphur limit in these engines will harm or permanently damage emissions control systems and/or shorten their service interval. Lubricity Lubricity is the capability of the fuel to prevent pump wear. The fluids lubricity describes the ability of the fluid to reduce the friction between surfaces that are under load. This ability reduces the damage that is caused by friction. Fuel injection systems rely on the lubricating properties of the fuel. Until fuel sulfur limits were mandated, the fuels lubricity was generally believed to be a function of fuel viscosity. The lubricity has particular significance to the current ultra low sulfur fuel, and low aromatic fossil fuels. These fuels are made in order to meet stringent exhaust emissions. The lubricity of these fuels must not exceed wear scar diameter of 0.52 mm (0.0205 inch). The fuel lubricity test must be performed on an HFRR, operated at 60 °C (140 °F). Refer to ISO 12156-1. NOTICE The fuels system has been qualified with fuel having lubricity up to 0.52 mm (0.0205 inch) wear scar diameter as tested by ISO 12156-1. Fuel with higher wear scar diameter than 0.52 mm (0.0205 inch) will lead to reduced service life and premature failure of the fuel system. Fuel additives can enhance the lubricity of a fuel. Contact your fuel supplier for those circumstances when fuel additives are required. Your fuel supplier can make recommendations for additives to use, and for the proper level of treatment. Distillation Distillation is an indication of the mixture of different hydrocarbons in the fuel. A high ratio of light weight hydrocarbons can affect the characteristics of combustion. Recommendation for Biodiesel Biodiesel is a fuel that can be defined as mono-alkyl esters of fatty acids . Biodiesel is a fuel that can be made from various feedstock. The most commonly available biodiesel in Europe is Rape Methyl Ester (REM) . This biodiesel is derived from rapeseed oil . Soy Methyl Ester (SME) is the most common biodiesel in the United States. This biodiesel is derived from soybean oil . Soybean oil or rapeseed oil are the primary feedstocks. These fuels are together known as Fatty Acid Methyl Esters (FAME) . Raw pressed vegetable oils are NOT acceptable for use as a fuel in any concentration in compression engines . Without esterification, these oils solidify in the crankcase and the fuel tank. These fuels may not be compatible with many of the elastomers that are used in engines that are manufactured today. In original forms, these oils are not suitable for use as a fuel in compression engines . Alternate base stocks for biodiesel may include animal tallow , waste cooking oils , or various other feedstocks. In order to use any of the products that are listed as fuel, the oil must be esterified . Fuel made of 100 percent FAME is generally referred to as B100 biodiesel or neat biodiesel. Biodiesel can be blended with distillate diesel fuel. The blends can be used as fuel. The most commonly available biodiesel blends are B5, which is 5 percent biodiesel and 95 percent distillate diesel fuel. B20, which is 20 percent biodiesel and 80 percent distillate diesel fuel. Note: The percentages given are volume-based. The U.S. distillate diesel fuel specification ASTM D975-09a includes up to B5 (5 percent) biodiesel. European distillate diesel fuel specification EN590: 2010 includes up B7 (7 percent) biodiesel. Note: Engines that are manufactured by Perkins are certified by use of the prescribed Environmental Protection Agency (EPA) and European Certification fuels. Perkins does not certify engines on any other fuel. The user of the engine has the responsibility of using the correct fuel that is recommended by the manufacturer and allowed by the EPA and other appropriate regulatory agencies. Specification Requirements The neat biodiesel must conform to the latest EN14214 or ASTM D6751 (in the USA). The biodiesel can only be blended in mixture of up to 20% by volume in acceptable mineral diesel fuel meeting latest edition of EN590 or ASTM D975 S15 designation. In United States Biodiesel blends of B6 to B20 must meet the requirements listed in the latest edition of ASTM D7467 (B6 to B20) and must be of an API gravity of 30-45. SEBU8726 71 Refill Capacities Fluid Recommendations In North America biodiesel and biodiesel blends must be purchased from the BQ-9000 accredited producers and BQ-9000 certified distributors. In other areas of the world, the use of biodiesel that is BQ-9000 accredited and certified, or that is accredited and certified by a comparable biodiesel quality body to meet similar biodiesel quality standards is required. Engine Service Requirements Aggressive properties of biodiesel fuel may cause debris in the fuel tank and fuel lines. The aggressive properties of biodiesel will clean the fuel tank and fuel lines. This cleaning of the fuel system can prematurely block of the fuel filters. Perkins recommend that after the initial usage of B20 biodiesel blended fuel the fuel filters must be replaced at 50 hours. Glycerides present in biodiesel fuel will also cause fuel filters to become blocked more quickly. Therefore the regular service interval should be reduced to 250 hours. When biodiesel fuel is used, crank case oil and aftertreatment systems may be influenced. This influence is due to the chemical composition and characteristics of biodiesel fuel, such as density and volatility, and to chemical contaminants that can be present in this fuel, such as alkali and alkaline metals (sodium, potassium, calcium, and magnesium). • Crankcase oil fuel dilution can be higher when biodiesel or biodiesel blends are used. This increased level of fuel dilution when using biodiesel or biodiesel blends is related to the typically lower volatility of biodiesel. In-cylinder emissions control strategies utilized in many of the industrial latest engine designs may lead to a higher level of biodiesel concentration in the sump. The long-term effect of biodiesel concentration in crankcase oil is currently unknown. • Perkins recommend the use of oil analysis in order to check the quality of the engine oil if biodiesel fuel is used. Ensure that the level of biodiesel in the fuel is noted when the oil sample is taken. Performance Related Issues Due to the lower energy content than the standard distillate fuel B20 will cause a power loss in order of 2 to 4 percent. In addition, over time the power may deteriorate further due to deposits in the fuel injectors. Biodiesel and biodiesel blends are known to cause an increase in fuel system deposits, most significant of which are deposits within the fuel injector. These deposits can cause a loss in power due to restricted or modified fuel injection or cause other functional issues associated with these deposits. Note: Perkins T400012 Fuel Cleaner is most effective in cleaning and preventing the formation of deposits. Perkins Diesel Fuel Conditioner helps to limit deposit issues by improving the stability of biodiesel and biodiesel blends. For more information refer to “Perkins Diesel Fuel System Cleaner”. Biodiesel fuel contains metal contaminants (sodium, potassium, calcium, and/or magnesium) that form ash products upon combustion in the diesel engine. The ash can have an impact on the life and performance of aftertreatment emissions control devices and can accumulate in DPF. The ash accumulation may cause the need for more frequent ash service intervals and cause loss of performance General Requirements Biodiesel has poor oxidation stability, which can result in long-term problems in the storage of biodiesel. Biodiesel fuel should be used within 6 months of manufacture. Equipment should not be stored with the B20 biodiesel blends in the fuel system for longer than 3 months. Due to poor oxidation stability and other potential issues, it is strongly recommended that engines with limited operational time either not use B20 biodiesel blends or, while accepting some risk, limit biodiesel blend to a maximum of B5. Examples of applications that should limit the use of biodiesel are the following: Standby Generator sets and certain emergency vehicles. Perkins strongly recommended that seasonally operated engines have the fuel systems, including fuel tanks, flashed with conventional diesel fuel before prolonged shutdown periods. An example of an application that should seasonally flush the fuel system is a combine harvester. Microbial contamination and growth can cause corrosion in the fuel system and premature plugging of the fuel filter. Consult your supplier of fuel for assistance in selecting appropriate anti-microbial additive. Water accelerates microbial contamination and growth. When biodiesel is compared to distillate fuels, water is naturally more likely to exist in the biodiesel. It is therefore essential to check frequently and if necessary, drain the water separator. Materials such as brass, bronze, copper, lead, tin, and zinc accelerate the oxidation process of the biodiesel fuel. The oxidation process can cause deposits formation therefore these materials must not be used for fuel tanks and fuel lines. 72 SEBU8726 Refill Capacities Fluid Recommendations Fuel for Cold Weather Operation The European standard EN590 contains climate dependant requirements and a range of options. The options can be applied differently in each country. There are five classes that are given to arctic climates and severe winter climates . 0, 1, 2, 3 and 4. Fuel that complies with EN590 CLASS 4 can be used at temperatures as low as −44 °C (−47.2 °F). Refer to EN590 for a detailed discretion of the physical properties of the fuel. The diesel fuel ASTM D975 1-D used in the United States of America may be used in very cold temperatures that are below −18 °C (−0.4 °F). Aftermarket Fuel Additives Supplemental diesel fuel additives are not generally recommended . This recommendation is due to potential damage to the fuel system or the engine. Your fuel supplier or the fuel manufacturer will add the appropriate supplemental diesel fuel additives. Perkins recognizes the fact that additives may be required in some special circumstances. Contact your fuel supplier for those circumstances when fuel additives are required. Your fuel supplier can recommend the appropriate fuel additive and the correct level of treatment. Note: For the best results, your fuel supplier should treat the fuel when additives are required. The treated fuel must meet the requirements that are stated in table 7 . Perkins Diesel Fuel System Cleaner Note: Perkins fuel cleaner is compatible with existing and U.S. EPA Tier 4 nonroad certified diesel engine emission control catalysts and particulate filters. Perkins fuel system cleaner contains less than 15 ppm of sulfur and is acceptable for use with ULSD fuel. i05344256 Fluid Recommendations General Lubricant Information Because of government regulations regarding the certification of exhaust emissions from the engine, the lubricant recommendations must be followed. • API • SAE American Petroleum Institute Society Of Automotive Engineers Inc. • ACEA Association des Constructers European Automobiles . • ECF-3 Engine Crankcase Fluid Licensing The Engine Oil Licensing and Certification System by the American Petroleum Institute (API) and the Association des Constructers European Automobilesand (ACRA) is recognized by Perkins . For detailed information about this system, see the latest edition of the API publication No. 1509. Engine oils that bear the API symbol are authorized by API. Perkins T400012 Fuel Cleaner is the only fuel cleaner that is recommended by Perkins . If biodiesel or biodiesel blends of fuel are to be used, Perkins require the use of Perkins fuel cleaner. The use of the fuel is in order to remove deposits within the fuel system that is created with the use of biodiesel. For more information on the use of biodiesel and biodiesel blends refer to “Recommendation for Biodiesel”. Perkins fuel cleaner will remove deposits that can form in the fuel system with the use of biodiesel and biodiesel blends. These deposits can create a loss of power and engine performance. Once the fuel cleaner has been added to the fuel, the deposits within the fuel system are removed after 30 hours of engine operation. For maximum results, continue to use the fuel cleaner for up to 80 hours. Perkins fuel cleaner can be used on an on-going basis with no adverse impact on engine or fuel system durability. Details instruction on the rate of which the fuel cleaner must be use are on the container. Illustration 41 Typical API symbol g01987816 SEBU8726 73 Refill Capacities Fluid Recommendations Terminology Certain abbreviations follow the nomenclature of SAE J754. Some classifications follow SAE J183 abbreviations, and some classifications follow the EMA Recommended Guideline on Diesel Engine Oil. In addition to Perkins definitions, there are other definitions that will be of assistance in purchasing lubricants. Recommended oil viscosities can be found in this publication, “Fluid Recommendations/ Engine Oil” topic (Maintenance Section). Engine Oil Commercial Oils NOTICE Perkins require the use of the following specification of engine oil. Failure to use the appropriate specification of engine oil will reduce the life of your engine. Failure to use the appropriate specification of engine oil will also reduce the life of your aftertreatment system. Table 9 Classifications for the 854 Industrial Engine Oil Specification API CJ-4 ACEA E9 ECF-3 API CJ-4 and ACEA E9 oil categories have the following chemical limits: • 0.1 percent maximum sulfated ash • 0.12 percent maximum phosphorous • 0. 4 percent maximum sulfur The chemical limits were developed in order to maintain the expected life of the engine aftertreatment system. The performance of the engine aftertreatment system can be adversely affected if oil that is not specified in table 9 is used. The life of your Aftertreatment system is defined by the accumulation of ash on the surface of the filter. Ash is the inert part of the particulate matter. The system is designed in order to collect this particulate matter. There is a small percentage of particulate matter that is left behind as the soot is burnt. This matter will eventually block the filter, causing loss of performance and increased fuel consumption. Most of the ash comes from the engine oil which is gradually consumed during normal operation. This ash is passes through the exhaust. To meet the designed life of the product, the use of the appropriate engine oil is essential. The oil specification that is listed in table 9 has low ash content. Maintenance intervals for engines that use biodiesel – The oil change interval can be adversely affected by the use of biodiesel. Use oil analysis in order to monitor the condition of the engine oil. Use oil analysis also in order to determine the oil change interval that is optimum. Note: These engine oils are not approved by Perkins and these engine oils must not be used: CC, CD, CD-2, CF-4, CG-4, CH-4 and CI-4. Lubricant Viscosity Recommendations for Direct Injection (DI) Diesel Engines The correct SAE viscosity grade of oil is determined by the minimum ambient temperature during cold engine start-up, and the maximum ambient temperature during engine operation. Refer to illustration 42 (minimum temperature) in order to determine the required oil viscosity for starting a cold engine. Refer to illustration 42 (maximum temperature) in order to select the oil viscosity for engine operation at the highest ambient temperature that is anticipated. Generally, use the highest oil viscosity that is available to meet the requirement for the temperature at start-up. 74 SEBU8726 Refill Capacities Fluid Recommendations • See the appropriate “Lubricant Viscosities”. Refer to the illustration 42 in order to find the correct oil viscosity grade for your engine. • At the specified interval, service the engine. Use new oil and install a new oil filter. • Perform maintenance at the intervals that are specified in the Operation and Maintenance Manual, “Maintenance Interval Schedule”. Oil analysis Some engines may be equipped with an oil sampling valve. If oil analysis is