88
Via E. Majorana, 2-4 42027 Montecchio Emilia (RE) ITALY Tel. +39 0522 869611 Fax +39 0522 869744 www.dieci.com - E-mail: [email protected] DP 4200 ATTENTION: ALWAYS KEEP A COPY OF THIS MANUAL ON THE MACHINE AT THE OPERATOR’S DISPOSAL MAINTENANCE MANUAL OPERATION AND AXH1113/UK

AXH1113_UK - Rev0 - Dumper 4200

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Page 1: AXH1113_UK - Rev0 - Dumper 4200

Via E. Majorana, 2-442027 Montecchio Emilia (RE) ITALYTel. +39 0522 869611 Fax +39 0522 869744www.dieci.com - E-mail: [email protected]

DP 4200

ATTENTION: ALWAYS KEEP A COPY OF THIS MANUAL

ON THE MACHINE AT THE OPERATOR’S DISPOSAL

MA

INTE

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AXH

1113

/UK

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EVERY MACHINE COMES WITH A COPY OF THE MANUAL HEREIN, WITH A COPY OF THE USER ANDMAINTENANCE MANUAL OF THE MOTOR WRITTEN BY THE MANUFACTURER OF THE SAME ANDWITH A COPY OF THE USE AND MAINTENANCE MANUAL OF EACH DEVICE OR PIECE OF EQUIP-MENT WITH WHICH THIS MACHINE IS RIGGED-OUT.

THESE MANUALS ARE WRITTEN BY THE RESPECTIVE SUPPLIERS OR THEY ARE REPRODUCEDIN FULL AND EXACTLY BY DIECI FOLLOWING SPECIFIC AUTHORISATION OF THE SUPPLIERS:THEY MAY BE FURTHER COMPLETED WITH OTHER SPECIFICATIONS WRITTEN BY DIECI.

Original title:Operation and Maintenance Manual Dumpers 4200

Dieci-052006MTKeR

IMPORTANT INFORMATION

The whole documentation supplied is integral and essential part of the product and shall be kept in an easily accessibleplace for all users, who shall read everything written in such documents very carefully before starting to use the equipment.

It is forbidden to use the machine or its accessories improperly or unreasonably, just like it is forbidden to makemodifications that may alter the structure or operating performance.

IT IS FORBIDDEN TO REPRODUCE THE CONTENTS OFTHIS MANUAL, NEITHER PARTIALLY NOR TOTALLY: DieciS.r.l. SAFEGUARDS THESE RIGHTS ACCORDING TO LAW.

Dieci S.r.l. is not liable for damages causedthrough the use of non-original spare parts

www.dieci.comVIA L. LANDINI, 19 - 42027

MONTECCHIO E. (RE) - ITALYTEL. ++39 0522-869611FAX ++39 0522-869744

e-mail:[email protected]

UFF. ASSISTENZA E RICAMBI

Tel. ++ 39 0522-86.97.40 - FAX ++ 39 0522-86.97.44

DEPARTAMENTO DE ASISTENCIA Y REPUESTOS

Tel. ++ 39 0522-86.97.40 - FAX ++ 39 0522-86.97.44

BUREAU ASSISTANCE ET PIEDES DE RECHANGE.

Tel. ++ 39 0522-86.97.40 - FAX ++ 39 0522-86.97.44

ASSISTANCE AND SPARE PARTS

Tel. ++ 39 0522-86.97.40 - FAX ++ 39 0522-86.97.44

Cod.AXH1113/UK

ATTENTION: A COPY OF THIS MANUAL SHALL BE ON THE MACHINE TO DISPOSITION OF THE OPERATOR

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Mod. DUMPER 4200

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3

INDEXINDEX ........................................................................................................................................................................... 3

CHAP ”A”INTRODUCTION GUARANTEEINTRODUCTION.........................................................................................................................................................A/3GUARANTEE ............................................................................................................................................................A/4DUMPERS IDENTIFYING ..........................................................................................................................................A/6

CHAP ”B”SAFETY RULESECOLOGY .................................................................................................................................................................B/3ALWAYS WORK IN CONDITIONS OF SAFETY........................................................................................................B/4WORK IN CONDITIONS OF SAFETY .......................................................................................................................B/5

CHAP ”C”USER INSTRUCTIONS GETTING TO KNOW YOUR VEHICLESAFETY REGULATIONS DURING USE ....................................................................................................................C/3PRELIMINARY CHECKS ...........................................................................................................................................C/4KNOWING YOUR VEHICLE ......................................................................................................................................C/5SEAT .........................................................................................................................................................................C/5SEAT-BELTS .............................................................................................................................................................C/6INTERIOR OF THE CAB ............................................................................................................................................C/7USING THE PUSH BUTTONS AND SWITCHES (USE) ...............................................................................................C/8CONTROL LEVER FOR REVERSING (USE) ............................................................................................................C/9CHANGING GEAR (USE) ..........................................................................................................................................C/9STARTING THE VEHICLE ....................................................................................................................................... C/10PEDALS AND LEVERS (USE) ................................................................................................................................ C/11TURNING THE DRIVER’S SEAT AROUND .............................................................................................................. C/11

CHAP ”D”MAINTENANCE AND ADJUSTMENTSSCHEDULE FOR MAINTENANCE AND ADJUSTMENTS ..........................................................................................D/3OIL COMPARISON TABLE ........................................................................................................................................D/4MANUTENZIONE E REGISTRAZIONE ..................................................................................................................D/5ENGINE .....................................................................................................................................................................D/6CONTROL (INCHING) OF HYDROSTATIC ENGINE ...................................................................................................D/8BRAKES ...................................................................................................................................................................D/8TRANSMISSIONI AND HYDRAULIC OIL ................................................................................................................. D/10FILTERS FOR HYDRAULIC AND HYDROSTATIC CIRCUIT OIL ............................................................................... D/11GEARBOX AND DIFFERENTIAL AXLES ................................................................................................................. D/12TYRES .................................................................................................................................................................... D/13BATTERY ................................................................................................................................................................ D/14SWIVELLING DRIVER’S SEAT ............................................................................................................................... D/15SAFETY STICKERS ................................................................................................................................................ D/16STORING THE VEHICLE ......................................................................................................................................... D/17USING AND STORING FUEL .................................................................................................................................. D/18CLEANING AND STORING DIESEL FUEL .............................................................................................................. D/19PRELOAD AND TORQUE TABLE FOR CLASS 1 NUTS AND BOLTS..................................................................... D/20PRELOAD AND TORQUE TABLE FOR CLASS 2 NUTS AND BOLTS..................................................................... D/21TORQUE TABLE FOR HYDRAULIC FITTINGS .................................................................................. D/22TROUBLE SHOOTING............................................................................................................................................. D/23

CHAP ”E”ELECTRIC CIRCUIT DIAGRAMS

CHAP ”F”HYDRAULIC CIRCUITS

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INTRODUCTIONGUARANTEE

VEHICLE IDENTIFICATION

A

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Mod. DUMPER 4200 Introduction - Guarantee

Identifying your vehicle

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DUMPERS -

ATTENTION and WARNING

These words and symbols are used throughout thismanual and on stickers to indicate operations that mayendanger parts of the vehicle (WARNING) or the safety ofthe operator (ATTENTION). Always read the instructionsvery carefully when you find:

ATTENTION or WARNING alongside this symbol

NOTE:the left and right sides of the vehicle as referred to in thismanual are to be considered looking at the truck from theback towards the front, or from the position of the operatorin the driver's seat.

INTRODUCTION

The purpose of this manual:

is to provide the owner and operator with instructions forefficient and safe use and maintenance of the dumper.

Following these instructions carefully, will allow you to obtainfull efficiency and a long working life from your vehicle, andwill help to make your work considerably easier.

Furthermore this manual is supplied to you directly by thedealer upon delivery of the vehicle, in order to make surethat you understand all the instructions correctly.However, should you have trouble understanding any partof this manual, do not hesitate to contact your nearestdealer for clarification, as it is of utmost importance thatthe operation and maintenance guide l ines be fullyunderstood and carefully observed. Routine maintenanceshould be carried out regularly, keeping a record of thevehicle's working hours.

When spare parts are required, it is essential that only ge-nuine spare parts be used. These can be supplied byyour local dealer who can also provide advice andinstructions for installing and using them. The use ofnon-genuine spare parts may cause damage to otherparts of the vehicle. We, therefore, advise our customersto purchase any spare parts required only from anauthorised agent or dealer.

Should the vehicle be destined for use in particularly se-vere conditions, (for example : very dusty places or sites,clay or very muddy ground), we advise consulting yournearest dealer for specific instructions. Failure to observethese instructions may result in the annulment of thevehicle's guarantee.

NOTE:This manual has been published for worldwide distributionand the availability of certain equipment referred to from timeto time as being essential or available on request may varyaccording to the geographical territory in which the vehicle isbeing used. You can obtain all necessary details about theequipment available in your area from your nearestdistributor or dealer.

NOTE:Due to manufacturing demands, machines from the standardproduction range may have certain details which differ fromthose mentioned in this manual. The company reserves theright to make such modifications without giving notice.

WARNING:in some of the illustrations, panels or guards have beenremoved in order to obtain a clearer illustration.Never use the vehicle without these panels or guards.

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Mod. DUMPER 4200 Introduction - Guarantee

Identifying your vehicle

GUARANTEE:EXTENT

Guarantee in countries with assistance centres

- The guarantee covers the replacement or repair offaults which have been proven defective in terms ofmaterial, manufacture or assembly.

- DIECI reserves the sole right to judge whether torepair or to replace defective parts.

- DIECI shall respond to claims using the means andmethods it deems most appropriate.

DIECI shall be responsible for:- Materials used.- Labour.- Travelling and accommodation expenses.

The customer shall be responsible for:- Packing and shipping costs for spare parts- Any other possible expenses not listed under those for

which DIECI is liable.

Guarantee in countries with no assistance centres

- This consists exclusively of free supply, ex works fromDIECI's plant, of replacements for parts proved to be offaulty material, faulty manufacture and/or assembly.

Examining replaced faulty parts

- DIECI, before acknowledging the guarantee, may askfor any faulty parts replaced during repairs, to bereturned with shipping costs to their charge.

Additional guarantee for repairs and replacement parts

- Any repairs done under or out of the guarantee, andspare parts replaced during repairs, are guaranteedfor 3 months from the date of repair or installation, ifthe original guarantee has expired.

GUARANTEE:DURATION, VALIDITY AND TAKING EFFECT

Guarantee: duration

The firm DIECI s.r.l. (hereinafter referred to as DIECI),guarantees its products for 12 months from delivery dateto the end customer, but not exceeding 18 months fromthe date the vehicle left the manufacturer's plant (in salesto distributors or dealers).

Guarantee: validity

The guarantee is valid from the beginning date on the"certificate of guarantee". When delivery is handled by thedistributor or dealer, DIECI reserves the right to verify thatthe beginning date on the guarantee corresponds to theshipping or delivery date on the transport document forthe product being guaranteed, and/or to the invoice dateand may ask to see the original copies of thesedocuments.

Guarantee: taking effect

The "certificate of guarantee" must be filled in completelyupon delivery of the product, directly by DIECI or byauthorized distributors or dealers. The guarantee goesinto effect automatically if the "certificate of guarantee" isfilled in by DIECI. If the dealer or distributor fills in the cer-tificate, sending a copy to DIECI, also by fax or by e-mail,the guarantee will go into effect within 8 days from thedate the product was delivered.

GUARANTEE

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GUARANTEE:REQUEST FOR REPAIR UNDER GUARANTEE

Guarantee: reporting a fault or faulty part

- The report must be made by the end user, or dealer,or distributor or by an authorised repair shop andmust be sent directly to DIECI's customer assistanceoffice, within no more than 8 days of the occurrence ofthe malfunction. The report must include a cleardescription of the malfunction and precise referencesto the vehicle (type, model and serial number).This information can be found on the vehicle in thepositions indicated in the OPERATION ANDMAINTENANCE MANUAL.

Obligation to immobilise the vehicle

- If there is a risk that the malfunction may jeopardisesafety and accident prevention or may cause furtherdamage, it is obligatory not to use the vehicle until ithas been repaired and tested.

Guarantee: excluded from the guarantee

The following conditions and parts are excluded from theguarantee:

- Components subject to wear or deterioration due toprolonged use: clutch, belts, brake pads, shoes,rollers, oils and fluids, filters, etc.

- Electrical circuits and components.- Damage caused by: cl imatic factors, natural

disasters, acts of vandalism, etc.- Any other malfunction not due to an ascertained original

fault or which does not come under DIECI's liability.

The following parts are also excluded from this guarantee andare covered by the guarantee of the relevant manufacturers:

- Diesel engines- Axles and reduction gears- Pumps and hydraulic engines- Tyres.

DIECI shall handle the application of the guarantee forthese parts.

CAUSES FOR:NON- EFFECT, NON-ACKNOWLEDGEMENT, TERMINATIONOF THE GUARANTEE

Guarantee: non-effect

The guarantee does not come into effect:

- If a copy of the "certificate of guarantee" has not beensent to DIECI, or if it has been sent late, or has notbeen filled in completely, or has not been filled in bythe proper authority.

Guarantee: non-acknowledgement

The guarantee is not acknowledged:

- If the malfunction is not reported following the prescribedmethod and within the established time limit.

- If DIECI's request for the return of any faulty partsreplaced during repairs is not complied with.

