TRANSLATION FROM

ORIGINAL LANGUAGE en_UK

DB 260

SELF LOADING CONCRETE MIXER

USE AND MAINTENANCE MANUAL

RIF. 9301444205 ed. 00

FIORI GROUP S.p.A.

Via per Ferrara, 7
41034 FINALE EMILIA (Modena Italia)
Tel. +39.0535.92357 - Fax +39.0535.90960
http://www.fiorigroup.com

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DB 260 REV. 01 10/07/2015
 CAUTION

STUDY THIS MANUAL BEFORE USING THE

MACHINE!
Operators and maintenance staff must read this
manual carefully before using the machine or
carrying out maintenance work. In case of doubts,
ask your Dealer or employer. Do not attempt
to guess at the operations to perform, as this
may cause serious personal injuries or property
damage. This manual must be kept onboard the
machine for prompt consultation at any time,
and must be handed over to the new owner if the
machine is resold.

CAUTION

For reasons of clarity, some illustrations in this

manual show the vehicle without guards.
Never use the vehicle without the guards and
do not start the engine when the engine guard
is open unless expressly indicated in the
maintenance operations.

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 CONTENTS 0
INTRODUCTION 1
TECHNICAL FEATURES 2
SAFETY PRECAUTIONS 3
OPERATION AND USE 4
MAINTENANCE 5
OPTIONAL EQUIPMENT 6
TECHNICAL ANNEXES

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 CONTENTS

1 INTRODUCTION
1.1. GENERAL RECOMMENDATIONS.................................................................................................. 13
1.2. SYMBOLS USED IN THE MANUAL ................................................................................................ 14
1.3. DIRECTION REFERENCES ............................................................................................................ 14
1.4. VEHICLE CONTROL AND DRIVING PHASES .............................................................................. 14
1.4.1. ROAD TRANSFER PHASE (PREFERENTIAL DRIVING DIRECTION) .......................................... 14
1.4.2. WORKING PHASE (SLOW SPEED DRIVING) ............................................................................... 14
1.5. INTENDED USE .............................................................................................................................. 15
1.6. UNAUTHORISED OR IMPROPER USE ......................................................................................... 15
1.7. DRIVER OF THE VEHICLE ............................................................................................................. 16
1.8. MANUFACTURER ........................................................................................................................... 17
1.8.1. TECHNICAL SERVICE REQUESTS ............................................................................................... 17
1.9. MACHINE IDENTIFICATION ........................................................................................................... 18
1.10. REGULATORY PROVISIONS ......................................................................................................... 20
1.11. DECLARATION OF CONFORMITY ................................................................................................ 21

2 TECHNICAL FEATURES
2.1. DIMENSIONS .................................................................................................................................. 23
2.2. TECHNICAL DATA ......................................................................................................................... 24

3 SAFETY PRECAUTIONS
3.0. FOREWORD ...................................................................................................................................... 27
3.1. PRECAUTIONS OF USE ....................................................................................................................27
3.1.1. PERSONAL PROTECTION DEVICES (PPD) ................................................................................. 27
3.1.2. VEHICLE LIMITS ............................................................................................................................. 27
3.1.3. NOISE LEVEL .................................................................................................................................. 28
3.1.4. VIBRATION LEVEL ......................................................................................................................... 28
3.1.4.a Vibration level on the “operator’s body” measured on the driver’s seat ........................................... 28
3.1.4.b Vibration level on the “hands/arms” measured on the steering wheel. ............................................ 28
3.1.5. SAFETY DEVICE CHECKS ............................................................................................................ 28
3.1.6. PRECAUTIONS WHEN USING ACCESSORIES ........................................................................... 28
3.1.7. PROHIBITION TO TRANSPORT PERSONS OR OBJECTS .......................................................... 28
3.1.8. GETTING ON AND OFF THE VEHICLE ......................................................................................... 29
3.1.9. DRIVER’S SEAT .............................................................................................................................. 29
3.1.10. DRIVER’S CAB / OPERATOR’S PROTECTIVE STRUCTURE ....................................................... 29
3.1.11. ROPS (ROLL OVER PROTECTIVE STRUCTURE) ........................................................................ 29
3.1.12. FOPS (FALLING OBJECT PROTECTIVE STRUCTURE) ............................................................... 30
3.1.13. SEATBELTS .................................................................................................................................... 30
3.1.14. CHECKS BEFORE STARTING THE VEHICLE .............................................................................. 30
3.1.15. STARTING THE VEHICLE ............................................................................................................... 30
3.1.16. PRECAUTIONS WHILE DRIVING .................................................................................................. 31
3.1.17. PRECAUTIONS WHILE DRIVING IN REVERSE ............................................................................ 31
3.1.18. DANGEROUS WORKING CONDITIONS ....................................................................................... 32

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3.1.19. WORKING AREA ............................................................................................................................ 32

3.1.20. VISIBILITY OF THE WORKING AREA ........................................................................................... 32
3.1.21. SITE CONDITIONS.......................................................................................................................... 33
3.1.22. PRECAUTIONS DURING OPERATIONS ....................................................................................... 33
3.1.23. WORKING ON SLOPES ................................................................................................................. 34
3.1.24. DRIVING ON ICY OR SNOW-COVERED SURFACES .................................................................. 34
3.1.25. ELECTRICAL LINES ....................................................................................................................... 34
3.1.26. CLOSED ENVIRONMENTS ............................................................................................................ 35
3.1.27. STOPPING THE VEHICLE .............................................................................................................. 35
3.1.28. PARKING THE VEHICLE ................................................................................................................. 35
3.1.29. TOWING AND RECOVERY............................................................................................................. 36
3.1.30. TRANSPORT ................................................................................................................................... 36
3.2. PRECAUTIONS AGAINST RESIDUAL RISKS ............................................................................... 37
3.2.1. SLIPPING......................................................................................................................................... 37
3.2.2. MOVING PARTS ............................................................................................................................. 37
3.2.3. SHEARING OR TRAPPING............................................................................................................. 37
3.2.4. CRUSHING ..................................................................................................................................... 37
3.2.5. OVERTURNING .............................................................................................................................. 38
3.2.6. TYRE BURSTING ............................................................................................................................ 39
3.2.7. ELECTRICAL RISKS ...................................................................................................................... 39
3.2.8. RISK OF SHORT-CIRCUIT ............................................................................................................. 39
3.2.9. BATTERY ........................................................................................................................................ 39
3.2.10. HOT AND PRESSURISED FLUIDS ............................................................................................... 40
3.2.11. RISK OF BURNS ............................................................................................................................. 40
3.2.12. VENTILATION.................................................................................................................................. 40
3.2.13. INTOXICATION................................................................................................................................ 40
3.2.14. FIRE PREVENTION......................................................................................................................... 41
3.3. PRECAUTIONS DURING MAINTENANCE OPERATIONS ........................................................... 42
3.3.1. CORRECT MAINTENANCE ........................................................................................................... 42
3.3.2. PRECAUTIONS DURING WELDING OPERATIONS ...................................................................... 45
3.3.3. FAULTS AND UNAUTHORISED MODIFICATIONS ........................................................................ 45
3.3.4. CLEANING THE VEHICLE .............................................................................................................. 45
3.3.5. WASTE FLUID/MATERIAL DISPOSAL........................................................................................... 46
3.4. WARNING AND SAFETY LABELS (RESIDUAL RISKS) ................................................................. 47
3.4.1. LOCATION OF THE WARNING AND SAFETY LABELS ............................................................... 47
3.4.2. MEANING OF THE WARNING AND SAFETY LABELS .................................................................... 49
3.5. SAFETY DEVICES ON THE VEHICLE .......................................................................................... 52
3.6. SAFETY DEVICES FOR ROAD USE ............................................................................................. 55

4 OPERATION AND USE

4.0. INTRODUCTION.............................................................................................................................. 57
4.1. REFERENCES AND DESCRIPTIONS OF THE MAIN DEVICES ................................................. 58
4.1.1. INSTRUCTION LABELS ON THE MACHINE ................................................................................ 59
4.2. CONTROLS AND GAUGES ........................................................................................................... 62
4.2.1. DRIVER’S SEAT .............................................................................................................................. 62

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4.2.1.a Steering wheel ................................................................................................................................ 62

4.2.1.b Height- and depth-djustable driver’s seat with seatbelt ................................................................. 62
4.2.1.c Service and emergency brake pedal .............................................................................................. 63
4.2.1.d Accelerator pedal ........................................................................................................................... 63
4.2.1.e Parking brake button ...................................................................................................................... 63
4.2.1.f Steering type selecting lever ........................................................................................................... 63
4.2.1.g (Mechanical) gearshift control lever ............................................................................................... 64
4.2.1.h Pivoting driving post locking lever .................................................................................................. 64
4.2.1.i Windscreen washer switch.............................................................................................................. 64
4.2.1.l Power socket................................................................................................................................... 64
4.2.1.m Heating/defrosting fan adjuster ....................................................................................................... 64
4.2.1.n Windscreen water switch ................................................................................................................ 64
4.2.1.o Rotating light switch ........................................................................................................................ 64
4.2.1.p Short Manual ................................................................................................................................... 65
4.2.1.q Hand accelerator lever .................................................................................................................... 65
4.2.1.r Rear windscreen wiper.................................................................................................................... 65
4.2.1.s Cabin light ....................................................................................................................................... 65
4.2.1.t Windscreen washer fluid tank ........................................................................................................ 65
4.2.1.u Fuses and Relays ........................................................................................................................... 65
4.2.2. DRIVING POST INSTRUMENT PANEL............................................................................................ 66
4.2.2.a Electronic control panel .................................................................................................................... 66
4.2.2.b Water Liter counter........................................................................................................................... 67
4.2.2.c Hour counter/revolution counter ....................................................................................................... 67
4.2.2.d Maintenance schedule .................................................................................................................... 68
4.2.2.e Forward/reverse gear selector ......................................................................................................... 68
4.2.2.f Slow / fast gear selector .................................................................................................................. 68
4.2.2.g Drum rotation switch ........................................................................................................................ 69
4.2.2.h Reset switch ..................................................................................................................................... 69
4.2.2.i Water pumps control switch ............................................................................................................ 69
4.2.2.k Hazard light toggle switch ............................................................................................................... 69
4.2.2.l Working light switch ........................................................................................................................ 69
4.2.2.m Engine starter and stopping switch ................................................................................................. 70
4.2.2.n Direction indicators switch and horn ................................................................................................ 71
4.2.3. OPERATING CONTROL PANEL..................................................................................................... 72
4.2.3.a Drum traverse swinging lever .......................................................................................................... 72
4.2.3.b Drum raising lever ............................................................................................................................ 72
4.2.3.c Unloading chute control lever........................................................................................................... 73
4.2.3.d Joystick for arm raising and bucket/loader rotation .......................................................................... 73
4.2.4. WATER FEEDING AND DISTRIBUTION CONTROLS .................................................................. 74
4.2.5. GROUND CONTROL PANEL (MIX CONTROL) ............................................................................ 75
4.2.6. OPERATION OF THE ELECTRONIC LITRE COUNTER AND
MIX CONTROL PROGRAMMING .................................................................................................. 76
4.3. INSTRUCTIONS FOR USE ............................................................................................................. 77
4.3.1. REFUELLING................................................................................................................................... 77
4.3.2. LEVEL CHECK ................................................................................................................................ 78
4.3.3. FILLING THE WATER TRANSFER PUMP BODY .......................................................................... 78

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4.3.4. ADJUSTING THE SEAT................................................................................................................... 79

4.3.5. ADJUSTING THE REAR-VIEW MIRROR........................................................................................ 79
4.3.6. DRIVING POST PIVOTING ............................................................................................................. 80
4.3.7. STARTING THE ENGINE ................................................................................................................ 81
4.3.8. ENGINE OPERATION AT LOW RPM ..............................................................................................82
4.3.9. ADJUSTING WHEEL ALIGNMENT ..................................................................................................82
4.3.10. TESTING THE PARKING BRAKE ....................................................................................................82
4.3.11. STARTING AND DRIVING THE VEHICLE .......................................................................................83
4.3.12. FIELD OF INDIRECT VISIBILITY OF THE REAR OF THE VEHICLE ............................................84
4.3.13. STOPPING THE VEHICLE ...............................................................................................................85
4.3.14. STOPPING THE ENGINE ................................................................................................................85
4.3.15. PARKING THE VEHICLE ..................................................................................................................85
4.4. TRANSPORTING THE VEHICLE .....................................................................................................86
4.4.1. LIFTING THE VEHICLE WITH A CRANE ........................................................................................87
4.5. TOWING AND RECOVERY ..............................................................................................................88
4.5.1 RELEASING THE PARKING BRAKE IN THE EVENT OF A BRAKE SUPPLY SYSTEM FAULT ......89
4.6. DRIVING ON PUBLIC ROADS .........................................................................................................90
4.7. HOMOLOGATION FOR ROAD USE (ITALY) ...................................................................................91
4.8. PRECAUTIONS FOR USE IN COLD CLIMATE CONDITIONS........................................................91
4.8.1 SUMMER/WINTER HEATING SYSTEM .........................................................................................92
4.9. PRECAUTIONS IN THE EVENT OF LONG PERIODS OF INACTIVITY ........................................93
4.10. WORKING PHASES .........................................................................................................................93
4.10.1. CORRECT USE OF THE VEHICLE .................................................................................................94
4.10.2. BEFORE GETTING ON THE VEHICLE (CHECKS AND WARNINGS) ............................................94
4.10.3. CORRECT USE ON SLOPES ..........................................................................................................94
4.10.4. CONCRETE COMPOSITION AND BATCHING TABLE....................................................................96
4.10.5. FIRST FILLING WITH MIXING WATER............................................................................................97
4.10.5.a Filling the tanks with mixing water ....................................................................................................97
4.10.5.b First filling with mixing water .............................................................................................................98
4.10.5.c Activating the water transfer pump....................................................................................................98
4.10.6. CEMENT LOADING ..........................................................................................................................99
4.10.6.a Cement in bags .................................................................................................................................99
4.10.6.b Cement in silos................................................................................................................................100
4.10.7. AGGREGATE LOADING ................................................................................................................100
4.10.7.a Heaped aggregate .........................................................................................................................100
4.10.8. MIXING AND SECOND FILLING WITH WATER ............................................................................101
4.10.9. CONCRETE UNLOADING..............................................................................................................102
4.10.9.a Concrete unloading from chute .......................................................................................................102
4.10.9.b Front unloading from chute..............................................................................................................103
4.10.9.c Unloading in formworks in traverse swinging mode ........................................................................104
4.10.9.d Direct unloading from hopper ..........................................................................................................105
4.10.9.e Concrete unloading from drum emergency door.............................................................................106
4.10.10. BUCKET, DRUM AND CHUTE WASHING ....................................................................................107
4.10.11. INTERNAL CLEANING OF THE MIXING DRUM ..........................................................................108
4.10.12. EXTRAORDINARY DRUM CLEANING OR BLADE REPLACEMENT ..........................................108

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5 MAINTENANCE
5.1. FOREWORD .....................................................................................................................................109
5.1.1. VISUAL EXTERNAL INSPECTION ................................................................................................... 110
5.1.2. CLEANING THE VEHICLE .............................................................................................................. 110
5.1.3. CHECKING FOR DAMAGES ............................................................................................................ 111
5.1.4. ACCESS TO THE MAIN DEVICES ................................................................................................... 111
5.1.4.1. PARTS CONTAINED IN THE TOOL KIT ........................................................................................... 111
5.1.4.2. ROUTINE MAINTENANCE AND CHECKS....................................................................................... 112
5.2. MAINTENANCE SCHEDULE............................................................................................................ 113
5.3. RUNNING-IN AND SERVICE ........................................................................................................... 113
5.4. SCHEDULED MAINTENANCE TABLE ............................................................................................. 114
5.5. ENGINE MAINTENANCE SCHEDULE ............................................................................................. 116
5.6. RECOMMENDED LUBRICANTS AND FLUIDS TABLE ................................................................... 118
5.7. GENERAL INSPECTIONS ................................................................................................................ 119
5.7.1. GREASE ........................................................................................................................................... 119
5.7.2. CLEANING AND DRAINING THE FUEL TANK ................................................................................120
5.7.3. FIFTH WHEEL LUBRICATION..........................................................................................................120
5.7.4. SCRAPER BLADE AND LOADING BUCKET HATCH BELLOWS ....................................................121
5.8. AXLE AND WHEELS ........................................................................................................................122
5.8.1. CLEANING THE AXLE AND DIFFERENTIAL BLEEDERS ...............................................................122
5.8.2. CHECKING AND TOPPING UP THE OIL LEVEL IN THE FRONT AND REAR AXLES ...................122
5.8.3. REPLACING THE OIL IN THE FRONT AND REAR AXLES .............................................................123
5.8.4. CHECKING AND ADJUSTING THE TYRE PRESURE .....................................................................124
5.8.5. REPLACING THE WHEELS .............................................................................................................125
5.9. BRAKES ............................................................................................................................................128
5.9.1. CHECKING AND TOPPING UP THE BRAKE FLUID LEVEL ..........................................................128
5.9.2. CLEANING THE BRAKE FLUID TANK BLEEDERS ........................................................................128
5.9.3. REPLACING THE BRAKING SYSTEM FLUID .................................................................................129
5.9.4. EFFICIENCY OF THE HAND BRAKE ..............................................................................................130
5.9.5. CHECKING THE WEAR CONDITION OF THE BRAKING SYSTEM ...............................................130
5.10. HYDRAULIC SYSTEM .....................................................................................................................131
5.10.1. CHECKING THE HYDRAULIC OIL...................................................................................................131
5.10.2. REPLACING THE HYDRAULIC OIL TANK BLEEDER ....................................................................131
5.10.3. CHANGE THE HYDRAULIC OIL FILTER CARTRIDGE...................................................................132
5.10.4. REPLACING THE HYDRAULIC OIL .................................................................................................133
5.10.5. CHECKING AND TOPPING UP THE DRUM REDUCTION GEAR OIL LEVEL ...............................134
5.10.6. DRUM REDUCTION GEAR OIL CHANGE .......................................................................................134
5.10.7. REPLACING THE DRUM REDUCTION GEAR OIL .........................................................................135
5.11. ENGINE ............................................................................................................................................136
5.11.1. CLEANING THE ENGINE AIR FILTER SEPARATOR .....................................................................136
5.11.2. CLEANING OR REPLACING THE ENGINE AIR FILTER CARTRDIGE...........................................136
5.11.3. CHECKING AND TOPPING UP THE COOLANT LEVEL ................................................................137
5.11.4. REPLACING THE ENGINE COOLANT ...........................................................................................138
5.11.5. CHECKING AND ADJUSTING THE ALTERNATOR BELT TENSIONING ........................................139

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5.11.6. FUEL SEDIMENT BOWL .................................................................................................................139

5.11.7. AIR BLEEDING IN THE ENGINE FUEL SUPPLY SYSTEM ............................................................140
5.11.8. REPLACING THE ENGINE FUEL SUPPLY PRE-FILTER AND FILTER ...........................................140
5.11.9.CHECKING AND TOPPING UP THE ENGINE OIL LEVEL ...............................................................141
5.11.10. REPLACING THE ENGINE OIL FILTER .........................................................................................142
5.11.11. REPLACING THE ENGINE OIL ......................................................................................................142
5.12. ELECTRIC COMPONENTS ................................................................................................................143
5.12.1. FUSES AND RELAYS .......................................................................................................................143
5.12.2. ELECTRONIC DASHBOARD WARNING LIGHTS ...........................................................................146
5.12.3. REPLACING THE LIGHT BULBS .....................................................................................................147
5.12.4. CHECKING AND TOPPING UP THE BATTERY ELECTROLYTE LEVEL ......................................148
5.12.5. BATTERY PINS CONTACT ..............................................................................................................149
5.12.6. BATTERY REPLACE ........................................................................................................................149
5.13. WATER SYSTEM ...............................................................................................................................150
5.13.1. CHECKING AND MAINTAINING THE LITRE COUNTER .................................................................150
5.13.2. CHECKING THE WATER TRANSFER PUMP EFFICIENCY ............................................................150
5.13.3. WATER PUMP EMERGENCY ACTIVATION ...................................................................................151
5.13.4. CLEANING PRE-FILTER OF THE WATER PUMP ..........................................................................151

6 OPTIONAL EQUIPMENT .............................................................................................................153

153

TECHNICAL ANNEXES ...............................................................................................................................161

ENGINE USE AND MAINTENANCE MANUAL

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INTRODUCTION

This manual has been designed to provide a practical guide for proper and safe use of the machine, as well as
for its correct routine maintenance.
Thorough and ongoing observance of the instructions contained herein will help ensure the machine optimal
performance, its operation economy as well as its longest life. In addition, this will allow you to use the
machine properly, thus helping to avoid the most common accidents which may occur during operation or
maintenance.

1.1 GENERAL RECOMMENDATIONS

This use and maintenance manual is an integral and essential part of the machine and must be delivered to
the user.
Read this manual carefully and thoroughly before starting, using and performing maintenance, refuelling or
any other operation on the machine.
The machine shall be entrusted to and operated by skilled staff only, which must have been duly trained on the
use of self-propelled vehicles of this type and on the relative safety rules and regulations.
The operator must observe all safety and accident prevention regulations as well as the Road Traffic Regulations
if the vehicle is road driven.
Furthermore, it is essential to carefully read the safety CAUTIONs found on the machine plates and labels,
and to strictly observe the instructions contained therein before starting, operating or repairing the machine or
performing maintenance operations on the same.
Each machine comes equipped with a copy of this manual.
The manual must be properly and safely stored in its compartment in the driver’s cab. It must be kept within
reach and in good conditions at all times. Do not use the machine if this manual is not in the cab and if you
have not read all the instructions carefully.
If the manual is lost or becomes illegible (pages torn, dirty, etc.) ask either your Dealer or the Manufacturer
immediately for a new copy.
The machine must be used for its intended purpose only. Any other use is to be considered improper and
consequently dangerous.
Thorough and ongoing observance of the instructions contained herein will help ensure a longer service life
and reduction of maintenance and stop time. In addition, this will help you to avoid the most common accidents
which may occur during operation or maintenance.
It is of mutual interest to observe the aforementioned instructions, and that the buyer undertakes to ensure that
this manual is an integral part of the machine, that it is actually consulted by the operator and by maintenance
staff and that the instructions provided are strictly observed, assuming full responsibility in relation thereto.
The buyer and the operator of the vehicle must read the use and maintenance manual carefully the first time
they are using the machine. If this vehicle is subject to a use or lease agreement, it is the owner’s duty to
make sure that the new user reads and understands this use and maintenance manual. In addition, make sure
that the new operator has fully inspected the vehicle and is knowledgeable with all of its labels, decals and
equipment, and that he has tested all the controls to understand and verify their proper functioning.
The Manufacturer reserves the right to make any and all modifications for product improvement purposes,
without updating this documentation.
For additional information, please feel free to contact your Dealer or the Manufacturer at your convenience.

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1.2 SYMBOLS USED IN THE MANUAL

To provide a clearer understanding of the information contained in this manual, major information or information
regarding danger is shown with the following symbols:

DANGER: Indicates a situation of imminent risk that, if not avoided, may result
in serious injury or even death.

CAUTION: Indicates a potential risk which, if not avoided, may result in injury of low or medium se-
verity. It may also be used to prohibit operations involving risks and which may cause
damages.

1.3 DIRECTION REFERENCES

A B

FRONT REAR

The position of the pivoting driving post determines the driving direction.
The right-hand side (RH) or left-hand side (LH) will be identified based on the current driving position of the
operator, as shown in fig. A - B.

1.4 VEHICLE CONTROL AND DRIVING PHASES

1.4.1 TRANSFER PHASE (PREFERENTIAL SPEED)

The driving post is turned toward the front of the machine.
Driving the machine on short or long stretches, with or without carrying material.

1.4.2 WORKING PHASE (SLOW SPEED DRIVING)

The driving post is turned toward the rear of the machine.
Driving the machine for bucket and materials loading.
Driving the machine at work sites, for approaching and manoeuvring steps to dump materials.

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1.5 INTENDED USE

This machine has been designed and manufactured to load aggregates, cement and water in the appropriate
quantities, and mix them homogeneously directly on the worksite, to produce quality concrete for on-site
casting.
Use of the machine on public roads is subject to road traffic regulations in force in the country of use.
This machine must be used by the driver only and cannot be used to transport other people.
This machine has been designed and manufactured for its intended use and purpose. Therefore, its technical
features shall be considered binding in order to use the machine for its intended purpose.
No modifications can be made to the machine without prior authorisation from FIORI, as they may lead to
dangerous situations. It is always necessary to strictly observe the safety rules and regulations illustrated in
this use and maintenance manual.

1.6 UNAUTHORISED OR IMPROPER USE

It is strictly forbidden to use the machine for any operation other than those described herein.
Under no circumstance may FIORI be held responsible for any other use of the machine or for non-observance
of the instructions provided by the Manufacturer.
The machine shall not be used for underground works or in potentially explosive workplaces. In the
event of underground works, contact FIORI to request information on the requirements to be observed
for adjusting the machine so that it is suitable for such purposes.
Any unauthorised modification to the machine relieves the Manufacturer from any responsibility for property
damage or personal injuries which may directly and/or indirectly arise in connection therewith.
The Manufacturer and its Distribution and After Sales Service Network accept no responsibility for any damage
which may arise in connection with not approved and malfunctioning components fitted on the machine during
maintenance or repair operations.
No objects of any kind may be transported on the machine or inside the driver’s cab.
Therefore no warranty, of any kind whatsover, is provided in relation to the product manufactured or traded by
the Manufacturer for damages due to non-approved malfunctioning parts and/or components.

DANGER: If the machine is used for any purpose other than its intended and allowed use,
the operator shall be responsible for his own safety as well as for the safety of any
other person involved.

CAUTION: FIORI accepts no responsibility for personal injury or property damage which may derive
from non observance of the provisions and instructions contained in this manual and from
non observance of safety and accident prevention regulations.