required, the oil sampling valve is used to obtain samples of the engine oil. The oil analysis will complement the preventive maintenance program. Illustration 42 g03363756 Lubricant Viscosities Supplemental heat is recommended for cold soaked starts below the minimum ambient temperature. Supplemental heat may be required for cold soaked starts that are above the minimum temperature that is stated, depending on the parasitic load and other factors. Cold soaked starts occur when the engine has not been operated for a period of time. This interval will allow the oil to become more viscous due to cooler ambient temperatures. Aftermarket Oil Additives Perkins does not recommend the use of aftermarket additives in oil. It is not necessary to use aftermarket additives in order to achieve the engines maximum service life or rated performance. Fully formulated, finished oils consist of base oils and of commercial additive packages. These additive packages are blended into the base oils at precise percentages in order to help provide finished oils with performance characteristics that meet industry standards. There are no industry standard tests that evaluate the performance or the compatibility of aftermarket additives in finished oil. Aftermarket additives may not be compatible with the finished oils additive package, which could lower the performance of the finished oil. The aftermarket additive could fail to mix with the finished oil. This failure could produce sludge in the crankcase. Perkins discourages the use of aftermarket additives in finished oils. To achieve the best performance from a Perkins engine, conform to the following guidelines: The oil analysis is a diagnostic tool that is used to determine oil performance and component wear rates. Contamination can be identified and measured by using oil analysis. The oil analysis includes the following tests: • The Wear Rate Analysis monitors the wear of the engines metals. The amount of wear metal and type of wear metal that is in the oil is analyzed. The increase in the rate of engine wear metal in the oil is as important as the quantity of engine wear metal in the oil. • Tests are conducted in order to detect contamination of the oil by water, glycol, or fuel. • The Oil Condition Analysis determines the loss of the oils lubricating properties. An infrared analysis is used to compare the properties of new oil to the properties of the used oil sample. This analysis allows technicians to determine the amount of deterioration of the oil during use. This analysis also allows technicians to verify the performance of the oil according to the specification during the entire oil change interval. i04358959 Fluid Recommendations General Coolant Information NOTICE Never add coolant to an overheated engine. Engine damage could result. Allow the engine to cool first. 75 SEBU8726 Refill Capacities Fluid Recommendations NOTICE If the engine is to be stored in, or shipped to an area with below freezing temperatures, the cooling system must be either protected to the lowest outside temperature or drained completely to prevent damage. NOTICE Frequently check the specific gravity of the coolant for proper freeze protection or for anti-boil protection. Table 10 Acceptable Water Property Maximum Limit Chloride (Cl) 40 mg/L Sulfate (SO4) 100 mg/L Total Hardness 170 mg/L Total Solids 340 mg/L Acidity pH of 5.5 to 9.0 Clean the cooling system for the following reasons: • Contamination of the cooling system For a water analysis, consult one of the following sources: • Overheating of the engine • Local water utility company • Foaming of the coolant • Agricultural agent NOTICE Never operate an engine without water temperature regulators in the cooling system. Water temperature regulators help to maintain the engine coolant at the proper operating temperature. Cooling system problems can develop without water temperature regulators. • Independent laboratory Many engine failures are related to the cooling system. The following problems are related to cooling system failures: Overheating, leakage of the water pump and plugged radiators or heat exchangers. • Corrosion These failures can be avoided with correct cooling system maintenance. Cooling system maintenance is as important as maintenance of the fuel system and the lubrication system. Quality of the coolant is as important as the quality of the fuel and the lubricating oil. Coolant is normally composed of three elements: Water, additives and glycol. Water Water is used in the cooling system in order to transfer heat. Distilled water or deionized water is recommended for use in engine cooling systems. DO NOT use the following types of water in cooling systems: Hard water, softened water that has been conditioned with salt and sea water. If distilled water or deionized water is not available, use water with the properties that are listed in Table 10 . Additives Additives help to protect the metal surfaces of the cooling system. A lack of coolant additives or insufficient amounts of additives enable the following conditions to occur: • Formation of mineral deposits • Rust • Scale • Foaming of the coolant Many additives are depleted during engine operation. These additives must be replaced periodically. Additives must be added at the correct concentration. Over concentration of additives can cause the inhibitors to drop out-of-solution. The deposits can enable the following problems to occur: • Formation of gel compounds • Reduction of heat transfer • Leakage of the water pump seal • Plugging of radiators, coolers, and small passages Glycol Glycol in the coolant helps to provide protection against the following conditions: 76 SEBU8726 Refill Capacities Fluid Recommendations • Boiling • Freezing • Cavitation of the water pump For optimum performance, Perkins recommends a 1:1 mixture of a water/glycol solution. Note: Use a mixture that will provide protection against the lowest ambient temperature. Note: 100 percent pure glycol will freeze at a temperature of −13 °C (8.6 °F). Most conventional antifreezes use ethylene glycol. Propylene glycol may also be used. In a 1:1 mixture with water, ethylene and propylene glycol provide similar protection against freezing and boiling. Refer to Table 11 and refer to table 12 . Table 11 Ethylene Glycol Concentration Freeze Protection 50 Percent −36 °C (−33 °F) 60 Percent −51 °C (−60 °F) NOTICE The 854 industrial engines must be operated with a 1:1 mixture of water and glycol. This concentration allows the NOx reduction system to operate correctly at high ambient temperatures. NOTICE Do not use a commercial coolant/antifreeze that only meets the ASTM D3306 specification. This type of coolant/antifreeze is made for light automotive applications. Perkins recommends a 1:1 mixture of water and glycol. This mixture of water and glycol will provide optimum heavy-duty performance as an antifreeze. This ratio may be increased to 1:2 water to glycol if extra freezing protection is required. A mixture of SCA inhibitor and water is acceptable but will not give the same level of corrosion, boiling and, freezing protection as ELC. Perkins recommends a 6 percent to 8 percent concentration of SCA in those cooling systems. Distilled water or deionized water is preferred. Water which has the recommended properties may be used. Table 13 NOTICE Do not use propylene glycol in concentrations that exceed 50 percent glycol because of the reduced heat transfer capability of propylene glycol. Use ethylene glycol in conditions that require additional protection against boiling or freezing. Table 12 Propylene Glycol Concentration Freeze Protection 50 Percent −29 °C (−20 °F) Coolant Service Life Coolant Type Service Life (1) Perkins ELC 6,000 Service Hours or Three Years Commercial Heavy-Duty Antifreeze that meets ASTM D6210 3000 Service Hours or Two Year Commercial SCA inhibitor and Water 3000 Service Hours or One Year (1) To check the concentration of glycol in the coolant, measure the specific gravity of the coolant. Coolant Recommendations • ELC Extended Life Coolant • SCA Supplement Coolant Additive • ASTM Materials American Society for Testing and The following two coolants are used in Perkins diesel engines: Preferred – Perkins ELC Acceptable – A commercial heavy-duty antifreeze that meets ASTM D6210 specifications Use the interval that occurs first. The cooling system must also be flushed out at this time. ELC Perkins provides ELC for use in the following applications: • Heavy-duty spark ignited gas engines • Heavy-duty diesel engines • Automotive applications The anti-corrosion package for ELC is different from the anti-corrosion package for other coolants. ELC is an ethylene glycol base coolant. However, ELC contains organic corrosion inhibitors and antifoam agents with low amounts of nitrite. Perkins ELC has been formulated with the correct amount of these additives in order to provide superior corrosion protection for all metals in engine cooling systems. 77 SEBU8726 Refill Capacities Fluid Recommendations Containers of several sizes are available. Consult your Perkins distributor for the part numbers. Before the cooling system is filled, the heater control (if equipped) must be set to the HOT position. Refer to the OEM in order to set the heater control. After the cooling system is drained and the cooling system is refilled, operate the engine until the coolant level reaches the normal operating temperature and until the coolant level stabilizes. As needed, add the coolant mixture in order to fill the system to the specified level. ELC Cooling System Maintenance Changing to Perkins ELC Correct additions to the Extended Life Coolant To change from heavy-duty antifreeze to the Perkins ELC, perform the following steps: ELC is available in a premixed cooling solution with distilled water. ELC is a 1:1 mixture. The Premixed ELC provides freeze protection to −36 °C (−33 °F). The Premixed ELC is recommended for the initial fill of the cooling system. The Premixed ELC is also recommended for topping off the cooling system. NOTICE Use only Perkins products for pre-mixed or concentrated coolants. Mixing Extended Life Coolant with other products reduces the Extended Life Coolant service life. Failure to follow the recommendations can reduce cooling system components life unless appropriate corrective action is performed. In order to maintain the correct balance between the antifreeze and the additives, you must maintain the recommended concentration of ELC. Lowering the proportion of antifreeze lowers the proportion of additive. This will lower the ability of the coolant to protect the system from pitting, from cavitation, from erosion, and from deposits. NOTICE Care must be taken to ensure that all fluids are contained during performance of inspection, maintenance, testing, adjusting and the repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates. 1. Drain the coolant into a suitable container. 2. Dispose of the coolant according to local regulations. 3. Flush the system with clean water in order to remove any debris. NOTICE Do not use a conventional coolant to top-off a cooling system that is filled with Extended Life Coolant (ELC). 4. Use an appropriate cleaner to clean the system. Follow the instruction on the label. Do not use standard supplemental coolant additive (SCA). 5. Drain the cleaner into a suitable container. Flush the cooling system with clean water. When using Perkins ELC, do not use standard SCA's or SCA filters. 6. Fill the cooling system with clean water and operate the engine until the engine is warmed to 49° to 66°C (120° to 150°F). ELC Cooling System Cleaning Note: If the cooling system is already using ELC, cleaning agents are not required to be used at the specified coolant change interval. Cleaning agents are only required if the system has been contaminated by the addition of some other type of coolant or by cooling system damage. Clean water is the only cleaning agent that is required when ELC is drained from the cooling system. NOTICE Incorrect or incomplete flushing of the cooling system can result in damage to copper and other metal components. To avoid damage to the cooling system, make sure to completely flush the cooling system with clear water. Continue to flush the system until all the signs of the cleaning agent are gone. 7. Drain the cooling system into a suitable container and flush the cooling system with clean water. 78 SEBU8726 Refill Capacities Fluid Recommendations Note: The cooling system cleaner must be thoroughly flushed from the cooling system. Cooling system cleaner that is left in the system will contaminate the coolant. The cleaner may also corrode the cooling system. 8. Repeat Steps 6 and repeat steps 7 until the system is completely clean. 9. Fill the cooling system with the Perkins Premixed ELC. ELC Cooling System Contamination NOTICE Mixing ELC with other products reduces the effectiveness of the ELC and shortens the ELC service life. Use only Perkins Products for premixed or concentrate coolants. Failure to follow these recommendations can result in shortened cooling system component life. ELC cooling systems can withstand contamination to a maximum of 10 percent of conventional heavy-duty antifreeze or SCA. If the contamination exceeds 10 percent of the total system capacity, perform ONE of the following procedures: • Drain the cooling system into a suitable container. Dispose of the coolant according to local regulations. Flush the system with clean water. Fill the system with the Perkins ELC. • Drain a portion of the cooling system into a suitable container according to local regulations. Then, fill the cooling system with premixed ELC. This procedure should lower the contamination to less than 10 percent. • Maintain the system as a conventional Heavy-Duty Coolant. Treat the system with an SCA. Change the coolant at the interval that is recommended for the conventional Heavy-Duty Coolant. Commercial Heavy-Duty Antifreeze and SCA NOTICE Commercial Heavy-Duty Coolant which contains Amine as part of the corrosion protection system must not be used. NOTICE Never operate an engine without water temperature regulators in the cooling system. Water temperature regulators help to maintain the engine coolant at the correct operating temperature. Cooling system problems can develop without water temperature regulators. Check the antifreeze (glycol concentration) in order to ensure adequate protection against boiling or freezing. Perkins recommends the use of a refractometer for checking the glycol concentration. A hydrometer should not be used. Perkins engine cooling systems should be tested at 500 hour intervals for the concentration of SCA. Additions of SCA are based on the results of the test. An SCA that is liquid may be needed at 500 hour intervals. Adding the SCA to Heavy-Duty Coolant at the Initial Fill Use the equation that is in Table 14 to determine the amount of SCA that is required when the cooling system is initially filled. Table 14 Equation For Adding The SCA To The Heavy-Duty Coolant At The Initial Fill V × 0.045 = X V is the total volume of the cooling system. X is the amount of SCA that is required. Table 15 is an example for using the equation that is in Table 14 . Table 15 Example Of The Equation For Adding The SCA To The HeavyDuty Coolant At The Initial Fill Total Volume of the Cooling System (V) Multiplication Factor Amount of SCA that is Required (X) 15 L (4 US gal) × 0.045 0.7 L (24 oz) Adding The SCA to The Heavy-Duty Coolant For Maintenance Heavy-duty antifreeze of all types REQUIRE periodic additions of an SCA. Test the antifreeze periodically for the concentration of SCA. For the interval, refer to the Operation and Maintenance Manual, “Maintenance Interval Schedule” (Maintenance Section). Cooling System Supplemental Coolant Additive (SCA) Test/Add. SEBU8726 79 Refill Capacities Fluid Recommendations Additions of SCA are based on the results of the test. The size of the cooling system determines the amount of SCA that is needed. Use the equation that is in Table 16 to determine the amount of SCA that is required, if necessary: Table 16 Equation For Adding The SCA To The Heavy-Duty Coolant For Maintenance V × 0.014 = X V is the total volume of the cooling system. X is the amount of SCA that is required. Table 17 is an example for using the equation that is in Table 16 . Table 17 Example Of The Equation For Adding The SCA To The HeavyDuty Coolant For Maintenance Total Volume of the Cooling System (V) Multiplication Factor Amount of SCA that is Required (X) 15 L (4 US gal) × 0.014 0.2 L (7 oz) Cleaning the System of Heavy-Duty Antifreeze • Clean the cooling system after used coolant is drained or before the cooling system is filled with new coolant. • Clean the cooling system whenever the coolant is contaminated or whenever the coolant is foaming. 