- If the obligation to immobil ise the vehicle is notcomplied with, the guarantee is not acknowledged forany damage caused by noncompliance.

Guarantee: termination

The guarantee is terminated:

- If the buyer does not fulf i l payment obligationsaccording to contract.

- If damage has been caused by carelessness,negligence, or by use that does not comply with thespecifications given in the operation and maintenancehandbook (incorrect manoeuvres, overloading, use ofincorrect fuel, poor maintenance, failure to usewarning instruments etc.)

- If the malfunction has been caused by applications,attachments, modifications or repair work notauthorised by DIECI or carried out using faulty spareparts.(For this reason, we recommend always usinggenuine spare parts).

* For "recommended periodic maintenance" refer to theOPERATION AND MAINTENANCE MANUAL.

Final terms

- In case of non-effect, non-acknowledgement andtermination of the guarantee, the buyer shall in nocircumstance be granted annulment of the contract,payment of damages, or an extension of the guarantee.

- Any conditions subject to guarantee other than thoselisted above must be agreed upon in writ ing andsigned by both parties.

Each time the machine is modified, it

must verified again to check its compliance

with Machine Directive EC/98/37.

In case of dispute, the Court of Reggio Emilia - ITALY,shall be recognised as the ult imate authority.

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Mod. DUMPER 4200 Introduction - Guarantee

Identifying your vehicle

DUMPERS

LIABILITY

- The vehicles are manufactured in compliance with EEC regulations in force when the vehicle was made available for purchase.

- Failure to observe the user and safety regulations or the use of the machine in less than perfect working conditionmay cause an accident punishable by law.

- The manufacturer is not liable for any injury to persons, or damage to things or animals caused by improper use ofthis vehicle or by any unauthorised structural modification, application or transformation.

- The manufacturer reserves the right to carry out any possible modifications to the vehicle for technical or commercialreasons without notice.

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Chassis type and serial number

Engine serial number

Essential data

DUMPERS IDENTIFYING

The vehicle can be identified by the serial number punchmarked on the front part of the chassis and inside thecab. In addition to this, the engine has its own serialnumber punch marked on the engine block itself.

To ensure prompt and efficient service when orderingspare parts or when requesting information or technicalexplanations, always give the engine and chassis serialnumber.

Chassis serial number .............................................................

Engine serial number ...............................................................

Cab serial number ....................................................................

Type of vehicle ............................................................................

Owner/ Operator .........................................................................

Dealer's or agent's address ....................................................

.......................................................................................................

Delivery date ...............................................................................

Guarantee expiry date ...............................................................

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Mod. DUMPER 4200 Introduction - Guarantee

Identifying your vehicle

IDENTIFYING VEHICLE PARTS

VEHICLE: LOCATION OF MAIN PARTS - LIST OF PART NAMES

1) CAB

2) TIPPING DUMPER

3) FUEL TANK

4) ENGINE BAY

LEFT SIDE

RIGHT SIDE

74

6

5

1

3

2

8 8

8

5) CHASSIS PUNCHING

6) FRONT LIGHTS

7) REAR LIGHTS

8) ANCHORING POINTS

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SAFETY RULES

B

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Safety RulesMod. DUMPER 4200

- ATTENTION

RECOGNISING THE SAFETY RULES

This is the WARNING SYMBOL FOR A POTENTIAL HAZARD

Wherever this symbol " " appears, on the vehicle or in this manual, you must take due care against injury hazard.Take all recommended precautions and observe regulations for use and maintenance in conditions of safety

UNDERSTANDING WARNING NOTICES

Some terms are used in this manual to point out various levels of danger, such as:

- DANGER

- ATTENTION

- WARNING

The above words are always accompanied by the potential hazard warning symbol.

ATTENTION - WARNING- DANGER: indicate a situation of imminent danger which, if not averted, may cause damage.

IMPORTANT: indicates a situation of imminent danger which, if not averted, may cause damage to the vehicle.

NOTE: indicates additional explanations for pieces of information.

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ECOLOGY

IMPORTANT ECOLOGICAL CONSIDERATIONS

A few helpful recommendations are listed here below.

Find out about current legislation in force in yourcountry.

Ask all suppliers of lubricating oils, fuels, antifreezeproducts, detergents, etc. for information on the effects ofthese products on people and on the environment andconcerning the regulations to be observed when using,stocking and disposing of them.

A FEW SUGGESTIONS

1. Do not refill the tanks using unsuitable jerrycans orpressurised combustible fuelling systems as they maycause leaks and loss of significant amounts of liquid.

2. In general, make sure your skin does not come intocontact with combustible l iquids, lubricating oils,acids, solvents, etc. The majority of these types ofproducts contain substances which are particularlyharmful to our health.

3. Modern lubricating oils contain additives. Do not burncontaminated combustible oils and/or oils used forconventional heating systems.

4. Take care not to spil l used engine cooling fluids,engine and transmission lubricating oils, hydraulic oil,brake oil etc. while pouring or draining them. Keep ina safe place until they are disposed of in compliancewith legal standards or according to local provisions.

5. Modern antifreeze liquids and their solutions, such as,for example, antifreeze and other additives, should bereplaced every two years. Make sure such liquids donot soak into the soil, they should be collected anddisposed of in the appropriate fashion.

6. Do not intervene directly on the air conditioning systems( optional ), by opening them. These systems containgas which should not be released into the atmosphere.Contact your dealer or an expert who has the necessaryspecial equipment at their disposal and who would, inany case, have to refill the system.

7. Immediately repair any leak or fault in the cooling orengine hydraulic systems.

8. Do not increase the pressure in a pressurisedsystem, this may cause the components to explode.

OBLIGATIONS

Waste material should not be scattered in theenvironment but should be disposed of in the appropriatefashion. Used lubricants, batteries, rags dirty with grease,brake pads etc. should be handed over to specialisedcompanies authorised to dispose of polluting waste.

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Safety RulesMod. DUMPER 4200

ALWAYS WORK IN CONDITIONS OF SAFETY

This warning symbol means there areimportant messages concerning your safety.

Read the safety regulations given and take all therecommended precautions in order to avoid potentialrisks and safeguard your own health and safety.

In this handbook you will finds this symbol combined withthe following key words:

ATTENTION - This is used for warnings of potentialdamage to the vehicle which could also involve theoperator's safety.

DANGER - This is used for warnings of potential dangerto the operator's safety or to the safety of other peopledirectly involved.

Failure to follow any instructions preceded by one of the keywords mentioned above (ATTENTION and DANGER) maycause serious injury or even death to the people involved.

In addition, this handbook also contains certain instructionsin italics, preceded by the words NOTE and WARNING,which mean the follow for the protection of the vehicle:

NOTE - This emphasizes to the operator the correcttechnique or procedure to be followed.

WARNING - This informs the operator of the risk of damageto the vehicle if the correct procedure is not respected.

IMPORTANT WARNINGS

This is a self-propelled wheel-mounted machine withdriver’s cab designed for use on asphalted or naturalroads but also on rough terrain.

The machine consists of a main supporting structure.

If this vehicle is put to any other use, it will beconsidered in contrast to the use for which it wasintended by DIECI who, consequently, cannot beconsidered responsible for any damage to things or tothe vehicle itself or for any injury to persons whichmight arise from such use.

The instructions for use, maintenance and repair as givenin this handbook must absolutely be followed in order toconsider that the vehicle has been put to the use forwhich it was intended by the manufacturer.

This machine must be used, assisted or repaired only bypersons preliminarily instructed on the vehicle and on thesafety regulations, in addition to being authorised to usethe vehicle itself.

The user must always observe the general safetyregulations and instructions for accident prevention, inaddition to traffic regulations if the vehicle is used onpublic roads.

Any arbitrary modification to the vehicle will relieve DIECIfrom all responsibility for any consequent damage orinjury which might derive from such modification.

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WORK IN CONDITIONS OF SAFETY

GENERAL WARNINGS

A USE OF THE MACHINE DIFFERENT FROM THATDESCRIBED IN THIS BOOKLET IS STRICTLY FORBIDDEN.

ATTENTION DANGER

THE MACHINE IN QUESTION IS NOT PREPARED FOR USEIN AN ENVIRONMENT OR SITES EXPOSED TO APOSSIBLE PRESENCE OF EXPLOSIVE GAS; THEREFOREIT MUST NOT BE USED IN SUCH PLACES.

To work in such an environment, it is necessary to ask theconstructor to apply the necessary modifications to the machine.

All the functions and procedures, relevant to the useand fitting out of the machine which are not mentionedin this manual are severely forbidden.

All the procedures and operational maintenance whichare not described in this manual are strictly forbidden, butmust be carried out by an authorized workshop.

- WARNING!:

DO NOT USE THE MACHINE IF YOU ARE UNDER THE EFFECTOF ALCOHOL, DRUGS OR EVEN IF YOU HAVE TAKENCERTAIN MEDICINES THAT MAY MAKE YOU DROWSYOR THAT MAY ALTER YOUR PROMPT REACTIONS.

Everything has been done to make your job safer inconstructing this machine. However, caution cannotbe substituted and there is no better way of preventingaccidents.

Read this handbook carefully before starting up yourvehicle, before using it, before carrying outmaintenance work, before refuelling or before carryingout any other jobs on your vehicle.

Time dedicated to reading this manual will provide anadequate knowledge of your vehicle, and will proveuseful and save you time and effort. Furthermore, itwill help you avoid any accidents.

Read all the safety details applied to the machine andobserve the written instructions before starting it up,setting it in motion, refuelling it or carrying out anymaintenance on it. Substitute any damaged, mislaidor illegible ones straightaway. Clean them when theyare covered in mud, cement or debris.

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Safety RulesMod. DUMPER 4200

(fig.1/B)

(fig.2/B)

FOLLOWING SAFETY REGULATIONS

Carefully observe and follow all safety warnings on thevehicle and read all safety warnings in this manual.

Safety warnings must be installed, kept up andreplaced whenever necessary.

If a safety warning or this manual should be damagedor missing, a replacement should be ordered fromyour DIECI dealer, just as you would order a sparepart (make sure you give the model and serial numberof your vehicle when placing the order).

Learn to use your machine and its controls correctlyand safely.

Only trained, qualif ied and authorised personnelshould be allowed to use this vehicle.

Make sure the vehicle is kept in suitable workingcondition.

Unauthorised modifications may endanger theoperation and/or safety of your vehicle and mayshorten its life.

The safety warnings listed in this chapter SAFETYREGULATIONS are given to illustrate basic safetyprocedures for your vehicle. If you are in any doubt,contact the person directly responsible for the vehiclebefore going ahead and using the vehicle or carryingout any maintenance work.

PREPARING FOR EMERGENCIES

You must be prepared in case there should be a fireor an accident.

Keep your first aid kit and fire extinguisher close tohand.

Carefully read the instructions stuck on theextinguisher itself to be able to use it properly.

Decide on your drill and priorities to be applied in caseof fire or an accident

Keep all emergency telephone numbers for doctors,the ambulance, the hospital and the fire brigadeclearly visible and near the telephone.

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(fig.3/B)

(fig.4/B)

(fig.5/B)

PROTECTIVE CLOTHING

Wear close fitting garments and accident preventionequipment suitable for work.

In certain cases, when working in particularly difficultconditions, it is necessary to wear special clothing orequipment.

The following must be available:

Protective helmet;

Protective shoes;

Protective goggles or protective face mask;

Protective gloves;

Protective headwear against noise;

Reflecting clothing;

Waterproof clothing;

Breathing apparatus or filtering mask;

Make sure all clothing and protective equipment is worncorrectly while working.

Do not wear loose clothing, chains, belts or otheraccessories which might get caught up in the controllever or in other parts of the vehicle.

To use the vehicle safely, the driver must give it his/herfull attention. Headphones to listen to the radio or tomusic, should not be worn while using the vehicle.

PROTECTING YOURSELF AGAINST NOISE

Prolonged exposure to loud noise can damage yourhearing or may cause loss of hearing.

Always protect your hearing by wearing antinoiseheadphones or earplugs to protect yourself fromexcessive and tiresome noises.

INSPECTING THE MACHINE

Inspect your vehicle carefully every day or every shift,examining it carefully before resuming work with it.

When inspecting the outside of the vehicle, make sureyou follow all the instructions listed under the chapterMAINTENANCE.

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Safety RulesMod. DUMPER 4200

(fig.6/B)

(fig.7/B)

(fig.8/B)

USING HANDLES AND STEPS

Falling is one of the major causes of personal injury.

Always face the vehicle when getting in or out, keepinga tight hold of the vehicle on the steps and handles.

Never use the controls as handles.

Never jump down from the vehicle. Never get on or offa moving vehicle.

Always keep footboards, steps and handles clean andmake sure they are not slippery.

ADJUSTING THE DRIVER'S SEAT

A badly adjusted seat can cause the driver to tirequickly and may thus lead to operations being carriedout incorrectly.

The seat should be adjusted according to the heightand weight of the driver.

The driver should be able to press the pedals rightdown and to operate correctly all control levers whilekeeping his/her back leaning well up against the backof the seat.

If this is not so, move the seat forward or backward,and check once again.

USING THE SEAT-BELT

The vehicle is equipped with a cab able to support theweight of the vehicle itself should it tip over (ROPS), itis, therefore, essential that the driver remains firmlyfastened in the seat thanks to the seat-belt to preventhim/her from falling out and possibly getting crushed.