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1.7 DRIVER OF THE VEHICLE

Road driving of the vehicle is naturally governed by Road Traffic Regulations, and therefore the driver shall be
equipped with a driving license as required.
In order to use the machine on the worksite, the operator must be of the minimum age established by applicable
legislation in the country of use. The operator may use the machine only after receiving adequate and specific
training.
This training must ensure that the machine is used correctly in relation to the risks which may arise for the
driver or other people.
Driving an earth moving machine always requires technical skills and training, in addition to a strong sense
of responsibility. The operator must therefore have specific psychophysical requisites to qualify for this job.
Therefore, only authorised personnel may use these vehicles.
The operators must be duly trained on the use of the machine and instructed about any possible risks at the
workplace.
We recommend that all staff follow a training course aimed at learning how to use the machine safely and
efficiently and getting specific knowledge on the engine and hydraulic system operation, in order to perform
cleaning and maintenance operations.
The machine must only be driven and serviced by persons who:
- have an excellent eyesight and colour perception, good hearing, co-ordination and sharp reflexes;
- are physically and mentally eligible for this type of job, and are able to meet the requirements connected with
the machine operation at peak performance levels;
- refrain from operating the machine when they are tired, unwell or under the influence of drugs, alcohol or
medicines which may affect their physical abilities or sharpness of their reflexes;
-are able to read and properly understand the instructions contained in this manual, according to the
Manufacturer’s purposes;
-have an excellent ability to assess weight, distance and size;
- are able to drive and control the machine at the worksite;
-have been trained on the operation of the machine and its maintenance, know its technical specifications, its
overall dimensions as well as its performance and limitations;
- are conscientious, careful and aware of the problems of their own safety and that of other people, animals,
property, the machine itself and the environment;
- are knowledgeable with the safety rules and regulations applicable to the workplace.
The Legal Representative of the company which owns the vehicle shall appoint the staff who possess the
above said requisites to perform the tasks required.
The operator is also responsible for and shall assure that:
- nobody approaches the machine when it is working;
- no unauthorised and untrained personnel may use the machine;
- the safety procedures learnt during the training course are observed every day;
- potential hazards in the workplace are recognised and avoided;
- the caution and warning labels and plates have been read and understood, and their instructions observed
(see Section 3 “Safety Labels and Decals”);
- the machine has been inspected and its proper working condition checked before starting the work shift;
- report any operational problems encountered before, or while operating the machine;
- reckless or careless actions, which may endanger his own safety as well as other people’s safety, are
avoided;
- common sense is used at all times and safety has absolute priority.
The machine is manufactured and supplied for its intended use, as specified in this manual. Operators are
reminded that, when using the machine, they must always and under all circumstances behave following
active safety principles, in order to enhance the overall safety level of the machine. Prior to commencing work,
the operator must check that all the safety devices are active and functioning properly: he/she is obliged to
refuse to start work in the event that the requirements for safe working are not met.

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INTRODUCTION

CAUTION: FIORI accepts no responsibility for any damage to persons, animals, property or the envi-
ronment resulting from the machine being operated and used by staff without the required
prerequisites.

1.8 MANUFACTURER

The machine and any offspin models are manufactured exclusively by:

FIORI GROUP S.p.A.

Via per Ferrara, 7
41034 FINALE EMILIA (Modena) Italia
Tel. +39.0535.92357 - Fax +39.0535.90960
http://www.fiorigroup.com

1.8.1 Technical Service Requests

In the event of any machine failure or malfunction, it is essential to follow the instructions below:

- If the trouble persists, do not try further actions or expedients. Contact the nearest authorised FIORI SERVICE
CENTRE or directly:

FIORI GROUP S.p.A.

Via per Ferrara, 7
41034 FINALE EMILIA (Modena) Italia
Tel. +39.0535.780250 - Fax +39.0535.90960

When you contact Fiori After Sales Service, make sure you have all necessary details available, which must
be provided to the Service staff so as to immediately identify the machine model and understand the problem.

- Provide all data shown on the identification plate secured on the machine.

- Make sure you have all diagrams and layouts contained in this manual available and within reach.

- Give a brief and very clear description of the current failure or malfunction.

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INTRODUCTION

F
2
C
E

A
*BF08M00600*

B D

1.9 MACHINE IDENTIFICATION

The identification data of the machine and its main components are punched on metal plates, which allow the
machine to be identified by the After Sales Service by means of specific ID numbers and letters.
The following information show where the identification plates and punched numbers are located, and give
examples of the symbols found on the machine.

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INTRODUCTION

A - VEHICLE SERIAL NUMBER

The serial number is punched on the bumper side, on the right-hand side of the machine (with respect to
the driving direction).
CAUTION: This number must always be provided whenever requesting assistance from the FIORI
After Sales Service Network. The serial number is also required to facilitate identifying the
machine in the event of theft.

B - VEHICLE AND MANUFACTURER’S DATA PLATE

The vehicle and Manufacturer’s data plate is found on the front right-hand bumper, as shown in the figure.
Please fill in the following data concerning your vehicle:
MODEL/TYPE................................................................................................................... DB 260 / BF08M
SERIAL NUMBER ................................................................................ •BF08M 0 0600• / •BF08M A 0600•
YEAR .............................................................................................................................................................

C - ENGINE DATA PLATE

The engine data plate is positioned on the power take-off side.
Write down your vehicle numbers in the space below for quick and easy reference:
MODEL No. ..................................................................... 2612/2400 (1104A-44) - 3058/2200 (1104D-44T)
SERIAL NUMBER ..........................................................................................................................................

D - AXLE DATA PLATE

The axle type and serial numbers are printed on the plate found on the axle central case.
Write down the information in the space below for quick reference:
FRONT AXLE TYPE .............................................................................................. • S128.10061.002.B01 •
SERIAL NUMBER ..........................................................................................................................................
REAR AXLE TYPE................................................................................................. • S128.40041.003.B01 •
SERIAL NUMBER ..........................................................................................................................................

E - TRANSMISSION DATA PLATE

The serial number and type are punched on the pump (1) and engine (2) plates.
Write down the information in the space below for quick reference:
1- PUMP MODEL.................................................................................................................... • A10VG45 •
SERIAL NUMBER ..................................................................................................................................
2- ENGINE MODEL ................................................................................................................. • A6VM80 •
SERIAL NUMBER ..................................................................................................................................

F - OPERATOR PROTECTION PLATE

The ROPS - FOPS operator’s protection plate is found inside the upper section of the structure.

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INTRODUCTION

1.10 REGULATORY PROVISIONS

The machine has been built in compliance with applicable European directives and laws, and conforms to the
standards of the indicated directives:

MACHINE
- Directive 2006/42/EC on “Machinery”
- Directive 2004/108/EC on “Electromagnetic Compatibility”
- Directive 2000/14/EC on “Noise emission”

ENGINE
- STAGE 0 - E.U. STAGE III A / EPA Tier 3

CABIN
- ROPS UNI 11023
- FOPS LEVEL I ISO 3449
- FOPS LEVEL II ISO 3449 (optional)

QUALITY STANDARD
FIORI GROUP S.p.A. is a certified company:
- ISO 9001 - 2008 “Quality”
- ISO 14001 - 2004 “Environment”
- BS OHSAS 18001 - 2007

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INTRODUCTION

1.11 DECLARATION OF CONFORMITY

The EC Declaration of conformity is the document undersigned by the Manufacturer which warrants and
certifies that the machine complies with all European regulatory provisions concerning the product. This
document is provided with the entire documentation on machine delivery. It must be carefully kept on board
and shall always accompany the machine until its end-of-life scrapping.
The declaration shows the machine identification data, the manufacturer’s details and applicable law
provisions.
Below is an EC declaration facsimile:

Declaration of conformity CE
for a new industrial machine

As a representative I declare that the following machine

1, Category : Self loading concrete mixer

2, Mark/Model : FIORI - DB260
3, Model : BF08M
4, Chassis number : *BF08M00000*
5, Manufacturer : FIORI GROUP S.p.A.
6, Year of manufacture : 2015

is designed and manufactured in compliance with the following European Directives:

- Directive 2006/42/CE "Safety of machinery"

- Directive 2004/108/CE "Electromagnetic compatibility"
- Directive 2000/14/CE "Noise emission"
according to the contents of Annex V (internal production control)
with the technical documentation retained by the manufacturer.

Measured sound power level 104 dB(A)

Guaranteed sound power level 106 dB(A)
Nominal drum output 2,5 mc

For proper and safe machine use, we recommend that you follow the instruc-
tions given in the "Use and Maintenance Manual".

Att. n°: 0000

Finale Emilia, lì FIORI GROUP S.p.A.

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TECHNICAL FEATURES

2.1 DIMENSIONS
- Minimum road transfer length ...........................................................................................................5,040 mm
- Maximum length with loader on the ground .....................................................................................5,910 mm
- Maximum width ................................................................................................................................2,210 mm
- Minimum height with loader on the ground ......................................................................................2,775 mm
- Maximum road transfer height ..........................................................................................................3,785 mm
- Maximum hopper unloading height ...................................................................................................1,845 mm
- Maximum chute unloading height......................................................................................................1,445 mm
- Minimum chute unloading height.......................................................................................................1,345 mm
- Front angle of attack ................................................................................................................................... 37°
- Rear angle of attack ................................................................................................................................... 56°
- Ground clearance under the differentials ............................................................................................370 mm
- Minimum wheel radius...................................................................................................................... 1,870 mm
- Minimum outside wheel radius ......................................................................................................... 4,085 mm

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TECHNICAL FEATURES

2.2 TECHNICAL DATA

DIESEL ENGINE : Stage 0 - No emission compliance

Model : ..............................................................................................................PERKINS serie aspirated 1,104
Total displacement, no Cylinders : ........................................................................................ 4,400cc - 4 in line
Injection : ............................................................................................................ direct with mechanical control
Cooling : .................................................................................................................................water, dry air filter
Max. power : ........................................................................................................................... 64.5 kW (87 Hp)
Adj. power. :......................................................................................................................... 64 kW (2,400 rpm)
Max. torque :...................................................................................................................... 293 Nm a 1,400 rpm

DIESEL ENGINE : E.U. Stage III A / EPA Tier 3

Model : .......................................................................................................PERKINS series turbo engine 1,104
Total displacement, no Cylinders : ........................................................................................ 4,400cc - 4 in line
Injection : ............................................................................................................ direct with mechanical control
Cooling : .................................................................................................................................water, dry air fi ter
Max. power : .......................................................................................................................... 74.5 kW (101 Hp)
Adj. power. :......................................................................................................................... 70 kW (2,200 rpm)
Max. torque :...................................................................................................................... 392 Nm a 1,400 rpm

ELECTRIC SYSTEM
Alternator: ........................................................................................................................................ 12 V - 55 A
Battery: ............................................................................................................................ 12 V - 132 Ah (600 A)
Road light system, rear working lights.

4X4 FOUR-WHEEL DRIVE

Hydrostatic “automotive” transmission with variable displacement pump and variable displacement hydraulic
motor with electro-hydraulic control, and reverse gear control on the steering wheel. Mechanical gearbox for
“working speed” and “road transfer” speed, with mechanical control.
SPEED
4 forward gears 2 reverse gears
Ist 0 - 3.5 Km/h 0 - 3.5 Km/h
IInd 0 - 7.6 Km/h 0 - 3.5 Km/h
IIIrd 0 - 10.4 Km/h 0 - 10.4 Km/h
IVth 0 - 25.0 Km/h 0 - 10.4 Km/h
Traction / weight ratio ................................................................................................................................. 40%

AXLES AND WHEELS

Front oscillating (± 7°) and steering with planetary reduction gears on the wheel hubs.
Rear and steering with planetary reduction gears on the wheel hubs and flanged gearbox.
Tyres: ........................................................................................................................................12.5-18 / 16 PR
Tyres (OPTIONAL) : ................................................................................................................. 405/70-20 14PR

BRAKES
Internal oil-bath disc service and emergency brakes acting on the 4 wheels, activation with pump on independ-
ent dual circuit.
Negative type parking brake, with internal oil-bath discs on the front axle and electro-hydraulically controlled
release.

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TECHNICAL FEATURES

STEERING
Assisted by means of load-sensing power steering on 4 steering wheels; steering selection device for: 2 steer-
ing wheels, 4 steering wheels - crab steering.

EQUIPMENT HYDRAULIC SYSTEM

Gear pump
Max. flow rate: ............................................................................................................................... 45 litres/min.
Maximum pressure: ............................................................................................................................... 180 bar
5-element distributor servo-controlled with multi-function joystick.
Chute lever distributor.
Aluminium heat exchanger for hydraulic oil cooling.
Pressurised closed-circuit intake with oil filter replaceable from the outside.

MIXING AND UNLOADING

Double-cone drum with double-spiral mixing screws and convex bottom.
Geometrical drum volume: ...............................................................................................................3,160 litres
Drum rotation speed: ............................................................................................................................. 23 rpm.
Class S1 concrete produced as : ......................................................................................................... 2.5 cu m
Counterframe mounted on “heavy-duty” ball fifth wheel, with 245° hydraulic rotation and automatic locking by
means of negative brake.
Drum rotation by means of a piston pump with variable flow rate and an orbital hydraulic motor in closed circuit
with infinitesimal electrical control positioned in the cabin and at the rear of the machine.
Drum raising up to the horizontal position by means of 2 double-acting jacks.
Unloading chute with hydraulic tilting by means of a double-acting jack and 180° rotation, independent from the
mixing drum inclination. Removable chute, for direct unloading from hopper.
2 unloading chute extensions provided as standard equipment.

WATER SYSTEM
“Self-priming” volumetric water pump with quick-suction.
Max. capacity: .............................................................................................................................. 250 litres/min.
Maximum head: ......................................................................................................................................... 4 bar
Two connected tanks positioned opposite each other made of polyethylene with a total capacity of 570 ..litres.
Mix Control system for programmable and controlled management of water feeding to the drum and of mixing
and unloading from the ground panel. Water feeding to the drum controlled by means of electromagnetic flow
meter and fed litre reading on both the cabin display and at the rear of the vehicle.
Water pump activation from the driver’s seat and from the ground panel. Suction selection from the ground
with quick-coupling pipes.

LOADER
Loading arms with self-compensated kinematic mechanism, double-acting loader lifting and return cylinders,
electro-hydraulically controlled hatch with standard Tip-Off function.
Volumetric capacity: ............................................................................................................................510 litres
Number of loaderfuls per load: ......................................................................................................... around 7/8

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TECHNICAL FEATURES

CABIN
Closed cabin with heating system, designed in accordance with ROPS & FOPS 1st Level standards .
Sliding side window
180° pivoting driving post. Anatomic seat with flexible suspension and height adjustment, seat belts.

SERVICE REFILL CAPACITIES

Fuel tank in polyethylene, ..................................................................................................................... 90 litres
Total hydraulic system capacity: ......................................................................................................... 100 litres
Engine oil: ............................................................................................................................................... 9 litres

WEIGHTS
Operating weight: ................................................................................................................................ 5,700 kg
Max gross weight: .............................................................................................................................. 11,900 kg
load-carring capacity: .......................................................................................................................... 6,200 kg

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SAFETY PRECAUTIONS

3.0 FOREWORD
This manual is intended as a practical and rational guide to proper use and prevention of the most common
causes of accidents during work and maintenance.
Below are the main rules that must strictly be followed:
- Carefully read this manual before any starting, use, maintenance, refuelling or other operations.
- Read and comply with all the SAFETY REGULATIONS given in this manual before carrying out any
operation.
- Prudence and judgement during appropriate use of the vehicle are essential and basic factors for the safety
of the operator and of other people working near the vehicle.
Therefore, before starting any work, you must know exactly what the functions of all the controls and the
stability characteristics of the vehicle are.

3.1 PRECAUTIONS OF USE

3.1.1 PERSONAL PROTECTION DEVICES (PPD)

Wear clothing suited to the work to be carried out on the site and do not wear loose or hanging clothes such
as ties, scarves, unbuttoned jackets, unzipped garments or sleeves with wide cuffs, which may get caught up
in the moving parts. Do not wear rings, wrist watches or any other jewellery.
The following protective clothing is to be worn as prescribed by the site regulations:
- Hardhat
- Non-slip shoes
- Protective goggles
- Protective gloves
- Anti-noise headsets (where applicable)
- Reflecting garments or vests
- Raincoats in bad weather
- Protective mask for cement loading

3.1.2 VEHICLE LIMITS

- The maximum overall performance level of the vehicle is optimised during functional testing before delivery.
- Do not use the vehicle outside the limits defined during design; exceeding these limits may be dangerous
and cause damage to the vehicle.
- Do not attempt to improve vehicle performance with unapproved modifications.
- Any alteration will lead to forfeiture of the warranty on the vehicle as well as on functional and accessory
equipment.

3.1.3 NOISE LEVEL

In compliance with directive 2000/14/EC the following sound power values were measured according to ISO
6394:
- Sound power level measured .........................................................................................................104 dB(A)
- Sound power level guaranteed .......................................................................................................106 dB(A)
- Equivalent sound pressure level measured at the operator’s ears according to ISO 6394 .............. 88 dB(A)

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SAFETY PRECAUTIONS

3.1.4 VIBRATIONS’ LEVEL

3.1.4.a Vibration level on the “operator’s body” measured on the driver’s seat
Based on measurements made in operating conditions on vehicles similar to this one, it is declared that the
mean level of vibrations on the “operator’s body” is equal to .............................................................. 1 m/sec²
This value is to be understood as RMS, weighted using the “broadband” method in compliance with ISO 7096
and ISO 2631-1 and determined according to a cycle indicated in ISO 25398 with attribution of the times
established by the company according to what are considered customary and probable vehicle operating
conditions.

3.1.4.b Vibration level on the “hands/arms” measured on the steering wheel.

Based on measurements made in operating conditions on vehicles similar to this one, it is declared that the
mean level of vibrations on the “hand/arms” is less than or equal to ................................................ 2.5 m/sec²

This value is to be understood as RMS, weighted using the “broadband” method in compliance with ISO
2631-1 and determined according to a cycle indicated in ISO 25398 with attribution of the times established by
the company according to what are considered customary vehicle operating conditions.

3.1.5 SAFETY DEVICE CHECKS

- Check that all the safety devices are properly installed and that they function properly and are undamaged.
- If any irregularities are found make the appropriate repairs.
- Incorrect use of the safety devices may cause serious accidents with the consequent risk of injury or death.
- Make sure that you use the safety devices correctly.

3.1.6 PRECAUTIONS WHEN USING ACCESSORIES

- During installation of optional components or equipment, problems may occur that put your safety at risk.
Therefore, always ask FIORI for advice before installation.
- FIORI is not responsible for injury, accidents or faults deriving from use of unauthorised equipment or
accessories.
- Before installation and use of accessories, read the instruction manual of the specific accessory and the
general information on accessories given in this manual.

3.1.7 PROHIBITION TO TRANSPORT PERSONS OR OBJECTS

- The vehicle is not homologated for transport of persons other than the operator, who must be seated on the
driver’s seat.
- During all working phases, do not allow anyone to come close to the vehicle.
- Do not allow anyone to climb onto the working equipment.
- Do not carry people onboard the vehicle.
- Do not use the vehicle to transport objects, except those needed for the job and equipped with special
couplings.
- Do not use the vehicle as platform or scaffolding and under no circumstances use it for any function not
specified by the manufacturer.

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3.1.8 GETTING ON AND OFF THE VEHICLE

- To get on the vehicle, use the steps and the handholds in proximity of the driver’s seat; it is prohibited to use
the control levers and devices as handholds.
- If the vehicle starts moving when you are not on it, do not jump on to try and stop it.
- It is prohibited to get on and off the vehicle when it is moving.
- Get off the vehicle only when it has come to a complete halt and is stable.
- Do not get on and off the vehicle by jumping or holding tools in your hands.
- Always face the vehicle when getting on and off the driver’s seat or other raised parts and support yourself
by keeping both hands and one foot or both feet and one hand on the steps and the handrail.
- Do not climb onto the engine compartment lid or other parts of the vehicle.

3.1.9 DRIVER’S SEAT

- Before getting into the operator’s cabin, always remove mud and oil from the soles of your shoes. If you push
a pedal with mud or oil on the soles of your shoes, your foot might slip causing accidents.
- Keep the area around the driver’s seat clean.
- Do not place any object at the foot of the driver’s seat or around the pedals and do not hang anything on
the control levers. The levers might accidentally be activated causing uncontrolled vehicle movement or
activation of the working equipment and hence dangerous conditions.
- Place all objects not needed for driving in the storage compartments provided.
- Do not carry objects in your pockets that may fall into the open compartments of the vehicle.
- Always keep the driver’s seat clear of foreign objects, especially if not secured.
- Do not leave components or tools scattered around the cabin.
- Do not use mobile phones in the cabin while driving or operating the vehicle.
- Never take dangerous objects into the cabin, for example, flammable or explosive objects.

3.1.10 DRIVER’S CAB / OPERATOR’S PROTECTIVE STRUCTURE

- DO NOT modify, repair or remove the operator protective structure. Should it be structurally damaged or
modified (e.g. by welding or drilling) the protection provided by the cabin/roof would be compromised,
creating a risk which may cause death or serious injury.
- After an accident, carefully inspect the protective structure, the driver’s seat, the seatbelt and all the pillars.
- Replace all the parts that show any sign of damage. Original spare parts must be used as indicated in the
Spare Parts Catalogue and can be ordered from FIORI.

3.1.11 ROPS (ROLL OVER PROTECTIVE STRUCTURE)

- The ROPS structure serves to protect the operator and cushion the impact in the event that the vehicle
overturns.
- The ROPS structure is an integral part of the cabin. Do not operate the vehicle without this protection
system.
- The ROPS structure is in compliance with the safety regulations for the vehicle type. If it is damaged, repaired
or modified without authorisation, its deformability may change. In this case, it will no longer be able to
correctly perform its protective function and must be replaced.
- If the structure has been involved in an accident, do not use the vehicle until the structure has been replaced
or inspected by qualified personnel.
- The ROPS structure guarantees protection if the seatbelt is properly fastened. For this reason, always keep
the seatbelt fastened while the vehicle is moving.

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3.1.12 FOPS (FALLING OBJECT PROTECTIVE STRUCTURE)

- The FOPS structure is installed to protect the operator from objects falling from heights.
- If the structure is damaged or modified without the Manufacturer’s permission, its stability will be reduced. In
this case, it will no longer be able to correctly perform its protective function and must be replaced.
- If the structure has been involved in an accident, do not use the vehicle until the structure has been replaced
or inspected by qualified personnel.
The FOPS structure cannot be installed on the vehicle as a standard part, as it is only required for certain types
of work.

3.1.13 SEATBELTS
- Check that the seatbelts do not show any sign of fraying or cuts and that they have not been subjected to
heavy strain (overturning) in which case they need to be replaced.
- Keep the seatbelts correctly positioned on the seat, do not let them get twisted and do not alter or modify
them in any way. Always keep them clean.
- Choose the most comfortable driving position in relation to your build.
- Adjust the seat position. Check functioning of the adjuster, the buckle and the winders (where fitted) and the
method that allows checking that the seatbelts are locked. Adjust the seatbelt tension so that it holds you in
place at the level of the hips leaving your abdomen completely free.
- Do not start work before having checked these safety conditions.

3.1.14 CHECKS BEFORE STARTING THE VEHICLE

- It is prohibited to start or operate the vehicle IF IT IS NOT IN PERFECT WORKING CONDITIONS (e.g. faulty
or malfunctioning).
- Before using the vehicle, make sure that there is no dangerous condition.
- Also check that you have enough fuel so as not to run the risk of being forced to stop, perhaps during a critical
manoeuvre.
- Check that the steering controls and the brakes function perfectly. In case of malfunctions, notify the
maintenance manager and stop the vehicle.
- Check that all the guards and safety devices are in the right position and in such a condition that they can be
operated.
- Check proper functioning of all the safety devices on the vehicle and in the working area.
- Should there be any problems, immediately inform your manager and do not start work if the necessary
safety conditions are not present.
- Do not make any botched repairs just for the sake of starting work.

3.1.15 STARTING THE VEHICLE

- Before starting the vehicle, check and adjust the seat position for optimal driving comfort and so that you can
easily reach the controls, and always fasten the seatbelts.
- Adjust the mirrors so that you can clearly see the area behind the vehicle from the driver’s seat.
- Check that the warning lights work properly and check the angle of the headlights and the working lights.
- Do not drive the vehicle unless you are properly seated on the driver’s seat.
- Never attempt to start the engine by short-circuiting the starter motor. This may cause fire or serious injury.
- Keep your head, body and limbs inside the driver’s cabin, to prevent injury from hitting objects outside the
cabin.
- Do not allow anyone other than yourself to get on the vehicle.
- Do not try to start the engine by rolling the vehicle down a slope.
- Check that no one is standing within the range of action of the vehicle before starting it and using the
equipment.

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3.1.16 PRECAUTIONS WHILE DRIVING

- Before moving the vehicle, check that there is no one in the vicinity.
- Use the horn and observe the signs, banners and signals.
- Always make sure that you can clearly see the entire working or manoeuvring area. If the cabin has windows,
they must always be kept clean and intact.
- Always lock the cabin door in closed position. Lock the cabin windows in open or closed position.
- Always check that the brakes function properly and do not use the vehicle if there are any malfunctions or
irregularities.
- Never turn the ignition switch key to neutral while the vehicle is moving.
- Hold the vehicle at such a speed that you have full control of it in any circumstances.
- Do not use the vehicle with the front lid open or without its guards and covers.
- While driving, do not activate any of the working equipment control levers.
- When driving on uneven ground, drive slowly and do not steer sharply. The vehicle might overturn.
- Always keep at a safe distance from other vehicles or obstacles, so that you always have the necessary
visibility.
- Avoid driving over obstacles, where possible. If you need to drive over an obstacle, drive at low speed. Never
drive over obstacles that will cause the vehicle to lean too far to one side.
- Pay attention to ground unevenness, poor visibility, and other vehicles in the vicinity.
- If the engine slows down and stops under load or runs at idle speed, inform the maintenance manager and
do not use the vehicle until it has been checked.
- When driving on public roads, observe the road regulations and before setting off consult with the competent
authorities and follow their instructions. This vehicle travels at a speed lower than that of normal motor
vehicles, therefore, keep to the edge of the road leaving the centre free for other vehicles to pass.
- If working in the dark, carefully check the working area, turn on all the lights available and do not work in
areas where visibility is poor.
- Do not make quick movements (e.g. continuously steering right and left) which may cause the vehicle to
overturn.
- Overtake only when absolutely necessary.
- When crossing bridges or similar structures, first check that the structure is strong enough to support the
weight of the vehicle and its load.

3.1.17 PRECAUTIONS WHILE DRIVING IN REVERSE

- Reversing at high speed can cause accidents; do not reverse at top speed and always drive at a safe speed
suited to the working conditions.
- If required, check that the camera display is on, in order to ensure maximum visibility of the area behind the
machine.
- When reversing always look in the direction the vehicle is moving. Watch out for people in the area and
immediately stop if anyone comes into the range of action of the vehicle and into the working area.
- If you cannot clearly see the entire working area, ask someone to guide you with hand signals. This person
must stand outside the working area and you must be able to see him or her clearly.