80 Maintenance Recommendations System Pressure Release SEBU8726 Maintenance Recommendations 1. Stop the engine. 2. Wait for 10 minutes. i03648938 System Pressure Release Coolant System Do not loosen the high pressure fuel lines in order to remove air from the fuel system. Engine Oil To relieve pressure from the lubricating system, turn off the engine. i05400894 Pressurized system: Hot coolant can cause serious burn. To open cap, stop engine, wait until radiator is cool. Then loosen cap slowly to relieve the pressure. The engine can have the ability to auto start. Ensure that the power supply is isolated before any service or repair is performed. To relieve the pressure from the coolant system, turn off the engine. Allow the cooling system pressure cap to cool. Remove the cooling system pressure cap slowly in order to relieve pressure. Fuel System To relieve the pressure from the fuel system, turn off the engine. High Pressure Fuel Lines Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death. The high pressure fuel lines are the fuel lines that are between the high pressure fuel pump and the high pressure fuel manifold and the fuel lines that are between the fuel manifold and cylinder head. These fuel lines are different from fuel lines on other fuel systems. This is because of the following differences: • The high pressure fuel lines are constantly charged with high pressure. • The internal pressures of the high pressure fuel lines are higher than other types of fuel system. Before any service or repair is performed on the engine fuel lines, perform the following tasks: Welding on Engines with Electronic Controls NOTICE Because the strength of the frame may decrease, some manufacturers do not recommend welding onto a chassis frame or rail. Consult the OEM of the equipment or your Perkins dealer regarding welding on a chassis frame or rail. Proper welding procedures are necessary in order to avoid damage to the engines ECM, sensors, and associated components. When possible, remove the component from the unit and then weld the component. If removal of the component is not possible, the following procedure must be followed when you weld on a unit equipped with an Electronic Engine. The following procedure is considered to be the safest procedure to weld on a component. This procedure should provide a minimum risk of damage to electronic components. NOTICE Do not ground the welder to electrical components such as the ECM or sensors. Improper grounding can cause damage to the drive train bearings, hydraulic components, electrical components, and other components. Clamp the ground cable from the welder to the component that will be welded. Place the clamp as close as possible to the weld. This will help reduce the possibility of damage. Note: Perform the welding in areas that are free from explosive hazards. 1. Stop the engine. Turn the switched power to the OFF position. 2. Ensure that the fuel supply to the engine is turned off. SEBU8726 81 Maintenance Recommendations Welding on Engines with Electronic Controls 3. Disconnect the negative battery cable from the battery. If a battery disconnect switch is provided, open the switch. 4. Disconnect all electronic components from the wiring harnesses. Include the following components: • Electronic components for the driven equipment • ECM • Sensors • Electronically controlled valves • Relays • Aftertreatment ID module NOTICE Do not use electrical components (ECM or ECM sensors) or electronic component grounding points for grounding the welder. Illustration 43 g01075639 Use the example above. The current flow from the welder to the ground clamp of the welder will not damage any associated components. (1) Engine (2) Welding electrode (3) Keyswitch in the OFF position (4) Battery disconnect switch in the open position (5) Disconnected battery cables (6) Battery (7) Electrical/Electronic component (8) Minimum distance between the component that is being welded and any electrical/electronic component (9) The component that is being welded (10) Current path of the welder (11) Ground clamp for the welder 5. Connect the welding ground cable directly to the part that will be welded. Place the ground cable as close as possible to the weld in order to reduce the possibility of welding current damage to the following components. Bearings, hydraulic components, electrical components, and ground straps. Note: If electrical/electronic components are used as a ground for the welder, or electrical/electronic components are located between the welder ground and the weld, current flow from the welder could severely damage the component. 6. Protect the wiring harness from welding debris and spatter. 82 Maintenance Recommendations Severe Service Application SEBU8726 7. Use standard welding practices to weld the materials. i04150276 Severe Service Application Severe service is the application of an engine that exceeds the current published standards for that engine. Perkins maintains standards for the following engine parameters: • Performance such as power range, speed range, and fuel consumption dusty, unless the equipment is cleaned regularly. Mud, dirt, and dust can encase components. Maintenance can be difficult. The buildup can contain corrosive chemicals. Buildup – Compounds, elements, corrosive chemicals, and salt can damage some components. Altitude – Problems can arise when the engine is operated at altitudes that are higher than the intended settings for that application. Necessary adjustments should be made. Incorrect Operating Procedures • Extended operation at low idle • Fuel quality • Frequent hot shutdowns • Operational Altitude • Operating at excessive loads • Maintenance intervals • Operating at excessive speeds • Oil selection and maintenance • Operating outside the intended application • Coolant type and maintenance Incorrect Maintenance Procedures • Environmental qualities • Extending the maintenance intervals • Installation • Failure to use recommended fuel, lubricants, and coolant/antifreeze • The temperature of the fluid in the engine Refer to the standards for the engine or consult your Perkins dealer or your Perkins distributor in order to determine if the engine is operating within the defined parameters. Severe service operation can accelerate component wear. Engines that operate under severe conditions may need more frequent maintenance intervals in order to ensure maximum reliability and retention of full service life. Due to individual applications, it is not possible to identify all of the factors which can contribute to severe service operation. Consult your Perkins dealer or your Perkins distributor for the unique maintenance that is necessary for the engine. The operating environment, incorrect operating procedures, and incorrect maintenance procedures can be factors which contribute to a severe service application. Environmental Factors Ambient temperatures – The engine may be exposed to extended operation in cold environments or hot environments. Valve components can be damaged by carbon buildup if the engine is frequently started and stopped in cold temperatures. Hot intake air reduces engine performance. Quality of the air – The engine may be exposed to extended operation in an environment that is dirty or SEBU8726 83 Maintenance Recommendations Maintenance Interval Schedule i05325425 Maintenance Interval Schedule “Fuel System Primary Filter (Water Separator) Element - Replace”............................................... 102 “Fuel System Secondary Filter - Replace” ........... 104 “Radiator - Clean” ................................................. 108 When Required Every 1000 Service Hours “Battery - Replace”...................................................85 “Water Pump - Inspect”..........................................111 “Battery or Battery Cable - Disconnect”...................86 Every 1500 Service Hours “Engine - Clean”.......................................................93 “Engine Crankcase Breather Element - Replace” ...95 “Engine Air Cleaner Element (Single Element) Inspect/Clean/Replace” ...........................................94 Every 2000 Service Hours “Engine Oil Sample - Obtain”...................................97 “Aftercooler Core - Inspect” .....................................84 “Fuel System - Prime”........................................... 101 “Engine Mounts - Inspect” .......................................96 Daily “Starting Motor - Inspect” ...................................... 109 “Coolant Level - Check”...........................................91 “Turbocharger - Inspect” ....................................... 109 “Driven Equipment - Check” ....................................93 Every 3000 Service Hours “Engine Air Cleaner Service Indicator - Inspect” .....94 “Alternator - Inspect” ................................................84 “Engine Air Precleaner - Check/Clean” ...................95 “Alternator and Fan Belts - Replace” .......................84 “Engine Oil Level - Check”.......................................96 “Diesel Particulate Filter - Clean”.............................93 “Fuel System Primary Filter/Water Separator Drain” .................................................................... 104 “Oxygen Sensor - Replace” .................................. 108 “Walk-Around Inspection” ......................................110 Every Week “Hoses and Clamps - Inspect/Replace”................ 106 Every 50 Service Hours or Weekly “Fuel Tank Water and Sediment - Drain” .............. 106 Every 50 Service Hours or Monthly “Radiator Pressure Cap - Clean/Replace”............ 109 Every 3000 Service Hours or 2 Years “Coolant (Commercial Heavy-Duty) - Change” .......87 Every 4000 Service Hours “Aftercooler Core - Clean/Test”................................84 “Fuel Tank Water and Sediment - Drain” .............. 106 Every 6000 Service Hours or 3 Years Every 500 Service Hours “Coolant Extender (ELC) - Add” ..............................90 “Fan Clearance - Check” ...................................... 100 Every 12 000 Service Hours or 6 Years Every 500 Service Hours or 1 Year “Battery Electrolyte Level - Check” ..........................86 “Cooling System Supplemental Coolant Additive (SCA) - Test/Add”.....................................................92 “Engine Air Cleaner Element (Single Element) Inspect/Clean/Replace” ...........................................94 “Engine Oil and Filter - Change”..............................97 “Coolant (ELC) - Change”........................................88 Commissioning “Fan Clearance - Check” ...................................... 100 84 Maintenance Recommendations Aftercooler Core - Clean/Test SEBU8726 i01807350 Aftercooler Core - Clean/Test (Air-To-Air Aftercooler) The air-to-air aftercooler is OEM installed in many applications. Please refer to the OEM specifications for information that is related to the aftercooler. i02322295 Aftercooler Core - Inspect Note: Adjust the frequency of cleaning according to the effects of the operating environment. Inspect the aftercooler for these items: damaged fins, corrosion, dirt, grease, insects, leaves, oil and other debris. Clean the aftercooler, if necessary. i02322311 Alternator - Inspect Perkins recommends a scheduled inspection of the alternator. Inspect the alternator for loose connections and correct battery charging. Check the ammeter (if equipped) during engine operation in order to ensure correct battery performance and/or correct performance of the electrical system. Make repairs, as required. Check the alternator and the battery charger for correct operation. If the batteries are correctly charged, the ammeter reading should be very near zero. All batteries should be kept charged. The batteries should be kept warm because temperature affects the cranking power. If the battery is too cold, the battery will not crank the engine. When the engine is not run for long periods of time or if the engine is run for short periods, the batteries may not fully charge. A battery with a low charge will freeze more easily than a battery with a full charge. For air-to-air aftercoolers, use the same methods that are used for cleaning radiators. Personal injury can result from air pressure. Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing. Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes. After cleaning, start the engine and accelerate the engine to high idle rpm. This will help in the removal of debris and drying of the core. Stop the engine. Use a light bulb behind the core in order to inspect the core for cleanliness. Repeat the cleaning, if necessary. Inspect the fins for damage. Bent fins may be opened with a “comb”. Note: If parts of the aftercooler system are repaired or replaced, a leak test is highly recommended. Inspect these items for good condition: Welds, mounting brackets, air lines, connections, clamps and seals. Make repairs, if necessary. i04407613 Alternator and Fan Belts Replace 1. Remove the guard that covers the alternator. Refer to the Original Equipment Manufacture (OEM) for the correct procedure. SEBU8726 85 Maintenance Recommendations Battery - Replace 5. Install the new belt, use belt configuration (A). Visually check that the belt is correctly aligned. 6. Turn the screw (2) clockwise in order to tension the belt. Ensure that the link adjuster (7) is at the maximum extension, refer to illustration 45 . 7. Tighten bolt (5), nut, and bolt (6) and tighten nut and bolt (1). Tighten these nuts and bolts to 50 N·m (37 lb ft). 8. Rotate bolt (2) counter clockwise two complete revolutions and tighten nut (3) to 30 N·m (22 lb ft). 9. Install the guard, refer to OEM for more information. i03559623 Battery - Replace Illustration 44 g02729648 2. Loosen bolt (5) and loosen nut and bolt 6. Also, loosen nut and bolt (1). 3. Loosen nut (3) and turn screw (2) counter clockwise. Turn the screw (2) in order to give clearance to remove the belt (4). 4. Remove belt (4) and visually check all pulleys that the belt operates. Ensure that all pulleys are clean and free from damage. Ensure that the pulleys rotate freely. Replace any component that is damaged. Batteries give off combustible gases which can explode. A spark can cause the combustible gases to ignite. This can result in severe personal injury or death. Ensure proper ventilation for batteries that are in an enclosure. Follow the proper procedures in order to help prevent electrical arcs and/or sparks near batteries. Do not smoke when batteries are serviced. The battery cables or the batteries should not be removed with the battery cover in place. The battery cover should be removed before any servicing is attempted. Removing the battery cables or the batteries with the cover in place may cause a battery explosion resulting in personal injury. 1. Switch the engine to the OFF position. Remove all electrical loads. 2. Turn off any battery chargers. Disconnect any battery chargers. 3. Ensure that the battery disconnect switch is in the OFF position. 4. Disconnect the NEGATIVE “-” cable from the NEGATIVE “-” battery terminal. Illustration 45 (A) Belt configuration g02603591 86 Maintenance Recommendations Battery Electrolyte Level - Check SEBU8726 5. Disconnect the POSITIVE “+” cable from the POSITIVE “+” battery terminal. Note: Always recycle a battery. Never discard a battery. Dispose of used batteries to an appropriate recycling facility. 6. Remove the used battery. 