Before starting up the vehicle, carefully check the belt,the buckle and that it is properly fixed to the structure. Ifthere should be any sign of damage or wear and tear,replace the seat-belt or the necessary part beforeusing the vehicle.

Always remain seated with the seat-belt correctlyfastened whenever using the vehicle in order to redu-ce the risk of injury in case of an accident.

Should there be any accident of any significance withthe vehicle, the seat-belts should be replaced, even ifthere is no apparent damage.

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B/9

(fig.11/B)

(fig.12/B)

(fig.10/B)

(fig.9/B)

MANOEUVRING AND USING THE VEHICLEIN SAFETY

Before starting the vehicle, make sure you know whereother people are positioned.

While the vehicle is operating or running, always keeplight signals on. These serve to warn people that thevehicle is about to move.

When working in a congested area, always havesomeone else to give the necessary signals.

OPERATE THE MACHINE FROM THE DRIVER'SSEAT ONLY

The vehicle could move suddenly if started up withoutfollowing the correct procedure, thus creating the riskof personal injury.

Start the engine only from the driver's seat.

NEVER start the engine by short circuiting between theterminals on the starting motor.

Before starting the engine, make sure all controllevers are in a neutral position.

STARTING UP USING AUXILIARY BATTERIES

Gas from the battery may explode, causing seriousdamage.

If the engine has to be started up using an auxiliarybattery, make sure that the instructions given in thechapter USER INSTRUCTIONS are strictly adhered to.

The operator must be in the driver's seat when startingthe engine in order to ensure the vehicle is undercontrol. Two people are required to start the enginefrom an auxiliary battery.

Do not use batteries which have been exposed to cold.

An error in the starting procedure when using anauxiliary battery may cause the battery to explode orthe vehicle to move suddenly.

DO NOT CARRY PASSENGERS ON YOUR VEHICLE

The operator should be the only person on board thevehicle. Passengers are not allowed.

Passengers may obstruct the operator's view, causingthe vehicle to be used in conditions which are NOT safe.

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(fig.16/B)

(fig.15/B)

(fig.13/B)

PROTECTION AGAINST FALLING OBJECTS

The vehicle is equipped with a cab suitable forprotection from objects falling from above (FOPS).

If there is any risk of objects falling from above, ahelmet should be worn.

SIGNALLING WHEN MORE THAN ONE VEHICLEIS BEING USED

When more than one vehicle is required for a particularjob, use signals normally familiar to all those present.Designate one person to signal and coordinate the workzone. Make sure that everyone follows directions given bythe person in charge of signalling.

DRIVING THE VEHICLE SAFELY

ATTENTION:

Manouevres on tilted surfaces maycause the vehicleto slide or tip over with consequent serious harm tothe driver or other persons.

Moving on tilted surfaces maycause the vehicle toslide or tip over. The necessary precautions shouldtherefore be taken.

INSPECTING THE WORK ZONE BEFORESTARTING OPERATIONS

There is the risk of the vehicle overturning, when workingalongside excavations or on the edge of the road.

Inspect the structure and condition of the terrain in thework zone before starting to operate.

Keep the vehicle well away from the edges ofexcavations and of the road.

When working on a slope or at the edge of a road,have someone to give the necessary signals.

Extra care should be taken, when working on icyterrain. If the temperature should go up, the terraincould melt and become slippery.

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(fig.19/B)

ATTENTION

(fig.17/B)

(fig.18/B)

MAKE SURE THERE IS NO ONE AT RISK WHILEREVERSING THE VEHICLE

Proceed as follows to ensure accidents are avoidedwhile reversing the vehicle or rotating:

Check the space around the vehicle.

MAKE SURE THERE IS NO ONE WITHIN STRIKINGDISTANCE .

MAKE SURE THERE IS NO ONE IN THE WORK ZONE.USE THE AUDIBLE ALARM OR OTHER SIGNALS TOWARN PERSONS PRESENT BEFORE STARTING THEVEHICLE.

- USE SOMEONE ON THE GROUND TO SUPERVISEREVERSING IF THE OPERATOR'S FIELD OF VISION ISOBSTRUCTED.

- ALWAYS MAKE SURE THE PERSON ON THE GROUNDREMAINS WITHIN SIGHT.

Use hand signals, compliant with local regulations,when work conditions are such that someone isneeded for signalling.

Keep windows, mirrors and lights clean and in goodcondition.

Dust, rain, fog, etc., may reduce visibility. If visibility isreduced, reduce speed accordingly and useappropriate lighting.

The vehicles are equipped with l ighting only fortransportation. If the vehicle is to be used at night,suitable external lighting should be arranged.

PROTECTING YOURSELF FROM FLYINGFRAGMENTS

In certain conditions, fragments of material may bethrown out while you are working. In such casesprotective goggles should be worn and anyone notequipped with goggles should be kept at a distance.

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(fig.20/B)

(fig.22/B)

WORKING WITH DUE CARE AND ATTENTION

While driving or manoeuvring the vehicle, keep of thevarious parts of the vehicle in mind. Remember certainparts protrude beyond the dimensions of the cab.

AVOIDING ELECTRIC CABLES

Do not work within a distance of less than 5 metresfrom electric cables.

Damp ground may increase the possible danger areafrom electric discharges.

PARKING THE VEHICLE IN SAFETY

Proceed as follows, to prevent accidents:

Park on flat ground;

Run the engine at a minimum with no load for 10seconds;

Position the key to halt the engine;

Remove the key from the switch;

Block the hydraulic controls using the appropriatedevices (where available);

If necessary, put wedges under the wheels;

The parking brake, when the engine is switched off,will be automatically engaged.

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(fig.23/B)

RAISING THE MACHINE

- ATTENTION: Make sure that the raising mechanismhas a suitable capacity for the weight of the vehicle.

The weight of the vehicle is indicated on the relevant metalplate, check the dimensions for the maximum and minimumheight from the ground and for the weight allowed.

The machine is equipped with lifting points marked withthe appropriate symbol. Before proceeding to lift thevehicle, make sure there is no one within range other thanrelevant staff. Attach the cords to the points shown in theillustration, taking particular care when actually lifting thevehicle. Proceed to slowly raise the vehicle.

- IMPORTANT:the cables must be able to support a minimumweight of 6 Tons.

TRANSPORTING SAFELY

The risk of overturning is always present, whenloading or unloading the vehicle from another meansof transport.

Make sure local regulations are respected whentransporting the vehicle on public roads.

Use a suitable truck or trailer to transport the vehicle.

Take all necessary precautions when loading orunloading the vehicle:

1. Choose a terrain that is solid and level.

2. Use a loading platform or ramp.

3. Have someone on the ground to assist in supervisingmanoeuvres.

4. Always use the lowest speed.

5. Do not set off any equipment when the vehicle isprecariously balanced.

6. Use the appropriate eye-bolts to hook up the vehicle tothe transportation vehicle.

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(fig.28/B)

(fig.27/B)

CARRYING OUT MAINTENANCE WORK SAFELY

Proceed as follows to prevent accidents:

Make sure you are familiar with maintenanceprocedures before starting work.

Keep the work zone clean and dry.

Do not lubricate parts or carry out any maintenancework when the vehicle is in motion.

Keep hands, feet and clothing well away from anyparts in motion.

Before doing any maintenance to your vehicle:

1. Park the vehicle on flat ground.2. Lower the bucket to ground level.3. Run the engine at a minimum with no load for 10

seconds to cool it down.4. Switch off the key in the ignition switch.5. Remove the key from the ignition.6. Let off any residual pressure in the hydraulic system,

repeatedly using the hydraulic distribution levers withthe engine switched off.

7. Hang up a sign saying maintenance work under way.This sign can be hung on the manipulators or cab door.

8. Leave the engine to cool down.

If you need to run the engine to carry out maintenance,do not leave the vehicle unattended.

If the vehicle needs to be raised, make sure you usesupports that are sufficiently strong.

If you need to work under any raised parts, (arms, shovel,etc.) block the parts with spacers placed on the cylinderrods or lean the parts on adequately sized supports.

Immediately repair any damage.

Replace any worn or broken parts.

Eliminate any accumulation of grease, oil or deposits.

Disconnect the wires from the battery beforeintervening on the electrical system or before doingany arc welding on the vehicle.

When carrying out electric welding, connect the earthof the welding machine near the area to be welded, inorder to prevent the electric current from passingthrough ball bearings, articulated joints, hydrauliccylinders or sliding parts.

Always consult this manual, in any case, whencarrying out routine maintenance.

KEEP AWAY FROM MOVING PARTS

Damage may be caused from entrapment in moving parts.

To prevent accidents, make sure that, while you areworking, hands, feet, clothing, jewellery and haircannot get caught up in moving parts.

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PREVENTING BURNS

- Jets of hot liquids:

After the vehicle has been used, the cooling liquid inthe engine is hot and under pressure. Any contactwith hot water or steam may cause serious burns.

Avoid any possible injury caused by hot water jets. Donot remove the radiator cap unti l the engine hascooled down. To open it, unscrew the cap as far aspossible. Before removing the cap, let off all pressure.

- Fluids and hot surfaces:

Oil from the engine, the gearboxes and the hydraulicsystem gets hot while the vehicle is in use. The engine,all rigid and flexible pipes and other parts get hot.

Wait until all parts cool down before starting anymaintenance and repair work.

WATCH OUT FOR PRESSURISED FLUIDS

Fluids such as fuel or hydraulic oil under pressure canpenetrate the skin and eyes causing serious injuries.

Avoid running this risk while you carry out repairoperations or maintenance in the machine,discharging the pressure (using the hydraulic leversof the distributors) before to disconnect or to repairpipes and hydraulic pieces

Before restarting the engine, make sure that allconnections have been properly tightened.

Use a piece of cardboard to check for any leaks; makesure your hands and body are adequately protectedagainst pressurised fluids. Use a face mask or safetygoggles to protect your eyes.

Should there be an accident, seek medical attentionimmediately. Any fluids which penetrate under the skinwill need to be removed surgically within a few hoursin order to prevent infection.

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(fig.32/B)

(fig.25/B)

FIRE PREVENTION

Make sure there are no leakages of inflammable liquids:

Fires or serious injuries can be caused by leakage offuel, oil and lubricants.

To prevent oil or diesel from leaking, make sure thatthere are no loose or missing clamps, no twistedflexible pipes and that there are no flexible pipesrubbing up against each other.

Do not bend any pipes under pressure. Never installdamaged piping.

Make sure there are no short circuits:

A short circuit can cause a fire.

Clean and fix down all electrical connections. Beforeevery work shift, make sure that there are no loose,twisted, hardened or damaged cables.

DO NOT USE THE VEHICLE i f electric wiring isdamaged or twisted etc.

Remove inflammable materials:

Fuel, oil, grease, waste, deposits or accumulated coal dustor any other inflammable components can start a fire.

Prevent fires by inspecting and cleaning the vehicle everyday, immediately removing anything inflammable.

Check the ignition switch:

In case of fire, a breakdown when stopping the enginewill obstruct the work of the fire brigade.

HANDLING DANGEROUS LIQUIDS SAFELYPREVENTING FIRES

Handle fuels carefully: they are easily inflammable. Iffuel is ignited, there may be an explosion or a fire.

Do not smoke while refuelling the vehicle. Do notrefuel if there are any naked flames or sparks.

Always switch the engine off to refuel.

Fill the tank in the open air.

All fuels, the majority of lubricants and some types ofantifreeze are inflammable.

Keep all inflammable liquids well away from risks of fire.

Do not burn or perforate pressurised containers.

Do not keep rags soaked in lubricants; they could bethe cause of fires and spontaneous ignition.

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(fig.36/B)

(fig.35/B)

(fig.34/B)

MOVING AWAY IN CASE OF FIRE

If there should be a fire, proceed as follows beforemoving away from the vehicle:

If there's enough time, stop the engine by turning offthe key in the ignition switch.

Move away from the vehicle. Only try to put out the fire ifyou have an efficient fire extinguisher available.

WATCH OUT FOR EXHAUST GAS

Exhaust gases from the engine are toxic and candamage your health.

If you need to work in a closed in area, make sure thatthere is sufficient air circulation and equip the vehiclewith suitable a cleaner.

PREVENTING THE BATTERY FROM EXPLODING

Battery gas could explode.

Keep any sparks, naked flames or lit cigarettes wellaway from the upper part of the battery.

Never place anything metallic between the clampswhen checking that the battery is charged. Use avoltmeter or densimeter.

Do not charge batteries that are very cold; they couldexplode. Warm up the battery to around 16 °C.

Battery electrolyte is a highly corrosive acid. If thebattery should explode, the electrolyte could spurt intoyour eyes and possibly cause blindness.

Make sure you always wear protective goggles whencarrying out maintenance to the battery.

DISPOSING OF WASTE APPROPRIATELY

Improper waste disposal is a threat to theenvironment. Lubricants, fuel, coolant, fi lters andbatteries are all potentially harmful waste products.

Do not spill or pour waste onto the ground, into thesewers or into water beds.

Contact your local authority or collection centres forinformation as to how to recycle or dispose of wasteproperly.

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C/1 - ATTENTION: - Read the SAFETY REGULATIONS (contained in this manual) carefully for the safety of staff and of the vehicle.