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3.1.18 DANGEROUS WORKING CONDITIONS

Before starting any operation, check that there are no dangerous working conditions in the surrounding area.
- Areas where there are slopes, humps, trees, demolished constructions, escarpments, gorges, tilled soil,
ditches, excavations, heavy traffic, crowded parking and service areas and closed places are classified as
risk areas.
- Check that there are no obstacles such as piping, cables, bottlenecks or loading limitations on the grounds,
bridges, pavements or access ramps.
- Establish the due safety measures to prevent danger on public roads in collaboration with the owners, users
and competent authorities.
- In places where there are underground water or gas pipes or high-voltage cable ducts, contact the public
utilities to find out their exact position. Ensure that these structures are not damaged.
- Take particular precautions when working near ditches, escarpments or close to open excavations.
- To carry out operations in water or when crossing sand banks, check the conditions of the bed and the depth
and speed of water flow.
- Always move slowly on very uneven ground and ridges, in the vicinity of slopes or gorges, and on icy or
slippery ground. Remember that the ground is wet and soft after heavy rains.
If the ground starts to cave in, the vehicle could tip over, sink in or overturn, causing serious injuries.
- If you work with the vehicle in tight spaces or have to pass through narrow doors or structures, manoeuvre
very carefully.
- Avoid crossing or going over obstacles such as rocks, felled trunks, steps, ditches and tracks.
- Always ensure good visibility. Check that there are no people or obstacles in the area around the vehicle.
- Check the conditions of the working area to ensure that you can operate and move safely.

3.1.19 WORKING AREA

The WORKING AREA is defined as the area in proximity of the vehicle where only persons that know its
operating capabilities may work.
The driver may operate only and exclusively when there is no one within the range of action. The driver must
warn anyone in the vicinity of the vehicle of the danger they are in by voice or sounding the horn.
If there is scaffolding or unstable structures near where you are working, keep at a safe distance so that you
do not risk touching these structures should you accidentally make an incorrect manoeuvre.

3.1.20 VISIBILITY OF THE WORKING AREA

- Always check that there is no one in the vicinity of the vehicle before starting work.
- Before getting on the vehicle, walk around it once and check that everything is in order.
- Dust, smoke, fog, etc. may reduce your vision and cause accidents.
- Always stop or slow down until the impediment has been removed and you have perfect visibility of the
working area.
- If you cannot clearly see the entire working area, ask someone to guide you with hand signals and delimit
an area of over 12 metres for forward movement. This person must stand outside the working area and you
must be able to see him or her clearly.
- If working in the dark, carefully check the working area, turn on all the lights available and do not work in
areas where visibility is poor.
- Always make sure that you can clearly see the entire working or manoeuvring area.
- If the cabin has windows, they must always be kept clean and intact.

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3.1.21 SITE CONDITIONS

- Before starting work, analyse and ask for the topography and geological characteristics of the area, so
that the appropriate measures can be taken to prevent landslides and the vehicle from overturning. Holes,
obstructions, rubble and other risks connected with the working areas may cause physical injury or death.
- Always carefully inspect the site to identify any of these risk elements before using the vehicle.
- Be aware of all the conditions on the site and always look in the direction you are driving before starting any
manoeuvre.
- Find out about the movements of persons and vehicles on the site. Follow the indications given by signals
and signs.
- Do not start work until you have ascertained all the safety conditions.

3.1.22 PRECAUTIONS DURING OPERATIONS

- Before and during operations do not drink alcohol, take medicines or other substances that may alter your
capability of working with machine tools.
If you are very tired or not feeling well, do not use the vehicle, and in any case pay the utmost attention at the
beginning and end of your shift.
- Contact the site manager for the safety regulations to be applied according to the laws in force.
- Watch out for people in the area and immediately stop if anyone comes into the range of action of the vehicle
and into the working area.
- During work keep an eye on the instruments and immediately stop the vehicle if any malfunctions are
indicated.
Pay attention to any unusual noise from the engine, the hydraulic device, the transmission components,
the working equipment, etc. If you hear any suspicious noise, immediately stop the vehicle and check what
causes it.
- If you need to continuously work in very noisy conditions, wear a protective headset in accordance with the
regulations in force.
- If working in the dark, carefully check the working area, turn on all the lights available and do not work in
areas where visibility is poor.
- If you cannot clearly see the entire working area, ask someone to guide you with hand signals and delimit
an area of over 12 metres for forward movement. This person must stand outside the working area and you
must be able to see him or her clearly.
While carrying out manoeuvres do not give signals or instructions at the same time as other persons. Signals
must be given by one person only. Always pay attention to the instructions given by the persons in charge.
- Always operate the hydraulic equipment seated in the driver’s seat, check that no one is within the range of
action of the vehicle and signal with the horn when you are about to make a manoeuvre.
- To prevent accidents due to collision with other objects, always operate at a safe speed when carrying out
manoeuvres, especially if you are in tight spaces and in places where there are other vehicles.
- Do not call out or give someone who is working a fright without good reason, and do not throw objects, not
even as a joke.
- Whenever you take a break, carefully check that all the controls are in NEUTRAL position and that the safety
devices are locked.

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3.1.23 WORKING ON SLOPES

- Moving or working on steep slopes, hills, river or lake embankments can be dangerous. Always drive up and
down slopes at low speed and pay attention. Obstacles or changes in the gradient may cause you to lose
control of the vehicle and consequently it might overturn.
- Before starting work, check the working area for any signs of holes, landslips, gravel or tilled soil that could
affect the working conditions and the stability of the vehicle.
- Always move in a straight line when going up or down a slope.
- Do not turn around on slopes or move across them.
- Never move sharply sideways, or even worse, with the vehicle axis turned 90º with respect to the direction
of the slope.

WARNING: Do not work on slopes with a gradient over the limit as this may cause the vehicle to
overturn.

- Do not drive downhill with the gear in neutral or excessively using the brakes. Select and engage the most
suitable gear that will allow maintaining the speed necessary to prevent losing control of the vehicle.
- If you need to drive down very steep slopes do not overrun the engine; select the most suitable gear before
setting off downhill.
- NEVER park or leave the vehicle unattended on a slope.
- Drive slowly over grass, fallen leaves or wet steel sheet.
- If the fuel reserve warning light comes on while you are working on a slope, immediately refuel; given that the
vehicle is inclined, the engine may take in air and stall unexpectedly, posing a grave danger to yourself and
to anyone standing downstream of the vehicle.
- The limit gradient must be assessed based on the type of ground, the load, the vehicle conditions and speed
and visibility.
- Driving on public roads: for gradients of more than 5% use the lowest gear.

3.1.24 DRIVING ON ICY OR SNOW-COVERED SURFACES

- If you need to work on icy or snow-covered surfaces, reduce the speed and avoid making sudden movements,
as the vehicle is much more sensitive and can easily slip sideways.
- When a lot of snow has fallen, pay the utmost attention as it is difficult to see the edges of the road.

3.1.25 ELECTRICAL LINES

- Working in proximity of electrical lines can be extremely dangerous and it is therefore essential that you take
the necessary precautions to eliminate the potential risks.
- Any job where parts of the vehicle are raised to a height that may reach the minimum safety distance laid
down in the national safety regulations is considered working in proximity of electrical lines.
- Do not work at a distance of less than 5 metres from overhead electrical lines, unless having notified the
electricity board and having provided for adequate protection to prevent accidental contact or coming
dangerously close to the line conductors.
- In order to work without any risk, keep as far away as possible from the electrical line and never violate the
minimum safety distance. Even only passing near high-voltage cables may cause electric shock and hence
burns or even death.
- Be prepared for any possible emergency situation and wear rubber shoes and gloves. Place a rubber mat on
the driver’s seat and be careful not to touch any part of the chassis with uncovered parts of your body. Ask
someone to warn you if the vehicle comes too close to electrical cables.
- During operations near high-voltage cables, do not allow anyone to approach the vehicle.
- Should you make contact with an electrical line, absolutely do not leave the vehicle touching the live metal
structures but wait until you have received confirmation that the power has been cut. In addition, do not allow
anyone to approach the vehicle.

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3.1.26 CLOSED ENVIRONMENTS

When you need to work in a tunnel or closed places (factory buildings, car parks etc.) it is advisable to check
before starting that there is sufficient air exchange and good ventilation to prevent build-up of toxic exhaust gas
or dust. In any event, it is always advisable to convey the engine exhaust gas to the outside using a flexible
hose. Open doors and windows to facilitate ventilation and wear an appropriate protective mask.

3.1.27 STOPPING THE VEHICLE

Do not leave the vehicle unattended with the engine running for any reason whatsoever.
If you want to stop the vehicle for any reason, follow the instructions given in the chapter STOPPING THE
VEHICLE and TURNING OFF THE ENGINE.
Always turn off the engine whenever you leave the vehicle.
Before leaving the vehicle, do the following:
- Make sure that there is no one near the vehicle.
- Slowly lower the equipment.
- Set all the controls to neutral position.
- Shift the gear lever to NEUTRAL and engage the control locking lever. Engage the parking brake.
- Remove the key from the ignition block.

3.1.28 PARKING THE VEHICLE

- Choose an area where no other vehicles are operating.
- Park the vehicle on solid and possibly level ground and apply the parking brake.
- Do not park the vehicle on embankments or beds of watercourses at the end of your shift or working day.
- Never park on a slope without first having blocked the vehicle with wedges or similar to prevent accidental
movement. To park on steep slopes, position the vehicle crosswise to the slope, check that there is no risk of
it slipping, engage the parking brake and wedge the wheels. Do not park with the wheels facing downhill.
- Lock the equipment controls.
- Always remove the key from the ignition block when you need to leave the vehicle parked to prevent accidental
or unauthorised starting.
- Secure and lock the vehicle when you have finished work and whenever you temporarily leave the vehicle.
Hand the keys to the person in charge. Check that all the manoeuvres provided in this manual have been
observed.
- If you expect to work in low temperatures, check that the cooling system is filled with the right percentage of
antifreeze.

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3.1.29 TOWING AND RECOVERY

CAUTION: The vehicle is not designed to tow other vehicles.
- If towing the vehicle (permitted for short distances only), use the warning signs according to the regulations
in force and follow the instructions given in this manual.
- Always wear protective gloves when handling the towing devices.
- DO NOT use cables or chains for towing.
- To tow the vehicle, exclusively use the couplings specified and adequate towing devices.
- Hook the vehicle with extreme care and make sure that the devices used are securely fastened before
towing.
- Never tow a vehicle on a slope.
- Do not allow anyone to stand in the vicinity of the vehicle being towed.
- Keep eye contact with the operators.
- Follow all the instructions given in the relative chapter.

3.1.30 TRANSPORT
- To load or unload the vehicle from the means of transport find a level area that offers a solid support for the
wheels of the transport vehicle.
- Ensure that the means of transport is of adequate capacity to carry the vehicle (see weights and dimensions
in the chapter “Technical Data”).
The weight, transport height and overall length of the vehicle vary depending on the working equipment,
therefore, check the dimensions.
Check that the overall dimensions are permitted by the Road Regulations.
- Use robust access ramps of adequate height and angle.
- Ensure that the ramp surface is clean and free of any traces of grease, oil, ice or other material residues.
Remove any dirt from the vehicle’s wheels. In the event of rain, the surface of the ramps may become
slippery: be extremely careful.
Check that the platform of the means of transport is well cleaned.
- Let the engine run at low speed and proceed slowly. The weight must be transferred gradually from the
loading ramp to the transport vehicle.
- Never steer on the ramps to correct the vehicle’s position. If necessary, drive off the ramps, correct the
direction and then drive back up.
The vehicle must be positioned in such a way that the loads on the axles are as specified for the transport
vehicle and that it is not unbalanced.
Securely tie the vehicle to the platform with chains or cables and block the wheels with wedges.
- Ensure that the engine is off and that the windows and door (if any) are closed.

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3.2 PRECAUTIONS AGAINST RESIDUAL RISKS

3.2.1 SLIPPING
- The driver’s seat, the steps and the handholds must always be kept clean and free of any foreign object or
traces of grease, oil, mud or water in order to reduce the risk of slipping.
- Pay attention to possible slippery steps and slippery ground around the vehicle.
- Always clean your shoes before getting on to prevent slipping or stumbling.

3.2.2 MOVING PARTS

- DO NOT come close to the moving parts of the vehicle with your limbs or other parts of your body. This may
cause serious injury or death by crushing or amputation.
- Keep objects away from the moving fan blades. The fan blades may project or cut objects.
- Turn off the engine and wait until all the moving parts have stopped before carrying out maintenance or any
other operation on the vehicle.

3.2.3 SHEARING OR TRAPPING

- It is advisable to keep at a safe distance from moving parts.
- Do not hang your legs or arms out of the vehicle as you might get seriously injured if you knock them against
obstacles.
- In some parts of the vehicle there are devices that may cause serious injury to your limbs. It is strictly
prohibited to insert any parts of your body in these devices when the engine is running.
- Wear suitable clothing that cannot get caught up in the moving parts of the vehicle.
- Never climb into or insert your hands, arms or other parts of your body in the moving parts between the working
equipment and the vehicle or between the cylinder and the working equipment. If someone inadvertently
activates the control levers, the play of the working equipment is altered with the risk of serious injury to the
body, hands or arms should they become entangled.
- Always keep your hands and fingers away from gaps and/or kinematic mechanisms.
- Do not use your fingers or hands to line up holes, but use appropriate tools.
- Remove any burrs or sharp edges from replaced and/or repaired parts.
- Should you need to access a moving part, always lock the working equipment and check that it is well
secured.

3.2.4 CRUSHING
The machine is a vehicle to all intents and purposes, therefore, be extremely careful when handling it and
watch out for persons, animals or objects around the working area.
- Check the efficiency of the controls and in particular the braking devices. Make sure that you can clearly
see the entire working area from the driver’s seat, also with the aid of the mirrors, video devices, lighting
equipment for night-time work, and keep them efficient and in working order.
- Before carrying out any operation with the vehicle, always check that you have sufficient room to work safely.
Ask someone on the ground to help you when carrying out operations in tight spaces or with poor visibility.
- Adjust the speed to the limits established for the various areas on the site, never exceed 15 km/h and drive
at walking speed in the vicinity of workstations.
- During manoeuvres, do not allow anyone to access the working area by posting appropriate signs and
cordoning off the area. The operator (or the person in charge) must ensure that this rule is observed, even
suspending work if necessary.
- If the driver needs to be contacted while he is working, approach the cabin from a point visible to the driver
and only after he has given his consent.
- The conditions of the ground must be such as to allow quickly stopping the vehicle.
- It is prohibited to stand underneath the working equipment.

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3.2.5 OVERTURNING
- The operator must be fully knowledgeable with the performance, weight and the maximum load the vehicle
can transport in relation to the ground conditions (flat, compact, uneven, sloping).
- Before starting to work, always check that the area on which the vehicle wheels stand is sufficiently solid
and capable of supporting its weight and, consequently, keep at a safe distance from the edge of the
excavation.
- Check that the site paths are adequate and that the working areas are clear and suitable for transit of the
vehicle and its stability.
- Analyse and record the topography and geological characteristics of the site in order to take the appropriate
preventive measures against the vehicle overturning, landslides or landslips.
- Consider the characteristics of the ground complementary to those of the vehicle; variables controlled by the
operator such as speed, angle of attack on slopes, gradient of the ground, load distribution etc., are essential
to minimise the risk of overturning.
- Follow the rules given in the chapter on driving on slopes.

CAUTION: Observing the recommended gradient limits does not mean that you can manoeuvre the
vehicle in total freedom in all load, ground or manoeuvring conditions on a slope. In any
event, it is advisable to halve the gradient values on wet or uneven ground.
- Avoid reaching the limit conditions and generally act with great caution and carefully: adapting to the ground
and visibility conditions by adjusting the speed and changing paths and avoid sudden braking, acceleration
and changes in direction.
- The vehicle may be used on sloping ground only within the limits indicated by the manufacturer. Where the
ground is particularly steep and inaccessible, it is advisable to have only experienced operators use the
vehicle.
- The vehicle may also overturn because of uneven ground, the ground caving in (especially when working near
the edge of the road or the manoeuvring surface), slipping on wet or muddy surfaces or making incorrect
or careless manoeuvres (sudden acceleration or steering, unbalanced load, excessive speed, etc.).
- Do not steer sharply at high speed.
- The vehicle centre of gravity may shift in relation to the size and position of the load, the gradient of the
ground and the movement of the vehicle.
- The vehicle is equipped with a ROPS safety cabin. Nevertheless, in the event of the vehicle overturning, if you
do not have the seatbelt fastened, you will be thrown out with the risk of getting crushed by the vehicle.

IN THE EVENT OF OVERTURNING

The protective structure makes the driver’s seat the only safe place to be should the vehicle overturn.
DURING OVERTURNING
Never leave the vehicle but remain seated firmly, gripping the seat or the steering wheel.
AFTER OVERTURNING
Make sure that the vehicle is stable and that it will not continue turning over, unfasten the seatbelt, quickly leave
the vehicle trying to get off at the top to avoid being crushed by the vehicle should it continue overturning.

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3.2.6 TYRE BURSTING

If the tyres or rims are incorrectly used, there is a risk of the tyres bursting or getting damaged.
Tyre maintenance, removal, repair and refitting require special tools and techniques, therefore, always have
these operations carried out by an AUTHORISED SERVICE CENTRE OR AUTHORISED PERSONS.
- Check that the wheel nuts are properly fastened before starting work. If necessary tighten the nuts.
- Always check that the tyre inflation pressure is as specified by the manufacturer and check that the tyres are
in good condition.
If the tyre pressure is too low, the tyre could overheat and burst. Also if the tyre pressure is too high, there is
a risk of the tyres bursting.
- Check the tyre pressure when the tyres are still cold. Do not release the pressure when it increases in a hot
tyre.
- Keep at a safe distance or stand next to the tyre when inflating it.
- Keep the working area clear of sharp objects that could damage the tyres.
Deflate the tyres before removing any foreign bodies that may have lodged in the tread.
- Never use overhauled rims, since improperly carried out welding or heat treatments might weaken them.
- Do not cut or weld the rims when the tyres are fitted and inflated.
- Never inflate the tyres with a gas different from compressed air.
- The tyre pressure values and permitted speed specified in this manual correspond to the values specified by
the manufacturer (see the pressures and loads table).
For more information, contact FIORI or the tyre manufacturer.

3.2.7 ELECTRICAL RISKS

Any operation on the electric system or the battery must be carried out by a qualified person.
Before any operation on the electric system, disconnect the battery by removing the key from the battery
master switch. Check that the cables and terminals of the electrical connections show no sign of corrosion,
cracks or burns; if so, immediately contact your local FIORI dealer.
In the event of an electrical fault, do not attempt to start the vehicle by running it downhill.

3.2.8 RISK OF SHORT-CIRCUIT

Do not under any circumstances start the engine by short-circuiting the starter motor terminal or the battery.

3.2.9 BATTERY
The battery electrolyte contains sulphuric acid and batteries generate flammable hydrogen gas which could
explode. Improper use may cause serious injury or fire.
- Do not use or charge the battery when the electrolyte level is below the minimum level mark. Check the
electrolyte level at regular intervals and add distilled water to bring it up to maximum level.
- ALWAYS wear protective goggles and rubber gloves when working with batteries.
- Do not smoke or use open flames near the battery.
- If the acid comes into contact with your clothes or skin, immediately rinse with abundant water. If the acid
comes into contact with your eyes, immediately rinse with abundant water and seek medical advice.
- The battery must never be tilted more than 45° in any direction, as this may cause the acid to leak out of the
battery.
- Do not connect a flat battery in series to a charged battery. Risk of explosion!

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3.2.10 HOT AND PRESSURISED FLUIDS

The hydraulic system is pressurised when the engine is running and may remain under pressure even after
the engine has been turned off.
Hot hydraulic oil causes serious burns.
- Wait for the oil to cool down before disconnecting the pipes. Pressurised fluid leaks may be invisible.
- DO NOT use your hands to check for leaks. Fluid leakage even from a very small hole may have sufficient
force to penetrate the skin.
If you need to check for leaks, use a piece of cardboard or wood.
Wear gloves to protect your hands from any oil splashes. DO NOT attempt to repair or tighten flexible hoses
or hydraulic unions when the hydraulic system of the vehicle is under pressure.
- TURN OFF the engine, discharge all the cylinders and release the pressure.
- Keep your face and hands away from loosened unions while you are checking the efficiency of the hydraulic
system. Wear protective goggles as the jet of pressurised hydraulic oil may penetrate your skin and cause
permanent injury to your eyes.
- If any fluid or oil leaks are found, immediately stop the vehicle and make the necessary repairs.
- Turn off the engine and check that all the hydraulic controls are in neutral position before removing covers,
unions, pipes, caps, etc.

3.2.11 RISK OF BURNS

- In order to prevent burns caused by boiling water or steam escaping while checking or draining the coolant,
wait for the water to cool down to a temperature such that you can touch the radiator cap without burning your
hand. Even when the coolant has cooled down, loosen the cap gradually to allow the pressure in the radiator
to drop before removing the cap completely.
- In order to prevent burns while checking or draining the oil, wait for the oil to cool down to a temperature such
that you can touch the drain cap without burning your hand. Even when the oil has cooled down, loosen the
drain cap gradually to allow the internal pressure to drop before removing the plug completely.
- Do not touch the silencer immediately after turning off the engine, as it is extremely hot and may cause
serious injury.

3.2.12 VENTILATION
Do not work with the vehicle in closed places unless equipped with a suitable combustion gas suction and
exhaust system.
Good ventilation is very important for vehicle operation. Carbon monoxide emission from the engine’s exhaust
may moreover cause suffocation in closed areas.

3.2.13 INTOXICATION
- Engine combustion smoke can be very dangerous and/or lethal for the human body if directly and continuously
inhaled.
- If you need to work in closed environments, take all possible precautions to ensure circulation of fresh air and
protect the airways by wearing a suitable mask.
- Avoid inhaling or contact with the battery acids which are highly toxic and cause serious burns.
- Be careful not to come into contact with cement as perspiration and other body fluids cause an irritating
alkaline reaction and in some people allergic reactions. Use protective gloves and goggles.

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3.2.14 FIRE PREVENTION

Fire caused by fuel or oil
Fuel and oil are highly flammable and dangerous. Always take the following precautions to prevent fires:
- Do not refuel with the engine on and in the presence of smoking materials and open flames. Do not use
matches, lighters or torches to illuminate the refuelling area.
- Do not smoke, use open flames or create sparks in the vicinity of the vehicle while refuelling or changing the
oil.
- The fuel nozzle must always remain in contact with the filler neck. Hold the fuel nozzle in contact throughout
refuelling to prevent sparks from being created due to build-up of static electricity.
- Do not leave the vehicle unattended while refuelling or topping up the oil.
Clean off any spillage after refuelling or topping up with oil.
Do not spill fuel on hot surfaces or on parts of the electric system.
- Store oil and fuel in a special room and do not allow access to unauthorised persons.
- Before carrying out any grinding or welding on the chassis, move any flammable material to a safe place.
- Do not weld or use a cutting torch to cut ducts or pipes that contain flammable liquids.
Use a non-flammable oil to clean the components. Do not use Diesel and petrol as they are highly
flammable.
- To ensure safety in the workplace, put all the cloths soaked with grease, oil or flammable liquids in a safe
metal container as they pose a risk of fire.
Store containers or cans only in their specifically allocated areas.
Do not pour flammable liquids into open, large and low containers.

FIRE CAUSED BY BUILD-UP OF FLAMMABLE MATERIAL

- Remove dry leaves, stone splinters, pieces of paper, dust or other flammable materials that have accumulated
or attached to the engine, the exhaust manifold, the silencer, the battery or in the internal guards.

FIRE IN THE ELECTRIC SYSTEM

- Short-circuits in the electric system may cause a fire.
- Check that there are no loose or damaged parts in the system. Tighten any loose connectors or wiring
terminals. If any cables or connections are corroded and/or damaged, immediately contact your local FIORI
dealer.
- Any operation on the electric system or the battery must be carried out by a qualified person. Before any
operation on the electric system, disconnect the battery by removing the key from the battery master
switch.
- Do not smoke and avoid sparks or flames in the recharging area to prevent the outbreak of fire.
- Recharge the battery only in adequately ventilated places to prevent accidental explosions due to gas build-
up.

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3.3 PRECAUTIONS DURING MAINTENANCE OPERATIONS

3.3.1 CORRECT MAINTENANCE
Before using or carrying out any operation on the vehicle always do the following:
- Carefully read all the instructions contained in this manual.
- Always read the labels and the instructions on the vehicle and in the manual before starting any operation on
the vehicle. The instructions contain important information (see the chapter “Safety Labels”).
- Repairs and maintenance on the vehicle may only be carried out by authorised persons. Do not allow
unauthorised persons to access the area. If necessary, have someone stand guard in the area.
- Before carrying out any operation, apply all the special safety devices.
- First of all, check that the maintenance operations have meticulously been carried out at the intervals
established.
- Always wear suitable protective clothing and any other protection required for the operation to be carried
out.
- Do not leave hammers or other tools lying around in the working area. Remove any traces of grease, oil
or other substances that might cause someone to slip. Always keep the workplace clean and tidy so that
you can carry out all the operations in complete safety. If the workplace is dirty and untidy, there is a risk of
tripping, slipping, falling and being injured.
- Check that all the tools provided are in good condition. Do not under any circumstances use tools with upset
heads and always wear protective goggles.
- Always keep the vehicle clean to prevent the formation of dirt and oil encrustations. This also reduces the risk
of fire and makes it easier to identify damaged components and detached parts.
- Do not lubricate or repair the vehicle when the engine is running, except where expressly indicated in this
manual.
- Do not allow anyone to tamper with the danger signs or make them illegible.
- Do not use parts of the vehicle, such as handholds or supports, to carry out the operations.
- Absolutely do not use matches, lighters, torches or open flames to illuminate dark areas.
- Use lights or lamps (vehicle and auxiliary lights) positioning them in such a way that other persons working
in the area are not blinded.

ROUTINE MAINTENANCE
- Always lower the equipment to the ground and release the hydraulic pressure from all the circuits before
starting to carry out maintenance on the vehicle.
- Connect all the safety devices on the vehicle and remove the ignition key.
- Depending on the type of maintenance to be carried out, disconnect the battery master switch and hang a
sign on the driver’s seat saying that maintenance is in progress.

EXTRAORDINARY MAINTENANCE
- Do not keep the engine running in closed spaces without adequate ventilation.
- Keep your head, body, limbs and hands away from moving and/or raised equipment.
- Do not remove any safety devices, lids, covers or guards if not for maintenance reasons.
If they need to be removed, be extremely careful and refit them before using the vehicle.
- If during maintenance you need to move the equipment using the hydraulic control, operate as follows:
- Before starting the engine, warn everyone in the vicinity to move away from the vehicle.
- Operate seated on the driver’s seat and never use the controls if not seated on the driver’s seat.
- Engage the parking brake.
- Signal when you are about to make a manoeuvre by voice and sounding the horn
- Manoeuvre slowly
- Always lock the arms or the parts that need to remain raised during the operation using external devices.
- To lift and transport heavy parts use cranes or hoists of adequate capacity. Sling the material as best you can.
Use eyebolts where required. Always check that no one is in the vicinity.