7. Install the new battery. Note: Before the cables are connected, ensure that the battery disconnect switch is in the OFF position. 8. Connect the POSITIVE “+” cable to the POSITIVE “+” battery terminal. 9. Connect the NEGATIVE “-” cable to the NEGATIVE “-” battery terminal. 10. Turn the battery disconnect switch to the ON position. i02747977 Battery Electrolyte Level Check When the engine is not run for long periods of time or when the engine is run for short periods, the batteries may not fully recharge. Ensure a full charge in order to help prevent the battery from freezing. If batteries are correctly charged, the ammeter reading should be very near zero, when the engine is in operation. All lead-acid batteries contain sulfuric acid which can burn the skin and clothing. Always wear a face shield and protective clothing when working on or near batteries. 1. Remove the filler caps. Maintain the electrolyte level to the “FULL” mark on the battery. If the addition of water is necessary, use distilled water. If distilled water is not available use clean water that is low in minerals. Do not use artificially softened water. 2. Check the condition of the electrolyte with a suitable battery tester. 3. Install the caps. 4. Keep the batteries clean. Clean the battery case with one of the following cleaning solutions: • Use a solution of 0.1 kg (0.2 lb) baking soda and 1 L (1 qt) of clean water. • Use a solution of ammonium hydroxide . Thoroughly rinse the battery case with clean water. i02323088 Battery or Battery Cable Disconnect The battery cables or the batteries should not be removed with the battery cover in place. The battery cover should be removed before any servicing is attempted. Removing the battery cables or the batteries with the cover in place may cause a battery explosion resulting in personal injury. 1. Turn the start switch to the OFF position. Turn the ignition switch (if equipped) to the OFF position and remove the key and all electrical loads. 2. Disconnect the negative battery terminal. Ensure that the cable cannot contact the terminal. When four 12 volt batteries are involved, two negative connection must be disconnected. 3. Remove the positive connection. 4. Clean all disconnected connection and battery terminals. 5. Use a fine grade of sandpaper to clean the terminals and the cable clamps. Clean the items until the surfaces are bright or shiny. DO NOT remove material excessively. Excessive removal of material can cause the clamps to not fit correctly. Coat the clamps and the terminals with a suitable silicone lubricant or petroleum jelly. 6. Tape the cable connections in order to help prevent accidental starting. 7. Proceed with necessary system repairs. 8. In order to connect the battery, connect the positive connection before the negative connector. SEBU8726 87 Maintenance Recommendations Coolant (Commercial Heavy-Duty) - Change i05326349 Coolant (Commercial HeavyDuty) - Change NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to Local regulations and mandates. Drain Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure. 1. Stop the engine and allow the engine to cool. Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the cooling system filler cap. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Clean the cooling system and flush the cooling system before the recommended maintenance interval if the following conditions exist: • The engine overheats frequently. • Foaming of the coolant is observed. • The oil has entered the cooling system and the coolant is contaminated. • The fuel has entered the cooling system and the coolant is contaminated. Note: When the cooling system is cleaned, only clean water is needed. NOTICE When any servicing or repair of the engine cooling system is performed, the procedure must be performed with the engine on level ground. This action will allow you to check accurately the coolant level. This action will also help in avoiding the risk of introducing an air lock into the coolant system. Illustration 46 g02513896 Typical example 2. Remove the drain plug (1) on the engine. Also, open drain cock or remove the drain plug on the radiator. Allow the coolant to drain. NOTICE Dispose of used engine coolant or recycle. Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems. The full distillation procedure is the only method acceptable by Perkins to reclaim the coolant. For information regarding the disposal and the recycling of used coolant, consult your Perkins dealer or your Perkins distributor. Flush 88 Maintenance Recommendations Coolant (ELC) - Change SEBU8726 1. Flush the cooling system with clean water in order to remove any debris. 2. Install the drain plug on the engine. Close the drain cock or install the drain plug on the radiator. NOTICE Do not fill the cooling system faster than 5 L (1.3 US gal) per minute, in order to avoid air locks. Cooling system air locks may result in engine damage. 3. Fill the cooling system with clean water. Install the cooling system filler cap. 4. Start and run the engine at low idle until the temperature reaches 49 to 66 °C (120 to 150 °F). 5. Stop the engine and allow the engine to cool. Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the cooling system filler cap. Remove the drain plug on the engine. Open the drain cock or remove the drain plug on the radiator. Allow the water to drain. Flush the cooling system with clean water. Fill 1. Install the drain plug on the engine. Close the drain cock or install the drain plug on the radiator. NOTICE Do not fill the cooling system faster than 5 L (1.3 US gal) per minute, in order to avoid air locks. Illustration 47 5. Clean the cooling system filler cap and inspect the gasket. If the gasket is damaged, discard the old filler cap and install a new filler cap. If the gasket is not damaged, use a suitable pressurizing pump in order to pressure test the filler cap. The correct pressure is stamped on the face of the filler cap. If the filler cap does not retain the correct pressure, install a new filler cap. 6. Start the engine. Inspect the cooling system for leaks and for correct operating temperature. Cooling system air locks may result in engine damage. 2. Fill the cooling system with Commercial HeavyDuty Coolant. Add Supplemental Coolant Additive to the coolant. For the correct amount, refer to the Operation and Maintenance Manual, “Fluid Recommendations” topic (Maintenance Section) for more information on cooling system specifications. Do not install the cooling system filler cap. 3. Start and run the engine at low idle. Increase the engine rpm to high idle. Operate the engine in order to open the engine thermostat. This operation will allow any air in the system to be purged. Decrease the engine speed to low idle. Stop the engine. 4. Maintain the coolant level at the maximum mark that is correct for your application. g02590196 Filler cap i05326371 Coolant (ELC) - Change NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to Local regulations and mandates. SEBU8726 89 Maintenance Recommendations Coolant (ELC) - Change NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Clean the cooling system and flush the cooling system before the recommended maintenance interval if the following conditions exist: • The engine overheats frequently. • Foaming of the coolant is observed. • The oil has entered the cooling system and the coolant is contaminated. • The fuel has entered the cooling system and the coolant is contaminated. Note: When the cooling system is cleaned, only clean water is needed when the ELC is drained and replaced. Note: Inspect the water pump and the water temperature regulator after the cooling system has been drained. This inspection can be a good opportunity to replace the water pump, the water temperature regulator, and the hoses, if necessary. Illustration 48 g02513896 Typical example 2. Remove the drain plug (1) on the engine. Also, open the drain cock or remove the drain plug on the radiator. Allow the coolant to drain. NOTICE When any servicing or repair of the engine cooling system is performed, the procedure must be performed with the engine on level ground. Level ground will allow you to check accurately the coolant level. This check will also help in avoiding the risk of introducing an air lock into the coolant system. Drain Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure. 1. Stop the engine and allow the engine to cool. Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the cooling system filler cap. NOTICE Dispose of used engine coolant or recycle. Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems. The full distillation procedure is the only method acceptable by Perkins to reclaim the coolant. For information regarding the disposal and the recycling of used coolant, consult your Perkins dealer or your Perkins distributor. Flush 1. Flush the cooling system with clean water in order to remove any debris. 2. Install the drain plug in the engine. Close the drain cock or install the drain plug on the radiator. NOTICE Do not fill the cooling system faster than 5 L (1.3 US gal) per minute, in order to avoid air locks. Cooling system air locks may result in engine damage. 3. Fill the cooling system with clean water. Install the cooling system filler cap. 90 Maintenance Recommendations Coolant Extender (ELC) - Add SEBU8726 4. Start and run the engine at low idle until the temperature reaches 49 to 66 °C (120 to 150 °F). 5. Stop the engine and allow the engine to cool. Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the cooling system filler cap. Remove the drain plug on the engine. Open the drain cock or remove the drain plug on the radiator. Allow the water to drain. Flush the cooling system with clean water. Fill 1. Install the drain plug on the engine. Close the drain cock or install the drain plug on the radiator. NOTICE Do not fill the cooling system faster than 5 L (1.3 US gal) per minute, in order to avoid air locks. Cooling system air locks may result in engine damage. Illustration 49 g02590196 Filler cap 2. Fill the cooling system with Extended Life Coolant (ELC). Refer to the Operation and Maintenance Manual, “Fluid Recommendations” topic (Maintenance Section) for more information on cooling system specifications. Do not install the cooling system filler cap. 3. Start and run the engine at low idle. Increase the engine rpm to high idle. Operate the engine in order to open the engine thermostat. This procedure will allow any air in the system to be purged. Decrease the engine speed to low idle. Stop the engine. 4. Maintain the coolant level at the maximum mark that is correct for your application. 5. Clean the cooling system filler cap and inspect the gasket. If the gasket is damaged, discard the old filler cap and install a new filler cap. If the gasket is not damaged, use a suitable pressurizing pump in order to pressure test the filler cap. The correct pressure is stamped on the face of the filler cap. If the filler cap does not retain the correct pressure, install a new filler cap. 6. Start the engine. Inspect the cooling system for leaks and for correct operating temperature. i05197396 Coolant Extender (ELC) - Add In order for Perkins ELC to achieve 12000 hours an extender must be added at 6000 hours. For a suitable extender, contact your Perkins dealer or Perkins distributor. SEBU8726 91 Maintenance Recommendations Coolant Level - Check i05149389 Coolant Level - Check Engines With a Coolant Recovery Tank Note: The cooling system may not have been provided by Perkins . The procedure that follows is for typical cooling systems. Refer to the OEM information for the correct procedures. Check the coolant level when the engine is stopped and cool. NOTICE When any servicing or repair of the engine cooling system is performed, the procedure must be performed with the engine on level ground. Level ground will allow you to check accurately the coolant level. This checking will also help in avoiding the risk of introducing an air lock into the coolant system. 1. Observe the coolant level in the coolant recovery tank. Maintain the coolant level to “COLD FULL” mark on the coolant recovery tank. Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure. Illustration 50 g02590196 Filler cap 4. Clean the filler cap and the receptacle. Reinstall the filler cap and inspect the cooling system for leaks. Note: The coolant will expand as the coolant heats up during normal engine operation. The additional volume will be forced into the coolant recovery tank during engine operation. When the engine is stopped and cool, the coolant will return to the engine. Engines Without a Coolant Recovery Tank Check the coolant level when the engine is stopped and cool. 2. Loosen filler cap slowly in order to relieve any pressure. Remove the filler cap. 3. Pour the correct coolant mixture into the tank. Refer to the Operation and Maintenance Manual, “Refill Capacities and Recommendations” for information on the correct mixture and type of coolant. Refer to the Operation and Maintenance Manual, “Refill Capacities and Recommendations” for the engine cooling system capacity. Do not fill the coolant recovery tank above “COLD FULL” mark. Illustration 51 Cooling system filler cap g00285520 92 Maintenance Recommendations Cooling System Supplemental Coolant Additive (SCA) - Test/Add SEBU8726 Add the SCA, If Necessary Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure. 1. Remove the cooling system filler cap slowly in order to relieve pressure. 2. Maintain the coolant level at the maximum mark that is correct for your application. If the engine is equipped with a sight glass, maintain the coolant level to the correct level in the sight glass. 3. Clean the cooling system filler cap and inspect the gasket. If the gasket is damaged, discard the old filler cap and install a new filler cap. If the gasket is not damaged, use a suitable pressurizing pump in order to pressure test the filler cap. The correct pressure is stamped on the face of the filler cap. If the filler cap does not retain the correct pressure, install a new filler cap. 4. Inspect the cooling system for leaks. i03644948 Cooling System Supplemental Coolant Additive (SCA) - Test/ Add Cooling system coolant additive contains alkali. To help prevent personal injury, avoid contact with the skin and the eyes. Do not drink cooling system coolant additive. Test for SCA Concentration Heavy-Duty Coolant/Antifreeze and SCA NOTICE Do not exceed the recommended six percent supplemental coolant additive concentration. Use a Coolant Conditioner Test Kit in order to check the concentration of the SCA. NOTICE Do not exceed the recommended amount of supplemental coolant additive concentration. Excessive supplemental coolant additive concentration can form deposits on the higher temperature surfaces of the cooling system, reducing the engine's heat transfer characteristics. Reduced heat transfer could cause cracking of the cylinder head and other high temperature components. Excessive supplemental coolant additive concentration could also result in radiator tube blockage, overheating, and/or accelerated water pump seal wear. Never use both liquid supplemental coolant additive and the spin-on element (if equipped) at the same time. The use of those additives together could result in supplemental coolant additive concentration exceeding the recommended maximum. Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure. NOTICE When any servicing or repair of the engine cooling system is performed the procedure must be performed with the engine on level ground. This will allow you to accurately check the coolant level. This will also help in avoiding the risk of introducing an air lock into the coolant system. 1. Slowly loosen the cooling system filler cap in order to relieve the pressure. Remove the cooling system filler cap. Note: Always discard drained fluids according to local regulations. 