USER INSTRUCTIONS VEHICLE

C

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Mod. DUMPER 4200 User Instruction Vehicle

ATTENZIONE A USE OF THE DUMPER DIFFERENT FROM THATDESCRIBED IN THIS BOOKLET IS STRICTLY FORBIDDEN.

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GENERAL WARNINGS

- ATTENTION

The vehicle should be used exclusively by competent,authorized personnel who have already made themselvesfamiliar with the contents of this manual.

- ATTENTION

Before using the machine or carrying out any particularlycomplex or dangerous manoeuvre, it is absolutelynecessary to practise in an area of the yard which isvacant and absent of obstacles..

- ATTENTION

When choosing the diagonal steering, always proceed slowly.

- ATTENTION

Tyres which are excessively blown-up or heated canexplode: for a correct tyre pressure follow the instructionsgiven in this manual. Do not weld or cut the wheel rims;any repair work should be done by a tyre-specialist.

- ATTENTION

Beside each command there is a clear and simplesymbol to ensure a better practicality and understandingof the operator.

- ATTENTION

If there should be any damage to potentially hazardousparts, stop the vehicle immediately. Do not resume workuntil the malfunction has been repaired.

SAFETY REGULATIONS DURING USE

- ATTENTION

The operator should use the vehicle and all its controlsonly when properly seated in the driver’s seat.

- ATTENTION

Working on a slope can be dangerous. The groundconditions change according to the atmosphericconditions (e.g.: rain, snow or ice). Therefore, pay greatattention to the condition of the ground where you areworking and proceed slowly.

- ATTENTION

Whilst transporting a load on a slope, advance with theload lifted in the direction of the rise to increase stability.Before putting the machine on ramps or trailers, it isadvisable to remove any traces of mud, ice or oil that canbe the cause of accidents.

- ATTENTION

On uneven, wet or muddy land surfaces you mustproceed slowly and very carefully.

- ATTENTION

Inefficient and incomprehensible communication can causeserious accidents. Inform people nearby before anyoperation. If you work with others, make sure that themanual signs to be used are understood by everyone.As places of work are often noisy, do not communicate verbally.

- ATTENTION

IT IS FORBIDDEN to use moveable hydraulic parts of thevehicle to lift people.

- ATTENTION

Before activating moveable hydraulic parts on the vehicle,make sure the surrounding area is free.

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Mod. DUMPER 4200 User Instruction Vehicle

PRELIMINARY CHECKS

IN ORDER TO CARRY OUT THE CHECKS LISTED BELOW,CONSULT THE CHAPTER: MAINTENANCE ANDADJUSTMENTS.

Getting ready to operate

Before starting to operate

Make sure that the vehicle is in good working order.In order to do this, proceed as follows to check the correctfunctioning of the vehicle and to ensure the best perfor-mance in full respect of all relevant regulations.

- Efficiency of parking brakes.- Engine oil level

(check and top up if necessary).- Hydraulic oil level

(check and top up if necessary).- Air filter clogging indicator

(check and if necessary clean it ).- Tyre condition and pressure (check).- Fuel level.- Signalling and warning devices (try out).- Braking efficiency.- Parking brake efficiency.- Lights.

If the vehicle is not used for a long time, it should bechecked thoroughly. Should there be any malfunctions,contact one the manufacturer’s authorised repair centres.

Checking the vehicle is clean

- Clean all windows, lights and rear-view mirrors.- Clean away any rubbish and dirt from the engine, from

articulated joints and from the radiator.- Make sure the footboard to get into the vehicle and the

handle are clean and dry.- Clean all safety stickers and manoeuvring indications.

Replace them if they should prove illegible or missing.

Checking for damage

- Make sure there are no damaged or missing parts.- Make sure all articulated pins are properly fastened.- Make sure there are no signs of possible cracks or

flaws or other damage to the windows.- Make sure there are no oil, fuel or cooling l iquids

leaks from underneath the vehicle.- Make sure the bolts on the wheels are properly

tightened.

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(fig.1/C)

(fig.2/C)

(fig.3/C)

1

2

GETTING INTO YOUR VEHICLE

SALITA IN MACCHINA

- Always face the driving cab when getting in or out ofyour vehicle. Make sure that your hands and shoesare clean and dry to prevent slipping and falling.

- Never hold on to the controls or to the steering wheelin the cab.

SEAT

Adjust the seat according to your weight and height.

Adjusting the weight

- It is important that you adjust the suspension of theseat according to your weight. This will ensure themaximum comfort while driving. Adjustment con covera range of weights from 50 to 120 Kg. Turn the knob"1" (f ig.2/C) clockwise (+) to adjust the seat to aheavier weight, turn it anticlockwise (-) for less weight.

Adjusting the seat forwards-backwards

- Pull the lever upwards "2" (fig.3/C) and slide the seatforwards or backwards unti l i t is in the positionrequired, then release the lever and make sure theseat is blocked.

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Mod. DUMPER 4200 User Instruction Vehicle

(tav.A)

(tav.C)

(tav.B)

SEAT-BELTS

1 - Fastening your seat-belt

In order to fasten your seat-belt, you should:

1. Slide the tab (1) into the buckle (2) (tav.A).

2. Make sure this has clicked in properly, then adjust thefit of the belt around your body (tav.B) .

- WARNING:The belt has been correctly adjusted when it fits tightlyaround your waist

2 - Unfasten your seat belt

In order to unfasten your seat-belt, you should:

1. Press the red button (3) on the buckle (2).

2. Slide the tab out (1) (tav.C).

- ATTENTION:Always fasten your seat-belt. Driving without a seat-belton, increases the risk of accidents.

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1 - FORWARD/NEUTRAL/REVERSE GEAR STICK

2 - HOUR METER

3 - GEAR INVERTED LED

4 - BATTERY CHERGE LED

5 - HIGH WATER TEMPERATURE LED

6 - HYDRAULIC OIL FILTER CLOGGED LED

7 - DUMPER TIPPING LED

8 - WORKING LIGHTS LED

9 - DRIVING LIGHTS LED

10 - INDICATOR LED

11 - LOW ENGINE OIL PRESSURE LED

12 - FUEL RESERVE INDICATOR

13 - REVOLVING LIGHT BUTTON

14 - EMERGENCY LIGHTS BUTTON

15 - CAB FAN BUTTON

16 - CAB CONDITIONING BUTTON (Optional)

17 - MECHANICAL GEAR ENGAGED LED

18 - SLOW/FAST GEAR SELECTOR

19 - PARKING BUTTON

20 - STARTER SWITCH

21 - LIGHTS SWITCH and BUZZER

2

1

3 4 5 6

8 11 12

13 14

17 18 19

20 21

7

109

15 16

INTERIOR OF THE CAB

PILOT LIGHTS AND SWITCHES

PILOT LIGHTS AND SWITCHES

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Mod. DUMPER 4200 User Instruction Vehicle

(fig.4/C) 1

(fig.5/C)

2

(fig.6/C)

3 41 2

1

USING THE PUSH BUTTONS AND SWITCHES (USE)

Button for headlights(fig.4/C Pos.”1”)Turn the knob one click clockwise to switch on the sidelights. Turn it two clicks to switch on the dippedheadlights. When the lights are switched on, the pilot lighton the dashboard will also light up.

Acoustic signal push button(fig.4/C Pos.”2”)Press down on the centre of the knob to set off theacoustic signal.

Button for headlights full beam (optional)Turn the knob a third and final click to switch on thelights full beam.

Switch for revolving light(fig.5/C Pos.”1”)This switch sets off the revolving light.It is advisable to keep this light on when working.When the light is on, the pilot light will light up on thedashboard.

Emergency lights switch(fig.5/C Pos.”2”)The switch turns on the flashing emergency lights.You are recommended always to work with the l ightswitched on. The LED on the dashboard lights up whenthe light is switched on.

Cab fan switch(fig.5/C Pos.”3”)The switch is used to turn the air fan on inside the cab.

Air conditioning switch (optional)(fig.5/C Pos.”4”)The switch is used to turn the air conditioning on in the cab.

Parking brake(fig.6/C Pos.”1”)The switch operates the parking brake (negative brake).Use it each time you leave the machine. When the brakeis engaged, the relative LED lights up on the dashboard.

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(fig.7/C)

1 F

N

R

(fig.8/C)

1

CONTROL LEVER FOR REVERSING (USE)

Lever to select vehicle movementforward/neutral/reverse(fig.7/C Pos.”1”)

The lever (fig.7/C Pos.”1”) allows you to change thedirection of the vehicle. If the lever is left in (Pos."N"), thegears are in neutral and the vehicle is partially braked.

- ATTENTION

in order to change direction to FORWARD/BACKWARD,proceed as follows:

- If the lever is moved to (Pos."F") the vehicle is put intogear to move FORWARD.

- If the lever is moved to (Pos."R") the vehicle is put intobackward gear.

- ATTENTION:it is dangerous to change the position of the forward/reverse gear lever when the engine is revving very high:the vehicle could, in fact, change direction very abruptly.In order to avoid accidents, before changing direction,release the accelerator and wait for the vehicle to stop. Ifthe lever for forward/reverse is moved from the neutralposition while the parking brake is on, the vehicle will notmove. When the vehicle is put into reverse, an acousticsignal is set off.

The engine can only be started up if the gear lever is inneutral "N" and the operator is correctly seated in thedriver’s seat.

- ATTENTION - When the driver’s seat is turned, thegear controls are inverted to keep in the same directionwith the driving direction. Indicators F (forward), N(neutral), R (reverse) refer to the driving direction with thedriver’s seat in the transfer position.

CHANGING GEAR (USE)

Controlling the mechanical speeds(fig.8/C)

To change gear, stop the machine completely, press the“inching*”pedal right down; turn the button (fig.8/CPos.”1”) to the required position, FAST (II) or SLOW (I)while still pressing the “inching*” pedal.

ATTENTION

Do NOT change gear while the machine is moving

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Mod. DUMPER 4200 User Instruction Vehicle

(fig.9/C)

N

(fig.10/C)

A

C

STARTING THE VEHICLE

Starting the engine

- ATTENTION

Before starting up the engine, proceed as follows:

1° Move the gear lever for direction into the neutralposition (fig.9/C Pos."N"). The engine will not start, ifthis is in any other position.

2° Remain seated in the driver’s seat.

3° Turn the ignition key (fig.10/C) clockwise to Pos."A":when the key is thus positioned, the following areswitched on:

- The pilot light for the oil pressure, engine on.- The pilot light for battery charging.- Acoustic signal that the key is in.This acoustic signal also serves to warn anyone in thevicinity that the vehicle is about to be started up. (if thisis not the case, do not start up the vehicle but consultthe chapter "Maintenance" in this manual).

4° Turn the ignition key (fig.10/C) to pos."C" to start up theengine.

5° Once the engine has started up, release the key.Once the engine has started up the pilot lights shouldgo out and the acoustic signal should go off.

6° Do not hold the key in the starting position (fig.10/CPos."C"), for more than 5 seconds.

7° If it takes several attempts to start up the engine, waitat least 15 seconds between attempts.

Warming up the engine once it has started up.

Let the engine tick over for 5 minutes at an averagenumber of revs. For the first 10 minutes keep the speedlow, likewise for the load lifting.The procedure describedabove should be repeated every time the engine has to bestarted up in cold weather.

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(fig.11/C)

32

1PEDALS / LEVERS (USE)

How to use the pedals

Accelerator pedal(fig.11/C Pos.”1”)

Press the accelerator pedal to increase vehicle speed,release it to slow down. The pedal influences the engineinjection pump directly When the pedal is released, theengine is partially braked.

Service brake pedal(fig.11/C Pos.”2”)

Press the service brake pedal to slow down or stop thevehicle. The brake lights ( stop ) come on when the pedalis pressed. Check frequently that both brake lights areworking properly. This pedal acts directly on the servicebrake inside the differential axles.

“INCHING” pedal(fig.11/C Pos.”3”)

This pedal makes it possible to move the vehicle slowlyand with precision even when revs are high. The pedalacts directly on the hydrostatic pump, reducing thecapacity. When the pedal is pressed right down, thevehicle stops and is partially braked.

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Mod. DUMPER 4200 User Instruction Vehicle

Hand accelerator control lever(fig.12/C)

The lever (fig.12/C Pos.”1”) located on the left hand side ofthe operator, serves the same purpose as the acceleratorpedal. If the lever is pulled upwards, the engine revs areincreased; if it is lowered, the engine revs are decreasedto the minimum.

N.B.- Use the lever when sitting in the driver’s seat.- This control lever can only be used when the gear is

in neutral and the parking brake is engage.

- ATTENTION:Do not use the hand accelerator when the vehicle isrunning or when the vehicle is on stabilizing feet.

Dumper movements lever(fig.13/C)

The lever (fig.13/C Pos.”1”) to the left of the operator isused to raise or lower the dumper.Pull the lever downwards (Pos.”B”) to raise the dumperand pull upwards (Pos.”A”) to lower the dumper.

Heating lever (optional) (just in closed cab)(fig.14/C)

The heating lever (f ig.14/C Pos.”1”) on the handaccelerator is used to turn the heating on in the cab.

Push the lever forwards (Pos.“B” - TAP CLOSED) to re-duce the heating.

Pull the lever back (Pos.“A” - TAP OPEN) to increase theheating.