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- If you need to remove or fit units on the vehicle that need to be supported by hydraulic or pneumatic lifting
devices, check that they are of adequate capacity to support and handle the load.
Do not allow anyone to pass in the vicinity of the vehicle and absolutely do not allow anyone to stand
underneath the raised equipment even when you are certain that it is locked.
- Do not work on or under the vehicle if it is only supported by hydraulic or pneumatic lifting devices without
locking valves.
Do not work under or near a tool, a vehicle or parts of it that have been removed if they are not adequately
supported.
- If you need to make repairs at the top of the vehicle, use ladders or platforms compliant to the safety regulations
in force and always pay the utmost attention.
- Loads lifted with jacks is always dangerous.
Before operating on parts lifted with jacks, it is obligatory to position adequate supports to ensure that they
are securely supported.
- If there is a risk of being hit by metal splinters (grinding) always wear safety goggles.

After maintenance or repairs never leave tools, cloths or any other material in compartments containing moving
parts.

BATTERY
- Before carrying out any operation on the electric system, always disconnect the battery by removing the key
from the battery master switch.
- If you need to replace the battery, first disconnect the negative and then the positive cable. To reconnect the
battery, first connect the positive and then the negative cable and then reinsert the key in the battery master
switch.
- To recharge the battery, correctly connect the auxiliary cables to the terminals. Never short-circuit them.
During battery recharging, flammable hydrogen gas is produced, therefore, leave the battery compartment
open to ensure more effective ventilation.
- Never check the battery charge by placing metal objects on the terminals.

ENGINE
- Do not operate on the vehicle with the engine on.
- Do not turn on the engine while the lid is raised.
- Do not check or even less adjust the alternator belt tension with the engine on.
- Do not adjust the fuel pump with the engine on.
- When handling flammable materials, keep at a certain distance from the exhaust manifold, the silencer or hot
points of the engine.

GREASING AND LUBRICATION

- Use only the products recommended by the manufacturer as indicated in the lubricants table.
- Lubricate and grease the vehicle at the intervals given in the scheduled maintenance table in this manual in
order to keep the vehicle in efficient and safe operating conditions.
- Wear clothing suited to the operations to be carried out.
- Position the vehicle on level ground, engage the parking brake and turn off the engine.
- If the lubrication and greasing points require the equipment to be raised, use the special safety devices
provided. IT IS DANGEROUS TO WORK UNDERNEATH THE EQUIPMENT WITHOUT THE SAFETY
DEVICES.

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TYRES
- The tyres are very heavy. Handle them carefully and when stored make sure that they cannot fall out of their
storage space and cause injury.
- Never attempt to repair a tyre on public roads.
- When a tyre needs to be changed, the first thing to do is engage the parking brake, shift the gear lever to
neutral, turn off the engine and remove the ignition key.
This operation must be carried out on level and solid ground.
Position a wedge under the wheel diametrically opposite the one to be replaced.
- Always stand the jack on a solid and flat surface.
- Check that the jack has sufficient lifting capacity for the vehicle.
- Use stands or other suitable supports to support the weight of the vehicle while you repair the tyres.
- Never lie under the vehicle, not even partially, or start the engine when the vehicle is lifted with a jack.
- Never hit the tyre or rim with a hammer.
- Check that the rim is clean and without rust or other damage. Do not weld, braze or repair a rim in any way
nor use a damaged rim.
- Do not inflate a tyre if the rim is not fitted on the vehicle and well fastened so that it cannot move in the event
that the tyre or the rim suddenly break.
- When fitting a new or repaired tyre, use a pressure gauge with a flexible hose connected to the valve so that
you can stand far away from the tyre during inflation. If possible, also use a safety cage.
- When checking the tyre pressure, also inspect the treads and the sides for any damage. Neglected damage
may lead to premature tyre breakage.
- The inflation pressure also determines the weight a tyre can support. Identify the tyre sizes in the pressure
and loads table. Do not exceed the load for any given pressure. Do not over- or under-inflate the tyres.
- Never inflate a steering tyre to over the maximum pressure recommended by the manufacturer as indicated
on the tyre, or over the maximum pressure indicated in the pressures and loads table and when the tyre is
not marked with the maximum pressure values.
- Inflating a tyre to over the permitted value with the bead not perfectly adjusted, there is a risk of the bead or
the rim breaking with an explosive force that could cause serious injury.
- Do not inflate a tyre that has been used deflated or at very low pressure, but first have it examined by a
qualified person.
- During inflation stand in a protected area with respect to the side of the tyre.
Never inflate using flammable gases or compressed air from systems with alcohol injectors.
- After refitting the wheel, tighten the wheel fastening nuts on the axle to the specified torque. Check the torque
of the nuts every day until it has stabilised.

REFUELLING
- Use only the products recommended by the manufacturer as indicated in the lubricants table.
- Refuel and top up at the intervals indicated in the scheduled maintenance table in this manual in order to
keep the vehicle in efficient and safe operating conditions.
- Wear clothing suited to the operations to be carried out.
- Any fluid top-ups must be carried out with the engine off and cold.
- Before checking or refuelling, make sure that there are no open flames or smoking materials in the area and
do not use matches, lighters or torches as light source.
- Unscrew the caps very slowly to release the pressure from the system before removing them completely.
- Be careful during refuelling and topping up as splashes of fuel and oil may cause slipping and injury.
Immediately and thoroughly clean off any soiled areas.

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3.3.2 PRECAUTIONS DURING WELDING OPERATIONS

- Welding operations must always be carried out by a qualified welder and in a place equipped with adequate
tools.
- If you are involved in welding operations, wear dark-glassed goggles or a mask, a hardhat, overalls, and
safety gloves and shoes.
Never look at the welding arc without wearing all the specific personal protection devices.
Eye protection must also be worn by anyone standing in the vicinity even if not directly involved in the
welding operations.
- Have a fire extinguisher at hand in the area where the welding operations are carried out.
- Remove the key from the battery master switch before carrying out any welding operations on the vehicle.
- When carrying out repairs by means of welding, the paint may get burned by the welding heat or dangerous
gases may be released.
Before starting to weld, remove the paint from the part to be welded.
- Do not use a torch to weld or cut a tube containing a combustible solution: this may cause fire or explosion.

3.3.3 FAULTS AND UNAUTHORISED MODIFICATIONS

- If faults are found during vehicle operation or maintenance (noise, vibration, unusual smells, fault signalling,
oil leaks, etc.) report to the person in charge so that the appropriate action can be taken. Do not start the
vehicle until the fault has been repaired.
- No modifications may be made to the vehicle without prior authorisation from FIORI, as modifications may
create risks.
- Before making any modification, consult with FIORI. FIORI is not responsible for any injury or damage
caused by unauthorised modifications.

3.3.4 CLEANING THE VEHICLE

- Parts soiled with oil or grease, broken tools or parts left lying around are dangerous as they may cause
slipping and falling. Always keep the vehicle and the workplace clean and tidy.
Thoroughly clean the floor, handrails, instruments, plates, lights and windows of the cabin.
- When using compressed air to clean parts, wear protective goggles, limit the pressure to maximum 2 bar
and adhere to the safety regulations in force.
- Accidental infiltration of water into the electric system may cause functional and operational problems. Do not
use pressurised water or steam to clean the electric system (sensors, connectors).
- Do not use petrol, solvents or other flammable liquids to clean parts; use approved non-flammable and non-
toxic commercial solvents.
- If inspection and maintenance are carried out when the vehicle is still soiled with oil or mud, you run the risk
of slipping and falling, or that the mud and dirt comes into contact with your eyes. Always keep the vehicle
clean.

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3.3.5 WASTE FLUID/MATERIAL DISPOSAL

- Incorrect disposal of waste fluids can seriously harm the environment. Before disposing of waste fluids,
contact the competent local authorities for the correct disposal procedures.
- Always collect the oil drained from the vehicle into suitable containers. Never drain the oil directly onto the
ground or into drains, rivers, oceans or lakes.
- For disposal of hazardous waste, such as oil, fuel, coolant, filters, batteries, and other waste materials,
observe the relative laws and regulations in force.

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3.4 WARNING AND SAFETY LABELS (RESIDUAL RISKS)

The warning and safety labels are found on your vehicle as shown in the figures below and serve as a guide
for your own safety and those that work with you. A label is positioned at each part of the vehicle that may be
a source of residual risk. Therefore, walk around the vehicle with this manual in hand and familiarise yourself
with where the various labels are positioned and read them.
Point them out to all the vehicle operators and always keep them legible; if they become illegible, order a set
from the FIORI Spare Parts Service Department.
Always keep the labels clean. Use detergent and water to clean the labels. Do not use organic solvents or
petrol as they may damage the labels.
1 - Clean the labels with soap and water and dry them with a soft cloth.
2 - Replace the damaged or missing labels with original FIORI labels.
3 - If you need to replace a component bearing a safety or warning label, make sure that the new component
has the same labels.
4 - When replacing labels make sure that the surface on which they are applied is clean, dry and without oil
or grease.

WARNING: The manufacturer declines all responsibility for personal injury or property damage if the
rules of conduct indicated on the labels are not observed or the labels are not kept in
perfect conditions.

3.4.1 LOCATION OF THE WARNING AND SAFETY LABELS

CABIN INTERIOR

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VEHICLE EXTERIOR

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3.4.2 MEANING OF THE WARNING AND SAFETY LABELS

DANGER: It is prohibited to approach and lean on the drum when it

is rotating as there is a risk of getting crushed or dragged.

DANGER: Do not climb onto the vehicle for inspections or to hitch a

ride as you may easily slip and fall.

DANGER: In the event of the vehicle overturning, do not leave the

vehicle but remain seated firmly gripping the steering wheel.
Vehicle equipped with ROPS protection.

DANGER: When the vehicle is moving, do not come close or let

anyone else come close to the moving parts as there is a risk of
crushing your hands.

DANGER: Vehicle with crab steering When the driving post is facing
the drum, steering is inverted with respect to steering wheel rotation; in
this case, it is prohibited to use this function as it is very easy to make
a mistake.

DANGER: When the vehicle is moving do not stand or allow anyone

to stand in the range of action of the vehicle, especially in the arm
movement areas.

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DANGER: This symbol indicates that the safety stop on the lifting
cylinder must be engaged before accessing the area underneath the
mixing drum.

DANGER: The acoustic signal indicates that the vehicle or parts of

it are moving, therefore, stand well away from the vehicle and do not
allow anyone to come into its range of action.

WARNING: The engine compartment contains moving components

(fan, belts) that may cause serious injury.
Before opening the lid to carry out maintenance operations in the
engine compartment, it is absolutely essential that you turn off the
engine.

WARNING: This symbol indicates an area that emanates strong

heat; to prevent burning yourself, approach it carefully and wait for it to
cool down before carrying out any maintenance operation.

WARNING: The battery contains an acid solution and must be

handled with care wearing protective goggles to prevent possible
splashing into your eyes. The vehicle is equipped with a device that
allows disconnecting the negative ground cable.

WARNING: Many parts of the vehicle are a source of danger (heat,

rotating devices, etc.) and can hence cause serious injury.
Before leaving the vehicle for inspections, refuelling or maintenance,
it is absolutely essential that you turn off the engine, remove the key
from the dashboard and consult this manual.

CAUTION: Using low gear on a dangerous slope: before driving on

slopes with a gradient of more than about 18% engage the mechanical
low gear.
Shift gear when the vehicle is stationary and stable, as it is not equipped
with a synchronised gearbox.

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WARNING: After completing the operations permitted by the control

engage the safety stop.

WARNING: Do not stand or allow anyone to stand underneath

raised equipment if the special safety device has not been installed.

MANDATORY RULE: This symbol indicates the location of the

use and maintenance manual; read the manual before starting to work
with the vehicle.

MANDATORY RULE: This symbol indicates that the seatbelt must

be used; always fasten the seatbelt when the vehicle is moving.

MANDATORY RULE: This symbol indicates that a hardhat must

be used; wear a hardhat for your own protection.

MANDATORY RULE: This symbol indicates that anti-noise

protection must be used; the average exposure to noise is over 85
Lpa.
Use adequate anti-noise protection in relation to your daily exposure
to noise.

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3.5 SAFETY DEVICES ON THE VEHICLE

CAUTION: To check proper functioning of the safety devices and the cleaning and replacement
intervals, refer to chapter 5.4 SCHEDULED MAINTENANCE TABLE
The vehicle is equipped with safety devices whose specific functions are described in the legend below:

C
F

D
E
B
1
A - REVERSING MICRO-SWITCHES (fig.1)
When the driving post is in the loading or transfer position it determines the FORWARD AND REVERSE
movement according to the driving position of the operator in that precise moment.
When the pivoting driving post is turned in the working direction, high gear cannot be engaged even if the
SLOW/FAST switch is set to fast.
Moreover, the vehicle can only operate when the driving post is correctly positioned in the driving direction.

B - SEAT BELTS (fig.1)

Always fasten the seatbelt when operating the vehicle.
The seatbelt is essential as it holds you anchored on the seat in the event of the vehicle overturning.
Periodically check the integrity, cleanliness and fastening of the structure.

C - PARKING BRAKE BUTTON (fig.1)

It lets you engage the parking brake with the engine running.
The vehicle is automatically braked when the engine is off with the key in the “0” position.

D - MECHANICAL ROTATION LOCK FOR PIVOTING DRIVING POST (fig.1)

Allows locking the driving post in the two driving positions.

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E- HAND ACCELERATOR MICROSWITCH (fig.1)

If the hand accelerator lever is not in the initial position, it is impossible to move the vehicle.

F - DEACTIVATION BUTTON FOR ARM DESCENT LOCKING VALVE (fig.1)

If the button is not pressed, the arm will not lower even if operating the joystick.

G L
M
N

2
G - GROUND CONTROL EMERGENCY STOP BUTTON (fig.2)
Positioned on the rear right-hand side of the vehicle, pressing it will automatically turn off the diesel
engine.

H - BATTERY MASTER SWITCH KEY (fig.2)

When the key is removed, the negative cable of the battery is disconnected and hence the power to
the electric system. It prevents unintentional starting of the engine during maintenance. It allows welding
operations to be performed without having to disconnect the battery terminals.

CAUTION: The battery master key does not have an emergency stop function. Removing the battery
master key when the engine is running, does not turn off the engine but only damages the
current alternator.

L - ROTATING BEACON (fig.2)

Fixed on the cabin roof, it signals the presence of the vehicle.

M - OPERATOR’S PROTECTION / CABIN WITH “FOPS - ROPS” STRUCTURE (fig.2)

Designed and constructed to safeguard the operator in the event of the vehicle overturning and objects
falling from heights.

N - REAR VIEW MIRROR (fig.2)

The rearview mirror is essential for visibility of the rear left-hand side of the vehicle.
Correctly position the mirror before starting.

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V R

1 U

T
Q P O

O - DRUM FALL STOP DEVICE (fig.3)

When the drum is raised and the valve handle is turned, the cylinders hydraulically lock even when the
engine is off, preventing accidental lowering during maintenance operations.

P - DRUM COUNTERFRAME ROTATION STOP DEVICE (fig.3)

When it is engaged, the drum counterframe cannot rotate; it is automatically engaged when the drum is
lowered parallel to the driving direction.
Keep it engaged during road transfers and when loading from a heap.

Q - DIESEL TANK CAP WITH KEY (fig.3)

It is fitted with an anti-drip valve in the event of the vehicle overturning.

R - ARM LOCKING CABLE (fig.3)

When the bucket arm is raised, it prevents accidental lowering of the arm during transfer and transport.

S - REAR SIDE HORN (fig.3)

Acoustically warns that the engine is starting and that the reverse gear is engaged. It also indicates when
the drum counterframe rotates.

T - ARM DESCENT SWITCH (fig.3)

Once the drum has rotated beyond 180° towards the front, the loading arms cannot be lowered.

CAUTION: During front unloading, always check that the arm is raised. During front unloading never
touch the arm control lever. It is advisable to engage the CONTROL LOCK (C).

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U - CAMERA (Standard only for specific countries) (fig.3)

It enables a complete view of the rear of the machine and of the area not directly visible to the operator, by
means of the display (1) placed at the back inside the cabin.

3.6 SAFETY DEVICES FOR ROAD USE

CAUTION: For road circulation in Italy and other countries, it is mandatory to adopt various safety
devices and ensure their correct application.
Always ensure that the vehicle complies with the local regulations concerning the equipment of these vehicles
when travelling on public roads.
Check that the signalling and light devices function properly.

C
4
A - STEERING SELECTOR (fig.4)

CAUTION: THE STEERING SELECTOR MUST BE POSITIONED

ON 2 STEERING WHEELS
Carry out this operation after aligning the rear wheels.

B - DRIVER’S SEAT (fig.4)

Turned forward (concrete mixer behind) in preferential driving direction and locked with the latch (2).

C - HAND ACCELERATOR MICROSWITCH (fig.4)

If the hand accelerator lever is not in the initial position, it is impossible to move the vehicle.

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I D E H
2

G 1

5
D - FLASHING LIGHT (fig.5)
It is mandatory to have an approved flashing light device and it must always be in perfect working order.

E - DRUM FIFTH WHEEL (fig.5)

The drum and its counterframe must be horizontal to the vehicle and locked with the special pin.

F - NUMBER PLATE (fig.5)

Check that the number plate is clean before driving on the road.

G - CONCRETE UNLOADING CHUTE (fig.5)

The unloading chute (1) must be turned crosswise and locked with the special screw pin (2).

H - LOADING ARM (fig.5)

The arm (1) must be locked in a vertical position with the special steel wire (2).

I - DOORS (fig.5)
Keep the doors closed while travelling.

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4.0. INTRODUCTION
This chapter is intended to help you learn how to manoeuvre with the vehicle. Read it carefully from start to
finish. When you have finished reading this chapter, you should have good knowledge of the vehicle and its
functioning.

Pay particular attention to the safety labels.

They are positioned to help you recognise the possible residual risks. Don’t just read them, but think about
what they really mean. Be aware of the risks and how to prevent them.

Once you have learned where the controls are and what they do, practice using them. Practice by using the
vehicle in the open on level ground and where there are no obstacles or persons around.

Learn to anticipate the reactions of the vehicle and its controls. Only start using the equipment when you are
sure that you have good command of the vehicle and can drive it safely.

Be careful when you use the equipment controls.

Practice in the open. Do not allow anyone to come near the vehicle. Do not act roughly on the controls, but use
them carefully until you fully understand the effect they have on the vehicle.

Finally, do not rush to learn to manoeuvre the vehicle. Take your time and do things calmly and safely.

CAUTION: Before starting to use or carry out maintenance on the vehicle, always read the safety
regulations for the operations to be carried out as set out in Chapter 3.

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H O E

G
F Q A

B C I
R
N
M

L
D
1
4.1. REFERENCES AND DESCRIPTIONS OF THE MAIN DEVICES (fig. 1)
The references and descriptions of the main devices of the vehicle are given here so that you can quickly get
to know and understand them when mentioned further on in this manual. Therefore, it is important that you
very carefully read the legend below.
A - Pivoting driving post
B - Fuel tank
C - Front axle
D - Rear axle / two-speed gearbox
E - Mixing drum
F - Loading bucket
G - Unloading hopper
H - Unloading chute
I - Water tank
L - Engine assembly / hydraulic pumps
M - Hydraulic oil tank
N - Water system
O - ROPS/ FOPS protection
P - Rotary frame
Q - Hydraulic bucket hatch
R - Mix Control

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4.1.1. INSTRUCTION LABELS ON THE MACHINE

Always keep the labels clean. Use detergent and water to clean the labels. Do not use organic solvents or
petrol as they may damage the labels.
1 - Clean the labels with soap and water and dry them with a soft cloth.
2 - Replace the damaged or missing labels with original FIORI labels.
3 - If you need to replace a component bearing a safety or warning label, make sure that the new component
has the same labels.
4 - When replacing labels make sure that the surface on which they are applied is clean, dry and without oil
or grease.

WARNING: The manufacturer declines all responsibility for personal injury or property damage if the
rules of conduct indicated on the labels are not observed or the labels are not kept in
perfect conditions.

Indicates the diesel fuel tank; for refuelling, see the instructions in this
manual.

Indicates the hydraulic oil tank; to top up the oil, see the instructions
in this manual.

Indicates the brake fluid tank; to top up the oil, see the instructions in
this manual.
exclusively use mineral oil.

For lifting, tying and towing the vehicle, use only the special couplings
marked with this symbol.

Indicates the engine coolant tank.

To fill the tank, see the instructions in this manual.

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Indicates the functions to run to directly fill the drum or the tanks with
water, with the warning to open the cap to avoid the tank from swelling.

Indicates the selection for the drum rotation direction. With the pivoting
post turned towards the drum: if the drum turns anticlockwise, the concrete
is unloaded; if it turns clockwise the concrete is mixed.

Indicates the joystick positions for arm raising, bucket rotation and
hydraulic hatch closing/opening.

Indicates the position of the hand accelerator that allows you to adjust the
engine rpm when the vehicle is stationary. The vehicle can only be moved
when the lever is in the initial position (0).

Indicates the three types of steering.

Indicates the lever positions for chute tilting.

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Indicates the lever positions for the rotation direction of the drum fifth
wheel.

Indicates the lever positions for drum raising.

Indicates the switch to reset the litre counter and other reset functions.

Indicates an area with live electrical contacts.

Act extremely carefully and do not to use too powerful jets of water, which
might compromise functioning of the electric system.

Indicates that, when turning the drum counterframe towards “front

unloading”, you need to check that the arms are fully raised so that they
do not interfere with or touch the engine compartment lid.

Indicates functioning of the litre counter and the water pump.

It stands for the exact position of the intake filter above the inlet joint,
when the suction pipe is placed on the rotating framework to prevent it
from breaking during the rotation of the same framework.

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4.2. CONTROLS AND GAUGES

Your safety and that of others in the vicinity depends on your good judgement and care in using the vehicle.
Therefore, you should know exactly where all the controls are positioned and what their function is.
Every vehicle has its limits: before using it, familiarise yourself with its speed, braking, steering, stability and
load capabilities.
This chapter provides all the useful information you need to quickly get to know and safely use the vehicle
controls.
The legend below divides this information into well-defined groups:

- Driver’s seat
- Driving post instrument panel
- Operating control panel

4.2.1. DRIVER’S SEAT

N F
O L M
A

I
P
C
G

Q B H

2
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4.2.1.a - A - Steering wheel (fig. 2).

Turn the steering wheel in the desired driving direction. Using the knob you can steer with just one hand
during loading operations.

4.2.1.b - B - Height- and depth-djustable driver’s seat with seatbelt (fig. 2).
Always fasten the seatbelt when you are driving the vehicle.

4.2.1.c - C - Service and emergency brake pedal (fig. 2).

Push the service brake pedal to slow down or stop the vehicle; use the brakes to avoid picking up speed
when you are going downhill.

CAUTION: If driving down steep slopes never use only the brake pedal, but also engage the lowest
gear and depress the brake pedal intermittently so as not to overheat the brakes.

The stop lights must come on when the brakes are engaged. Only use the vehicle if both stop lights are
functioning properly.

4.2.1.d - D - Accelerator pedal (fig. 2).

The pedal controls the engine speed and the automotive system controls the vehicle speed when a gear
is engaged.

4.2.1.e - E - Parking brake button (fig. 2).

It permits to block the machine during any work break with engine turned on.
To lock, firmly push the button
To unlock, turn the button and release.

With engine turned off the machine brakes automatically.

The indicator light means the parking brake is engaged and the key turned.

The indicator light means there is a malfunction in the parking brake circuit.

4.2.1.f -F - Steering type selecting lever (fig. 2).

This lever allows you to select the type of steering according to the situation you are in.

2 RS Two front steering wheels.

CRAB Crab steering, i.e. with the same steering angle on the front
and the rear wheels.
4 RS Four steering wheels with the rear wheels in the opposite
direction to the front ones.

CAUTION: Before any road transfers, check that the four wheels are
properly aligned (see the procedure described in Chapter
4.3.9).
It is prohibited to use CRAB STEERING if the driving post
is facing the drum. In this position steering is inverted with
respect to steering wheel rotation.

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4.2.1.g - G - (Mechanical) gearshift control lever (fig. 2).

The gear lever allows you to select two basic speeds:
Position I - Low or working speed
Position O - NEUTRAL
Position II - High or road transfer speed

CAUTION: Select the speed when the vehicle is stationary and stable.
Before driving uphill or downhill on steep slopes, always select the lowest gear with the
vehicle stationary and stable.

4.2.1.h - H - Pivoting driving post locking lever (fig. 2).

The lever allows the operator to lock the driving post in the transfer A and loading B positions.
If the driving post is not securely locked in the positions A or B, dedicated microswitches will not allow vehicle
movement.

CAUTION: The driving post must be turned in the direction as shown in Fig. A for road transfers and
in Fig. B for the drum loading phases. Turn the driving post with the vehicle stationary and
stable and the gear selector in neutral position.
This operation may be carried out while you are seated on the driver’s seat. Check that it is
locked into place at the end of the operation.

A B

4.2.1.i - I - Windscreen washer switch (fig. 2).

Snap switch to turn on the front wiper.

4.2.1.l - L - Power socket (fig. 2).

It draws current from the 12V battery by means of a bayonet coupling.

4.2.1.m - M - Heating/defrosting fan adjuster (fig. 2).

Turns on the fan for defrosting the windows or heating the closed cabin.

4.2.1 n - N - Windscreen water switch (fig. 2).

Allows you to pump the windscreen washer fluid.

4.2.1.o - O - Rotating light switch (fig. 2).

Snap switch to turn on the rotating beacon on the cabin roof.

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4.2.1.p - P - Short Manual (fig. 2).

Quick manual for the main starting and driving functions and maintenance of the vehicle.

4.2.1.q - Q - Hand accelerator lever (fig. 2).

Allows the operator to adjust the engine RPM when the vehicle is stationary; use only during concrete
mixing and unloading and to operate the water transfer pump.
Before activating it, check that the electrical gear selector lever is in neutral position.

CAUTION: Always shift the lever back to “0”, otherwise the vehicle will not move forward since the
forward/reverse selector is disabled.

R S

T U
3
4.2.1.r - R - Rear windscreen wiper (fig. 3).
Act on the snap switch to turn on the rear wiper.

4.2.1.s - S - Cabin light (fig. 3).

Act on the lever to turn on the cabin light.