2. If necessary, drain some coolant from the cooling system into a suitable container in order to allow space for the extra SCA. 3. Add the correct amount of SCA. Refer to the Operation and Maintenance Manual, “Refill Capacities and Recommendations” for more information on SCA requirements. SEBU8726 93 Maintenance Recommendations Diesel Particulate Filter - Clean 4. Clean the cooling system filler cap and inspect the gasket. If the gasket is damaged, discard the old filler cap and install a new filler cap. If the gasket is not damaged, use a suitable pressurizing pump in order to pressure test the filler cap. The correct pressure is stamped on the face of the filler cap. If the filler cap does not retain the correct pressure, install a new filler cap. Note: Only the wall flow type of aftertreatment requires a service period, in order to remove the ash. The wall flow aftertreatment uses active regeneration in order to remove soot. For information on removal of the (1) diesel particulate filter, refer to Disassembly and Assembly, “DPF - Remove”. Also, refer to System Operation Testing and Adjusting, “Diesel Particulate Filter Clean”. i04650530 i02151646 Diesel Particulate Filter - Clean Wear goggles, gloves, protective clothing, and a National Institute for Occupational Safety and Health (NIOSH) approved P95 or N95 half-face respirator when handling a used Diesel Particulate Filter or Catalytic Converter Muffler. Failure to do so could result in personal injury. Driven Equipment - Check Refer to the OEM specifications for more information on the following maintenance recommendations for the driven equipment: • Inspection • Adjustment • Lubrication • Other maintenance recommendations The muffler, catalytic converter/muffler, and diesel particulate filter will become extremely hot during engine operation. A hot muffler, catalytic converter/muffler and diesel particulate filter can cause serious burns. Allow adequate cooling time before working on or near the muffler, catalytic converter/muffler and diesel particulate filter. Perform any maintenance for the driven equipment which is recommended by the OEM. i03991933 Engine - Clean Personal injury or death can result from high voltage. Moisture can conductivity. create paths of electrical Make sure that the electrical system is OFF. Lock out the starting controls and tag the controls “ DO NOT OPERATE”” . NOTICE Accumulated grease and oil on an engine is a fire hazard. Keep the engine clean. Remove debris and fluid spills whenever a significant quantity accumulates on the engine. Illustration 52 Typical example g02524596 Periodic cleaning of the engine is recommended. Steam cleaning the engine will remove accumulated oil and grease. A clean engine provides the following benefits: 94 Maintenance Recommendations Engine Air Cleaner Element (Single Element) - Inspect/Clean/Replace SEBU8726 • Easy detection of fluid leaks i02335405 Engine Air Cleaner Service Indicator - Inspect • Maximum heat transfer characteristics • Ease of maintenance Note: Caution must be used in order to prevent electrical components from being damaged by excessive water when the engine is cleaned. Pressure washers and steam cleaners should not be directed at any electrical connectors or the junction of cables into the rear of the connectors. Avoid electrical components such as the alternator, the starter, and the ECM. Protect the fuel injection pump from fluids in order to wash the engine. Aftertreatment During the engine cleaning process, ensure that water or cleaning fluids cannot enter the aftertreatment system. If cleaning fluids enters the aftertreatment system, damage could occur. Some engines may be equipped with a different service indicator. Some engines are equipped with a differential gauge for inlet air pressure. The differential gauge for inlet air pressure displays the difference in the pressure that is measured before the air cleaner element and the pressure that is measured after the air cleaner element. As the air cleaner element becomes dirty, the pressure differential rises. If your engine is equipped with a different type of service indicator, follow the OEM recommendations in order to service the air cleaner service indicator. The service indicator may be mounted on the air cleaner element or in a remote location. i04150591 Engine Air Cleaner Element (Single Element) - Inspect/ Clean/Replace Refer to Operation and Maintenance Manual, “Engine Air Cleaner Service Indicator-Inspect”. NOTICE Never run the engine without an air cleaner element installed. Never run the engine with a damaged air cleaner element. Do not use air cleaner elements with damaged pleats, gaskets or seals. Dirt entering the engine causes premature wear and damage to engine components. Air cleaner elements help to prevent airborne debris from entering the air inlet. NOTICE Never service the air cleaner element with the engine running since this will allow dirt to enter the engine. Illustration 53 g00103777 Typical service indicator Observe the service indicator. The air cleaner element should be cleaned or the air cleaner element should be replaced when one of the following conditions occur: • The yellow diaphragm enters the red zone. • The red piston locks in the visible position. Test the Service Indicator A wide variety of air cleaners may be installed for use with this engine. Consult the OEM information for the correct procedure to replace the air cleaner. Service indicators are important instruments. • Check for ease of resetting. The service indicator should reset in less than three pushes. • Check the movement of the yellow core when the engine is accelerated to the engine rated speed. The yellow core should latch at the greatest vacuum that is attained. SEBU8726 95 Maintenance Recommendations Engine Air Precleaner - Check/Clean If the service indicator does not reset easily, or if the yellow core does not latch at the greatest vacuum, the service indicator should be replaced. If the new service indicator will not reset, the hole for the service indicator may be restricted. The service indicator may need to be replaced frequently in environments that are severely dusty. i02343354 Engine Air Precleaner - Check/ Clean Engine Breather NOTICE Ensure that the engine is stopped before any servicing or repair is performed. The crankcase breather is a very important component in order to keep your engine emissions compliant . • The filter element within the crankcase breather must be serviced at the prescribed service interval. • The correct filter element must be installed before the engine is operated. • The installation of the filter element is very important . • The quality of the filter element that is installed is very important. • The filter element protects the engine from excessive quantities of oil from entering the induction system. The filter element also protects the engine aftertreatment system. Note: Excessive quantities of oil that enter the induction system of the engine can rapidly increase the engine speed without control. Illustration 54 g00287039 Remove the Breather Element Typical example 1. Remove the guard that covers the engine breather, refer to the Original Equipment Manufacture (OEM) for more information. (1) Wing nut (2) Cover (3) Body Remove wing nut (1) and cover (2). Check for an accumulation of dirt and debris in body (3). Clean the body, if necessary. After cleaning the precleaner, install cover (2) and wing nut (1). Note: When the engine is operated in dusty applications, more frequent cleaning is required. i04725716 Engine Crankcase Breather Element - Replace Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin. Illustration 55 Typical example g02827199 96 Maintenance Recommendations Engine Mounts - Inspect SEBU8726 2. If necessary, remove breather pipes on cover (6). Remove nuts (7) and remove cover (6) from housing (1). 3. Remove circlip (4) and remove the breather element (3) and discard. 4. Remove the O ring seal (5) from the cover. Install the Breather Element Ensure that all the components are clean and free from damage. i02323089 Engine Mounts - Inspect Note: The engine mounts may not have been supplied by Perkins . Refer to the OEM information for further information on the engine mounts and the correct bolt torque. Inspect the engine mounts for deterioration and for correct bolt torque. Engine vibration can be caused by the following conditions: • Incorrect mounting of the engine • Deterioration of the engine mounts • Loose engine mounts Any engine mount that shows deterioration should be replaced. Refer to the OEM information for the recommended torques. i04728471 Engine Oil Level - Check Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin. Illustration 56 g02827300 Typical example (A) Diameter (B) Diameter 1. Install a new O ring seal (5) onto the cover (6). Note: The breather element must have the correct orientation before installation. Diameter (A) is visibly larger than diameter (B). 2. Install diameter (A) of the breather element (3) onto the shaft (2). When correctly installed the part number of the breather element will be visible. 3. Install circlip (4) and cover (6). Install nuts (7) and tighten to 25 N·m (18 lb ft). If necessary, install breather pipes to cover. 4. Install the guard, refer to OEM. Illustration 57 g02829378 Typical example NOTICE Perform this maintenance with the engine stopped. Note: Ensure that the engine is either level or that the engine is in the normal operating position in order to obtain a true level indication. SEBU8726 97 Maintenance Recommendations Engine Oil Sample - Obtain Note: After the engine has been switched OFF, wait for 10 minutes in order to allow the engine oil to drain to the oil pan before checking the oil level. • The date of the sample 1. Maintain the oil level between the MIN mark and the mark MAX on the engine oil dipstick. Do not fill the crankcase above the MAX mark. • Engine number NOTICE Operating your engine when the oil level is above the MAX mark could cause your crankshaft to dip into the oil. The air bubbles created from the crankshaft dipping into the oil reduces the oils lubricating characteristics and could result in the loss of power. 2. Remove the oil filler cap and add oil, if necessary. Clean the oil filler cap. Install the oil filler cap. If an increase in the oil level is noticed, refer to Troubleshooting, “Oil Contains Fuel”. • Engine model • Service hours on the engine • The number of hours that have accumulated since the last oil change • The amount of oil that has been added since the last oil change Ensure that the container for the sample is clean and dry. Also ensure that the container for the sample is clearly labelled. To ensure that the sample is representative of the oil in the crankcase, obtain a warm, well mixed oil sample. To avoid contamination of the oil samples, the tools and the supplies that are used for obtaining oil samples must be clean. i01907674 Engine Oil Sample - Obtain The condition of the engine lubricating oil may be checked at regular intervals as part of a preventive maintenance program. Perkins include an oil sampling valve as an option. The oil sampling valve (if equipped) is included in order to regularly sample the engine lubricating oil. The oil sampling valve is positioned on the oil filter head or the oil sampling valve is positioned on the cylinder block. Perkins recommends using a sampling valve in order to obtain oil samples. The quality and the consistency of the samples are better when a sampling valve is used. The location of the sampling valve allows oil that is flowing under pressure to be obtained during normal engine operation. Obtain the Sample and the Analysis Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin. In order to help obtain the most accurate analysis, record the following information before an oil sample is taken: The sample can be checked for the following: the quality of the oil, the existence of any coolant in the oil, the existence of any ferrous metal particles in the oil and the existence of any nonferrous metal particles in the oil. i05327085 Engine Oil and Filter - Change Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 98 Maintenance Recommendations Engine Oil and Filter - Change SEBU8726 The engine oil service reset procedure must be completed after the engine oil, and filter have been changed. Refer to “Engine Oil Service Reset” for more information. Do not drain the engine lubricating oil when the engine is cold. As the engine lubricating oil cools, suspended waste particles settle on the bottom of the oil pan. The waste particles are not removed with draining cold oil. Drain the oil pan with the engine stopped. Drain the oil pan with the oil warm. This draining method allows the waste particles that are suspended in the oil to be drained properly. Failure to follow this recommended procedure will cause the waste particles to be recirculated through the engine lubrication system with the new oil. Drain the Engine Lubricating Oil After the oil has drained, replace the drain plug. If necessary replace the seal on the drain plug. Install drain plug and tighten to 34 N·m (25 lb ft). Replace the Oil Filter NOTICE Perkins oil filters are manufactured to Perkins specifications. Use of an oil filter that is not recommended by Perkins could result in severe damage to the engine bearings, crankshaft, as a result of the larger waste particles from unfiltered oil entering the engine lubricating system. Only use oil filters recommended by Perkins . 1. Using a suitable tool remove the engine oil filter. Ensure that the vessel that will be used is large enough to collect the waste oil. After the engine has been run at the normal operating temperature, stop the engine. Ensure that the application that the engine is installed is on level ground. Use one of the following methods to drain the engine oil pan: Illustration 59 g02516777 Typical example 2. Clean sealing surface (2). Illustration 58 g02519103 3. Apply clean engine oil to O ring seal (3) on the new oil filter. Typical example • If the engine is equipped with a drain valve, turn the drain valve knob counterclockwise in order to drain the oil. After the oil has drained, turn the drain valve knob clockwise in order to close the drain valve. NOTICE Do not fill the oil filters with oil before installing them. This oil would not be filtered and could be contaminated. Contaminated oil can cause accelerated wear to engine components. • If the engine is not equipped with a drain valve, remove the oil drain plug (1) in order to allow the oil to drain. If the engine is equipped with a shallow oil pan, remove the bottom oil drain plugs from both ends of the oil pan. 4. Install the engine oil filter, spin on the oil filter until the O ring seal contacts the oil filter base. Then, rotate the oil filter ¾ of a full turn, by hand only. SEBU8726 99 Maintenance Recommendations Engine Oil and Filter - Change Vertically Up Oil Filter Illustration 61 g02829378 4. Remove the engine oil level gauge in order to check the oil level. Maintain the oil level between the MIN mark and MAX mark on the engine oil level gauge. Do not fill the crankcase above the MAX mark. Illustration 60 g02596778 Engine Oil Service Reset (4) Vertically up oil filter Some oil filters may be installed vertically up. Use the same procedure in order to replace the oil filter. Ensure that all the oil has drained from the filter before removal. Fill the Oil Pan 1. Remove the oil filler cap. Refer to this Operation and Maintenance Manual, “Fluid Recommendations” for more information on suitable oils. Fill the oil pan with the correct amount of new engine lubricating oil. Refer to this Operation and Maintenance Manual, “Refill Capacities” for more information on refill capacities. NOTICE If equipped with an auxiliary oil filter system or a remote filter system, follow the OEM or the filter manufactures recommendations. Under filling or over filling the crankcase with oil can cause engine damage. 2. Start the engine and run the engine at “LOW IDLE” for 2 minutes. Perform this procedure in order to ensure that the lubrication system has oil and that the oil filters are filled. Inspect the oil filter for oil leaks. 