1

(fig.12/C)

1 A

B

(fig.13/C)

(fig.14/C)

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(fig.16/C)

1

(fig.15/C)

1A

B

Steering reverse lever(fig.15/C)

This lever (fig.15/C Pos."1") makes it possible to keep thesteering wheel turning in the same direction when thedriver’s seat has been changed round.

1- (driving on public roads compulsory position)The lever must be brought to position ”A”

2- (to load and unload the vehicle)When the driver’s seat has been changed round, thelever should be brought to position ”B”

N.B. If the lever is not positioned correctly according to theposition of the seat, the acoustic and visual alarm will be set off.

Use this lever when the parking brake is on and the gearis in neutral.

- ATTENTION: When the driver’s seat is turnedaround, the controls for the direction of the vehicle areautomatically inverted (the movement of the control levercontinues to correspond to the direction of the vehicle)

TURNING THE DRIVER’S SEAT AROUND(fig.16/C)

Use the blocking pedal to turn the driver’s seat around,(fig.16/C Pos.”1”) this pedal is situated under the seatand allows you to manually turn the seat around.

N.B. It is forbidden to drive the vehicle with the seat turnedaround to face the drum. This position, with the seatturned around, should be used only during loading.

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Mod. DUMPER 4200 User Instruction Vehicle

BA C

(fig.18/C)

(fig.17/C)

1

Steering control lever(fig.17/C Pos.”1” - fig.18/C)

Using this lever you can obtain 3 types of steering.

N.B. : The type of steering should be chosen when thevehicle is at a halt.

- Set the lever to position "A" (fig.17/C) to select4 WHEELSTEERING.

- Set the lever to position "B" (fig.17/C) to select2 WHEELSTEERING (FRONT).

- Set the lever to position "C" (fig.17/C) to selectDIAGONAL MOVEMENT.

- ATTENTION:

Proceed as follows, to align the wheels correctly:

1 - Set the lever to pos. "A" or "C".

2 - Straighten the rear wheels.

3 - Set the lever to pos. "B".

4 - Straighten the front wheels.

5 - Set the lever to pos. "A" and blockit with the appropriate safety lock.

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MAINTENANCE and ADJUSTMENTS

D

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Mod. DUMPER 4200 Maintenance - Adjustments

- ATTENTION:

the floor of the cab is the only part of the vehicle on those that onecan step. It is forbiden to go up on others parts of the machine. Incase of necessity, use a stairway with characteristic capable. Theinspect ions must be made with the engine not operat ing inaccordance with the prescription indicated in the present manual.

- WARNING:

maintenance and repairing operations must be carried out inauthorised repair centres by qualified personnel.

The operator can only carry out the following checks:liquid level check, air filter cleaning, tyre pressure check.

These operations must be carried out in the respect of thesafety regulations described in the present handbook.The knurled plates and the floor of the cab are the only partsof the vehicle on those that one can step. Use a stairway(with characteristic capable) for the maintenance parts thatare not reached from the floor.

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Period in hours

DESCRIPTION

10

Transmission shafts

Pedal pinsDriver’s seat rotation pivot

Consult the engine handbook

Consult the engine handbook

Consult the engine handbook

Check hydraulic oil levelReplace oil in the hyrdraulic circuitReplace or clean filters for hydraulic oil tankReplace outer filters for hydraulic oilCheck for leaks on hydraulic circuit piping

Check battery electrolyte level

Check oil level in differential sumpCheck oil level in epicycloidal reduction gearReplace oil in differential sumpReplace oil in epicycloidal reduction gearGrease differential axlesTighten wheel nutsCheck gear oil levelReplace gear oil

Check tyre pressureCheck all nuts and bolts are tightAdjust parking brake

Check brake oil levelReplace brake oil

ENGINE

GROUP

FUELLING SYSTEM

HYDRAULIC CIRCUITAND TRANSMISSION

ELECTRIC CIRCUIT

DIFFERENTIAL AXLESAND GEAR-BOX

VARIOUS

GREASING

COOLING SYSTEM

XX

X

50 100

250

500

1000

2000

OO

O

O

O

OOO

O

OO

O

OO

OOO

O

X

SCHEDULE FOR MAINTENANCE AND ADJUSTMENTS

The operations marked with an X must be carried out by your DIECI dealer.

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Mod. DUMPER 4200 Maintenance - Adjustments

OIL COMPARISON TABLE

HJDRUS H.I.46

AGIP

CHEVRON

ESSO

IP

MOBIL

ROLOIL

TEXACO

TOTAL

SHELL

Q8

SUPERGREASE G2

GRMU/EP2

DURALITHEP2

BEACONEP2

ATHESIA EPGREASE2

MOBILUX 2

LITEXEP/2

MULTIFAKEP2

MULTISEP2

SUPERGREASE G2

RUBIA XT

URSA SUPER TD

DOLOMITI SUPERHD TURBO 15W40

RIMULDA D

T700 SAE 15W40

DELVAC SUPER1300

TAURUS TURBO15W40

ESSOLUBE XT 201

DELO 450 15W40

SIGMA TURBO ARNICA/46

EP HYDRAULIC 46

INVAROL EP46

LI/46

HJDRO NV46

HAENDEL 46

TELLUS T46

EQUIVIS ZS/46

RANDO HD Z 46

DEXRON FLUID 2

DEXRON 2 EXTRA

DEXRON 2

ATF DEXRON 2

HIDROMATIC DEX

ATF 220

AUTO 14

ATF DEXRON 2

DEXRON 2

DEXRON 2

ANTIFREEZER

PERMANENT

ANTIFREEZER

SIGIL GREEN

ROL FLUID

ANTIFREEZER

ANTIFREEZER

ANTIFREEZER

ANTIFREEZER

ANTIFREEZER

AXA1459

SA

E85

W90

(AP

I GL5

-MIL

2105

-B)

YOU ARE NOTALLOWED TO

UTILIZE SYNTETIC OIL

UTILIZE ONLYOIL MOBIL DTE-15-M

EQUAL TO HW-46 MOBIL

BRAKE FLUID COOLING FLUIDAXLES ANDGEARBOX OIL

ENGINE OIL HYDRAULIC OIL GREASE

- ATTENTION:

RUNNING IN

The operations indicated below must be carried out only once when the indicated time period has elapsed after the newvehicle has been put into service. After this adhere to the intervals specified in the general maintenance schedule.

After 10 hours of work:1 - Check for leaks and eliminate.2 - Check and tighten all hydraulic connections and nuts and bolts.

After 100 hours of work:1 - Change engine oil.2 - Change engine oil filter cartridge.3 - Change fuel filter cartridge.

After 250 hours of work:1 - Change hydraulic oil.2 - Change filter cartridge on hydraulic circuit.

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1

(fig.1/D)

SAFETY REGULATIONS DURING MAINTENANCE

- ATTENTION: When changing the oil, certain basicrules for personal hygiene should be respected.Before changing the oil, apply a suitable protective handcream. Wear protective clothing, overalls, gloves in PVC,etc. Once the oil has been changed, wash away anycontact with the dirty oil. Any clothing dirtied by the oilshould be removed and washed. Prolonged contact withoil, can be harmful to your health, for this reason it isimportant that the instructions given above are followed.

Vehicle maintenance

Keep hands, tools and clothing well away from all movingparts. Do not touch the pipe and exhaust manifold whichcould be hot and could cause burns.

Do not allow anyone who is not expert to get too close tothe vehicle.

Do not work underneath the vehicle with a jack as youronly means of support. Place some tripods under thevehicle as a safety measure.

MAINTENANCE AND ADJUSTMENTS

Preliminary service inspection

Once your new DIECI VEHICLE has completed 50 hourswork, the instructions given in the chapter GUARANTEEshould be carefully followed.

Hour Counter(fig.1/D Pos.”1”)

The engine hour counter shows how many hours thevehicle has worked. The first figure on the right, a black fi-gure on a white background, indicates tenths of an hour.The other figures are white on a black background. Usethe counter to ensure maintenance is carried out at thecorrect intervals.

Routine maintenance

This chapter provides complete details on the correct proce-dure to be followed in order to maintain the vehicle in perfectworking order. This chapter also gives information as tohow to carry out the various adjustments necessary to keepthe vehicle tuned. The vehicle must receive regular routinemaintenance in order to give the best results.It is recommended that all services are carried out asprescribed in the service schedule recommended by DIECI.Remember that it is the responsibility of the owner and/oruser to keep the machine in safe working conditions and fitfor driving on the road.

Maintenance should be carried out at the intervals indicatedin the table "pag.D3" using only high quality lubricants.

Maintenance is best carried out indoors and at the end ofa working day so that all oils are hot and can be easilydrained off.

Before starting any maintenance work whatsoever, switchoff the engine, remove the key from the ignition, positionwedges under the wheels and appropriate locks on thehydraulic cylinders.

Before using a greasing gun, clean the pipes.

Before removing the draining and fuelling caps, clean thesurrounding area.

Always use a clean container to collect used oil and fuel.

Protecting the environment

It is illegal to pollute sewers, culverts or the soil. Use onlyauthorised collection centres, including the areasdesignated by the local authorit ies or workshopsequipped with the necessary tools for the disposal ofused oils. If in doubt, contact your local authority forrelevant instructions.

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Mod. DUMPER 4200 Maintenance - Adjustments

We advise you to carefully read the informationcontained in the instruction manual and toobserve it. In this way, accidents can be avoided,the constructor’s guarantee will be valid and theengine will always be efficient and ready for use.

ENGINE

CONSULT THE CONSTRUCTOR’SINTRUCTION AND MAINTENANCE MANUALALWAYS ATTACHED TO THE MACHINE.

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ATTENTION - IMPORTANT

Before you start to service the ENGINE, blockthe engine bay hood with the dedicated safetylever, as i l lustrated in the photo below.

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Mod. DUMPER 4200 Maintenance - Adjustments

(fig.4/D)

CONTROL (INCHING) OF HYDROSTATIC ENGINE(fig.3/D)

Adjusting the INCHING pedal (left pedal)(fig.3/D Pos.”1”)

This pedal does not need adjusting, because it isconnected directly to the INCHING valve (fig.3/D Pos.”1”)which hydraulically controls the functions and movementsof the hydraulic engine.

BRAKES(fig.2/D Pos.”2”)

- ATTENTION:If the pedal can be pushed down too far or seems too ‘elastic’,contact your DIECI dealer to have this fault corrected.

- ATTENTION:Hydraulic brakes do not need adjusting.

Brake fluid(fig.4/D)

Consult the Summary Table at the start of the chapter toknow how often this should be done (pag. D/3)

- ATTENTION: it is essential that the following safetyprecautions regarding the brake fluid are strictlyobserved:

· Always keep the fluid in its original container.

· Keep it out of children’s reach.

· Do not mix it with other fluids or oils.

· Keep the container tightly sealed.

· Avoid any contact with skin or eyes.

· Wear appropriate protective clothing and gloves.

· If any fluid should get into contact your eyes, rinse themimmediately with plenty of water and consult a doctor.

· If any fluid should get onto your skin, wash the areacarefully, take off any contaminated clothing, and if theskin seems dry, apply a moisturising cream.

· If any fluid is swallowed, consult a doctor. Show himthe label or the container.

· Only use the brake fluid recommended by DIECI(See pag.D4 oil comparison table).

To top up the brake fluid in the tank (located under theseat) (fig.4/D Pos.”1”), unscrew the cap from the tank andmake sure it is full.

(fig.2/D)

1

(fig.3/D)

2

1

1

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Piping and brake fluid(fig.5/D)

Change the brake fluid and check the piping.

Consult the Summary Table at the start of the chapter toknow how often this should be done(pag. D/3).

- ATTENTION:Check the condition of all brake pipes regularly, includingflexible pipes. Contact your DIECI dealer to have anydamaged, corroded or worn pipes replaced.

- ATTENTION:Always use the recommended type of oil, as indicated inthe lubrication table (See pag.D4 oil comparison table).

- ATTENTION:Try the vehicle out on the road every time you change thebrake fluid.

(fig.5/D)

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Mod. DUMPER 4200 Maintenance - Adjustments

(fig.6/D)

(fig.7/D)

1

21

4

33

TRANSMISSIONI AND HYDRAULIC OIL

Hydraulic oil level(fig.6/D Pos.”1”)

Routine maintenance should be carried out at theprescribed intervals (pag.D/3).

For normal use of the machine, the oil level should bekept visible in the appropriate transparent indicator on thehydraulic oil tank.

1. Park the vehicle on a level surface.

2. Lower the dumper and switch the engine off.

3. Check the oil level on the transparent indicator.

4. If necessary, remove the cap from the tank (fig.7/DPos.”1”) and top up with oil until the correct level hasbeen reached (fig.6/D Pos.”1”).

Changing the oil and filters(fig.7/D)

Consult the Summary Table at the start of the chapter toknow how often this should be done (pag.D/4)

Changing the oil suction filter on the hydrualic circuit.

1. Park the machine on flat ground and lower the dumper.

2. Switch off the engine and remove the ignition key.

3. Place a container under the drain cock(located under the tank).

4. Remove the intake and drain plug to drain the oil away(fig.7/D Pos.”1” and “4”).

5. Unscrew the bolts from the tank covering plate(fig.7/D Pos.”2”)

6. Unscrew the filters (fig.7/D Pos.”3”) located inside thetank using an adjustable screw spanner.

7. Mount the new filters tightening them with the spanner.

8. Replace the drain plug and cap. Then refill the tankthrough the refuelling opening (fig.7/D Pos.”1”).

9. Make sure it is level via the dedicated instrument (fig.6/DPos.”1”) after having started the engine and operated allthe hydraulic controls to discharge any air bubbles.