4.2.1.t - T - Windscreen washer fluid tank (fig. 3).

The water tank is positioned on the inside of the control panel; to access the tank for filling open the rear
cover by undoing the retaining screws.

4.2.1.u - U - Fuses and Relays (fig. 3).

The fuses and relays are positioned inside the driving post. Using the key provided, open the door to
access the fuses and the relays.

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4.2.2 DRIVING POST INSTRUMENT PANEL

6
5 7

4 8

3 9

2 10

1 11

16 17

15 12
14 13
4
4.2.2.a Electronic control panel (fig. 4)

1 - Yellow warning light: indicates when the next service is due.

2 - Yellow warning light: indicates that the fuel tank is in reserve.

3 - Red warning light: indicates a fault in the parking brake circuit.

4 - Red warning light: indicates that the parking brake is engaged.

5 - Red warning light: indicates that the engine oil pressure is low.

6 - Red warning light: indicates that the generator battery charge is low.

7 - Red warning light: indicates that the engine coolant is overheated.

8 - Red warning light: indicates that the engine air filter is clogged.

9 - Yellow warning light: function not available.

10 - Yellow warning light: indicates that there is water in the fuel sediment bowl.

11 - Red warning light: indicates that the hydraulic oil filter is clogged.

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12 - Red warning light: indicates that the hydraulic oil level is low.

13 - Red warning light: indicates the preheating phase of the engine spark plugs.

14 - Green warning light: indicates that the position lights or low beams are on.

15 - Green warning light: indicates that the direction indicators are on.

16 - Illuminated tortoise: indicates that low gear is engaged.

17 - Display: displays the hours of operation, fuel level, engine rpm and litre counter.

Note: if the FIORI BATCH CONTROLLER is installed on the machine, all functions of the litre
counter located on the electronic dashboard are not active, as the functions are displayed on the
operating panel.

E 17

18

5
4.2.2.b Water liter counter (fig. 5)
The three digits at the top of the display (17) indicate the total litres of water in the tank.
The litre counter can be reset by pressing and holding down the reset button E for at least 3 seconds with the
ignition key turned to the first click (on position) or with the engine on.

4.2.2.c Hour counter/revolution counter (fig. 5)

When turning on with the ignition key in position 1 (vehicle power), the instrument panel runs a brief test turning
on all the segments of the display after which the instrument panel warning lights will show the vehicle status.
Subsequently, at the bottom of the numerical display (18), the hours remaining until the next service is due
are shown for 5 seconds. These are immediately followed by the actual total hours of vehicle operation, again
shown for 5 seconds, after which the engine rpm are shown.
The operating hour counter (18) cannot be reset. The hours of operation are totalled correctly only if the engine
is running at a speed of more than 200 rpm. Counting does not depend on the number of engine revolutions,
but only on the time that has actually elapsed.
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4.2.2.d Maintenance schedule (fig. 5)

In case the warning light (1) stays on, it means that it is almost time to do maintenance to the machine (the
warning light indicates this event about 20 hours before the deadline set by FIORI).
The preset service interval is every 500 hours. Therefore, the warning light will flash after 500, 1000, 1500,
2000, ... hours.
Once the vehicle has been serviced, the flashing warning light can be reset and the counter reset to start the
countdown to the next service.
To reset flashing, hold the reset button (E) on the driving post instrument panel pressed down for 20 seconds.
After 20 seconds the word “RESET” will appear on the display and the warning light (1) will come on. To reset
the counter, release the button and press it again for another 2 seconds.
After the 2 seconds the new service interval will appear on the display and after another 3 seconds the panel
returns to normal display.
If you cut the power by disconnecting the battery master switch or remove the key before the operation is
complete, or you do not carry out the sequence as described above, flashing will not be reset.

CAUTION: It may be reset only after the pre-set due date and not before.

B D
G

A C
6
4.2.2.e - A - Forward/reverse gear selector (fig. 6).

Push the selector forward to engage forward gear.

Always return the selector to neutral position when the vehicle is stationary and parked.

Push the selector backward to engage reverse gear.

4.2.2.f - B - Slow movement switch (fig. 6).

Flick the switch forward to use the normal driving functions. This function is enabled only with
the selector (A) forward to engage forward gear.

Flick the switch backward (tortoise) to maintain a constant low speed, useful to carry out
dangerous manoeuvres, precision manoeuvres in tight spaces and to drive downhill using the
engine brake.

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4.2.2.g - C - Drum rotation switch (fig. 6).

This selector is used to control drum rotation. Turn the driving post towards the drum (secondary driving
direction) and follow the instructions below:

Clockwise drum rotation during concrete loading and mixing.

In neutral position, the set speed remains fixed.

Anticlockwise drum rotation during concrete unloading.

Repeatedly act on the selector to increase the drum rotation speed. Act on the selector in opposite direction to
reduce the speed or until stopping the drum.

CAUTION: Because of minimal hydraulic leakage, the drum tends not to remain stationary.
Periodically check drum rotation by acting on the selector.

4.2.2.h - D - Reset selector (fig. 6).

This selector is used to reset the litre counter and the hours to the next service due.
This selector is used to reset the litre counter simultaneously on the instrument panel and on the Mix
Control (optional) keeping the two displays in phase.
(for litre counter programming see chapter 4.2.6).
CAUTION: The water pump and the litres of water pumped into the drum can also be controlled from the
rear of the vehicle by means of the MIX CONTROL (see chapter 4.2.6).

Note: if the FIORI BATCH CONTROLLER is installed on the machine, all functions of the litre
counter located on the electronic dashboard are not active, as the functions are displayed on the
operating panel.

4.2.1.i - E - Water pumps control switch (fig. 6).

This switch controls use of the vehicle water pump.
Follow the instructions below:

1st click - Pump on (warning light S1 on)

2nd click - Pump off (warning light S1 off).

WARNING: The pump stops automatically when the water tanks are full.

4.2.1.k - F - Hazard light toggle switch (fig. 6).

Snap switch to turn on the four hazard warning lights.

4.2.1.l - G - Working light switch (fig. 6).

Snap switch to turn on the rear working lights.

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5 6

10

0
1

2 1

3 18
13

7
4.2.2.m Engine starter and stopping switch (fig.7)
It is activated with the ignition key and can be set to four different positions. The key can only be removed if
the switch is in the off position.

0 Off position/engine stop

Engine stopping position.

1 On position
In this position the switch connects the battery to all the electrical circuits, except the lights and hazard-light
circuits. (The hazard warning light circuit is permanently powered).
The instrument runs a short test by turning on all the segments of the display. During this phase the engine
will not start, the instrument panel warning lights will signal the vehicle status by means of the generator
warning light (6) and the engine oil warning light (5), while the warning light that indicates that there is water
in the fuel sediment bowl (10) will emit only a test flash.
Subsequently, at the bottom of the numerical display (18) will be displayed, simultaneously and for 5 seconds,
the hours remaining until the next service is due and the maintenance warning light (1), immediately followed
by 5 seconds in which the actual total hours of vehicle operation will be displayed.
At the end, the engine rpm will be displayed.
When the ignition key is released from the positions 2 and 3 it automatically returns to this position.

2 Pre-heating position
When starting the engine in cold climates, hold the key in pre-heating position for no more than 10 seconds; the
spark plugs pre-heating warning light (13) will indicate activation and go off when turning back to position 1.

3 Starting position
Activates the starter motor that turns the engine.
As soon as the engine starts, the dashboard lights up and the engine rpm is displayed.

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8
4.2.2.n Direction indicators switch and horn (fig.8).
The light switch and the selector allow activating the following functions:

- Direction indicators
Shift the selector (1) forward to indicate a left turn.
Shift the selector (1) backward to indicate a right turn

- Horn
Press on the light lever switch (2) to activate the horn

- Light switch
The lights come on only if the ignition key is inserted

- Position lights:
turn the knob (3) forward by one click

- Low beams:
turn the knob (3) forward by 2 clicks.

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4.2.3 OPERATING CONTROL PANEL

C D

A
B

9
4.2.3 a - A - Drum traverse swinging lever (fig. 9).
The lever controls rotation of the fifth wheel of the drum.
Before turning the drum, lift it from its seat by releasing the safety stop (see chapter 3.5 Fig. 3 O)

Position 1 - Clockwise drum traverse swinging.

Position N - Neutral.

Position 2 - Anticlockwise drum traverse swinging.

4.2.3 b - B - Drum raising lever (fig. 9).

The lever controls drum raising.
Follow the instructions below:

Position 1 - Drum raising.

Position N - Neutral.

Position 2 - Drum lowering.

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4.2.1.c - C - Unloading chute control lever (fig. 9).

This lever allows tilting the unloading chute using a jack. This operation can be carried out from the
driver’s seat.

Shifting the lever to the right, the chute is tilted downward and to the left upward.

4.2.3 d - D - Joystick for arm raising and bucket/loader rotation (fig. 9 - 10).

F 3
F
N D
2
1 E

1 F
4 3

E
2 4
10
The joystick controls arm raising and loader rotation.
Arms / hydraulic hatch:
Position “1” - Arm lowering: only with button E pressed to prevent accidental manoeuvres.
Position “2” - Arm raising: without pressing button E.
Bucket / loader
Position “3” - Downward loader rotation. Press button F to close the hydraulic loader hatch.
Position “4” - Upward loader rotation. Press button F to open the hydraulic loader hatch.
Position “N” - Neutral.

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4.2.4 WATER FEEDING AND DISTRIBUTION CONTROLS (fig. 11).

1 2

F H

D
E C A

11
The following parts control feed and distribution of the mixing and washing water:

A – Suction coupling
- Water suction from external water sources (tanks, ditches, etc.) by means of a flexible suction hose E.
- Water suction from the vehicle tank.

B – Delivery switching valve

Position 1 - Water delivery to the drum from an external source or from the vehicle tank.
Position 2 - Water delivery to the tank from an external source.

C – Litre counter
Totals the amount of water pumped into the drum and shows it on the driving post and the Mix Control
display.

D – Water suction pump

Self-priming volumetric pump with bronze impeller.

E – Flexible suction hose with suction filter F

To be positioned in the water source involved:
reservoir, ditch, external tank, etc.

G – Washing nozzle
Used to wash the bucket, drum and chute and is positioned at the rear of the vehicle.
To be connected to the union H of the switching valve B turning the lever to position 2.

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4.2.5 GROUND CONTROL PANEL (MIX CONTROL) (OPTIONAL) (fig. 12).

E A

D C B
12
Some operations controlled from the cabin can also be carried out from the rear right-hand side (driving
direction) of the vehicle, more precisely:
Emergency engine stop, drum rotation, water pump activation, check of litres of water pumped into the drum
and, on request, chute raising.
A - Emergency engine stop from the ground (safety)
- Press the button in the event of danger.
- Turn the button to the right and release it to turn the engine back on after eliminating the risk.
B - Drum rotation switch
- Up for clockwise rotation (mixing).
- Down for anticlockwise rotation (unloading).
C - Water pump jog switch
- Up to activate the water pump (red LED on). Activate it again to stop the pump (LED off)
D - Litre counter switch
- Up to program the litres: programs the litres of water to be pumped into the mix. Holding it down for 3-4
seconds the number of litres set is shown and each time it is pressed again the value increases.
- Down to reset: resets the litres shown on the display (E) or decreases the value set each time it is
pressed.
When the set amount of water has been pumped in, the water pump automatically turns off.
For programming, see chapter 4.2.6.
E - Liquid crystal display
- Displays the litres pumped into the drum

CAUTION: Before approaching the MIX CONTROL warn the operator in the cabin of your presence.
Collaboration and eye contact between the various operators around the vehicle is essential
for your own and others’ safety.

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4.2.6 OPERATION OF THE ELECTRONIC LITRE COUNTER AND MIX CONTROL PROGRAMMING

Note: if the FIORI BATCH CONTROLLER is installed on the machine, value 0000 must be set to dis-
able the MIX CONTROL programming.

- The litre counter indicates the litres of water pumped into the mixing drum.
- The reset key D is used to reset the progressive litre counter.
Programming
You can program the number of litres to be pumped into the drum (only with MIX CONTROL) so that the pump
automatically stops when the preset value is reached.

CAUTION: When the preset value is reached, it is no longer possible to start the pump directly unless
the litre counter is reset.
If the value set is 0 (zero), the pump can only be operated manually and must be stopped
by the operator.

CAUTION: If the water runs out, the litre counter does not work and hence, because the pump does
not stop, the rubber impeller can easily burn.

Setting
A- Initial status: the display E indicates 0 and the lever D is (always) in central position.
B- Push the lever upwards and hold it until the display indicates:

After about 5 seconds, the display will indicate a flashing 0 (zero).

C- Release the lever for a second and, while 0 continues flashing, program the volume of water by pushing the
lever upwards to obtain an increase in steps of ten ( 0, 10, 20, etc.) or downwards to obtain a decrease in
steps of ten (0, 9990, 9980, 9970, etc.)
D- Release the lever when the display indicates the desired value. The number will turn to 0 (zero) within 5
seconds and setting is complete.

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4.3 INSTRUCTIONS FOR USE

It is essential that the first time you use this vehicle you familiarise yourself with the use of all the controls.
Therefore, practice all the vehicle handling procedures both during the working phase and during road
transfer so that you develop a good feeling for the controls and the equipment movement times.
This chapter is intended as a valid guide for those that already know the vehicle well and can hence easily and
quickly understand the instructions given.

Checks before starting work

- Check that the vehicle has been equipped with all the required equipment.
- Check that all the maintenance operations set out in Chapter 5 of this manual have been carried out.
- If repairs were made, check tightness of all the screws and nuts and the adjustments.

CAUTION: Before starting to use or carry out maintenance on the vehicle, always read the safety
regulations for the operations to be carried out as set out in Chapter 3.

13
4.3.1 REFUELLING (fig. 13)
- Refuel the vehicle with purified diesel fuel without water residues.
- Use a pump equipped with filter with a delivery nozzle that goes down into the filler neck after removing the
cap (1).
It is advisable to refuel at the end of the working day thus avoiding condensation during the night.

CAUTION: Do not run out of fuel so emptying the tank (keep an eye on the fuel reserve warning light).
Should this occur, you will need to bleed the air from the engine fuel supply system.

DANGER: Before checking or filling the fuel tank, make sure that there are no open flames
or smoking materials in the area. Do not refuel with the engine on. Do not use
matches, lighters or torches as light source.

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4 3

14
4.3.2 LEVEL CHECK (fig. 14)
Before starting the vehicle check the following:
- Engine oil level (1)
- Engine coolant level (2)
- Hydraulic oil level (3)
- Brake fluid level (4)
- Clean the contacts of the reverse gear microswitches (5).
The procedures are described in chapter 5 on maintenance.

1 2
A

C
D
15
4.3.3 FILLING THE WATER TRANSFER PUMP BODY (fig.15).

For proper operation of the self-priming pump, this must contain water.
Remove the closing cap C and take out the pre-filter D.
Check that it contains water through the suction pipe union A.
If there is no water, refit the pre-filter D, fill the pump body with water through the suction union A holding the
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delivery switching valve B in position 1 or 2 but not in the central position.

Finally, refit the closing cap C.

2
1
16
4.3.4 ADJUSTING THE SEAT (fig. 16)

CAUTION: Before starting the vehicle, adjust and lock the seat in the most suitable and comfortable
position, so that you can easily reach all the controls, and fasten the seatbelt.

Use the lever (1) to adjust the seat distance from the pedals and the lever (2) to adjust the springing hardness
(according to your weight). Use the knob (3) to adjust the seat height. .

17
4.3.5 ADJUSTING THE REAR-VIEW MIRROR (fig. 17)

CAUTION: Operation to be carried out before starting the vehicle.

To adjust the field of vision of the sideview mirror (1), turn it so that you can see the rear left-hand side of the
vehicle as shown in the figure.

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B A
1

2
18
4.3.6 DRIVING POST PIVOTING (fig. 18)
CAUTION: Turn the driving post with the vehicle stationary and stable.
This operation may be carried out while you are seated on the driver’s seat. Check that it is
locked into place after the operation.

The driving post must always face forward A during road transfer and backward B, turned 180° for the drum
loading phases.
Press the lever (1) to release the driving post, turn it in the desired direction and relock the lever (1).
If the driving post is not perfectly locked, dedicated microswitches (2) will not allow vehicle movement.

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3 4

19
4.3.7 STARTING THE ENGINE (fig. 19)

DANGER: Before starting the engine, check that there is no one in the vicinity of the vehicle.
Do not operate the vehicle in closed places without ventilation.

- Check that the parking brake (1) is applied.

- Check that the electrical forward/reverse gear selector (2) is in neutral position (otherwise the vehicle will not
start).
- Check that the emergency button at the rear of the vehicle is deactivated and that the hand accelerator (3)
is in rest position.
- Start the engine by turning the ignition key (4).
- When the engine has started, release the key and check that the engine oil pressure, battery low and coolant
temperature warning lights are off.

CAUTION: Do not try to activate the starter motor with the key inserted for more than 20-30 seconds.
If the engine does not start, wait 2 minutes before retrying, allowing the starter motor to
cool down.
When the engine has started, let it run at about 1000 rpm for a few minutes to allow the oil to warm
up and lubricate all the parts; this is essential in cold climates.

CAUTION: STARTING AT LOW TEMPERATURES

Turn the ignition key clockwise by one click, wait until the display is in operating mode and
turn the ignition key to pos. 2 waiting 10-15 seconds in the pre-heating position, then turn it
to position 3 to turn on the engine. Do not hold the accelerator pedal depressed during the
preheating phase.

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4.3.8 ENGINE OPERATION AT LOW RPM

It is unadvisable to leave the engine running at idle speed for too long.
Therefore, if you can foresee that the engine will be running at idle speed for a long period of time, always turn
it off.
Nonetheless, if you need to keep the engine running, make sure that the engine speed is sufficient to supply
the necessary engine oil pressure, indicated by the relative warning light on the instrument panel turning off.

4.3.9 ADJUSTING WHEEL ALIGNMENT

Whenever you drive on the road or for long stretches, it is essential to check proper alignment of the four
wheels to prevent running into translation problems.
To align the four wheels, operate as follows:
Turn the driving post to the PREFERENTIAL driving direction and turn the steering wheel to move the rear
wheels into a straight line with the vehicle.
Shift the selection lever to the “2 RS” position and use the steering wheel to align the front wheels with the
rear ones (visually check).
Select the type of steering based on the type of translation to be performed with the vehicle.
After this procedure the steering will be synchronized.
During translation with “2 RS” the rear wheels remain in fixed position thanks to a check valve.

4.3.10 PARKING BRAKE (fig. 19)

CAUTION: When the engine is turned on, the parking brake automatically disengages if the button (1)
is released.
The next time the vehicle is turned off the parking brake automatically engages because
the residual pressure is cancelled out.

DANGER: Do not use the parking brake to slow down the vehicle, except in emergencies, as
the vehicle would stop suddenly reducing the efficiency of the brake.

To disengage it, turn the button (1) and release it.

For temporary stops on slopes or where necessary engage the parking brake by pressing the button (1).
To release the brake in the event of a braking system failure, see chapter 4.5.1.

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4.3.11 STARTING AND DRIVING THE VEHICLE (fig. 20)

A
C

E B D
20
CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out
as set out in Chapter 3.

- Lock the driving post in the road transfer position using the dedicated lever and check that it is firmly secured.
- Start the engine following the procedure described above.
- Keep the engine running for the period of time necessary to warm up the hydraulic system oil.
- Disengage the parking brake.
- Check that the hand accelerator (E) is set to “0” and the selector (A) is in neutral position. If the hand
accelerator (E) is set to “1”, the machine does not move when the selector (A) is moved to the desired driving
direction.
- Depress the service brake pedal (B) and shift the gear lever (C) to position “1” for driving on steep slopes or
to position “2” for flat stretches.

CAUTION: Mechanical gears must only be selected with the vehicle stationary and stable.

- Set the gear selector (A) to the desired driving direction. This selection can also be performed while the
vehicle is moving.
- Check that you can safely move forward, then start depressing the accelerator pedal (D) to move the
vehicle.

DANGER: Steer maintaining an adequate speed and act gradually on the steering wheel,
especially when you are on a slope.

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4.3.12 FIELD OF INDIRECT VISIBILITY OF THE REAR OF THE VEHICLE

(Standard only for specific countries) (fig. 21)

CAMERA:
FAR FILED OF VIEW

CAMERA:
NEAR FIELD OF VIEW

1mt.

3
2

21
Looking at the images on the display (2) transmitted by the camera (1) and using the rearview mirror (3), you
have a wide view of the area behind the vehicle. This allows you to safely reverse from and approach the
unloading area.
CAUTION: For the display (2) operation, refer to its user manual that comes with the vehicle.

DANGER: Check that the display (2) is properly set for direct visibility (NO MIRROR).

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4.3.13 STOPPING THE VEHICLE

CAUTION: Whenever you interrupt work for any reason, always set the joystick safety switch to locked
position.
Before leaving the vehicle, set all the controls to neutral position.

- Release the accelerator pedal.

- Gradually depress the brake pedal till the machine stops.
- Shift the gear selector to neutral position.
- Engage the parking brake.
- Lower the drum and bucket.

CAUTION: Never perform reversing manoeuvres to stop the machine.

4.3.14 STOPPING THE ENGINE

CAUTION: Never leave the vehicle with the engine on.

- With the engine at idle speed, turn the key to “0” and remove it even if only temporarily leaving the vehicle.

4.3.15 PARKING THE VEHICLE

CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out
as set out in Chapter 3.

CAUTION: Never stop or park on a slope without first blocking the vehicle to prevent it from moving.

CAUTION: Always face the vehicle when getting on or off and check that your shoes and hands are
clean and dry to prevent slipping and falling.

Where possible, stop the vehicle on level and dry ground.

Remove the ignition key before leaving the vehicle.
- Deactivate all the unnecessary switches.
Check that all the switches are deactivated before leaving the vehicle. If necessary, leave the hazard lights
on.
- Leaving and locking the vehicle
Use the handles and steps to get off the vehicle. If you leave the vehicle, close and lock all the windows and
the door (if present). Check that the fuel tank cap and the engine compartment lid are locked.

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4.4 TRANSPORTING THE VEHICLE (fig. 22)

5910

2780
> 4000

900
10-15%

22
CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out
as set out in Chapter 3.

CAUTION: Use transport vehicles of adequate capacity driven by qualified personnel.

Before loading the vehicle onto the means of transport, check that it carries no other
load.

CAUTION: To secure the vehicle on the means of transport, use the special fastening points indicated
with labels.

CAUTION: Do not use the canopy ledges to anchor the vehicle during transport.

Note: Before transporting the vehicle, ensure compliance with the regulations and laws of the areas you will
be travelling through.
Before loading the vehicle onto the means of transport, check that it does not interfere with the ramp
angle of the trailer. See the section Specifications for the minimum height of the vehicle from the
ground.
Make sure that the transport vehicle is adequate. See the section “Specifications” for the vehicle weight
and dimensions.

- Have someone on the ground guide you in carrying out the manoeuvres.
- Raise the bucket.
- Drive very slowly going up and down the ramps and on the platform limiting use of the accelerator and the
steering wheel to the minimum indispensable.
- Once the vehicle is positioned, lower the bucket and apply the parking brake. When the bucket is raised or
the rotating beacon is mounted on the cabin, the height exceeds 4 metres and transport is not permitted.
- Secure the vehicle as described above.
- Firmly anchor the vehicle on the platform and lock the wheels with wedges.
- Check that the lid or other moving parts are properly closed.
- Measure the maximum height of the vehicle from the ground.
Inform the driver of the transport vehicle of the overall height before he sets off.

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4.4.1 LIFTING THE VEHICLE WITH A CRANE (fig. 23)

2700 1550

10° 10°

DRY WEIGHT
5.700 KG
23
950 1350

CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out
as set out in Chapter 3.
CAUTION: Before lifting the vehicle, check that it does not carry any load and that the crane used is of
adequate capacity to support the weight of the vehicle; see the section “Specifications”
for the weights and dimensions.

CAUTION: For lifting with a crane it is advisable to use adequate rocker arms in order not to damage
parts of the vehicle when the chains tauten.
Use only the lifting points marked on the vehicle.

- Turn the drum as you would for road transfer.

- Raise the loader arm and lock it with a tie-rod (1).
- Hook the chains onto the special hooks.

DANGER: During lifting, stand well away from the vehicle and do not stand under the load.
Sudden movements or the chains snapping may cause injury and even death.

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4.5 TOWING AND RECOVERY (fig. 24)

24
CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out
as set out in Chapter 3.

CAUTION: Remember that towing may cause further damage to the vehicle.
Tow the vehicle only as far as the breakdown truck. Drive very slowly and for short stretches
(5 km/h) to prevent the hydraulic oil in the closed circuit from overheating.

- Lower the drum and raise the arm locking it with a tie-rod.
- Connect a suitable tow bar to the front lifting couplings (1).
- Release the negative brake (Chapter 4.5.1) and move the speed control lever (mechanical) (2) to neutral.
- Turn on the hazard lights and the rotating beacon.
- An operator must be on board to drive and stop the vehicle, correctly seated in the driver’s seat with the
seatbelt fastened, the driving post facing the preferential driving direction and the steering lever positioned
on 2RS. If you need to steer make sure that you understand the actions of the driver of the towing vehicle.
Follow his instructions and comply with all the relative regulations. Bear in mind that steering is harder when
the engine is off.
- Use a towing vehicle with a towing capacity of more than 11,900 kg with full load and 5,700 kg when unladen.
- When you have finished the towing operations, restore the negative brake (Chapter 4.5.1).

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4.5.1 RELEASING THE PARKING BRAKE IN THE EVENT OF A BRAKE SUPPLY SYSTEM FAULT
(fig. 25)

1
1

25
Carry out this operation on a flat surface after blocking the wheels with wedges.
- Tighten the four screws (1) of the axles using a no. 14 wrench tightening them by one turn each one after
another in sequence until they are at the end of travel mechanically releasing the brake.
- To resume the brake original conditions, follow the above procedures in reverse order.

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4.6 DRIVING ON PUBLIC ROADS (fig. 26)

1
4

26
CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out
as set out in Chapter 3.

CAUTION: THE STEERING SELECTOR MUST BE POSITIONED

ON 2 STEERING WHEELS
- Direct the driving post in the preferential driving direction.
- Activate all the safety devices as indicated in chapter 3.6.
- Lower the drum fully.
- Raise the bucket as far as it will go and tie it with the safety cable (1) so that the arm is locked.
- Direct the chute (2) into retracted position and lock it with the lever (3).
- Check that all the warning lights function properly.
- Turn on the rotating beacon (4) provided.
- With the vehicle stationary, shift the gear lever to 2nd gear for transfers on flat surfaces or moderate slopes,
or to 1st gear for medium to steep slopes.
- Keep an eye on the instruments and check that they function properly.
- Strictly observe the road regulations.
If traffic slows down, move onto the hard shoulder to allow faster vehicles to pass.