3. Stop the engine and allow the oil to drain back to the oil pan for a minimum of 10 minutes. NOTICE Failure to perform a schedule oil and filter service with an engine oil service reset will trigger an engine derate. The low oil warning lamp has two functions. The lamp on solid will indicate that the engine has low oil pressure. The lamp flashing will indicate the engine oil and filter MUST be changed and the engine oil service reset MUST be completed. The lamp will only flash with the key in the ON position, with the engine in operation the lamp will be extinguished. Note: If the engine oil and filter have been changed before the warning lamp has started to flash, the engine oil service reset procedure MUST still be completed. Upon completion of the reset procedure, the lamp will flash three times. Some applications may have other methods in order to perform an engine oil service reset. For assistance with the engine oil service reset contact your Perkins distributor, or your OEM. Use one of the following procedures after the engine oil and filter has been changed in order to complete an engine oil service reset: 100 Maintenance Recommendations Fan Clearance - Check Throttle Control Option Note: Some application the maximum throttle position can before the throttle peddle has reached the stop. The actual maximum position of the throttle must be known before starting the procedure. With the known maximum position the middle position of the throttle can be calculated. The throttle must be positioned in the required positions for the prescribed period in order to perform an engine oil service reset. 1. Turn the keyswitch to the ON position, and wait 15 seconds, but not more than 30 seconds. Go to step 2. 2. Move the throttle to the maximum position for more than 15 seconds, but less than 30 seconds. 3. Return throttle to zero position for more than 15 seconds, but less than 30 seconds. SEBU8726 5. Return the multi-state switch to position 0 for more than 15 seconds, but less than 30 seconds 6. Turn the multi-state switch to position 1 for more than 15 seconds, but less than 30 seconds. Return the multi-state switch to position 0. The engine oil service reset procedure is complete. Turn the keyswitch to the OFF position. 7. On completion of the sequence, the low oil warning lamp will flash three times. Each flash will be for 1 second with a 1 second interval. This sequence of flashes indicates that the warning lamp has been reset and the engine can be started and operated normally. 8. If the procedure has been interrupted before completion, turn the power off for 20 seconds before starting again. 4. Move the throttle to the maximum position for more than 15 seconds, but less than 30 seconds. 5. Return throttle to zero position for more than 15 seconds, but less than 30 seconds. 6. Move the throttle to the middle position for more than 15 seconds, but less than 30 seconds. Return the throttle to zero position. The engine oil service reset procedure is complete. Turn the keyswitch to the OFF position. 7. On completion of the sequence, the low oil warning lamp will flash three times. Each flash will be for 1 second with a 1 second interval. This sequence of flashes indicates that the warning lamp has been reset and the engine can be started and operated normally. 8. If the procedure has been interrupted before completion, turn the power off for 20 seconds before starting again. Multi-State Switch Option 1. Turn the keyswitch to the ON position, and wait 15 seconds, but not more than 30 seconds. Go to step 2. 2. Turn the multi-state switch to position 1 for more than 15 seconds, but less than 30 seconds. 3. Return the multi-state switch to position 0 for more than 15 seconds, but less than 30 seconds. 4. Turn the multi-state switch to position 1 for more than 15 seconds, but less than 30 seconds. i04401341 Fan Clearance - Check There are different types of cooling systems. Refer to the OEM for information on clearance for the fan. Ensure that the engine is stopped. Ensure that the battery disconnect switch is in the OFF position. Ensure that the cooling system is full. The clearance between the cover (1) and the fan (2) will require checking. The gap (A) between the edge of the cover and the tip of the fan blade must be checked in four equally spaced positions. SEBU8726 101 Maintenance Recommendations Fuel System - Prime Illustration 62 g02585058 Typical example Adjustment of the cover will change the clearance (gap) between the edge of the cover and the tip of the fan blade. Ensure that the cover is centralized to the fan. The clearance (A) must be set to 10 ± 1 mm (0.39370 ± 0.03937 inch). i04366913 Fuel System - Prime NOTICE Do not crank the engine continuously for more than 30 seconds. Allow the starting motor to cool for two minutes before cranking the engine again. If air enters the fuel system, the air must be purged from the fuel system before the engine can be started. Air can enter the fuel system when the following events occur: • The fuel tank is empty or the fuel tank has been partially drained. Note: Refer to Systems Operation, Testing, and Adjusting, “Cleanliness of Fuel System Components” for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system. • The low-pressure fuel lines are disconnected. Ensure that all adjustments and repairs are performed by authorized personnel that have had the correct training. Use the following procedures in order to remove air from the fuel system: • A leak exists in the low-pressure fuel system. • The fuel filter has been replaced. 102 Maintenance Recommendations Fuel System Primary Filter (Water Separator) Element - Replace 1. Ensure that the fuel system is in working order. Check that the fuel supply valve (if equipped) is in the “ON” position. 2. Operate the hand priming pump. Count the number of operations of the pump. After approximately 80 depression of the pump stop. Note: As the fuel system is primed, the pressure will increase within the fuel system and this increase in pressure can be felt during priming. 3. The fuel system should now be primed and the engine should be able to start. 4. Operate the engine starter and crank the engine. After the engine has started, operate the engine at low idle for a minimum of 5 minutes. Ensure that the fuel system is free from leaks. Note: Operating the engine for this period will help ensure that the fuel system is free of air. DO NOT loosen the high-pressure fuel lines in order to purge air from the fuel system. This procedure is not required. SEBU8726 Note: Refer to Systems Operation, Testing, and Adjusting, “Cleanliness of Fuel System Components” for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system. NOTICE Ensure that the engine is stopped before any servicing or repair is performed. Remove the Element 1. Turn the fuel supply valve (if equipped) to the OFF position before performing this maintenance. 2. Place a suitable container under the water separator in order to catch any fuel that might spill. Clean up any spilled fuel. Clean the outside body of the filter assembly. 3. Make a temporary Mark (A) across the filter before the assembly is removed. After the engine has stopped, you must wait for 10 minutes in order to allow the fuel pressure to be purged from the high-pressure fuel lines before any service or repair is performed on the engine fuel lines. If necessary, perform minor adjustments. Repair any leaks from the low-pressure fuel system and from the cooling, lubrication, or air systems. Replace any highpressure fuel line that has leaked. Refer to Disassembly and Assembly Manual, “Fuel Injection Lines - Install”. If you inspect the engine in operation, always use the proper inspection procedure in order to avoid a fluid penetration hazard . Refer to Operation and Maintenance Manual, “General hazard Information”. If the engine will not start, refer to Troubleshooting, “Engine Cranks but will not Start”. i05326388 Fuel System Primary Filter (Water Separator) Element Replace Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when changing fuel filters or water separator elements. Clean up fuel spills immediately. Illustration 63 g03374220 Typical example 4. Install a suitable tube onto drain (3). Open the drain valve (2). Rotate the drain valve counterclockwise. Two full turns are required. Loosen vent screw (1). Note: Two complete rotations of the valve will release the valve from the filter element. 5. Allow the fuel to drain into the container. Remove the tube and install the valve into the filter element. Engage the threads of the valve into the filter element. Do not secure the valve. SEBU8726 103 Maintenance Recommendations Fuel System Primary Filter (Water Separator) Element - Replace 6. Tighten the vent screw (1) securely . Remove the wiring harness from connection (4). Illustration 65 g03374224 Typical example Illustration 64 g03374223 Typical example 7. Using a suitable tool, remove the filter bowl (6). Rotate the filter assembly counterclockwise in order to remove the filter assembly. Use a suitable tool in order to remove the filter assembly. 8. Rotate the filter element counterclockwise and remove the filter element (5). Clean the filter bowl. Install the Element 1. Locate the thread in the filter element (8) onto the threads (9). Spin on the element. Do not tighten. 2. Lubricate the O ring seal (7) with clean engine oil. Do NOT fill the bowl with fuel before the assembly is installed. 3. Do NOT use a tool in order to install the filter assembly. Tighten the filter bowl (6) by hand. Install the filter bowl (6) and align with your temporary marks (A). 4. Tighten the valve (2) securely. Remove the container and dispose of the fuel in a safe place. 5. The secondary filter element must be replaced at the same time as the primary filter element. Refer to the Operation and Maintenance Manual, “Fuel System Filter - Replace”. 104 Maintenance Recommendations Fuel System Primary Filter/Water Separator - Drain i05326334 Fuel System Primary Filter/ Water Separator - Drain SEBU8726 3. Install a suitable tube onto drain (3). Open the drain valve (2). Rotate the drain valve counterclockwise. Two full turns are required. Loosen vent screw (1). Note: Two complete rotations of the valve will release the valve from the filter element. 4. Allow the fluid to drain into the container. Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when changing fuel filters or water separator elements. Clean up fuel spills immediately. 5. Engage the threads of the valve into the filter element and tighten the drain valve by hand pressure only. Tighten vent screw securely. 6. Remove the tube and remove the container. i04367528 NOTICE Ensure that the engine is stopped before any servicing or repair is performed. NOTICE The water separator can be under suction during normal engine operation. Ensure that the drain valve is tightened securely to help prevent air from entering the fuel system. 1. Place a suitable container under the water separator in order to catch any fluid that might spill. Clean up any spilled fluid. 2. Ensure that the outer body of the filter assembly is clean and free from dirt. Fuel System Secondary Filter Replace Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when changing fuel filters or water separator elements. Clean up fuel spills immediately. NOTICE Ensure that the engine is stopped before any servicing or repair is performed. Refer to Systems Operation, Testing, and Adjusting, “Cleanliness of Fuel System Components” for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system. Remove the Element 1. Turn the fuel supply valve (if equipped) to the OFF position before performing this maintenance. 2. Place a suitable container under the fuel filter in order to catch any fuel that might spill. Clean up any spilled fuel. Clean the outside body of the filter assembly. Illustration 66 Typical example g03374226 SEBU8726 Illustration 67 105 Maintenance Recommendations Fuel System Secondary Filter - Replace g02522536 Illustration 68 g02522538 Typical example Typical example 3. Make a temporary Mark (A) across the filter before the assembly is removed. Install a suitable tube onto drain (4). Open the drain valve (3). Rotate the drain valve counterclockwise. Two full turns are required. Loosen vent screw (1). 7. Rotate the filter element counterclockwise and remove the filter element (5). Clean the filter bowl. Install the Element Note: Two complete rotations of the valve will release the valve from the filter element. 4. Allow the fuel to drain into the container. Remove the tube and install the valve into the filter element. Engage the threads of the valve into the filter element. Do not secure the valve. 5. Tighten the vent screw (1) securely. 6. Remove the filter bowl (2). Rotate the filter assembly counterclockwise in order to remove the assembly. Use a suitable tool in order to remove the filter bowl. Illustration 69 g02522540 Typical example 1. Locate the thread in the filter element (7) onto the threads (8). Spin on the element. Do not tighten. 2. Lubricate the O ring seal (6) with clean engine oil. Do NOT fill the filter bowl (2) with fuel before the filter assembly is installed. 106 Maintenance Recommendations Fuel Tank Water and Sediment - Drain SEBU8726 3. Do not use a tool in order to install the filter assembly. Tighten the assembly by hand. Install the filter bowl (2) and align with your temporary Marks. 4. Tighten the drain valve (3). Turn the fuel supply valve to the ON position. 5. The Primary filter element must be replaced at the same time as the secondary filter element. Refer to the Operation and Maintenance Manual, “Fuel System Primary Filter (Water Separator) Element Replace”. 6. Prime the fuel system. Refer to the Operation and Maintenance Manual, “Fuel System - Prime” for more information. Open the drain valve on the bottom of the fuel tank in order to drain the water and the sediment. Close the drain valve. Check the fuel daily. Allow five minutes after the fuel tank has been filled before draining water and sediment from the fuel tank. Fill the fuel tank after operating the engine in order to drive out moist air. This will help prevent condensation. Do not fill the tank to the top. The fuel expands as the fuel gets warm. The tank may overflow. Some fuel tanks use supply pipes that allow water and sediment to settle below the end of the fuel supply pipe. Some fuel tanks use supply lines that take fuel directly from the bottom of the tank. If the engine is equipped with this system, regular maintenance of the fuel system filter is important. Fuel Storage Tanks i02348492 Fuel Tank Water and Sediment - Drain Drain the water and the sediment from the fuel storage tank at the following intervals: • Weekly • Service intervals NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates. • Refill of the tank This will help prevent water or sediment from being pumped from the storage tank into the engine fuel tank. If a bulk storage tank has been refilled or moved recently, allow adequate time for the sediment to settle before filling the engine fuel tank. Internal baffles in the bulk storage tank will also help trap sediment. Filtering fuel that is pumped from the storage tank helps to ensure the quality of the fuel. When possible, water separators should be used. Fuel Tank i02518232 Fuel quality is critical to the performance and to the service life of the engine. Water in the fuel can cause excessive wear to the fuel system. Water can be introduced into the fuel tank when the fuel tank is being filled. Condensation occurs during the heating and cooling of fuel. The condensation occurs as the fuel passes through the fuel system and the fuel returns to the fuel tank. This causes water to accumulate in fuel tanks. Draining the fuel tank regularly and obtaining fuel from reliable sources can help to eliminate water in the fuel. Drain the Water and the Sediment Fuel tanks should contain some provision for draining water and draining sediment from the bottom of the fuel tanks. Hoses and Clamps - Inspect/ Replace Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death. If you inspect the engine in operation, always use the proper inspection procedure in order to avoid a fluid penetration hazard. Refer to Operation and Maintenance Manual, “General hazard Information”. SEBU8726 107 Maintenance Recommendations Hoses and Clamps - Inspect/Replace Inspect all hoses for leaks that are caused by the following conditions: • Cracking • Softness • Loose clamps Replace hoses that are cracked or soft. Tighten any loose clamps. Check for the following conditions: • End fittings that are damaged or leaking • Outer covering that is chafed or cut • Exposed wire that is used for reinforcement Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure. 1. Stop the engine. Allow the engine to cool. 2. Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the cooling system filler cap. • Flexible part of the hose that is kinked or crushed Note: Drain the coolant into a suitable, clean container. The coolant can be reused. 3. Drain the coolant from the cooling system to a level that is below the hose that is being replaced. • Armoring that is embedded in the outer covering 4. Remove the hose clamps. A constant torque hose clamp can be used in place of any standard hose clamp. Ensure that the constant torque hose clamp is the same size as the standard clamp. 5. Disconnect the old hose. Due to extreme temperature changes, the hose will harden. Hardening of the hoses will cause hose clamps to loosen. This can result in leaks. A constant torque hose clamp will help to prevent loose hose clamps. 7. Install the hose clamps with a torque wrench. • Outer covering that is ballooning locally Each installation application can be different. The differences depend on the following factors: • Type of hose 6. Replace the old hose with a new hose. Note: For the correct coolant, see this Operation and Maintenance Manual, “Fluid Recommendations”. 8. Refill the cooling system. Refer to the OEM information for further information on refilling the cooling system. • Anticipated expansion and contraction of the hose 9. Clean the cooling system filler cap. Inspect the cooling system filler cap's seals. Replace the cooling system filler cap if the seals are damaged. Install the cooling system filler cap. • Anticipated expansion and contraction of the fittings 10. Start the engine. Inspect the cooling system for leaks. • Type of fitting material Replace the Hoses and the Clamps Refer to the OEM information for further information on removing and replacing fuel hoses (if equipped). The following text describes a typical method of replacing coolant hoses. Refer to the OEM information for further information on the coolant system and the hoses for the coolant system. 108 Maintenance Recommendations Oxygen Sensor - Replace SEBU8726 i05324852 Oxygen Sensor - Replace Personal injury can result from air pressure. Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing. Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes. Pressurized air is the preferred method for removing loose debris. Direct the air in the opposite direction to the fans air flow. Hold the nozzle approximately 6 mm (0.25 inch) away from the radiator fins. Slowly move the air nozzle in a direction that is parallel with the radiator tube assembly. The pressurized air will remove debris that is between the tubes. Pressurized water may also be used for cleaning. The maximum water pressure for cleaning purposes must be less than 275 kPa (40 psi). Use pressurized water in order to soften mud. Clean the core from both sides. Illustration 70 g03373217 Typical example The oxygen sensor (1) must be replaced at 3000 hours. Refer to the Disassembly and Assembly, “Oxygen Sensor - Remove and Install” for the procedure. The electronic service tool will be required in order to perform a reset after a new oxygen sensor is installed. i04245214 Radiator - Clean The radiator is not usually supplied by Perkins . The following text describes a typical cleaning procedure for the radiator. Refer to the OEM information for further information on cleaning the radiator. Note: Some application will require a fuel cooler to be installed. The fuel cooler is a type of radiator that uses air to cool the fuel and the fuel cooler will require cleaning. Note: Adjust the frequency of cleaning according to the effects of the operating environment. Inspect the radiator for these items: Damaged fins, corrosion, dirt, grease, insects, leaves, oil and other debris. Clean the radiator, if necessary. Use a degreaser and steam for removal of oil and grease. Clean both sides of the core. Wash the core with detergent and hot water. Thoroughly rinse the core with clean water. If the radiator is blocked internally, refer to the OEM Manual for information regarding flushing the cooling system. After cleaning the radiator, start the engine. Allow the engine to operate at low idle speed for 3 to 5 minutes. Accelerate the engine to high idle. The high idle speed will help in the removal of debris and the drying of the core. Slowly reduce the engine speed to low idle and then stop the engine. Use a light bulb behind the core in order to inspect the core for cleanliness. Repeat the cleaning, if necessary. Inspect the fins for damage. Bent fins may be opened with a “comb”. Inspect these items for good condition: Welds, mounting brackets, air lines, connections, clamps and seals. Make repairs, if necessary. SEBU8726 109 Maintenance Recommendations Radiator Pressure Cap - Clean/Replace i03639888 Radiator Pressure Cap - Clean/ Replace Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure. NOTICE When any servicing or repair of the engine cooling system is performed the procedure must be performed with the engine on level ground. This will allow you to accurately check the coolant level. This will also help in avoiding the risk of introducing an air lock into the coolant system. 1. Stop the engine and allow the engine to cool. Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the radiator pressure cap. 2. Check coolant level. Refer to Operation and Maintenance Manual, “Cooling System Coolant Level - Check”. i04407666 Turbocharger - Inspect Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool. NOTICE Turbocharger bearing failures can cause large quantities of oil to enter the air intake and exhaust systems. Loss of engine lubricant can result in serious engine damage. Minor leakage of oil into a turbocharger under extended low idle operation should not cause problems as long as a turbocharger bearing failure has not occurred. When a turbocharger bearing failure is accompanied by a significant engine performance loss (exhaust smoke or engine rpm up at no load), do not continue engine operation until the turbocharger is renewed. A visual inspection of the turbocharger can minimize unscheduled downtime. A visual inspection of the turbocharger can also reduce the chance for potential damage to other engine parts. Do not inspect the engine with the engine in operation. 3. Install new radiator pressure cap. i02177969 Starting Motor - Inspect Perkins recommends a scheduled inspection of the starting motor. If the starting motor fails, the engine may not start in an emergency situation. Check the starting motor for correct operation. Check the electrical connections and clean the electrical connections. Refer to the Systems Operation, Testing and Adjusting Manual, “Electric Starting System Test” for more information on the checking procedure and for specifications or consult your Perkins dealer or your Perkins distributor for assistance. Illustration 71 Typical example g02603804 110 Maintenance Recommendations Walk-Around Inspection SEBU8726 1. Ensure that the turbocharger is clean and free from dirt before removing components for inspection. 2. Remove the air intake pipe (1). Visually inspect the piping for the presence of oil. A small amount oil will be expected, this oil is due to the breather system design. Clean the interior of the pipe in order to prevent dirt from entering during reassembly. 3. Check for obvious heat discoloration of the turbocharger. Check for any loose bolts or any missing bolts. Check for damage to the oil supply line (3) and the oil drain line (2). Check for cracks in the housing of the turbocharger. Ensure that the compressor wheel can rotate freely. Check that there are no visual signs of damage to the compressor wheel. 4. Check for the presence of oil. If oil is leaking from the back side of the compressor wheel, there is a possibility of a failed turbocharger oil seal. The presence of oil may be the result of extended engine operation at low idle. The presence of oil may also be the result of a restriction of the line for the intake air (clogged air filters). A restriction can cause the turbocharger to slobber. 5. Install the air intake pipe to the turbocharger housing. Ensure that all clamps are installed correctly and that all clamps are tightened securely. For more information, refer to Systems Operation, Testing, and Adjusting, “Turbocharger Inspect”. i04367583 Walk-Around Inspection Inspect the Engine for Leaks and for Loose Connections A walk-around inspection should only take a few minutes. When the time is taken to perform these checks, costly repairs and accidents can be avoided. For maximum engine service life, make a thorough inspection of the engine compartment before starting the engine. Look for items such as oil leaks or coolant leaks, loose bolts, worn belts, loose connections, and trash buildup. Make repairs, as needed: • The guards must be in the correct place. Repair damaged guards or replace missing guards. • Wipe all caps and plugs before the engine is serviced in order to reduce the chance of system contamination. NOTICE For any type of leak (coolant, lube, or fuel) clean up the fluid. If leaking is observed, find the source and correct the leak. If leaking is suspected, check the fluid levels more often than recommended until the leak is found or fixed, or until the suspicion of a leak is proved to be unwarranted. NOTICE Accumulated grease and/or oil on an engine is a fire hazard. Remove the accumulated grease and oil. Refer to this Operation and Maintenance Manual, “Engine - Clean” for more information. • Ensure that the cooling system hoses are correctly clamped and that the cooling system hoses are tight. Check for leaks. Check the condition of all pipes. • Inspect the water pump for coolant leaks. Note: The water pump seal is lubricated by the coolant in the cooling system. It is normal for a small amount of leakage to occur as the engine cools down and the parts contract. Excessive coolant leakage may indicate the need to replace the water pump. Remove the water pump. Refer to Disassembly and Assembly, “Water Pump Remove and Install”. For more information, consult your Perkins dealer or your Perkins distributor. • Inspect the lubrication system for leaks at the front crankshaft seal, the rear crankshaft seal, the oil pan, the oil filters, and the rocker cover. • Inspect the piping for the air intake system and the elbows for cracks and for loose clamps. Ensure that hoses and tubes are not contacting other hoses, tubes, wiring harnesses, etc. • Ensure that the areas around the rotating parts are clear. • Inspect the alternator belts and any accessory drive belts for cracks, breaks, or other damage. • Inspect the wiring harness for damage. Belts for multiple groove pulleys must be replaced as matched sets. If only one belt is replaced, the belt will carry more load than the belts that are not replaced. The older belts are stretched. The additional load on the new belt could cause the belt to break. SEBU8726 111 Maintenance Recommendations Water Pump - Inspect High Pressure Fuel Lines i04406817 Water Pump - Inspect Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death. After the engine has stopped, you must wait for 10 minutes in order to allow the fuel pressure to be purged from the high-pressure fuel lines before any service or repair is performed on the engine fuel lines. If necessary, perform minor adjustments. Repair any leaks from the low-pressure fuel system and from the cooling, lubrication, or air systems. Replace any highpressure fuel line that has leaked. Refer to Disassembly and Assembly Manual, “Fuel Injection Lines - Install”. A failed water pump may cause severe engine overheating problems that could result in the following conditions: • Cracks in the cylinder head • A piston seizure • Other potential damage to the engine If you inspect the engine in operation, always use the proper inspection procedure in order to avoid a fluid penetration hazard. Refer to Operation and Maintenance Manual, “General hazard Information”. Visually inspect the high-pressure fuel lines for damage or signs of fuel leakage. Replace any damaged high-pressure fuel lines or high-pressure fuel lines that have leaked. Ensure that all clips on the high-pressure fuel lines are in place and that the clips are not loose. • Inspect the rest of the fuel system for leaks. Look for loose fuel line clamps. • Drain the water and the sediment from the fuel tank on a daily basis in order to ensure that only clean fuel enters the fuel system. Illustration 72 • Inspect the wiring and the wiring harnesses for loose connections and for worn wires or frayed wires. Check for any loose tie-wraps or missing tiewraps. Note: The water pump seals are lubricated by the coolant in the cooling system. • Inspect the ground strap for a good connection and for good condition. Note: If engine coolant enters the engine lubricating system, the lubricating oil and the engine oil filter must be replaced. Draining will remove any contaminate and will prevent any irregular oil samples. • Disconnect any battery chargers that are not protected against the current drain of the starting motor. Check the condition and the electrolyte level of the batteries, unless the engine is equipped with a maintenance free battery. • Check the condition of the gauges. Replace any gauges that are cracked. Replace any gauge that cannot be calibrated. g02601196 Typical example (1) Weep hole Visually inspect the water pump for leaks. In order to install a new water pump, refer to the Disassembly and Assembly Manual, “Water Pump Remove and Install”. 112 SEBU8726 Warranty Section Emissions Warranty Information Warranty Section Warranty Information i05328140 Emissions Warranty Information • EPA Protection Agency • CARB United States Environmental California Air Resources Board Note: The warranty of the engine applies to engines that are operated within the areas of the world where the following regulations apply: US EPA Tier 4 Interim, EU Stage IIIB or Japanese MLIT Step 4. If an engine is operated in regions of the world where these regulations do not apply the warranty will be void. Contact your Perkins dealer or your Perkins distributor for more information. For a full warranty statement contact your Perkins dealer or your Perkins distributor. For customers that have a valid user name and password, for perkins.com. Login then go to TIPSS, and the warranty information can be accessed. Maintenance Recommendations Efficiency of the emission control and the engine performance depends on adherence to proper operation and maintenance recommendations and use of recommended fuels and lubricating oils. According to recommendations, major adjustments and repairs should be made by your authorized Perkins distributor or your authorized Perkins dealer. Various chemical fuel additives which claim to reduce visible smoke are available commercially. Although additives have been used to solve some isolated smoke problems in the field, additives are not recommended for general use. The engines should be certified without smoke depressants according to federal smoke regulations. The aftertreatment system can be expected to function properly for the life-time of the engine (emissions durability period) subject to prescribed maintenance requirements being followed. SEBU8726 113 Reference Information Section Engine Protection Plans Reference Information Section www.perkins.com NOTICE Dependant upon engine type and application. Reference Materials i04224089 Engine Protection Plans (Extended Service Contract) Extended Service Contracts-purchased in minutes, protected for years. Extended Service Contracts (ESC) protect you from the stress that unexpected repair work brings to your life by covering the cost of getting your engine up and running again. Unlike other extended warranties, Perkins Platinum ESC protects you against all component part failures. Purchase peace of mind from only £0.03 / $0.05 / euro 0.04 a day and let an ESC make your dreams a reality. Why buy an Extended Service Contract? 