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(fig.8/D)

12

FILTERS FOR HYDRAULIC AND HYDROSTATICCIRCUIT OIL

Hydraulic oil suction filters(SEE MANUAL)

Consult the Summary Table of MANUAL

Changing the suction filters for the hydraulic circuit oil(SEE MANUAL)

Changing the oil filter/s on the hydrostatic circuit

Consult the Summary Table at the start of the chapter toknow how often this should be done (pag. D/3)

Oil filters on the hydrostatic circuit (fig.8/D)

1. Place a container under the filter to collect the oilpouring out.

2. Close the sluices (red in colour) located near the filter(fig.8/D Pos.”1”).

3. Remove the filter cartridge (fig.8/D Pos.”2”) using aribbon spanner or similar tool.

4. Clean the filter fitting making sure the old sealing ringis removed. Grease the new sealing ring with a fewdrops of oil.

5. Mount the new cartridge and tighten it only by hand.DO NOT use a spanner.

6. - ATTENTION: open the sluices.

7. Run the engine and check for any leaks.Recheck the oil level and top it up if necessary.

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Mod. DUMPER 4200 Maintenance - Adjustments

GEARBOX AND DIFFERENTIAL AXLES

N.B. THE ILLUSTRATIONS PROVIDED ARE ONLY ANINDICATION AND MAY NOT CORRESPOND TO THEVEHICLE IN YOUR POSSESSION.

Consult the Summary Table at the start of this chapterto know how often this should be done (pag. D/3)

Gearbox:Changing the oil (fig.9 /D)

1. With the vehicle on a level surface, place a containerunder the gearbox and then remove the drain plug(Pos.”2”) and the oil level cap (Pos.”1”).

2. Leave the oil to drain away completely.

3. Replace the drain plug and tighten it securely.

4. Refill with the correct type of oil through the opening(Pos.”1”) until it reaches the right level.

Differential axle:Changing the oil (fig.10/D)

1. With the vehicle on a level surface, place a containerunder the plug on the differential axle and then removethe drain plug (Pos.”2”) and the oil level cap (Pos.”1”).

2. Leave the oil to drain away completely.

3. Replace the drain plug and tighten it securely.

4. Refill with the correct type of oil through the opening(Pos.”1”) until it reaches the right level.

Epicycloidal reduction gear:Changing the oil (fig.11/D)

1. Turn the wheel hub so that the oil plug is in the lowerposition and drain off the oil into a container (Pos.”3”).

2. Turn the hub so that the oil plug is in the upper positionand add the recommended type of oil (Pos.”1”).

3. To check if enough oil has been added, simply turnthe wheel hub unti l the oil plug is in the middleposition (Pos.”2”).

4. The above procedure should be repeated for all fourreduction gear assemblies.

DRIVE SHAFTS(fig.12/D)

Consult the Summary Table at the start of the chapter toknow how often this should be done (pag.D/3).

Lubricate the parts indicated until the grease overflows.

- ATTENTION: Make sure all nuts and bolts havebeen adequately tightened on the shaft coupling flanges.

(fig.12/D)

2

3

(fig.9/D)

(fig.10/D)

(fig.11/D)

1

2

3

2

1

12

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(fig.13/D) Inflation cage

TYRES

Check tyre pressure every 100 hours and every twoweeks.

Consult the Summary Table at the start of the chapter toknow how often this should be done (pag. D/3)

Check and adjust tyre pressure and make sure that thetread and sides are not damaged. Pressure should bechecked when the tyres are cold.

1. Keep all oils, grease and corrosive liquids well awayfrom the tyres to prevent any damage to the rubber.

2. Tyres which have any cuts or are excessively wornshould be replaced immediately.

PRESSURE

- Tyre pressure must be kept at the level indicated inthe Table.

- The tyre pressure given corresponds to therecommendations of the manufacturer, and shouldtherefore be respected as far as possible.

- Check the size of the tyres installed and the ply numberto ensure they are inflated to the correct pressure.

SPECIFICATIONS

Model Tyres Bar

16/(70)-20 14 PR 4,5 Bar

To ensure maximum efficiency do not use tyres with morethan 80% consumed.

- ATTENTION:When inflating the tyres for the first time, make sure allpersons not involved stay well away from the area anduse adequate protection (fig.13/D).

Inflate the tyres to the pressure specified.

Do not inflate beyond the levels indicated in the table.

- ATTENTION:Always remain to one side of the tyres when checking thetyres on the vehicle and inflating them to the correct level.

TIGHTENING WHEEL NUTS

- ATTENTION:When tightening the nuts on the wheels, the torqueshould correspond to the following table:

WHEEL STUD 18 kgm 50WHEEL STUD 22 kgm 60

ATTENTION:Always tighten the nuts positioned opposite each other(and not consecutively)

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Mod. DUMPER 4200 Maintenance - Adjustments

BATTERY

Taking the battery out

The vehicle is equipped with a battery located behind thehydraulic oil tank (fig.14/D Pos.”1”).

Prima di rimuovere la batteria scollegarla tramite l’appo-sito interruttore (fig.14/D Pos.”2”) seguendo le indicazioniriportate nell’adesivo sottostante.

To remove the battery:

1. Open the engine bonnet and lift the lid of the batteryholding box.

2. Disconnect the NEGATIVE wire (earth) from the battery.3. Disconnect the POSITIVE wire (red) from the battery.4. Remove the battery from the vehicle.

Battery maintenance

Consult the Summary Table at the start of the chapter toknow how often this should be done (pag.D/3)

- ATTENTION:the battery contains sulphuric acid electrolyte, a corrosivesubstance which must be handled with due caution.· Irritant for skin and eyes.· Keep it out of children’s reach.· Avoid any contact with skin or eyes.· Wear appropriate protective clothing, gloves and goggles.· If any fluid should get into your eyes, rinse them

immediately with plenty of water and consult a doctor.· If any fluid is swallowed, consult a doctor. Show him

the label or the container.

- ATTENTION:Recharge the battery in a well venti lated place andALWAYS switch off the electricity supply beforedisconnecting the clamps.

- ATTENTION:Always use a voltmeter or a densimeter to check if thebattery is sufficiently charged. If you need to check thelevel of the electrolyte, use a torch, never a naked flame.

- ATTENTION:· Keep well away from sparks, flames and cigarettes.

A naked flame near a battery could cause anexplosion and personal injury.

· DO NOT make any sparks with the wire clamps whilerecharging the battery or while starting the vehicleengine with an auxiliary battery.

· Make sure the caps and vent have been correctlymounted and have been firmly tightened.

· Check the condition of the battery making sure thelevel of electrolyte is sufficient.

· Clean the upper part of the battery, make sure the clampsare firmly mounted and cover them with some vaseline.

(fig.14/D)

1

ON OFF

Low maintenance battery

During normal use, low maintenance batteries do notneed topping up. If there should be any trouble with thealternator, always check the level of the electrolyte. Thelevel must be 15 mm above the plates. If it is too low, topit up by adding disti l led water. If the battery shouldaccidentally become flat, it is highly recommended thatthe battery is recharged in the workshop. It should berecharged using a maximum 7 A battery charger.

2

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(fig.15/D)

SWIVELLING DRIVER’S SEAT

SEAT ROTATION PIVOT

Consult the Summary Table at the start of the chapter toknow how often this should be done (pag.D/3)

Lubricate the seat rotation pivot as shown (fig.15/D).

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Mod. DUMPER 4200 Maintenance - Adjustments

SAFETY STICKERS

Consult the Summary Table at the start of the chapter toknow how often this should be done (pag. D/3)

Replace any Danger, Attention, Caution and Instructzionsstickers which are illegible or missing. If any stickers are lostor damaged, spare stickers are available from your localDIECI dealer.

Cleaning your vehicle

- Use water to soften up any dirt stuck to the surface. Ifyou use a pressurised water jet, make sure you do notwet any electrical components such as the alternatorand the starting motor.

- To touch up any small marks on the body work, askyour DIECI dealer for tins of paint for this purpose.

- Make sure all safety stickers are present. Replace anystickers which have been lost or removed while cleaning.

Cleaning the cab

- When the soft upholstery gets dirty, rub it clean. Dip acloth into hot water and detergent and squeeze it asdry as possible.

- The driver’s seat and the floor should be cleaned witha vacuum cleaner and stiff brush. If necessary, use adamp cloth to remove any stubborn stains.

- Do not use jets of water inside the cab.

- Clean the seat-belts with a sponge dipped in hotsoapy water and simply leave them to dry.

- The fabric seats should be cleaned with a stiff brushor vacuum cleaner. Plastic seats should be cleanedwith a damp cloth.

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STORING THE VEHICLE

If the vehicle has to be left in the garage for any lengthof time, the following precautions should be taken tosafeguard your vehicle:

1. Clean the vehicle.

2. Lubricate all the oilers.

3. Drain the oil from the engine and replace it with new oil.

4. Clean the fuel system and change the filter cartridges.

5. Remove the battery and store it somewhere warm anddry. Recharge it periodically.

6. Raise the vehicle onto tripods to take the weight off the tyres.

7. Drain the coolant from the radiator and the cylinderblock and refill them with a solution of antifreeze andwater as instructed previously.

8. Cover the exhaust opening.

9. Cover the exposed rods on the hydraulic cylinders witha fine layer of grease.

Preparing the vehicle after storage:

1. Inflate the tyres to the correct pressure.

2. Remove the tripods from the axles.

3. Fill the fuel tank.

4. Check the level of the various oils.

5. Check the level of the various oils.

6. Put in a fully charged battery.

7. Remove the cover from the exhaust pipe.

8. Switch on the engine and make sure all controls areworking properly.

9. Leave the engine running for a few minutes.

10. Make sure the brakes are working properly.

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Mod. DUMPER 4200 Maintenance - Adjustments

(fig.16/D)

1

Fuel for low temperatures

If the engine needs to be used at temperatures which fallbelow 0°C, special winter fuels can be used. These fuelshave a lower degree of viscosity and restrict the formationof paraffin in the fuel. The formation of paraffin preventsthe fuel from passing through the filter.

USING AND STORING FUEL

Diesel

Before handling fuel, filling the tank, etc., the followingrules should be complied with:

Never add different types of fuel, such as petrol, alcohol,to the diesel.

. It is forbidden to refuel with the engine switched on.· Clean the area around the fuel cap. Refill the fuel tank at the

end of every day to reduce condensation during the halt.· Never leave the fuel cap off.· Keep the fuel pump gun under control, while filling the tank.. DO NOT SMOKE WHILE CARRYING OUT THE JOBS

MENTIONED ABOVE.· Do not fill the tank right up. Leave room for the fuel to

expand and immediately clean any spillage.· If you should lose the original cap, replace it with an

original spare. Not any cap will fit.

Fuel tank opening(fig.16/D Pos.”1”)

Turn the cap anticlockwise to remove it.

Specifications for recommended fuel

To ensure good performance, use a high quality fuel.The specifications of the recommended fuel are givenhere below.

Cetane number 45 minimum.

Viscosity 2/4,5 centistokes at 40°C.

Density 0,8201860 kg/litre at 15°C

Sulphur 0,20% in weight, maximum.

Distillation 85% at 350°C.

Cetane numberThe cetane number: measures the ignition properties.Fuel with a lower cetane number might make it difficult tostart up the engine cold and could effect combustion.

ViscosityViscosity is the resistance to flow; if the degree of viscosity isbeyond the limit, it might effect the engine performance.

DensityA lower density reduces the engine power, higher densityincreases the engine power and the smokiness of theexhaust fumes.

SulphurA high sulphur level wears out the engine and createspollution.

DistillationDistillation indicates the mixture of different hydrocarbonsin the fuel. A high proportion of light hydrocarbons mighteffect the type of combustion.

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(fig.17/D)

(fig.18/D)

CLEANING AND STORING DIESEL FUEL

It is essential that the fuel is kept clean. The advice givenhere below will help to prevent alterations to the fuelspecifications.

1. Never use zinc containers.

2. Never use cloths which might leave deposits, to cleanthe inside of the containers or components of thefuelling system.

3. The capacity of the cistern must ensure that theintervals between one refuelling and the next are nottoo long. A capacity of 3000 litres is sufficient for anaverage sized company.

4. The storage cistern (fig.17/D) should be covered andplaced on supports which are sufficiently high toexploit the force of gravity when refuelling the vehicle.A bathtub for the fuel collecting has to be positionedbelow the storage cistern. It should also be equippedwith an opening big enough to allow someone toaccess the cistern for cleaning.

5. The delivery tap must be bigger at the bottom in order tohold back any deposits; it should also be equipped witha removable filter. The cistern should be tilted 40 mm permetre towards the plug to drain off the deposits.

6. Fuel barrels (fig.18/D) must be stored under cover toprevent water from seeping in. The barrels shouldalso be tilted slightly, so that any water will run to theupper rim. The fuel barrels should not be stored fortoo long before being used.

7. If the barrels are kept in the open, the cap must betightly closed to prevent water from seeping in.

8. After refilling the cistern or the barrels, it is advisable toleave the fuel to stand for at least two hours so that anywater or impurities can deposit before the fuel is used.

Page 65: AXH1113_UK - Rev0 - Dumper 4200

D/20 - ATTENTION: - Read the SAFETY REGULATIONS (contained in this manual) carefully for the safety of staff and of the vehicle.