CAUTION: If you need to change a tyre, make sure that the type and tread are those specified by the
MANUFACTURER.
Not all tyres are homologated for road circulation with the required loads and speeds.

CAUTION: The vehicle may circulate on the road with a full load and empty according to the carrying
capacity indicated on the homologation plate.

CAUTION: At regular intervals, check proper functioning of the lights and immediately replace any
blown bulbs.

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4.7 HOMOLOGATION FOR ROAD USE (ITALY)

This vehicle is classified as an operating vehicle according to Italian law.
In order to circulate on the road, it must be homologated and registered.
Pursuant to the regulations in force, the vehicle is equipped with an additional danger signalling device.
The yellow rotating beacon must always be turned on when circulating on the road.
The danger signal, consisting in the simultaneous illumination of the direction indicators, must be activated
when the vehicle is stationary on the road and in any situation where it is a hindrance to traffic.
Anyone who circulates on the road with a vehicle that does not comply with or violates applicable legislation
will be punished with a fine.
The MANUFACTURER must provide the declaration of conformity for road circulation.
The related documentation must be submitted by the Purchaser to the local Directorate-General for Road
Traffic and Privately Operated Transport Vehicles, for obtaining the registration certificate (logbook) and
number plate.

CAUTION: The declaration of conformity alone is absolutely not sufficient for road circulation. It is
mandatory to register the vehicle.
The declaration of conformity must be submitted the Driver within 12 months from the date
of issue; failure to do so may cause the Directorate-General for Road Traffic and Privately
Operated Transport Vehicles to reject issuance of the registration certificate (logbook) and
number plate.

4.8 PRECAUTIONS FOR USE IN COLD CLIMATE CONDITIONS

1 2
27
At the end of each work shift, empty the plastic water tanks to prevent them from swelling and bursting.
Unscrew the caps (1) as shown in the figure, positioned underneath the two tanks to let the water drain out.
Empty the water transfer pump by undoing the screw (2) to let the water drain out.
If you are forced to work in temperatures close to 0°C, check that the radiator is filled with an antifreeze mixture
to prevent the water from freezing.
- Check the quality of the antifreeze coolant at least once a year, for example, at the beginning of the cold
season. The coolant must be changed every two years.
- The antifreeze mixture must be made up of equal quantities of antifreeze and water. The corrosion inhibitor
contained in the antifreeze must be diluted if using a solution with less than 50% antifreeze. Concentrations
of more than 50% antifreeze may have a negative effect on coolant performance.
- Use an antifreeze of the type and brand as indicated in the RECOMMENDED LUBRICANTS AND FLUIDS
table and calculate the percentage water/antifreeze in relation to the ambient temperature using the table
provided by the manufacturer.
- After refilling/topping-up, run the engine for a few minutes to allow the water and antifreeze to mix well.

CAUTION: To use the vehicle at low temperatures, you also need to change the lubricants and use
types with an appropriate viscosity (see the RECOMMENDED LUBRICANTS AND FLUIDS
TABLE).
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4.8.1 SUMMER/WINTER HEATING SYSTEM (fig. 28)

DANGER: Open the lid only with the engine off and cold.

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

CLOSED

OPEN

28

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4.9 PRECAUTIONS IN THE EVENT OF LONG PERIODS OF INACTIVITY

CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out
as set out in Chapter 3.
In order to protect the chrome-plated parts against atmospheric agents during long periods of inactivity, take
some basic precautions.
- Vehicles that remain outdoors, e.g. on a yard, for long periods of time must be parked with the loader
lowered; the rods can also be protected with external guards 1.
If the vehicle is not to be used for a long period of time, follow the instructions below.
- Clean the vehicle and lubricate it through the grease nipples.
- Remove the battery, store it in a warm place and recharge it at least once a month.
- Protect the jack rods with grease to prevent encrustations and corrosion.
- Empty the water tanks and the transfer pump as described in the paragraph above.
- Position the vehicle in a sheltered place and/or cover it with a waterproof sheet.
- Do not leave biodesel (where used) inside the engine supply circuit.
- To keep the engine lubricated, let it run for at least 20 minutes no less than once a week.

CAUTION: For more information, contact an AUTHORISED FIORI WORKSHOP.

1
29

4.10 WORKING PHASES

CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out
as set out in Chapter 3.

It is essential that the operator becomes familiar with all the controls and, for a first period of time, practices
in a relatively isolated area where he will freely perform all the manoeuvres and operations, which will soon
become routine operations by regularly using the vehicle.
This chapter analyses all the working phases that should be carried out in sequence, in order to obtain optimal
vehicle performance and comply with all the safety regulations.
1 - Before getting on the vehicle (checks and warnings).
2 - Correct use of the vehicle on slopes
3 - First filling with mixing water
4 - Cement loading
5 - Aggregate loading
6 - Mixing and second filling with mixing water
7 - Concrete unloading
8 - Bucket, drum and chute washing

CAUTION: During road transfer, the driving post must face forward.

CAUTION: Always fasten the seatbelts.

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4.10.1 CORRECT USE OF THE VEHICLE

During transfer the operator should keep the driving post turned toward the front of the machine. When driving
on public roads follow the specific safety rules of chapter 3.
Working in worksite the operator should proceed with the machine in transfer lay out. If it is necessary to
proceed with the turret rotated working phase (e.g. unloading operations for foundations, inability to maneuver,
etc.), ask for a person to stand on the ground who can give useful info with manual signals for delimiting an
advancement area of more than 12 m.

4.10.2 BEFORE GETTING ON THE VEHICLE (CHECKS AND WARNINGS)

CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out
as set out in Chapter 3.

Before using the vehicle, you must perform some safety checks.
Some of these checks are aimed at verifying proper vehicle operation, others involve your own safety.
Have any and all defects or malfunctions repaired by a mechanical engineer.
Before performing all checks, make sure that the parking brake is applied.

Cleanliness
- Check that the light glass covers and the rearview mirrors are clean.
NOTE: Check that the rearview mirrors are positioned so that you have the best possible visibility of the area
behind the vehicle.
- Remove grime and dirt from the cylinders, pins and the radiator.
- Make sure that the steps and handhold are clean and dry.
- Clean all the adhesive safety labels. Replace any illegible or missing labels.

Damage
- Check that there are no damaged or missing parts.
- Check that all the articulation pins are properly in place and lubricated.
- Check the windows for any cracks or damage.
- Check that there are no oil, fuel or coolant leaks underneath the vehicle.

Check all the devices as indicated in the scheduled maintenance table in chapter 5 and make any necessary
repairs.

4.10.3 CORRECT USE ON SLOPES

When working on slopes, take some precautions to prevent risks to yourself and others in the vicinity. Carry
out the following checks and operations:
- Always check the working area for snow, small landslips, gravel and tilled soil which may suddenly change
the working conditions and vehicle stability.
Maximum surmountable gradient when loaded (ramps, obstacles, jerking).................................... 23° (41.6%)
Maximum permissible gradient on steep roads during transfer:
front .................................................................................................................................................... 14° (25%)
Side ..................................................................................................................................................... 4.6° (8%)

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CAUTION: Observing the recommended gradient limits does not mean that you can manoeuvre the
vehicle in total freedom in all load, ground or manoeuvring conditions on a slope. In any
event, it is advisable to halve the gradient values on wet or uneven ground.

30

DANGER: Driving on slopes with a gradient above the prescribed one may cause the vehicle
to lose stability and consequently overturn.

RIGHT WRONG

31

- Do not change direction on slopes or move sideways, up or down the slope; if this is not possible, make
several diagonal manoeuvres holding the vehicle axis as parallel as possible to the direction of the slope.
- Never make sharp diagonal movements or, even worse, with the vehicle axis turned 90° with respect to the
direction of the slope.
- If the fuel reserve warning light comes on while you are working on a slope, immediately refuel; given that the
vehicle is inclined, the engine may take in air and stall unexpectedly, posing a grave danger to your safety.

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4.10.4 CONCRETE COMPOSITION AND BATCHING TABLE

The volumes and/or weights of the individual components vary in relation to the breaking load and the product
characteristics, also considering practical experience.
The table below gives approximate values.
- Recommended operating cycle to produce workable concrete (A):
1) Pump in about 80-90% of the total quantity of water.
2) Add all the cement
3) Add all the gravel
4) Add all the sand
5) Add the remaining percentage of water.
- Approximate mixing time: 4-5 minutes
- Approximate total cycle time (aggregate loading, adding water, mixing, unloading): 15 minutes.

FOR A YIELD OF 1 SQUARE METRE OF CONCRETE (approximate values)

TYPE OF CONCRETE OR AGGREGATE MIXTURE

AGGREGATE CEMENT WATER
kg GRAVEL m3 SAND m3 lt

STANDARD FOR FOUNDATIONS 150 0,80 0,40 100

200 0,80 0,40 120

200 0,80 0,40 120

(A) FOR OPERATIONS WITH 250 0,80 0,40 140
FORMWORKS
300 0,80 0,40 150

(A) REINFORCED CONCRETE, 300 0,80 0,40 150

IRON EXCLUDED 350 0,80 0,40 160

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4.10.5 FIRST FILLING WITH MIXING WATER

4.10.5.a Filling the tanks with mixing water (fig. 32)

L
1 2

H E

F
A C 32
CAUTION: In the event of pump failure, check that there is water in the pump body (see chapter
4.3.3).

- Fill with water through the water inlet pipe

To fill the tank, use an external water source introducing water through the hole L.
You can fill from both water tanks positioned opposite each other as they are connected.

- Filling with water using the transfer pump

CAUTION: Check that the pre-filter is fitted inside the filler neck A of the pump, and always use the
filter F during suction from water sources, since the pump may take in small parts that
could damage the pump propeller.

- Remove the closing cap C checking that the pre-filter is fitted, insert the flexible suction hose E into the
suction pipe filler neck A of the pump.
- Insert the tube leading to the tank into the delivery filler neck H.
- Move the valve B to the correct position (with delivery to tank 2).
- Position the flexible suction hose E in the relative water source (reservoir, external tank, ditch etc.).
- Open both covers L to prevent the water tank from swelling.
- Check that the suction filter F is completely immersed (the maximum difference in height from the union A
must be 4-5 m).
- Start the engine.
- Activate the transfer pump (engine rpm ideally about 2000).
- Wait until the tank is full (when water starts flowing from the water inlet pipe and from the tank).
- Stop the transfer pump and close the cover L.

CAUTION: The pump automatically stops when the water tanks are full.

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4.10.5.b First filling with mixing water (fig. 32)

The mixing water is managed by two different systems:

- External water source (tanks, reservoirs, ditches, etc.).
- Vehicle tank
The first system allows you to both fill the vehicle tank and directly fill the drum with mixing water.
The second system only allows you to fill the drum with mixing water.

- Filling with water from an external water source

- Position the flexible suction hose E in the relative water source. Check that the hose coupling is connected
to the suction pump union A and that the suction filter F is intact.
- Set the switching valve B to position “1” and then continue directly filling the drum with mixing water.

- Filling with water from the vehicle tank

- When the tank is full, set the switching valve B to position “1” checking that the coupling of the hose
leading from the vehicle tank is connected to the suction pipe union A of the pump.

A B
33
4.10.5.c Activating the water transfer pump (fig. 33)
- Check that all the control levers are in neutral position.
- Start the engine.
- Rotate the drum.
- Increase the rotation speed until reaching maximum speed.
- Accelerate the engine by acting on the hand accelerator for 2/3 of its total travel (1800-2000 rpm).
- Activate the transfer pump with the switch A in the cabin OR USING THE MIX CONTROL by means of switch
B.
- Check the quantity of water pumped in on the litre counter, which in this first phase should be 80-90% of the
total quantity.
- Refer to the CONCRETE COMPOSITION AND BATCHING table, chapter 4.10.4, to calculate the optimal
quantity of water.

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4.10.6 CEMENT LOADING

DANGER: It is strictly prohibited to climb onto the vehicle, whether it is in the mixing phase
or stationary.

34
4.10.6.a Cement in bags (fig. 34)

CAUTION: Wear a protective mask.

- Keep the drum rotating.

- Raise the bucket about 0.5 metres and hold it in fully tilted position with the hatch closed.
- Calculate the quantity of cement to be loaded referring to the CONCRETE COMPOSITION AND BATCHING
TABLE in chapter 4.10.4.
- Manually fill the bucket with cement, tearing open the bags on the serrated blade of the bucket.
- Remove the paper bags.
- Raise the arm to its maximum height.
- Open the unloading hatch and wait until the cement has poured into the drum through the hopper, helping it
along by vigorously shaking the bucket with the arm.

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3735

35
4.10.6.b Cement in silos (fig. 35)
- Keep the drum rotating at top speed.
- Raise the bucket arm to its maximum height (3,735 mm)
- Move to underneath the unloading point of the silo.
- Calculate the quantity of cement to be loaded referring to the CONCRETE COMPOSITION AND BATCHING
TABLE in chapter 4.10.4.
- Open the unloading hatch and fill the drum using the silo dosage system.

4.10.7 AGGREGATE LOADING

36
4.10.7.a Heaped aggregate (fig. 36)

- Keep the drum rotating at top speed.

- Lower the arm after checking that the hatch has closed.
- On the mechanical gearbox, select the 1st working speed (low).
- Dig into the heap with the bucket and at the same time raise the arm, that way filling the bucket with a larger

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amount of material and reducing the arm raising time.

- Raise the arm to its maximum height while moving backward.
- Stop the vehicle.
- Open the unloading hatch and wait until the cement has poured into the drum through the hopper helping it
along by vigorously shaking the bucket with the arm.
- Approach the heap again while lowering the arm.
- Repeat the operations described above at least 8÷9 times. This is the bucket yield on average to obtain
optimal drum loading.

CAUTION: You can shift to reverse gear even if the vehicle has not completely stopped.

4.10.8. MIXING AND SECOND FILLING WITH WATER (fig. 37)

37
- Keep the drum rotating for about 2 minutes after the last aggregate loading phase.
- Add the remaining amount of water, about 30% of the total, following the procedures described in chapter
4.10.5 to obtain the desired fluidity.

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4.10.9 CONCRETE UNLOADING

CAUTION: Always set the gear selector to neutral position.

Move the arms up to the maximum height with the hydraulic hatch closed.

CAUTION: If someone on the ground assists you during unloading, be extremely careful in carrying
out the manoeuvres and keep eye contact at all times.

CAUTION: Avoid sudden inversion of drum rotation when the drum is full or partially full and raised on
uneven, bumpy or soft ground.

CAUTION: When working on side slopes do not rotate the rotary frame with the unloading chute facing
downhill. Avoid steep slopes when you need to traverse with the rotary frame.
Keep the arms at the maximum height.

CAUTION: Carefully rotate the drum to prevent unbalancing the wheels.

B E

C A
38
4.10.9.a Concrete unloading from chute (fig. 38)

- Keep the drum rotating in the mixing direction (clockwise).

- Approach the unloading area.
- Stop the vehicle.
- Loosen the lever A that locks the chute B.
- Move the chute B directing it to the correct unloading position.
Operate the lever E positioned in the driving post to adjust the chute height. This control acts on the chute
tilting cylinder C.
- Arrange any extensions D and lock the chuteB using the lever provided A.
- Bring the engine rpm up to a medium speed.
- Invert the drum rotation direction for unloading by acting on the selector in the cabin or the one on the
ground.
- Adjust the drum rotation speed. The concrete unloading speed depends on the engine speed, the drum
rotation speed, the height to which the drum is raised and the fluidity of the concrete.
- Raise the drum but not necessarily to its maximum height.
- Visually inspect regular concrete unloading.

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- To move on to the next area after completing unloading in the first area, follow the instructions below:
- Lower the drum if it is still relatively full and reposition it on the longitudinal axis.
- Revert the drum rotation direction to mixing (clockwise).
- Approach and position in the new unloading area and follow all the instructions given above.

A B

39
4.10.9.b Front unloading from chute (fig. 39)

CAUTION: During front unloading, never lower the loader arm.

The new version of the FIORI concrete mixer allows front unloading from the left-hand side, directly visible by
the operator in the cabin.
To make use of this new feature, some preliminary operations must be carried out to prevent damage to the
engine casing and the skid unit. Proceed as follows:
- Check that the engine casing is closed and at a standstill.
- Lower the front left light unit A
CAUTION: Move the chute back into place after unloading, as this is essential for road transfer.
- Turn and lock the chute B with the mouth facing the outside of the vehicle, and secure it with a setscrew.
- Raise the loader arm to its maximum height, then turn the counterframe to the desired position making sure
that the arms are completely raised so as not to interfere with the engine compartment lid.
- Then continue with the normal unloading operations.

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B
FRONT DISCHARGE

0°
A 24
SIDE DISCHARGE

40
4.10.9.c Unloading in formworks in traverse swinging mode (fig. 40)

CAUTION: The unbalance due to the weight variations of the vehicle may alter the stability conditions.
Therefore, be extremely careful when rotating the drum.

To unload concrete into form works or foundations using the side unloading hatch operate as follows:
- Keep the drum rotating in the mixing direction (clockwise).
- Approach the unloading area with the forward movement line parallel to the unloading line.
Stop the vehicle.
- Arrange any extensions in the unloading chute.
- Bring the engine rpm up to a medium speed.
- Direct the rotary frame by operating the lever B that drives fifth wheel rotation.

Move the chute A directing it to the correct unloading position.

- Invert the drum rotation direction for unloading by acting on the selector in the cabin.
- Accelerate the engine and adjust the drum rotation speed. The concrete unloading speed depends on
the engine speed, the drum rotation speed, the height to which the drum is raised and the fluidity of the
concrete.
- Visually inspect regular concrete unloading.
- Drive slowly in the working direction, avoiding sudden braking or acceleration.

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4.10.9.d Direct unloading from hopper (fig. 41 - 42)

C
41
The concrete can be unloaded directly from the hopper by removing the unloading chute A.
In this way, you can use a maximum height of 1,845 mm.
- Remove the 2 screws B from the relative supports.
- Remove the chute A with its mount.
- Remove the chute tilting cylinder C.
- Keep the drum rotating in the mixing direction.
- Approach the unloading area.
- Stop the vehicle.

1845 1845

42
CAUTION: If someone on the ground assists you during unloading, be extremely careful in carrying
out the manoeuvres and keep eye contact at all times.

- For side unloading, orient the rotary frame in the most appropriate position.
- Bring the engine rpm up to a medium speed.
- Invert the drum rotation direction for unloading by acting on the selector in the cabin or the one on the
ground.
- Adjust the drum rotation speed. The concrete unloading speed depends on the engine speed, the drum
rotation speed, the height to which the drum is raised and the fluidity of the concrete.
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- Raise the drum but not necessarily to its maximum height.

- Visually inspect regular concrete unloading.
- To move on to the next area after completing unloading in the first area, follow the instructions below:
- Lower the drum if it is still relatively full and reposition it on the longitudinal axis.
- Revert the drum rotation direction to mixing (clockwise).
- Approach and position in the new unloading area and follow all the instructions given above.

4.10.9.e Concrete unloading from drum emergency door

DANGER: This operation must be performed by Authorised FIORI Workshops qualified

personnel.

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4.10.10. BUCKET, DRUM AND CHUTE WASHING (fig. 43)

G
2

43
CAUTION: The washing operations can be carried out both with the nozzle provided (pressure of 4.5
bar) and with an optional nozzle operating at a pressure of around 150 bar.

- Set the drum to rotate clockwise like for mixing.

- Fill the drum with water and gravel following the procedures as described above (chapter 4.10.5) in a
quantity sufficient to dilute and detach the concrete residues.
- Connect the washing nozzle G to the pump delivery.
Set the switching valve B to position “2”
- Externally wash the bucket, drum and chute as well as all the parts normally soiled with concrete.
- Raise the drum.
- Change drum rotation from clockwise to anticlockwise.
- Drain out all the water in the drum and wash the chute and the extensions.
- Remove the extensions.
- Lower the bucket and wash it inside and out.

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4.10.11. INTERNAL CLEANING OF THE MIXING DRUM (fig. 44)

44

DANGER: Do not climb onto wet and slippery parts of the vehicle and be extremely careful in
all the movements you make.

CAUTION: Do not insert the washing nozzle in the drum mouth when it is rotating.

The main device of the vehicle, for which it was designed, is the drum. It is essential to thoroughly clean
the inside of the drum to prevent concrete encrustations from reforming on the mixing blades for as long as
possible.
Therefore, in addition to washing the vehicle when you have finished work as described in chapter 4.10.10, it
is advisable to wash the inside of the drum. Proceed as follows:
- Lower the loader to the ground.
- Fully raise the drum counterframe in order to bring the unloading hatch close to the ground.
- Wash the inside of the drum as thoroughly as possible using the washing nozzle.
- When done, turn the drum anticlockwise and drain out the water.

4.10.12 EXTRAORDINARY DRUM CLEANING OR BLADE REPLACEMENT

DANGER: Do not climb into the drum while it is still mounted on the vehicle.
Extensive use of the vehicle and not thoroughly washing the drum after mixing will wear out the blades or
cause them to clog up with solidified concrete.

Having to work inside the drum to solve these problems, it is obligatory to go to an equipped workshop
and dismantle the drum from the vehicle so that these operations can be carried out on the ground in safe
conditions.

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5.1 FOREWORD
This manual provides all the information necessary for routine maintenance on the FIORI vehicles.
This chapter addresses the persons that will physically be carrying out routine maintenance and provides the
rules to follow to achieve the end result, namely,
repair when necessary and help ensure functionality of the FIORI vehicle over time.
The service intervals given in this chapter refer to normal operating conditions.
The service intervals may vary in the running-in period or in specific conditions.
The main purpose of this chapter is to indicate all the operations to be carried out at the same service interval
thus facilitating the procedures and reducing the vehicle stop time.

CAUTION: All the operations described in detail in this chapter are considered routine maintenance.
Given the care that needs to be taken to remove and refit parts of the vehicle, the persons
that physically carry out the operations are responsible for their success and assuring that
functionality is restored.

CAUTION: For extraordinary maintenance, contact your nearest AUTHORISED FIORI WORKSHOP.

CAUTION: Carefully read all the safety regulations set out in Chapter 3, in particular the general and
specific WARNINGS FOR MAINTENANCE.

Before and after the lubrication operations, clean the covers, grease nipples and caps to prevent dirt
infiltrations.

Lubrication is of primary importance in preventive maintenance, and the useful life of the vehicle depends on
it. Therefore, it is absolutely essential that you follow the instructions given in this manual for the lubricants to
use and the service intervals.

CAUTION: Do not pollute the environment.

In accordance with national and international laws, lubricants, fluids, coolants and
impregnated filtering elements are classified as polluting and toxic waste. They must be
stored and disposed of at special facilities.

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5.1.1 VISUAL EXTERNAL INSPECTION (fig. 1)

A
G
B
D

F
1
Every day, before starting work or at the end of the day, it is advisable to quickly check the vehicle and take any
necessary action, thus considerably reducing maintenance costs and the vehicle stop times.
Check the following:
A- Arm - bucket articulations
B- Hydraulic system and pipes
C- Instruments and gauges
D- Engine and radiator
E- Tyres
F- Transmission
G- Jacks and pins

5.1.2 CLEANING THE VEHICLE

Clean the vehicle with water. Pay particular attention to the bottom of the vehicle. Do not let mud to deposit
under the engine and the transmission. Check that the radiator grille is not clogged.

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5.1.3 CHECKING FOR DAMAGES

- Check that all the pins are properly in place and well secured with the respective stops.
- Check the light and signalling devices.
- Check the tyres for sharp or cutting objects.
- Check that all the adhesive safety labels are in place and undamaged. Replace them if necessary.

Seatbelt

CAUTION: Replace the seatbelt if worn or damaged following an accident.

- Check that the seatbelt is not frayed or stretched.

- Check that the buckles are intact and working.
- Check that the fastening screws are properly fitted and tightened.

ROPS & FOPS structures

DANGER: Modified or improperly repaired ROPS/FOPS structures are dangerous. Do not

repair them following an accident and do not use the vehicle until the structure
has been checked and repaired by qualified personnel. The vehicle may not be
used without the ROPS structure.

- Check the structure for mechanical damage.

- Check that the retaining screws are all in place, well fitted and properly tightened.

5.1.4 ACCESS TO THE MAIN DEVICES

5.1.4.1 PARTS CONTAINED IN THE TOOL KIT

5
7
2

4
6

1 - no.1 double fork wrench 10 - 13

2 - no.1 double fork wrench 17 - 19
3 - no.1 double fork wrench 24 - 27
4 - no.1 oil filter wrench
5 - no.1 M18 T-wrench
6 - no.1 flat-blade/cross-slotted screwdriver
7 - no.1 manual grease pump

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5.1.4.2 ROUTINE MAINTENANCE AND CHECKS (fig. 2)

B A

2
CAUTION: Never open the various access doors if the machine is not parked on a flat surface with the
engine off and the parking brake engaged.

- Driving post
To access the use and maintenance manual and the fuses and relays, open the driving post door (A) with the
key provided.
To access the windscreen washer water tank, undo the screws of the panel (B).

- Engine compartment lid

Unlock the lid (C) with the key provided and raise it to access the following parts:
- Engine oil cap, level gauge and filter
- Engine accelerator cables
- Starter motor and alternator
- Hydraulic oil tank cap
- Radiator
- Engine air filter
- Hydraulic oil filter.

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5.2 MAINTENANCE SCHEDULE

- Service
- Every 8 hours or daily
- Every 500 hours or 12 months
- Every 1000 hours or 24 months
- Every 2000 hours or 48 months

For engine maintenance, a copy of the maintenance schedule as indicated in the engine manufacturer’s
instruction manual is annexed (Chapter 5.5).

CAUTION: For all the operations on the engine, refer to the engine manufacturer’s instruction manual
provided separately from this manual.

5.3 RUNNING-IN AND SERVICE

The running-in period for this vehicle is at least 100 hours.
Therefore it is recommended to observe the instructions mentioned below to avoid any possible trouble:
- Let the engine run for a few minutes at medium RPM after each cold start.
- Do not run the engine at high RPM for long periods of time. Always use it at 50% to 80% of its maximum
power.
- Regularly check for water or oil leaks.
- Regularly check tightness of the screws and nuts.
After the first 500 hours of operation, in addition to the routine maintenance operations to be carried out (as
set out in chapter 5), it is advisable to carry out some additional operations (SERVICES) which subsequently
will be required at longer intervals.
Servicing includes a series of operations to be carried out on the vehicle:
- Engine oil change
- Hydraulic oil filter replacement
- Air, oil and diesel filter replacement

CAUTION: The instructions for engine maintenance and running-in are given by way of example. Follow
the instructions given in the engine manufacturer’s instruction manual.