1. No surprises - total protection from unexpected repair cost (parts, labor, and travel). 2. Enjoy longer lasting product support from Perkins global network. 3. Genuine Perkins parts ensure continued engine performance. 4. Highly trained technicians carry out all repairs. 5. Transferable coverage should you sell your machine. Flexible coverage provides the right level of protection for your Perkins Engine. Coverage can be extended to 2 years/ 1,000 hours right up to 10 year/ 40,000 You can buy an ESC at any time during standard warranty - even the last day! Each Perkins Distributor has highly trained and experienced Perkins Product Support Service Technicians. The Support Service are equipped, and available around the clock to get your engine running again with the minimum of downtime. Buying an ESC means that you get all this for free. To purchase an Extended Service Contract, is quick and simple! Contact your local Perkins Distributor now and the distributor can provide you with a quote in minutes. You can locate your nearest Perkins Distributor by visiting: 114 SEBU8726 Index Section Index A After Starting Engine........................................ 55 After Stopping Engine...................................... 64 Aftercooler Core - Clean/Test (Air-To-Air Aftercooler) .................................................... 84 Aftercooler Core - Inspect................................ 84 Alarms and Shutoffs ........................................ 32 Alternator - Inspect .......................................... 84 Alternator and Fan Belts - Replace.................. 84 B Battery - Replace............................................. 85 Battery Electrolyte Level - Check .................... 86 Battery or Battery Cable - Disconnect ............. 86 Before Starting Engine ...............................14, 53 Burn Prevention................................................. 9 Batteries....................................................... 10 Coolant......................................................... 10 Induction System ........................................... 9 Oils............................................................... 10 C Cold Weather Operation.................................. 60 Hints for Cold Weather Operation................ 60 Idling the Engine .......................................... 61 Recommendations for Coolant Warm Up .... 61 Recommendations for the Coolant .............. 61 Viscosity of the Engine Lubrication Oil......... 61 Cold Weather Starting ..................................... 53 Configuration Parameters................................ 50 Customer Specified Parameters.................. 50 System Configuration Parameters............... 50 Coolant (Commercial Heavy-Duty) - Change .. 87 Drain ............................................................ 87 Fill................................................................. 88 Flush ............................................................ 87 Coolant (ELC) - Change .................................. 88 Drain ............................................................ 89 Fill................................................................. 90 Flush ............................................................ 89 Coolant Extender (ELC) - Add ......................... 90 Coolant Level - Check ..................................... 91 Engines With a Coolant Recovery Tank....... 91 Engines Without a Coolant Recovery Tank . 91 Cooling System Supplemental Coolant Additive (SCA) - Test/Add .............................. 92 Add the SCA, If Necessary .......................... 92 Test for SCA Concentration ......................... 92 Crushing Prevention and Cutting Prevention .. 12 D Diagnostic Lamp.............................................. 49 Diesel Particulate Filter - Clean ....................... 93 Diesel Particulate Filter Regeneration............. 56 Modes of Regeneration................................ 57 Regeneration ............................................... 56 Regeneration Indicators............................... 56 Regeneration Switch.................................... 57 Regeneration System Warning Indicators ... 57 Driven Equipment - Check............................... 93 E Electrical System ............................................. 14 Grounding Practices .................................... 15 Emergency Stopping ....................................... 64 Emissions Certification Film ............................ 28 Emissions Warranty Information.....................112 Maintenance Recommendations ................112 Engine - Clean ................................................. 93 Aftertreatment .............................................. 94 Engine Air Cleaner Element (Single Element) - Inspect/Clean/Replace................. 94 Engine Air Cleaner Service Indicator Inspect ........................................................... 94 Test the Service Indicator............................. 94 Engine Air Precleaner - Check/Clean.............. 95 Engine Crankcase Breather Element Replace.......................................................... 95 Engine Breather........................................... 95 Engine Diagnostics.......................................... 49 Engine Electronics........................................... 16 Engine Mounts - Inspect.................................. 96 Engine Oil and Filter - Change ........................ 97 Drain the Engine Lubricating Oil .................. 98 Engine Oil Service Reset ............................. 99 Fill the Oil Pan.............................................. 99 Replace the Oil Filter.................................... 98 Engine Oil Level - Check ................................. 96 Engine Oil Sample - Obtain ............................. 97 Obtain the Sample and the Analysis............ 97 SEBU8726 115 Index Section Engine Operation............................................. 56 System Check.............................................. 56 Engine Operation with Active Diagnostic Codes ............................................................ 49 Engine Operation with Intermittent Diagnostic Codes........................................... 49 Engine Protection Plans (Extended Service Contract) .......................................................113 Engine Starting ...........................................14, 53 Engine Stopping .........................................14, 64 F Fan Clearance - Check.................................. 100 Fault Logging................................................... 49 Features and Controls ..................................... 32 Fire Prevention and Explosion Prevention ...... 10 Fire Extinguisher.......................................... 12 Lines, Tubes, and Hoses ............................. 12 Regeneration ............................................... 12 Fluid Recommendations.............................72, 74 ELC Cooling System Maintenance.............. 77 Engine Oil .................................................... 73 General Coolant Information........................ 74 General Lubricant Information ..................... 72 Fluid Recommendations (Fuel Specification).. 66 Diesel Fuel Characteristics ......................... 69 Diesel Fuel Requirements ........................... 66 General Information ..................................... 66 Foreword............................................................ 4 California Proposition 65 Warning ................. 4 Literature Information..................................... 4 Maintenance .................................................. 4 Maintenance Intervals.................................... 4 Operation ....................................................... 4 Overhaul ........................................................ 4 Safety............................................................. 4 Fuel and the Effect from Cold Weather............ 62 Fuel Conservation Practices............................ 59 Fuel Related Components in Cold Weather .... 62 Fuel Filters ................................................... 63 Fuel Heaters ................................................ 63 Fuel Tanks.................................................... 62 Fuel System - Prime ...................................... 101 Fuel System Primary Filter (Water Separator) Element - Replace ..................... 102 Install the Element ..................................... 103 Remove the Element ................................. 102 Fuel System Primary Filter/Water Separator - Drain .......................................................... 104 Fuel System Secondary Filter - Replace ....... 104 Install the Element ..................................... 105 Remove the Element ................................. 104 Fuel Tank Water and Sediment - Drain.......... 106 Drain the Water and the Sediment............. 106 Fuel Storage Tanks .................................... 106 Fuel Tank ................................................... 106 G Gauges and Indicators .................................... 32 Aftertreatment Lamps .................................. 33 Indicator Lamps ........................................... 33 General Hazard Information .............................. 6 Asbestos Information ..................................... 8 Containing Fluid Spillage ............................... 8 Dispose of Waste Properly............................. 9 Fluid Penetration............................................ 8 Pressurized Air and Water ............................. 7 General Information......................................... 17 H High Pressure Fuel Lines ................................ 12 Hoses and Clamps - Inspect/Replace ........... 106 Replace the Hoses and the Clamps .......... 107 I Important Safety Information ............................. 2 L Lifting and Storage........................................... 30 M Maintenance Interval Schedule ....................... 83 Commissioning ............................................ 83 Daily ............................................................. 83 Every 1000 Service Hours ........................... 83 Every 12 000 Service Hours or 6 Years ....... 83 Every 1500 Service Hours ........................... 83 Every 2000 Service Hours ........................... 83 Every 3000 Service Hours ........................... 83 Every 3000 Service Hours or 2 Years .......... 83 Every 4000 Service Hours ........................... 83 Every 50 Service Hours or Monthly ............. 83 Every 50 Service Hours or Weekly .............. 83 Every 500 Service Hours ............................. 83 Every 500 Service Hours or 1 Year.............. 83 116 SEBU8726 Index Section Every 6000 Service Hours or 3 Years .......... 83 Every Week.................................................. 83 When Required............................................ 83 Maintenance Recommendations..................... 80 Maintenance Section ....................................... 66 Model View Illustrations................................... 17 Engine and Aftertreatment........................... 17 Engine View with Through Flow Diesel Particulate Filter ......................................... 22 Engine View with Wall Flow Diesel Particulate Filter ........................................................... 21 Monitoring System........................................... 35 Programmable Options and Systems Operation ................................................... 35 Monitoring System (Table for the Indicator lamps) ............................................................ 33 Mounting and Dismounting.............................. 12 O Operation Section............................................ 30 Overspeed....................................................... 36 Oxygen Sensor - Replace ............................. 108 P Plate Locations and Film Locations (Aftertreatment).............................................. 27 Plate Locations and Film Locations (Aftertreatment).............................................. 28 Through-Flow Diesel Particulate Filter (DPF) ................................................................... 28 Plate Locations and Film Locations (Aftertreatment) Wall Flow Diesel Particulate Filter (DPF) ..... 27 Plate Locations and Film Locations (Engine) .. 25 Serial Number location................................. 25 Product Description ......................................... 22 Aftermarket Products and Perkins Engines ................................................................... 24 Electronic Engine Features.......................... 23 Engine Cooling and Lubrication................... 23 Engine Diagnostics ...................................... 23 Engine Service Life ...................................... 24 Engine Specifications .................................. 22 Product Identification Information.................... 25 Product Information Section ............................ 17 Product Lifting.................................................. 30 Product Storage (Engine and Aftertreatment)............................................... 30 Condition for Storage ................................... 30 R Radiator - Clean............................................. 108 Radiator Pressure Cap - Clean/Replace ....... 109 Reference Information..................................... 29 Record for Reference................................... 29 Reference Information Section .......................113 Reference Materials .......................................113 Refill Capacities............................................... 66 Cooling System............................................ 66 Lubrication System ...................................... 66 S Safety Messages ............................................... 5 Universal Warning.......................................... 5 Safety Section ................................................... 5 Self-Diagnostics............................................... 49 Sensors and Electrical Components ............... 37 Full Engine Views ........................................ 37 Sensors and Electrical Components (Aftertreatment).............................................. 46 Differential Pressure sensor......................... 48 Through Flow Aftertreatment ....................... 48 Wall Flow Aftertreatment.............................. 47 Severe Service Application.............................. 82 Environmental Factors................................. 82 Incorrect Maintenance Procedures.............. 82 Incorrect Operating Procedures................... 82 Starting Motor - Inspect ................................. 109 Starting the Engine .......................................... 54 Starting the Engine ...................................... 54 Starting with Jump Start Cables ...................... 54 Stopping the Engine ........................................ 64 System Pressure Release............................... 80 Coolant System............................................ 80 Engine Oil .................................................... 80 Fuel System ................................................. 80 T Table of Contents............................................... 3 Turbocharger - Inspect .................................. 109 W Walk-Around Inspection .................................110 High Pressure Fuel Lines............................ 111 SEBU8726 117 Index Section Inspect the Engine for Leaks and for Loose Connections ..............................................110 Warranty Information ......................................112 Warranty Section ............................................112 Water Pump - Inspect .....................................111 Welding on Engines with Electronic Controls .. 80 118 Index Section SEBU8726 ©2013 Perkins Engines Company Limited All Rights Reserved