Mod. DUMPER 4200 Maintenance - Adjustments

categories of fine pitch nuts and bolts

MS

mm mmmm mm 2

S

33068.530643.4

51627.047840.8

55294.651373.0

74319.868869.5

78751.373133.5

106683.799042.5

143711.8133608.7

173668.0161161.9

187026.1174074.5

221177.8205491.0

236637.0220451.9

274120.1254927.0

290804.3271119.8

332490.0309464.8

3 6 . 7 04 5 . 6 5

7 1 . 3 08 8 . 6 7

7 4 . 6 79 3 . 8 4

1 2 0 . 9 41 5 0 . 2 9

1 2 5 . 7 41 5 7 . 6 3

1 9 9 . 2 72 4 9 . 4 9

3 0 3 . 0 23 8 1 . 5 7

4 1 8 . 5 95 2 3 . 2 0

4 3 9 . 3 45 5 5 . 7 7

5 8 6 . 3 27 3 6 . 3 3

6 1 2 . 8 27 7 8 . 1 0

7 9 9 . 4 81008 .27

8 3 0 . 3 31057 .75

1041 .401317 .38

3 0 . 5 83 8 . 0 4

5 9 . 4 27 3 . 8 9

6 2 . 2 37 8 . 2 0

1 0 0 . 7 81 2 5 . 2 4

1 0 4 . 7 81 3 1 . 3 6

1 6 6 . 0 62 0 7 . 9 1

2 5 2 . 5 13 1 7 . 9 8

3 4 8 . 8 34 3 6 . 0 0

3 6 6 . 1 24 6 3 . 1 5

4 8 8 . 6 06 1 3 . 6 1

5 1 0 . 6 86 4 8 . 4 2

6 6 6 . 2 38 4 0 . 2 2

6 9 1 . 9 48 8 1 . 4 6

8 6 7 . 8 31097 .82

27557.125536.2

43022.539867.3

46078.842810.8

61933.257391.3

65626.160944.6

88903.182535.4

119759.8111340.6

144723.3134301.6

155855.1145062.1

184314.8171242.5

197197.5183709.9

228433.4212439.1

242337.0225933.2

277075.0257887.3

2 1 . 7 52 7 . 0 5

4 2 . 2 55 2 . 5 5

4 4 . 2 55 5 . 6 1

7 1 . 6 78 9 . 0 6

7 4 . 5 19 3 . 4 1

1 1 8 . 0 91 4 7 . 8 5

1 7 9 . 5 62 2 6 . 1 2

2 4 8 . 0 63 1 0 . 0 5

2 6 0 . 3 53 2 9 . 3 5

3 4 7 . 4 54 3 6 . 3 4

3 6 3 . 1 54 6 1 . 1 0

4 7 3 . 7 65 9 7 . 4 9

4 9 2 . 0 56 2 6 . 8 2

6 1 7 . 1 27 8 0 . 6 7

19596.118159.1

30593.828350.1

32767.230443.3

44041.440811.6

46667.443338.4

63220.058691.9

85162.579175.5

102914.495503.3

110830.3103155.2

131068.3121772.4

140229.3130638.1

162441.5151067.8

172328.5160663.6

197031.1183386.5

1 6 . 3 12 0 . 2 9

3 1 . 6 93 9 . 4 1

3 3 . 1 94 1 . 7 0

5 3 . 7 56 6 . 7 9

5 5 . 8 87 0 . 0 6

8 8 . 5 71 1 0 . 8 9

1 3 4 . 6 71 6 9 . 5 9

1 8 6 . 0 42 3 2 . 5 3

1 9 5 . 2 62 4 7 . 0 1

2 6 0 . 5 93 2 7 . 2 6

2 7 2 . 3 63 4 5 . 8 2

3 5 5 . 3 24 4 8 . 1 2

3 6 9 . 0 44 7 0 . 1 1

4 6 2 . 8 45 8 5 . 5 0

14697.113619.3

22945.321262.6

24575.422832.5

33031.030608.7

35000.632503.8

47415.044018.9

63871.959381.6

77185.871627.5

83112.777366.4

98301.291329.3

105172.097978.6

121831.2113300.9

129246.4120497.7

147773.4137539.9

13.591 6 . 9 1

2 6 . 4 13 2 . 8 4

2 7 . 6 63 4 . 7 5

4 4 . 7 95 5 . 6 6

4 6 . 5 75 8 . 3 8

7 3 . 8 09 2 . 4 0

1 1 2 . 2 31 4 1 . 3 2

1 5 5 . 0 31 9 3 . 7 8

1 6 2 . 7 22 0 5 . 8 4

2 1 7 . 1 62 7 2 . 7 1

2 2 6 . 9 72 8 8 . 1 9

2 9 6 . 1 03 7 3 . 4 3

3 0 7 . 5 33 9 1 . 7 6

3 8 5 . 7 04 8 7 . 9 2

12247.611349.4

19121.117718.8

20479.519027.0

27525.925507.2

29167.127086.5

39512.536682.4

53226.649484.7

64321.559689.6

69268.964472.0

81917.776107.8

87643.381648.8

101526.094417.4

107705.3100414.7

123144.5114616.6

1 0 . 8 71 3 . 5 3

2 1 . 1 32 6 . 2 7

2 2 . 1 22 7 . 8 0

3 5 . 8 34 4 . 5 3

3 7 . 2 64 6 . 7 0

5 9 . 0 47 3 . 9 2

8 9 . 7 81 1 3 . 0 6

1 2 4 . 0 31 5 5 . 0 2

1 3 0 . 1 71 6 4 . 6 7

1 7 3 . 7 22 1 8 . 1 7

1 8 1 . 5 82 3 0 . 5 5

2 3 6 . 8 82 9 8 . 7 5

2 4 6 . 0 23 1 3 . 4 1

3 0 8 . 5 63 9 0 . 3 3

9798.19079.5

15296.914175.0

16383.615221.6

22020.720405.8

23333.721669.2

31610.029345.9

42581.339587.8

51457.247751.7

55415.151577.6

65534.160886.2

70114.765319.1

81220.875533.9

86164.280331.8

98515.691693.3

0.100.14

0.100.14

0.100.14

0.100.14

0.100.14

0.100.14

0.100.14

0.100.14

0.100.14

0.100.14

0.100.14

0.100.14

0.100.14

0.100.14

M8

M10

M10

M12

M12

M14

M16

M18

M18

M20

M20

M22

M22

M24

4.8 5.8 6.8 8.8 10.9 12.9

torqueNm

preloadN

PRELOAD AND TORQUE TABLEFOR CLASS 1 NUTS AND BOLTS

torqueNm

preloadN

torqueNm

preloadN

torqueNm

preloadN

torqueNm

preloadN

torqueNm

preloadN

res

ista

nt

se

cti

on

fric

tio

nc

oe

ffic

en

t

fin

e p

itc

h

Page 66: AXH1113_UK - Rev0 - Dumper 4200

D/21 - ATTENTION: - Read the SAFETY REGULATIONS (contained in this manual) carefully for the safety of staff and of the vehicle.

16452.215184.4

24079.122273.6

30196.527896.5

48075.344439.9

70087.364813.5

95816.088631.5

132442.2122729.3

160424.1148453.2

206678.2191521.5

257530.0238922.5

297784.4275946.1

1 4 . 3 01 7 . 5 1

2 3 . 5 22 9 . 0 4

3 4 . 4 44 2 . 3 1

6 7 . 8 78 3 . 5 6

1 1 6 . 2 01 4 3 . 1 7

1 8 4 . 8 42 2 8 . 0 3

2 8 7 . 3 63 5 7 . 0 9

3 9 6 . 4 94 8 9 . 9 2

5 6 0 . 5 46 9 6 . 5 6

7 6 6 . 8 59 5 7 . 8 0

9 6 9 . 1 51204 .33

1 1 . 9 21 4 . 5 9

1 9 . 6 02 4 . 2 0

2 8 . 7 03 5 . 2 6

5 6 . 5 66 9 . 6 4

9 6 . 8 31 1 9 . 3 1

1 5 4 . 0 31 9 0 . 0 2

2 3 9 . 4 72 9 7 . 5 8

3 3 0 . 4 14 0 2 . 2 6

4 6 7 . 1 15 8 0 . 4 7

6 3 9 . 0 57 9 8 . 1 6

8 0 7 . 6 31003 .61

13710.112653.7

20065.918561.4

25163.723247.0

40062.737033.3

58406.154011.2

79846.673859.6

110368.5102274.4

133686.7123711.0

172231.9159601.2

214608.3199102.1

248153.7229955.1

8 .471 0 . 3 7

1 3 . 9 41 7 . 2 1

2 0 . 4 12 5 . 0 7

4 0 . 2 24 9 . 5 2

6 8 . 8 68 4 . 8 4

1 0 9 . 5 31 3 5 . 1 3

1 7 0 . 2 92 1 1 . 6 1

2 3 4 . 9 62 9 0 . 3 2

3 3 2 . 1 74 1 2 . 7 8

4 5 4 . 4 35 6 7 . 5 8

5 7 4 . 3 17 1 3 . 6 8

9749.48998.2

14269.113199.2

17894.216531.2

28489.026334.8

41533.238408.0

56779.852522.4

78484.372728.5

95066.187972.3

122476.0113494.2

152610.4141583.7

176464.9163523.6

6 .357 .78

1 0 . 4 51 2 . 9 0

1 5 . 3 01 8 . 8 0

3 0 . 1 63 1 . 1 4

5 1 . 6 46 3 . 6 3

8 2 . 1 51 0 1 . 3 4

1 2 7 . 7 21 5 8 . 7 1

1 7 6 . 2 22 1 7 . 7 4

2 4 9 . 1 33 0 9 . 5 8

3 4 0 . 8 24 2 5 . 6 9

4 3 0 . 7 35 3 5 . 2 6

7312.16748.6

10701.89899.4

13420.712398.4

21366.819751.1

31149.928806.0

42584.939391.8

58863.254546.3

71299.665979.2

91857.085120.6

114457.8106187.8

132348.6122642.7

5 .306 .48

8 .711 0 . 7 6

1 2 . 7 51 5 . 6 7

2 5 . 1 43 0 . 9 5

4 3 . 0 35 3 . 0 3

6 8 . 4 68 4 . 4 5

1 0 6 . 4 31 3 2 . 2 6

1 4 6 . 8 51 8 1 . 4 5

2 0 7 . 6 12 5 7 . 9 8

2 8 4 . 0 23 5 2 . 7 4

3 5 8 . 9 44 4 6 . 0 5

4 .245 .19

6 .978 .60

1 0 . 2 01 2 . 5 4

2 0 . 1 12 4 . 7 6

3 4 . 4 34 2 . 4 2

5 4 . 7 76 7 . 5 6

8 5 . 1 41 0 5 . 8 0

1 1 7 . 4 81 4 5 . 1 6

1 6 6 . 0 82 0 6 . 3 9

2 2 7 . 2 22 8 3 . 7 9

2 8 7 . 1 63 5 6 . 8 4

4874.74499.1

7134.56599.6

8947.18265.6

14244.513167.4

20766.619204.0

28389.926261.2

39242.136364.2

47533.043986.1

61238.056747.1

76305.270791.9

88232.481761.8

0.100.14

0.100.14

0.100.14

0.100.14

0.100.14

0.100.14

0.100.14

0.100.14

0.100.14

0.100.14

0.100.14

6093.45623.9

8918.28249.5

11183.910332.0

17805.616459.2

25958.324005.0

35487.432826.5

49052.745455.3

59416.354982.7

76547.570933.9

95381.588489.8

110290.5102202.2

M6

M7

M8

M10

M12

M14

M16

M18

M20

M22

M24

categories of wide pitch nuts and bolts

MS

mm mmmm mm 2

S

4.8 5.8 6.8 8.8 10.9 12.9

5 10 1.00 20,10

- 11 1.00 28,90

6 13 1.25 36.60

8 16 1.50 58.00

10 18 1.75 84.30

12 21 2.00 115.00

14 24 2.00 157.00

14 27 2.50 192.00

17 30 2.50 245.00

17 34 2.50 303.00

19 36 3.00 353.00

PRELOAD AND TORQUE TABLEFOR CLASS 2 NUTS AND BOLTS

torqueNm

preloadN

torqueNm

preloadN

torqueNm

preloadN

torqueNm

preloadN

torqueNm

preloadN

torqueNm

preloadN

res

ista

nt

se

cti

on

fric

tio

nc

oe

ffic

en

t

wid

e p

itc

h

Page 67: AXH1113_UK - Rev0 - Dumper 4200

D/22 - ATTENTION: - Read the SAFETY REGULATIONS (contained in this manual) carefully for the safety of staff and of the vehicle.