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5.4 SCHEDULED MAINTENANCE TABLE

Description of the symbols used in the table:

= Check and repair = Replace

= Clean = Grease or lubricate

REGULAR MAINTENANCE INTERVALS

WORKING AREA EVERY 8 EVERY 500 EVERY 1000 EVERY 2000

HOURS OR HOURS OR HOURS OR HOURS OR
DAILY 12 MONTHS 24 MONTHS 48 MONTHS

COMPLETE VEHICLE

SEAT BELT CONDITION AND FASTENING

STEERING OPERATION

FIFTH WHEEL
GENERAL INSPECTIONS

GREASE NIPPLES (SEE THE SPECIFIC TABLE)

ACCELERATOR CABLES

HYDRAULIC CYLINDER ROD CONDITIONS

DRAINING THE FUEL TANK

WASHER STUB AXLE PINS

PROTECTIVE STRUCTURE

AIR FILTER GASKETS

CLEANING THE AIR FILTER SEPARATOR

TYRE / WHEEL TIGHTENING TORQUES

AXLES AND
WHEELS

AXLE AND DIFFERENTIAL BLEEDERS

AXLE - GEARBOX OR DIFFERENTIAL OIL

BRAKING SYSTEM TANK CAP BLEEDER

BRAKES

NEGATIVE PARKING BRAKE

PARKING BRAKE TEST

BRAKING SYSTEM FLUID

OPERATION OF THE HYRAULIC SERVICE DEVICES

HYDRAULIC SYSTEM

HYDRAULIC SYSTEM OIL

HOSE RUBBING AND DAMAGE

HYDRAULIC OIL TANK CAP BLEEDER

HYDRAULIC OIL FILTER

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REGULAR MAINTENANCE INTERVALS

WORKING AREA EVERY 8 EVERY 500 EVERY 1000 EVERY 2000

HOURS OR HOURS OR HOURS OR HOURS OR
DAILY 12 MONTHS 24 MONTHS 48 MONTHS

DRUM REDUCTION GEAR OIL

REDUCTION
GEARS

SLEVING RING REDUCTION GEAR OIL

LIGHT INDICATORS AND ACOUSTIC ALARMS

ELECTRIC EQUIPMENT OPERATION

ELECTRIC COMPONENTS

INSTRUMENT PANEL

BATTERY ELECTROLYTE LEVEL

PARKING BRAKE BUTTON

BATTERY PINS

HAND ACCELERATOR MICROSWITCH

PIVOTING POST MICRO SWITCHES

LITER COUNTER
SYSTEM
WATER

WATER TRANSFER PUMP

PRE-FILTER WATER TRANSFER PUMP

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5.5 ENGINE MAINTENANCE SCHEDULE

CAUTION: This table copy is purely indicative. For all maintenance operations, refer to the table in the
engine manufacturer’s instruction manual provided with this manual.

When necessary
Battery .............................................................................................................. Replace
Battery or battery cable .................................................................................... Disconnect
Engine .............................................................................................................. Clean
Engine air filter (double) ................................................................................... Clean - Replace
Engine air filter (single) ..................................................................................... Inspect - Replace
Fuel System...................................................................................................... Prime
Heavy duty........................................................................................................ Check

Daily
Coolant level ..................................................................................................... Check
Driven equipment ............................................................................................. Check
Air filter ............................................................................................................clogging indicator Inspect
Engine air prefilter .........................................................................................Check - Clean
Engine oil level ................................................................................................. Check
Primary fuel system filter/water separator ........................................................ Drain
V-Belts ............................................................................................................. Inspect – Adjust - Replace
Visual inspection

Every 50 hours of operation or weekly

Fuel tank water and sediment .........................................................................Drain

Every 500 hours of operation

V-Belts .............................................................................................................. Inspect – Adjust - Replace

Every 500 hours of operation or 1 year

Battery electrolyte level Check - Add
(SCA) Coolant ................................................................................................. Test - Add
Crankcase bleeder (filter box) .......................................................................... Replace
Engine air filter (double) ..................................................................................Clean - Replace
Engine oil and filter ........................................................................................... Replace
Primary fuel system filter (water separator) ..................................................... Replace
Secondary fuel system filter ............................................................................. Replace
Hoses and clamps ............................................................................................ Inspect – Replace
Radiator ............................................................................................................Clean

Every 1000 hours of operation

Engine valve clearance .................................................................................... Inspect - Adjust

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Every 2000 hours of operation

Aftercooler radiator core ................................................................................... Check

Alternator .......................................................................................................... Inspect
Engine mounts.................................................................................................. Inspect
Starter motor..................................................................................................... Inspect
Turbocharger ..................................................................................................Inspect
Water pump ....................................................................................................Inspect

Every 3000 hours of operation

Alternator belt .................................................................................................Check – Adjust - Replace

Fuel injector ....................................................................................................Test - Replace

Every 3000 hours of operation or 2 years

Cooling system coolant

(commercial for heavy duty) ...........................................................................Replace

Every 4000 hours of operation

Aftercooler radiator core .................................................................................Clean - Test

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5.6 RECOMMENDED LUBRICANTS AND FLUIDS TABLE

RECOMMENDED AMBIENT TEMPE- INTERNATIONAL
DEVICE TO BE REFILLED Q.TY VISCOSITY
LUBRICANT RATURE IN ° C CLASSIFICATION

ETHYLENE GLYCOL
B.S. 6580.92
COOLING SYSTEM 20 l ENI ANTIFREEZE 50% ETHYLENE GLYCOL -35° ÷ +50° ASTM D 3306
EXTRA 50% WATER ASTM D 4985
ASTM D 1384
CUNA NC 956-16

ACEA E7 - E5 - E3 - B3
I SIGMA 110 mm2/s (40°)
ENGINE 9l -10° ÷ +50° API GL4 / API CE/SF
PERFORMANCE 15W 40 (CCMC D4 - G4)
E7 15W 40
MIL - L 2104 D

AXLE BODY 6,6 kg

ENI 72 CTS
HUBS 0,95+0,95 kg MULTI-THT/SL80W -25° ÷ +50° API GL 4
80W
GEARBOX 1,5 kg

ENI DIN51524
ARNICA 22 22 -27° ÷ +25° PARTE 3HVLP
HYDRAULIC SYSTEM ~ 100 l CETOP RP 91H HV
ARNICA 46 46 -10° ÷ +35°
ISO L-HV
ARNICA 68 68 -3° ÷ +45° DENISON HF0-HF2

BRAKING SYSTEM 0,75 l ENI LHM 20 CTS -40° ÷ +50° PSA-B-712710

SUPER ISO 7308

ENI GR GREASE
VARIOUS GREASING PRODUCTS 0,5 kg -40° ÷ +50°
LP1 NLGI 1

ISO-L-CKD
DIN 51517 TEIL 3 CLP
DRUM REDUCTION GEAR 2 kg ENI BLASIA 150 141 mm2/s (40°C) -21° ÷ +200° ANSI / AGMA 9005 - 94
CAS 101316 - 72 - 7
CAS 64741 - 95 - 3

FIFTH WHEEL REDUCTION GEAR 2 kg ENI 72 CTS API GL 4

-25° ÷ +50°
MULTI-THT/SL80W 80W

FUEL TANK 90 l DIESEL ASTM N2

D TYPE TT, HIGH QUALITY AND BRAND

The oil quantities indicated are those needed for periodic oil changes, following the draining and filling
procedures described in detail for each unit.

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5.7 GENERAL INSPECTIONS

5.7.1 GREASE (fig. 3)

9
A

12
9

8 1

12 10
7 13 6
11 5

7 8

2
4 2 4
3 3
3
CAUTION: For the greasing operations, park the vehicle on flat ground and lower the arm. Remove the
ignition key and apply the parking brake.

CAUTION: Daily grease the drum rollers to keep them free of concrete residues. Do not use graphite
grease on the bearings.

The vehicle must be greased regularly in order to keep it in efficient operating conditions. Grease using the
pump A provided, and stop greasing as soon as fresh grease starts flowing out from the openings.

EVERY 8 HOURS EVERY 40 HOURS OF EVERY 160 HOURS OF

POS. WORKING AREA Q.
OR DAILY OPERATION OR WEEKLY OPERATION OR MONTHLY
1 PIVOTING DRIVING POST 1 X
2 AXLE HUBS 4+4 X
3 TRANSMISSION SHAFT 3 X
4 OSCILLATING CHASSIS 2 X
5 MIXER ROTATION SAFETY STOP DEVICE 1 X
6 DRUM LIFTING CYLINDERS 2+2 X
7 ARM LIFTING CYLINDERS 2+2 X
8 LOADER CONNECTING ROD AND TIE-ROD 3+3 X
9 LOADER CYLINDERS 2+2 X
10 MIXER ROLLERS 1+1 X

11 UNLOADING CHUTE 1 X
12 LIFTING ARM 2+2 X
13 MIXER ROTATION FIFTHWHEEL 2 X

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5.7.2 CLEANING AND DRAINING THE FUEL TANK (fig. 4)

CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out
as set out in Chapter 3.

DANGER: Extinguish all smoking

materials and open
flames as there may be
flammable vapours.

With the engine off, position an adequately-

sized container under the fuel tank. Unscrew
the cap A and let the fuel flow out until it is
clean and free of impurities that have remained
at the bottom of the tank.

A
4

5.7.3 FIFTH WHEEL LUBRICATION (fig. 5)

B C
5
- Park the vehicle on flat ground and make sure the drum is empty.
- After the drum has been raised, engage the drum descent stop lock by turning the two handles A of the lifting
cylinder cocks, lastly turn it so the rack can be accessed easily.
- Turn the engine off, take the ignition key out and make certain the parking brake is on.
- Lubricate pinion C with grease using a hard bristle brush.
- Grease the internal rack B with the nipples.

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5.7.4 SCRAPER BLADE AND LOADING BUCKET HATCH BELLOWS (fig. 6)

6
- Check the wear and tear of the scraper blade A on the loading bucket and replace it if damaged.
- Check that bellows B protecting the cylinder rods are in proper working order and replace them if damaged.

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5.8 AXLE AND WHEELS

5.8.1 CLEANING THE AXLE AND DIFFERENTIAL BLEEDERS (fig. 7)

CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out
as set out in Chapter 3.

DANGER: Never use petrol, solvents or flammable liquids in general for cleaning.
Use only approved non-flammable and non-toxic commercial solvents.

- Remove any dirt from the bleeders (1) located on both the axles and the differentials.

5.8.2 CHECKING AND TOPPING UP THE OIL LEVEL IN THE FRONT AND REAR AXLES (fig. 7)

1 2

4
1

1 2

6 4

7
CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out
as set out in Chapter 3.

- Park the vehicle on level ground, turn off the engine, apply the parking brake, lower the arm and remove the
ignition key.
- Unscrew the filler cap (2) - (3) and the level gauge caps (4) - (5) (in horizontal position).
- If oil trickles from the level gauge caps (4) - (5) - (6), it is not necessary to top up; if not, top up using a funnel
adding oil through the filler cap (2) - (3) and the level gauge cap (6) until reaching the optimal level.
- Screw all the caps back on after topping up.

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5.8.3 REPLACING THE OIL IN THE FRONT AND REAR AXLES (fig. 8)

3 1

8
CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out
as set out in Chapter 3.

- Park the vehicle on level ground, turn off the engine, apply the parking brake, lower the arm and remove the
ignition key.
- Position two pans under the front and rear axles by the draining caps.
- Unscrew the draining caps (1), (2) and (3). Position the cap (3) at the bottom by turning the planetary
reduction gear.
- Unscrew the level gauge cap (4) and (5).
- Drain out all the oil and screw the draining caps (1) and (2) back on.
- Turn back the planetary reduction gear so that the plug (3) is in the position as shown in the figure. Using a
funnel, add the required type of oil until reaching the optimal level.
- Unscrew the filler cap (6) and (7).
- Using a funnel, add the required type of oil through the filler cap (6) and (7) until oil trickles from the hole in
the level gauges (4) and (5).

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5.8.4 CHECKING AND ADJUSTING THE TYRE PRESURE (fig. 9)

CAUTION: Tyre maintenance and inflation are potentially dangerous operations. If possible, it is
advisable to have tyre maintenance and fitting carried out by a SPECIALISED CENTRE or
SKILLED PERSONNEL.

CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out
as set out in Chapter 3.

TYRES PRESSURE WHEEL NUT TIGHTENING TORQUE

12.5 -18 16PR 5,0 bar

9
330 Nm
405/70-20 14PR (OPTIONAL) 3,5 bar (OPTIONAL)

Upon delivery of the vehicle, check the tyre inflation pressure and subsequently check it weekly.
Make sure that the tyres are inflated to the pressure specified by the manufacturer.
Check the tyre pressure when they are cold.
The inflation pressure also determines the weight a tyre can support. Identify the tyre sizes in the pressure and
loads table. Do not over- or under-inflate the tyres.
Incorrect tyre inflation causes tyre problems, therefore do not under-inflate A or over-inflate B.
If a tyre has completely deflated, call in a mechanic who will use an inflation cradle and suitable tools.
Before inflating a tyre, check that the wheel is properly fitted.
Only use air pumps fitted with a pressure regulator to be set to no more than 1 bar above the specified tyre
inflation pressure.
Make sure that the flexible air hose is properly connected to the tyre valve.

CAUTION: Check and tighten the rim bolts before each work shift, alternately going from one bolt to
the one diametrically opposite in the order shown in the figure.

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5.8.5 REPLACING THE WHEELS

CAUTION: Tyre maintenance and inflation are potentially dangerous operations. If possible, it is
advisable to have tyre maintenance and fitting carried out by a SPECIALISED CENTRE or
SKILLED PERSONNEL.

CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out
as set out in Chapter 3.

8
10
When you need to change a tyre, first of all engage the parking brake, shift the gear selector to neutral, turn off
the engine and remove the ignition key.
Position a wedge under the wheel diametrically opposite the one to be changed as shown in the figure.

11

DANGER: It is prohibited to change a tyre on a slope or near canals or ditches to prevent the
vehicle from overturning and causing serious injury.

This operation must be performed on a solid, flat surface.

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B
A
12
CAUTION: Jack up the vehicle ONLY when the drum is empty and in rest position. Ensure that there
are always 3 wheels resting on level and solid ground.

DANGER: The front axle is oscillating and, during lifting, there is a risk of crushing your limbs
between the axle and the chassis. Incorrectly jacking up may moreover cause the
vehicle to overturn posing a grave risk to anyone working in the vicinity.

CAUTION: Pay attention to the support area underneath the jack; this area must be capable of supporting
the entire weight of the vehicle.

Fit the jack A under the central body B of the front axle.
To replace the rear tyres, fit the jack A under the screwed-on plate C of the axle shaft or, in the case of a round-
section axle shaft, fit an adapter (fork) in the jack.
Slowly jack up the vehicle until the arch rests on the chassis, then continue jacking up slowly until the deflated
tyre lifts off the ground and then proceed with repairing it.

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13
During tyre change or repair, always fit adequate stands or supports D capable of supporting the weight of the
vehicle under the axles.
After fitting the wheel, tighten the nuts in the order shown in the figure illustrating wheel nut tightening.

14
If you want to invert a wheel, operate as shown in the figure; you cannot interchange the tyres crosswise,
because of the type of tread.
Fit the wheels with the tyre tread facing in the direction shown in the figure.

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5.9 BRAKES

5.9.1 CHECKING AND TOPPING UP THE BRAKE FLUID LEVEL (fig. 15)

15
CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out
as set out in Chapter 3.

CAUTION: It is essential to use only the fluid indicated in the RECOMMENDED LUBRICANTS AND
FLUIDS TABLE; using unsuitable fluids will damage the braking system. Regularly check
good functioning of all the braking components.

CAUTION: In the event of malfunctioning, immediately contact the nearest AUTHORISED FIORI
WORKSHOP.

The brake fluid tank is installed to the side of the revolving driving post.
Always check the brake fluid level before you start using the vehicle.

5.9.2 CLEANING THE BRAKE FLUID TANK BLEEDERS (fig. 15)

DANGER: Never use petrol, solvents or flammable liquids in general for cleaning.
Use only non-flammable and non-toxic commercial solvents.
Always wear protective goggles with side screens when working with compressed
air.
Limit the pressure to 2 bar according to the regulations in force.

- Unscrew the bleeder cap A.

- Clean the cap surface with a brush and solvent.
- Clean the bleeder hole with a pointed tool and then dry it with a blast of compressed air.
- Screw the bleeder cap A back on.

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5.9.3 REPLACING THE BRAKING SYSTEM FLUID (fig. 16)

16
CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out
as set out in Chapter 3.

CAUTION: Block all the wheels with wedges at the front and rear and always engage the parking brake
before operating on the system lines.

CAUTION: Air in the braking system will lead to poor braking performance. Always bleed the air after
working on the braking system. If you are not sure that all the air has been bled from the
system, have it checked by skilled technicians.

CAUTION: Do not pollute the environment. Keep used oils in special containers and send them to
companies specialised in storage and disposal of polluting and hazardous waste.

- Move the vehicle onto flat ground, engage the parking brake, turn off the engine and remove the ignition
key.
- Loosen the bleeder A and depress the brake pedal until all the fluid has drained into a pan positioned under
the axle.
- Tighten the bleeders A.
- Top up the brake fluid tank B with the recommended fluid.
- Bleed the air from the system as described below.
- Ask someone to assist you by getting onto the driving post, to depress the brake pedal.
- Unscrew the bleeder A by half a turn and have your colleague depress the brake pedal until bubble-free fluid
flows from the bleeder.
- Repeat the operation on all the axle bleeders A.
- Regularly top up the brake fluid tank.

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5.9.4 TESTING THE HAND BRAKE (fig. 17)

17

CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out
as set out in Chapter 3.

DANGER: Before testing the efficiency of the parking brake, check that there is no one near
the vehicle.

The efficiency of the hand brake helps ensure that the machine will remain still under full load on a gradient
of 25%.
- Ensure that the parking brake button (1) is fully pressed down.
- If you notice that the vehicle moves, contact an AUTHORISED FIORI SERVICE CENTRE.

CAUTION: Do not use the vehicle if the parking brake is not fully efficient.

5.9.5 CHECKING THE WEAR CONDITION OF THE BRAKING SYSTEM

This type of operation must be carried out by an AUTHORIZED FIORI SERVICE CENTRE.

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5.10 HYDRAULIC SYSTEM

5.10.1 CHECKING THE HYDRAULIC OIL (fig. 18)

MAX
MIN
A

18
CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out
as set out in Chapter 3.

CAUTION: Slowly loosen the bleeder cap to release the residual pressure. Carry out this operation
only with the engine off.

- Move the vehicle onto flat ground, engage the parking brake, turn off the engine and remove the ignition
key.
- Wait until the oil reaches the ambient temperature.
- Open the engine compartment lid.
- Check the hydraulic oil level with the dipstick A.
- If it needs topping up, add oil through the filler neck.

5.10.2 REPLACING THE HYDRAULIC OIL TANK BLEEDER (fig. 18)

CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out
as set out in Chapter 3.

CAUTION: Slowly loosen the bleeder cap to release the residual pressure. Carry out this operation
only with the engine off.
- The bleeder cap A is disposable and hence does not need to be cleaned.
- Replace it only if broken or clogged with an identical one in order to keep the system adequately
pressurised.

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5.10.3 CHANGE THE HYDRAULIC OIL FILTER CARTRIDGE (fig. 19)

C A

19
CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out
as set out in Chapter 3.

CAUTION: Slowly loosen the bleeder cap to release the residual pressure. Carry out this operation
only with the engine off.
CAUTION: Do not pollute the environment. Keep the filters in special containers and send them to
companies specialised in storage and disposal of polluting and hazardous waste.

CAUTION: If the filter clogged warning light is permanently illuminated even when the oil is hot (35°C),
the suction filter needs to be replaced.

- Move the vehicle onto flat ground, engage the parking brake, turn off the engine and remove the ignition
key.
- Raise the engine compartment lid.
- Remove the level gauge and filler cap. A and the filter cover C.
- Remove the cartridge D.
- Manually refit the new cartridge D taking care to correctly position the seals.
- Clean and refit the filter cover C, taking care to correctly position the seal.
- Check the level in the tank with the dipstick A and if topping up is required, fill with the specified oil until
reaching the indicated level, then screw the filler cap A back on.
- It is essential to keep a stock of spare cartridges D, which can be ordered from the AUTHORISED FIORI
SERVICE CENTRES or directly from FIORI SPARE PARTS DEPARTMENT.

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5.10.4 REPLACING THE HYDRAULIC OIL (fig. 20)

MAX
MIN
A

B E
20
CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out
as set out in Chapter 3.

CAUTION: Slowly loosen the bleeder cap to release the residual pressure. Carry out this operation
only with the engine off.

CAUTION: Do not pollute the environment. Keep used oils in special containers and send them to
companies specialised in storage and disposal of polluting and hazardous waste.

- Move the vehicle onto flat ground, engage the parking brake, turn off the engine and remove the ignition
key.
- Raise the engine compartment lid.
- Remove the bleeder and filler cap A.
- Unscrew the drain cap B and drain all the oil from the tank into a container.
- When the tank is empty, screw the drain cap B back in and fill the tank with the recommended oil until
reaching the required level, checking with the dipstick A.
- The engine must be started at first with successive activations of the starter motor without fully starting
the engine. Once started, keep it at idle speed for a few minutes before checking proper operation of the
hydraulic functions.
- Bleed any air that may have formed in the system by loosening the bleeder pipe E.

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5.10.5 CHECKING AND TOPPING UP THE DRUM REDUCTION GEAR OIL LEVEL (fig. 21)

21
CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out
as set out in Chapter 3.

- Raise the drum to horizontal position.

- Turn the drum so that the level gauge A of the reduction gear is positioned in the horizontal lateral part.
- Move the vehicle onto flat ground, engage the parking brake, turn off the engine and remove the ignition
key.
- The optimal level is in the middle of the sight glass of the level gauge.
- If you need to top up, unscrew the cap B and add oil until reaching the optimal level.

5.10.6 DRUM REDUCTION GEAR OIL CHANGE (fig. 20)

CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out
as set out in Chapter 3.

CAUTION: Do not pollute the environment. Keep used oils in special containers and send them to
companies specialised in storage and disposal of polluting and hazardous waste.

- Move the vehicle onto flat ground and engage the parking brake.
- Turn the drum until the level gauge cap A is positioned at the bottom of the reduction gear.
- Turn off the engine and remove the ignition key.
- Unscrew the level gauge cap A and the filler cap B then drain out all the oil into a prearranged container.
- Screw the level gauge cap back on and then turn the drum so that the level gauge hole A is in horizontal
position and the filler cap hole B positioned at the top.
- Fill with the recommended oil using a syringe.
- Screw the filler cap B back on.

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5.10.7 REPLACING THE DRUM REDUCTION GEAR OIL (fig. 22)

22
CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out
as set out in Chapter 3.

CAUTION: Do not pollute the environment. Keep used oils in special containers and send them to
companies specialised in storage and disposal of polluting and hazardous waste.

- Move the vehicle onto flat ground, engage the parking brake, turn off the engine and remove the ignition
key.
- Work from underneath the vehicle to access the reduction gear.
- Unscrew the drain cap A and drain out all the oil into a prearranged container.
- Add the specified oil through the filler cap B using a syringe.
- Screw the caps A and B back on.

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5.11 ENGINE
5.11.1 CLEANING THE ENGINE AIR FILTER SEPARATOR (fig. 23)

23
- Move the vehicle onto flat ground, engage the parking brake, turn off the engine and remove the ignition
key.
- Open the engine compartment lid to access the filter, squeeze the lower part of the separator A with your
fingers to open it, letting the dust accumulated inside drop out.

5.11.2 CLEANING OR REPLACING THE ENGINE AIR FILTER CARTRDIGE (fig. 24)

C
B

A
24
CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out
as set out in Chapter 3.

CAUTION: Do not pollute the environment. Keep the filters in special containers and send them to
companies specialised in storage and disposal of polluting and hazardous waste.

DANGER: Always wear protective goggles with side screens when working with compressed
air.
Limit the pressure to 2 bar according to the regulations in force.
- Move the vehicle onto flat ground, engage the parking brake, turn off the engine and remove the ignition
key.

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- Open the engine compartment lid and check the air filter.
- Remove the cover A.
- Remove the cartridge B and replace it with a new one if necessary.
- Remove the cartridge B and clean it with a blast of dry compressed air from the inside to the outside, taking
care not to let any dust and dirt drop into the manifold.
- After cleaning the cartridge, check that there is no internal damage using a torch to illuminate the inside.
- If light filters through to the outside the cartridge must be replaced.
- Also replace the cartridge when the rubber seal is damaged.
- Before refitting the cartridge clean the inside of the filter body and the separator.
- Check the state of wear of the seals C and replace them if necessary.
- Refit the cartridge and make sure that it is properly in place.
- Close the cover A.
- It is essential to keep a stock of spare cartridges B, which can be ordered from the AUTHORISED FIORI
SERVICE CENTRES or directly from FIORI SPARE PARTS DEPARTMENT.

5.11.3 CHECKING AND TOPPING UP THE COOLANT LEVEL (fig. 25)

MIN

25
CAUTION: Use only coolant of the type and brand recommended by the manufacturer, as indicated in the
Recommended Lubricants and Fluids table in the right WATER/ANTIFREEZE percentages.

DANGER: Do not remove the cap when the engine is still hot.
The fluid is under pressure, therefore, before removing the filler cap, turn it slowly
to release the pressure.

- Move the vehicle onto flat ground, engage the parking brake, turn off the engine and remove the ignition
key.
- Open the engine compartment lid.
- Check the fluid level in the tank.
- If the level is low, wait until the fluid has reached ambient temperature, slowly unscrew the cap A and top up
until reaching the optimal level.

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5.11.4 REPLACING THE ENGINE COOLANT (fig. 26)

A
B

C
D
26

CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out
as set out in Chapter 3.

CAUTION: Do not pollute the environment. Keep used fluids in special containers and send them to
companies specialised in storage and disposal of polluting and hazardous waste.

DANGER: Do not remove the cap when the engine is still hot.
The fluid is under pressure, therefore, before removing the filler cap, turn it slowly
to release the pressure.

CAUTION: Use only coolant of the type and brand recommended by the manufacturer, as indicated in the
Recommended Lubricants and Fluids table in the right WATER/ANTIFREEZE percentages.