Mod. DUMPER 4200 Maintenance - Adjustments

60° oval insert - BSP thread

THREAD

N.m

1/18-28

12-14

TORQUE TABLE FOR HYDRAULIC FITTINGS

1/4-19

14-16

3/8-19

25-28

1/2-14

45-60

5/8-14

55-70

3/4-14

90-110

1”-11

120-140

1”1/2-11

200-245

1”1/4-11

170-190

60° oval insert - METRICO thread

THREAD

N.m

10x1

12-14

12x1,5

13-15

14x1,5

15-18

16x1,5

25-28

18x1,5

27-30

22x1,5

50-60

26x1,5

60-75

30x1,5

110-130

28x1,5

80-100

SERIES / RANGE “L”

THREAD

N.m

12x1,5

13-15

14x1,5

15-18

16x1,5

25-28

18x1,5

27-30

22x1,5

50-60

26x1,5

30-75

36x1,5

120-140

30x2

85-105

45x1,5

170-190

52x1,5

190-230

SERIES / RANGE “S”

THREAD

N.m

14x1,5

15-18

16x1,5

25-28

18x1,5

27-30

20x1,5

43-54

22x1,5

50-62

30x2

90-110

24x1,5

60-75

36x2

125-145

42x2

170-190

52x2

200-245

Page 68: AXH1113_UK - Rev0 - Dumper 4200

D/23 - ATTENTION: - Read the SAFETY REGULATIONS (contained in this manual) carefully for the safety of staff and of the vehicle.

TROUBLE SHOOTING

- ATTENTION: Only authorised staff should interveneon the vehicle to eliminate any trouble or breakdown.

Make sure "User Instructions" and "Safety Regulations"have been read and clearly understood before attemptingany repair work on the vehicle.

This symbol: " " means that the trouble canNOT be remedied without the assistance of an authorisedDIECI Service workshop.

GROUP TROUBLE PROBABLE CAUSE REMEDY

Hydraulic oil suction filter isclogged

Remove the oil f i l ter andreplace it

Hydrostatic transmissiondamaged

Repair or replace thetransmission

HYDRAULICSYSTEM

Diesel engine malfunctionConsult the engine UserInstructions and Maintenancehandbook

The vehicle is losing speed

GROUP TROUBLE PROBABLE CAUSE REMEDY

Direction lever is engaged Position the lever to neutral

No fuel Fill up the tank

Battery’s flat Recharge the batteryor replace it

Fuse has burnt out Change the fuse

OthersConsult the engine UserInstructions and Maintenancemanual

Will not startENGINE

Page 69: AXH1113_UK - Rev0 - Dumper 4200

D/24 - ATTENTION: - Read the SAFETY REGULATIONS (contained in this manual) carefully for the safety of staff and of the vehicle.

Mod. DUMPER 4200 Maintenance - Adjustments

GROUP TROUBLE PROBABLE CAUSE REMEDY

Direction lever in neutral Position the lever to oneof the directions

Slow-fast lever in neutral Put into gear

The vehicle doesn’tmove in any direction

HYDROSTATICTRANSMISSION

Parking brake lever and/orworking brake on

Release the lever/s

Hydrostatic transmissiondamaged

Repair or replace thetransmission

Electric circuit damaged Check the circuit

GROUP TROUBLE PROBABLE CAUSE REMEDY

No oil in the brake oil tank Drain the circuit or top upthe tank

Brake pump damaged

Brake pads worn Change the brake pads

Repair or replace

The vehicle doesn’tbrake

BRAKES

GROUP TROUBLE PROBABLE CAUSE REMEDY

The wheels are notcorrectly aligned Realign them

Wrong steering mode selected Reposition the leverfor different steering mode

Control distributor damaged Repair or replace thedistributor

Oil leaking from hydraulicsteering cylinders

Replace the gaskets

The vehicle movesdiagonally / the wheelsare not aligned

STEERING

Unsuitable brake fluidin differential sump circuit

Consult the oilcomparison table

Fluid leaking from the circuit Check for leaks

Page 70: AXH1113_UK - Rev0 - Dumper 4200

D/25 - ATTENTION: - Read the SAFETY REGULATIONS (contained in this manual) carefully for the safety of staff and of the vehicle.

NOTES

Page 71: AXH1113_UK - Rev0 - Dumper 4200

D/26 - ATTENTION: - Read the SAFETY REGULATIONS (contained in this manual) carefully for the safety of staff and of the vehicle.

Mod. DUMPER 4200 Maintenance - Adjustments

NOTES

Page 72: AXH1113_UK - Rev0 - Dumper 4200

E/1

ELECTRIC CIRCUIT DIAGRAMS

E

Page 73: AXH1113_UK - Rev0 - Dumper 4200

E/2

Mod. DUMPER 4200

PAGE INTENTIONALLY LEFT BLANK

Page 74: AXH1113_UK - Rev0 - Dumper 4200

E/3

KEY OF STANDARD SYSTEM DWG. NO. E25800-028F

NAME DESCRIPTION SHEET

1143325555554221111553343341555343333553511111245112513332225111

A49 PREHEATING CONTROL UNITB1 BATTERYB5 INCLINOMETER SENSORB6 HORNB7 STOP MICROSWITCHB9 CLUTCH MICROSWITCHB10 SEAT MICROSWITCHB11 POWER STEERING LEVER MICROSWITCHB14 HANDBRAKE 2 MICROSWITCHB17 HYDRAULIC OIL FILTER CLOGGING PRESSURE SWITCHB20 HYDRAULIC OIL FILTER CLOGGING PRESSURE SWITCHB23 DIESEL FLOATB28 FIFTH WHEEL ROTATION PRESSURE SWITCHB30 MECHANICAL GEAR LIMIT SWITCHB33 FAST GEAR ENGAGED PRESSURE SWITCHB38 WATER THERMISTORB40 ENGINE OIL PRESSUREB41 WATER THERMO-CONTACTB42 FILTER THERMISTORB53 HANDBRAKE 1 MICROSWITCHB97 BRAKE OIL ACCUMULATION PRESSURE SWITCHE1 FRONT RH LIGHTE2 FRONT LH LIGHTE3 LAMPE22 REAR RH LIGHTE24 REAR LH LIGHTE95 FLASHING BEACONF1 ENGINE STOP FUSEF2 POSITIVE +15 FUSEF3 NEG.BRAKE POWER SUPPLY + HANDBRAKE MICROSWITCH + SEAT MICROSWITCH FUSEF4 HORN POSITIVE FUSEF5 +30 WARNING FUSEF6 +15/54 FLASHING BEACON FUSEF7 SIDE LIGHTS FUSEF8 SIDE LIGHTS + SIDE LIGHTS LED FUSEF9 DIMMERS FUSEF10 FULL BEAM FUSEF11 PUSH BUTTON CONTROL PANEL POSITIVE FUSEF12 LED LIGHTING + HEATING SWITCH POWER SUPPLY FUSEF13 +15 WINDSCREEN WASHERS PUMP FUSEF14 CURRENT SOCKET FUSEFG1 +30 POWER SUPPLY FUSEFG2 ALTERNATOR FUSEFG3 POSITIVE STARTING FUSEFG4 FILTER PREHEATING RELAY FUSEG44 ALTERNATORH21 REVERSING BUZZERH60 INCLINOMETER LEDH61 HYDRAULIC OIL CLOGGING LEDH62 HIGH WATER TEMPERATUREH63 BATTERY LEDH64 DRIVE INVERTED LEDH65 RESERVE LEDH66 LOW ENGINE OIL PRESSURE LEDH67 INDICATORS LEDH68 FULL BEAM LEDH69 LIGHTS LEDH73 1ST MECHANICAL GEAR LEDH74 2ND MECHANICAL GEAR LEDH79 ALARMS BUZZERH99 BRAKE OIL ACCUMULATION PRESSURE LEDK37 HEATED STARTER RELAYK45 STARTING RELAYK46 FILTER PREHEATING RELAY

Page 75: AXH1113_UK - Rev0 - Dumper 4200

E/4

Mod. DUMPER 4200

KEY OF STANDARD SYSTEM DWG. NO. E25800-028F

NAME DESCRIPTION SHEET

22222344115155255521334345522555221534225532334555225241113524415

K85 MACHINE OFF ALARM RELAYK86 STARTING SAFETY RELAYK87 FORWARD GEAR RELAYK88 REVERSE GEAR RELAYK89 1ST/2ND MECHANICAL GEAR LED RELAYK92 FLASHINGM4 FRONT WINDSCREEN WIPERSM13 REAR WINDSCREEN WIPERSM43 STARTER MOTORP57 HOUR METERR12 CURRENT SOCKETR36 FILTER PREHEATINGS54 PUSH BUTTON CONTROL PANEL NO CONTACTS55 PUSH BUTTON CONTROL PANEL NO CONTACTS58 FORWARD/REVERSE GEAR SELECTORS70 NEGATIVE BRAKE SWITCHS71 MIX/DISCHARGE BUTTONS72 SLOW/FAST GEAR ENGAGED SWITCHS75 1ST/2ND MECHANICAL GEAR BUTTONS76 STARTER PANELS77 LIGHTS SELECTORS78 INDICATORS SWITCHS80 FLASHING BEACON SWITCHS81 WARNING SWITCHS82 WINDSCREEN WASHERS PUMP BUTTONS83 AIR CONDITIONING SWITCHS84 HEATING SWITCHY15 FORWARD GEAR SVY16 REVERSE GEAR SVY18 DISCHARGE TANK SVY19 TANK MIX SVY29 NEGATIVE BRAKE SVY31 1ST MECHANICAL GEAR SVY32 2ND MECHANICAL GEAR SVY39 ENGINE STOP SVY56 FAST HYDRAULIC GEAR SVX1 6-WAY CONNECTORX13 2-WAY CONNECTORX15 2-WAY CONNECTORX16 2-WAY CONNECTORX18 2-WAY CONNECTORX19 2-WAY CONNECTORX2 6-WAY CONNECTORX21 2-WAY CONNECTORX22 4-WAY CONNECTORX24 4-WAY CONNECTORX25 2-WAY CONNECTORX26 3-WAY CONNECTORX27 3-WAY CONNECTORX29 2-WAY CONNECTORX31 2-WAY CONNECTORX32 2-WAY CONNECTORX34 3-WAY CONNECTORX35 21-WAY MARK CONNECTORX4 2-WAY CONNECTORX46 11-WAY CONNECTORX50 9-WAY CONNECTORX51 2-WAY DEUTSCH CONNECTORX52 18-WAY MIC 70 CONNECTORX56 2-WAY CONNECTORX90 11-WAY MARK CONNECTORX93 12-WAY MIC 70 CONNECTORX94 2-WAY CONNECTORX96 2-WAY CONNECTORX98 6-WAY CONNECTOR

Page 76: AXH1113_UK - Rev0 - Dumper 4200

E/5

WIRE COLOURS

A SKY BLUEB WHITEC ORANGEG YELLOWH GREYL BLUEM BROWNN BLACKR REDS PINKV GREENZ VIOLET

NOTE:WIRES WITH A COMBINATION OF TWO COLOURS ARE MARKED WITH THE FOLLOWING SYMBOLSINDICATING HOW THE ABOVE COLOURS HAVE BEEN COMBINED

EXAMPLE:

Y/G -> YELLOW/GREEN (HORIZONTAL STRIPES)

Y-G-> YELLOW-GREEN (VERTICAL STRIPES)

Page 77: AXH1113_UK - Rev0 - Dumper 4200

E/6

Mod. DUMPER 4200

deifitrecdilaVylnoypoc

5

HOURMETER

PREHEATINGCONTROL UNIT

THERMO-STARTER

RELAY

Page 78: AXH1113_UK - Rev0 - Dumper 4200

E/7

deifitrecdilaVylnoypoc

FORWARD/REVERSE

GEAR SWITCH

Page 79: AXH1113_UK - Rev0 - Dumper 4200

E/8

Mod. DUMPER 4200

deifitrecdilaVylnoypoc

FLASHINGINDICATORSWITCH

Page 80: AXH1113_UK - Rev0 - Dumper 4200

E/9

deifitrecdilaVylnoypoc

PRE-ARRAGEMENTSFOR INCLINOMETER SENSOR

ARRANGEMENTS

Page 81: AXH1113_UK - Rev0 - Dumper 4200

E/10

Mod. DUMPER 4200

deifitrecdilaVylnoypoc

Page 82: AXH1113_UK - Rev0 - Dumper 4200

F/1 - ATTENTION: - Read the SAFETY REGULATIONS (contained in this manual) carefully for the safety of staff and of the vehicle.

HYDRAULIC CIRCUITS

F

Page 83: AXH1113_UK - Rev0 - Dumper 4200

F/2

Mod. DUMPER 4200

- ATTENTION: - Read the SAFETY REGULATIONS (contained in this manual) carefully for the safety of staff and of the vehicle.

PAGE INTENTIONALLY LEFT BLANK

Page 84: AXH1113_UK - Rev0 - Dumper 4200

F/3 - ATTENTION: - Read the SAFETY REGULATIONS (contained in this manual) carefully for the safety of staff and of the vehicle.

Page 85: AXH1113_UK - Rev0 - Dumper 4200

F/4

Mod. DUMPER 4200

- ATTENTION: - Read the SAFETY REGULATIONS (contained in this manual) carefully for the safety of staff and of the vehicle.

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ervizio ssistenza ecnica - Via E. Majorana, 2-4 - 42027 Montecchio Emilia (RE) ITALYTel. +39 0522 869611 - Fax . +39 0522 869744. .

- E-mail:

A TS A T

www.dieci.com [email protected]

S Via E. Majorana, 2-442027 Montecchio Emilia (RE) ITALYTel. +39 0522 869611 Fax +39 0522 869744www.dieci.com - E-mail: [email protected]

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ATTENTION: ALWAYS KEEP A COPY OF THIS MANUAL

ON THE MACHINE AT THE OPERATOR’S DISPOSAL

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