CAUTION: In addition to the operations described below, also refer to the engine manufacturer’s
instruction manual.
- Move the vehicle onto flat ground, engage the parking brake, turn off the engine and remove the ignition
key.
- Wait until the fluid reaches the ambient temperature.
- Slowly unscrew the radiator cap A.
- To fully drain out the fluid, unscrew the drain cap B positioned on the side of the engine monobloc, to allow
the fluid to flow out. Position a receptacle under the radiator and remove the sleeve C to drain out all the
fluid.
- Refit the sleeve C and screw the drain plug B back in, then slowly add the recommended fluid through the
filler neck of the radiator until it is full.
- Screw the cap A back on.
- Close the engine compartment lid.
- Start the engine and let it run for a few minutes.
- Let the engine cool down.
- Check the fluid level in the tank D and top up if necessary.

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5.11.5 CHECKING AND ADJUSTING THE ALTERNATOR BELT TENSIONING

CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out
as set out in Chapter 3.

DANGER: Open the lid only with the engine off.

CAUTION: If you have any doubts about the operating procedures, also refer to the instruction manual
provided separately from this manual. Where necessary, ask an AUTHORISED FIORI
SERVICE CENTRE or WORKSHOP for assistance.

CAUTION: In addition to the operations described below, also refer to the engine manufacturer’s
instruction manual.
- Move the vehicle onto flat ground, engage the parking brake, turn off the engine and remove the ignition
key.
- Open the engine compartment lid and check the tension and wear of the alternator belt.
- To work on the belt, refer to the engine manufacturer’s manual attached.

5.11.6 FUEL SEDIMENT BOWL (fig. 27)

27
CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out
as set out in Chapter 3.

DANGER: Open the lid only with the engine off.

CAUTION: If you have any doubts about the operating procedures, also refer to the instruction manual
provided separately from this manual. Where necessary, ask an AUTHORISED FIORI
SERVICE CENTRE or WORKSHOP for assistance.

CAUTION: In addition to the operations described below, also refer to the engine manufacturer’s
instruction manual.

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- Move the vehicle onto flat ground, engage the parking brake, turn off the engine and remove the ignition
key.
- Open the engine compartment lid; the bowl is positioned on the left-hand side of the engine.
- It does not require particular care, only check that there is fuel in the injection circuit.
- Periodically check if the sediment bowl is clogged or contains water.
- Always bleed the air from the system after cleaning the bowl.

5.11.7 AIR BLEEDING IN THE ENGINE FUEL SUPPLY SYSTEM

CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out
as set out in Chapter 3.

DANGER: Open the lid only with the engine off.

CAUTION: If you have any doubts about the operating procedures, also refer to the instruction manual
provided separately from this manual. Where necessary, ask an AUTHORISED FIORI
SERVICE CENTRE or WORKSHOP for assistance.

CAUTION: In addition to the operations described below, also refer to the engine manufacturer’s
instruction manual.
The air must be bled from the fuel system in the following cases:
- Long periods of inactivity.
- Filter and/or pipe replacement.
- Fuel tank completely empty.

5.11.8 REPLACING THE ENGINE FUEL SUPPLY PRE-FILTER AND FILTER

CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out
as set out in Chapter 3.

CAUTION: Do not pollute the environment. Keep the filters in special containers and send them to
companies specialised in storage and disposal of polluting and hazardous waste.

DANGER: Open the lid only with the engine off.

CAUTION: If you have any doubts about the operating procedures, also refer to the instruction manual
provided separately from this manual. Where necessary, ask an AUTHORISED FIORI
SERVICE CENTRE or WORKSHOP for assistance.

- Move the vehicle onto flat ground, engage the parking brake, turn off the engine and remove the ignition
key.
- For the operations to be carried out, refer to the engine manufacturer’s manual attached.
- It is essential to keep a stock of spare filters, which can be ordered from the AUTHORISED FIORI SERVICE
CENTRES or directly from FIORI SPARE PARTS DEPARTMENT.

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5.11.9 CHECKING AND TOPPING UP THE ENGINE OIL LEVEL (fig. 28)

B
A

28
CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out
as set out in Chapter 3.

DANGER: Open the lid only with the engine off.

CAUTION: If you have any doubts about the operating procedures, also refer to the instruction manual
provided separately from this manual. Where necessary, ask an AUTHORISED FIORI
SERVICE CENTRE or WORKSHOP for assistance.

CAUTION: In addition to the operations described below, also refer to the engine manufacturer’s
instruction manual.

- Move the vehicle onto flat ground, engage the parking brake, turn off the engine and remove the ignition
key.
- Wait until the oil reaches the ambient temperature.
- Unscrew the cap B.
- Check that the oil level is between the two marks on the dipstick A
- Screw the cap B back on put the dipstick A back into place.
If the oil is at minimum level, add oil until the level is at the maximum mark on the dipstick.

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5.11.10 REPLACING THE ENGINE OIL FILTER

CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out
as set out in Chapter 3.

CAUTION: Do not pollute the environment. Keep the filters in special containers and send them to
companies specialised in storage and disposal of polluting and hazardous waste.

DANGER: Open the lid only with the engine off.

CAUTION: If you have any doubts about the operating procedures, also refer to the instruction manual
provided separately from this manual. Where necessary, ask an AUTHORISED FIORI
SERVICE CENTRE or WORKSHOP for assistance.

- Move the vehicle onto flat ground, engage the parking brake, turn off the engine and remove the ignition
key.
- For the operations to be carried out, refer to the engine manufacturer’s manual attached.
- It is essential to keep a stock of spare filters, which can be ordered from the AUTHORISED FIORI SERVICE
CENTRES or directly from FIORI SPARE PARTS DEPARTMENT.

5.11.11 REPLACING THE ENGINE OIL

CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out
as set out in Chapter 3.

CAUTION: Do not pollute the environment. Keep used fluids in special containers and send them to
companies specialised in storage and disposal of polluting and hazardous waste.

DANGER: Open the lid only with the engine off.

CAUTION: If you have any doubts about the operating procedures, also refer to the instruction manual
provided separately from this manual. Where necessary, ask an AUTHORISED FIORI
SERVICE CENTRE or WORKSHOP for assistance.

CAUTION: In addition to the operations described below, also refer to the engine manufacturer’s
instruction manual.

- Move the vehicle onto flat ground, engage the parking brake, turn off the engine and remove the ignition
key.
- For the operations to be carried out, refer to the engine manufacturer’s manual attached.

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5.12 ELECTRIC COMPONENTS

5.12.1 FUSES AND RELAYS

- Driver’s seat fuses (fig. 29)

22 23

16 15 14 13 12 11 5 4 3 2 1

21 20 19 18 17 10 9 8 7 6
29

POS. AMPERAGE COLOUR POS. AMPERAGE COLOUR

1 15A blue 13 7,5A brown

2 7,5A brown 14 7,5A brown
3 10A red 15 15A blue
4 5A beige 16 3A violet
5 15A blue 17 3A violet
6 7,5A brown 18 15A blue
7 15A blue 19 15A blue
8 10A red 20 15A blue
9 10A red 21 15A blue
10 5A beige 22 5A beige
11 5A beige 23 10A red
12 3A violet

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List of fuses
01 - (F101) - Courtesy light and socket power supply.
02 - (F102) - Power supply for arm lowering enable, relay (K101).
03 - (F103) - Power supply for front windscreen wipers, rear windscreen wipers and windscreen washer pump
control.
04 - (F104) - Power supply for water pump control, litre counter sensor, relay (K102).
05 - (F105) - Power supply for heating fan control.
06 - (F106) - Relay power supply (K107).
07 - (F107) - Power supply for parking brake control, neutral enable on forward drive control, relay (K103),
neutral relay.
08 - (F108) - Power supply for acoustic indicator and rear camera (optional).
09 - (F109) - Power supply for direction indicators and stop light bulb.
10 - (F110) - Power supply for drum rotation control, frame rotation pressure gauge.
11 - (F111) - Power supply for water in the fuel, LCD instrument, 1st and 2nd gear warning lights, relay coil
(K107), relay coil (K108), relay coil (K111).
12 - (F112) - Front LH and rear RH position light, power supply for rear working light control
13 - (F113) - RH low beam headlight.
14 - (F114) - LH low beam headlight.
15 - (F115) - Power supply for additive pumps (optional).
16 - (F116) - Front RH and rear LH position light, position light indicator.
17 - (F117) - Power supply for weighing central unit (optional).
18 - (F118) - Power supply for emergency lights, rotating beacon control.
19 - (F119) - Relay power supply (K109).
20 - (F120) - Relay power supply (K110).
21 - (SPARE 1) - Spare fuse.
22 - (SPARE 2) - Spare fuse.
23 - (SPARE 3) - Spare fuse.

- Fuses above the engine power takeoff (fig. 30)

24 26

27

25

30
24 - 30A - green - power supply for start starter motor relay.
25 - 40A - yellow - power supply for fuse/relay printed circuit.
26 - 50A - red - start switch power supply.
27 - 60A - blue - engine preheating relay power supply.
CAUTION: If a fuse blows or a relay burns, find the cause before replacing it with a new one.

DANGER: Do not operate bypassing the fuse as there is a risk of short- circuit.
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- Driver’s seat relays (fig. 31)

11 12 13

10

9
8 7 6 5 4 3 2 1

31
01 - K101 - Micro relay for arm lowering enable and Tip-Off control enable.
02 - K102 - Micro relay for water pump control.
03 - K103 - Micro relay for forward drive enable with accelerator lever on OFF.
04 - K104 - Micro relay for start enable with gear in neutral.
05 - K105 - Micro relay for forward drive enable.
06 - K106 - Available.
07 - K107 - Engine off micro relay.
08 - K108 - Micro relay for start enable without water in the fuel.
09 - K109 - A/C compressor mini relay (optional).
10 - K110 - Mini relay for rear working lights.
11 - K111 - Micro relay for machine operating acoustic indicator control.
12 - K112 - Diode module for neutral and gearshift enable.
13 - K113 - Flashing hazard lights/direction indicators

- Relays above the engine power takeoff (fig. 32)

14

15

32
14 – Starter motor relay.
15 – Engine preheating relay.
CAUTION: If a fuse blows or a relay burns, find the cause before replacing it with a new one.

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5.12.2 ELECTRONIC DASHBOARD WARNING LIGHTS (fig. 33)

33
In the event of malfunctioning of the electronic panel, contact the nearest AUTHORISED FIORI SERVICE
CENTRE or FIORI SPARE PARTS DEPARTMENT directly. In the event of replacement, the panel is delivered
already programmed.

CAUTION: Note down the hours of operation before replacing the electronic control panel.

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5.12.3 REPLACING THE LIGHT BULBS (fig. 34)

DANGER: Modifications or repairs to the electric system made incorrectly or without taking
the technical specifications of the system into account may cause malfunctions
with a risk of fire.

When a light is not working, check that the corresponding fuse is intact before replacing the bulb.
Before replacing a burnt bulb, check that the contacts are not oxidised.
Burnt bulbs must be replaced with new ones of the same type. Bulbs with insufficient power provide poor light,
whereas too powerful bulbs absorb too much energy.
After replacing a headlight bulb always check the orientation for safety reasons.

F
C-D-G

B
A
B
34

A - low beam bulb.................................................................................................................... 12V - 55W H7

B - direction indicator bulb ...................................................................................................... 12V - P21W
position light/side marker bulb ........................................................................................... 12V - R5W
C - Stop light/position light bulb .............................................................................................. 12V – P21/5W
direction indicator light bulb ................................................................................................ 12V - P21W
D - number plate light bulb ...................................................................................................... 12V - W5W
E - rotating beacon bulb ......................................................................................................... 12V - 55W H1
F - courtesy light bulb .............................................................................................................. 12V - C5W
G - working light bulb ............................................................................................................... 12V - 886 50W

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5.12.4 CHECKING AND TOPPING UP THE BATTERY ELECTROLYTE LEVEL (fig. 35)

D
B
C A
35
CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out
as set out in Chapter 3.

DANGER: Wear protective goggles when operating on the battery. The battery contains
SULPHURIC ACID. If it comes into contact with your skin or eyes, immediately
rinse with water for at least 15 minutes and immediately seek medical advice.

DANGER: Wear protective gloves and clothing when handling the battery; do not tilt or turn
the battery upside down as acid could leak from the bleeder holes. Extinguish open
flames or smoking materials before checking or charging the battery. Batteries
release FLAMMABLE VAPOURS.

CAUTION: If the battery is partly discharged, replace it with an identical one or ask an electrical repair
shop to recharge it, or emergency start the vehicle.

CAUTION: Do not pollute the environment. The batteries are classified as polluting and hazardous
waste according to the law.

- The battery installed requires little maintenance, therefore, in normal conditions of use, the electrolyte does
not need to be topped up.
- Nevertheless, every 6 months check that the electrolyte level is between the MAX and MIN notches marked
on the battery.
- Before operating on the battery, remove the battery disconnection key D to cut the power to the system.
- To access the battery loosen the nut A, unscrew the nut B and turn the ladder C.
- To top up the electrolyte level, remove the caps E and fill up with distilled water without exceeding the
maximum level.
For a longer battery life, it is advisable to follow these additional instructions:
- Turn off the lights when the engine is off or in idle.
- Do not turn off the engine for short stops because the battery uses a lot of power to start the engine.
- Regularly check that the cable terminals are properly secured and lubricated with Vaseline.
- Always keep the top of the battery clean.
- Before working on the terminals, disconnect the end on the earth cable.

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5.12.5 BATTERY PINS CONTACT

CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out
as set out in Chapter 3.

- Disconnect the battery by removing the key from the battery master switch and proceed as described above
to access the battery, remove the terminals and thoroughly clean their ends.
- Refit the terminals and grease them with a layer of Vaseline grease.
- Refit the battery into place and reconnect it by inserting the key in the battery master switch.

5.12.6 BATTERY REPLACE

CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out
as set out in Chapter 3.

CAUTION: For this operation contact an electrical repair shop and always replace the battery with one
of the same amperage.

CAUTION: Do not pollute the environment. Keep the old battery in a suitable container and send it to
companies specialised in storage and disposal of polluting and hazardous waste.

- Disconnect the battery by removing the key from the battery master switch.
- Proceed as described above to access the battery.
- Remove the terminals.
- Unscrew the retaining clip.
- Remove the battery from its seat and replace it.
- Refit the battery following the removal operations in reverse order, and remember to grease the terminals
with Vaseline grease.

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5.13 WATER SYSTEM

5.13.1 CHECKING AND MAINTAINING THE LITRE COUNTER (fig. 36)

HORIZONTAL INSTALLATION

36
CAUTION: Do not use metal or abrasive objects to clean the duct.
CAUTION: Do not use solvents, diesel or petrol to clean the external parts of the equipment or parts
in its immediate vicinity.
To keep the litre counter and the pump in good working condition, run clean water through the duct at the end
of each daily work shift.
Every six months or in the event of malfunctioning, clean the duct of the litre counter and the relative pipes with
a special non-aggressive detergent for the parts in rubber, nylon, brass, polypropylene and stainless steel.

5.13.2 CHECKING THE WATER TRANSFER PUMP EFFICIENCY (fig. 37)

B
F
H

A
C

M
37
- Keep the engine running at 2000 rpm.
- Activate the transfer pump M.
- Check by means of the flow meter C that the water flow rate is higher than 250 litres/min.
- Also check for leaks from the valve unions B and from the suction pipe unions A and H.
- Check that the suction filter F is in proper working order.

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5.13.3 WATER PUMP EMERGENCY ACTIVATION (fig. 38)

38
To activate a pump that has stopped because of an electrical fault, remove the cap A on the control panel and,
using a screwdriver, act on the distributor button to activate the pump manually.

5.13.4 CLEANING PRE-FILTER OF THE WATER PUMP (fig. 39)

C
D
39
Before starting the daily work shift, you must clean the pre-filter of the water pump.
Remove the closing cap C from the pump, take out the pre-filter D and check whether it is dirty inside. To
remove it, use a jet of clean water or compressed air.
Finally, reposition it inside the filler neck and refit the closing cap C.

CAUTION: Check that there is water inside th pump (see chapter 4.3.3 for the related procedure).

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6 CONTENTS
6.1 DRUM CLOSING HATCH.............................................................................................................. 154
6.1.1. OPERATION .................................................................................................................................. 154
6.2 POWER JET CLEANER .................................................................................................................. 155
6.2.1. TECHNICAL DATA ....................................................................................................................... 155
6.2.2. INSTRUCTION LABELS ON THE MACHINE ................................................................................ 155
6.2.3. REFERENCES AND DESCRIPTIONS OF THE MAIN DEVICES ................................................ 156
6.2.4. USING THE POWER JET CLEANER............................................................................................ 157
6.2.5. PRECAUTIONS FOR USE IN COLD CLIMATE CONDITIONS .................................................... 158
6.2.6. SCHEDULED MAINTENANCE TABLE .......................................................................................... 158
6.2.7. CLEANING OR REPLACING THE FILTER CARTRIDGE ............................................................. 159

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6.1 DRUM CLOSING HATCH

The hatch closes the drum opening, thus avoiding concrete spillage, specially when the machine is driven on
uphill stretches.

1
6.1.1. OPERATION
The hatch opens automatically when the counterframe is lifted using the lever B in the cabin (as described in
chapter 4.2.3.b).
The hatch is closed automatically when the counterframe is lowered by means of lever B.

DANGER: Do not climb on the machine, do not place your limbs or parts of your body in the
drum opening: risk of crushing if the hatch is closed inadvertently!
Do not use the arms as lifting device.

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6.2 POWER JET CLEANER

The high-pressure power jet cleaner allows thorough cleaning of the machine parts or other objects.

6.2.1. TECHNICAL DATA

- Hydraulically-driven water cleaner pump.
- Maximum oil flow rate ......................................................................................................................... 25 l/min.
- Maximum water output flow rate ..................................................................................................... 16.8 l/min.
- Maximum oil input pressure ................................................................................................................ 190 bar
- Maximum water output pressure .......................................................................................................... 228 bar

6.2.2. INSTRUCTION LABELS ON THE MACHINE

Indicates that the water filter of the power jet cleaner system must
periodically be cleaned.

Indicates the positions of the lever for use of the power jet cleaner or the
water suction pump.

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6.2.3. REFERENCES AND DESCRIPTIONS OF THE MAIN DEVICES (fig. 2).

2 1
C D E

L
H

I
B

F G A 2
The following parts control water feed and distribution through the power jet cleaner:
A - Power jet cleaner.
Positioned behind the cabin under the water suction pump.
B - Low-pressure nozzle.
C - High-pressure nozzle.
D – Pressure regulating valve.
Turning the valve clockwise releases the pressure and anticlockwise increases the pressure.
E - Switch
Position “1” - Water suction pump activation.
Position “2”- Power jet cleaner pump activation.
F - High-pressure hose.
Connects the pump to the power jet cleaner.
G - Water pressure gauge.
Shows the pressure of the water flowing from the pump.
H - Water pump.
Positioned at the rear of the chassis in the tool compartment.
I - Switch
Turn switch lever E to position “2” to trigger the switch that enables water sensor L. If the sensor detects
that there is no water flow due to the empty tank, pump H automatically stops.

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6.2.4 USING THE POWER JET CLEANER (fig. 3)

2 1
C D
S

H
E
B

F G A 3

DANGER: The high energy of the pressurised jet may be extremely dangerous. Keep away
from persons, animals and any delicate object when the pump is operating.
Never direct the pressurised jet at persons, animals, electrical equipment and fragile
parts in general. Never put your hands in the pressurised jet (RISK OF INJURY).
Never leave the hose F under pressure. This may cause damage to persons or
things should you involuntarily pull the trigger of the power jet cleaner.

CAUTION: Wear protective goggles and clothing during use of the power jet cleaner.
Always hold the power jet cleaner with both hands when it is operating.

- Start the engine and engage the parking brake.

- Press the switch S on the dashboard in the cabin to activate the water pump circuit.
- Turn the lever of the switch Eto position (2) to activate the power jet cleaner pump H.
- Open the catches and extract the power jet cleaner A , unwind the high-pressure hose F from its reel and
screw it onto the power jet cleaner.
- Turn the valve D on the power jet cleaner until the low-pressure nozzle B is completely open.
- Hold the trigger of the power jet cleaner pulled and let the pump run until all the air has been expelled from
the tubes and the water flows uniformly and continuously from the nozzles B and C .
- Gradually close the valve D on the power jet cleaner until the pointer of the water pressure gauge G indicates
that the operating pressure has been reached (150 bar).
- Close and open the power jet cleaner two or three times to check proper functioning. Releasing the trigger,
the pump must stop and restart as soon as the trigger is pulled again; the pressure gauge reading must drop
by 10-15 bar to return to the set value.
- When you have finished work, fully open the low-pressure nozzle B of the power jet cleaner.
- Turn the lever of the switch E to position (1) to close the oil inlet to the pump H.

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6
OPTIONAL EQUIPMENT

- Pull the trigger of the power jet cleaner to discharge all the residual pressure in the tubes to ground.

CAUTION: If during use you notice that the pump becomes noisier and the jet discontinuous, it means
that it is taking in air. Immediately open the low-pressure nozzle B and correct the fault.

CAUTION: Use only nozzles with a fan-pattern jet to clean delicate surfaces, holding the nozzle 75cm
away from the surface to be cleaned.

CAUTION: In the event of malfunctioning, immediately contact the nearest AUTHORISED FIORI
WORKSHOP.

6.2.5. PRECAUTIONS FOR USE IN COLD CLIMATE CONDITIONS

If you have to work in ambient temperatures close to 0°C, the pump has to be operated without pressure for
one minute with the power jet cleaner open so that any ice that has formed can melt.

CAUTION: If the pump has frozen, do not operate it until the entire system has defrosted.

- Clean the pump with water mixed with a solution of antifreeze for radiators or an oily lubricating and anti-
oxidant solution.
- Do not operate the pump with cold oil.
- If the hoses have frozen, let them defrost before starting work.
- When you have finished work, disconnect the water inlet tube and fully discharge the pressure by holding the
regulating valve on the power jet cleaner open. Use the breather valve to drain out the residual water in the
pump cover.

6.2.6. SCHEDULED MAINTENANCE TABLE

Description of the symbols used in the table:

= Check and repair = Replace

= Clean = Grease or lubricate

REGULAR MAINTENANCE INTERVALS

WORKING AREA EVERY 8 EVERY 500 EVERY 1000 EVERY 2000

HOURS OR HOURS OR HOURS OR HOURS OR
DAILY 12 MONTHS 24 MONTHS 48 MONTHS

POWER JET CLEANER PUMP

POWER JET CLEANER FILTER

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 6
OPTIONAL EQUIPMENT

6.2.7. CLEANING OR REPLACING THE FILTER CARTRIDGE (fig. 4)

A
4
CAUTION: Before proceeding, always read the safety regulations for the operations to be carried out
as set out in Chapter 3.
CAUTION: Do not pollute the environment. Keep the filters in special containers and send them to
companies specialised in storage and disposal of polluting and hazardous waste.
- Move the vehicle onto flat ground, engage the parking brake, turn off the engine and remove the ignition
key.
- The filter is positioned between the water tank and the rear wheel on the left-hand side of the machine.
- Remove the cover A.
- Remove the cartridge B and replace it with a new one if necessary.
- Remove the cartridge B and clean it with a blast of dry compressed air from the inside to the outside.
- After cleaning the cartridge, check that there is no internal damage using a torch to illuminate the inside.
- If light filters through to the outside the cartridge must be replaced.
- Also replace the cartridge when the rubber seal is damaged.
- Before refitting the cartridge clean the inside of the filter body and the separator.
- Refit the cartridge and make sure that it is properly in place.
- Close the cover A.
- It is essential to keep a stock of spare cartridges B, which can be ordered from the AUTHORISED FIORI
SERVICE CENTRES or directly from FIORI SPARE PARTS DEPARTMENT.

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 TECHNICAL ANNEXES

CAUTION

For a better consultation you can ask for the

vehicle’s wiring - hydraulic diagrams in PDF format
at the FIORI email address: info@fiorigroup.com

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 TECHNICAL ANNEXES

HYDRAULIC DIAGRAM

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 TECHNICAL ANNEXES

LIST OF COMPONENTS IN THE HYDRAULIC DIAGRAM

1 DRUM SUPPORT ROTATION MOTOR

2 COUNTERFRAME LIFTING JACKS
3 SERVICE DISTRIBUTOR
4 LOADER OPENING/CLOSING JACK
5 ARM LIFTING JACK
6 LOADER HATCH CLOSING JACK
7 CHUTE LIFTING JACK
8 CHUTE CONTROL BLOCK
9 NEGATIVE BRAKE CONTROL UNIT - GEARBOX
10 NEGATIVE BRAKE
11 SOLENOID VALVE FOR ARM LOWERING ENABLE
12 BUCKET CONTROL SELECTOR - HATCH
13 WATER PUMP MOTOR
14 FRONT AXLE
15 REAR AXLE
16 CHECK VALVE
17 STEERING SELECTION DISTRIBUTOR
18 FLOW INVERTER
19 HYDRAULIC STEERING
20 PRIORITY VALVE
21 RETURN OIL COLLECTION BLOCK
22 HEAT EXCHANGER
23 HYDROSTATIC TRACTION MOTOR
24 DRUM ROTATION MOTOR
25 DRUM ROTATION PUMP
26 HYDROSTATIC TRACTION PUMP
27 HEAT ENGINE
28 DOUBLE PUMP
29 PRESSURISED FILTER

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 SEBU7833-03
September 2008

Operation and
Maintenance
Manual
1103 and 1104 Industrial Engines
DC (Engine)
DD (Engine)
DJ (Engine)
DK (Engine)
RE (Engine)
RG (Engine)
RJ (Engine)
RR (Engine)
RS (Engine)
RT (Engine)
DF (Engine)
DG (Engine)
 Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or
pictorially presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,
work method or operating technique that is not specifically recommended by Perkins is used,
you must satisfy yourself that it is safe for you and for others. You should also ensure that the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Perkins dealers or Perkins distributors have the most current information available.

When replacement parts are required for this

product Perkins recommends using Perkins
replacement parts.
Failure to heed this warning can lead to prema-
ture failures, product damage, personal injury or
death.
SEBU7833-03 3
Table of Contents

Table of Contents
Foreword ................................................................. 4

Safety Section
Safety Messages .................................................... 5

General Hazard Information ................................... 6

Burn Prevention ...................................................... 7

Fire Prevention and Explosion Prevention .............. 8

Crushing Prevention and Cutting Prevention ........ 10

Mounting and Dismounting ................................... 10

Before Starting Engine .......................................... 10

Engine Starting ...................................................... 11

Engine Stopping .................................................... 11

Electrical System ................................................... 11

Product Information Section

Model Views ......................................................... 13

Product Identification Information ........................ 19

Operation Section
Lifting and Storage ................................................ 24

Gauges and Indicators .......................................... 27

Engine Starting ..................................................... 28

Engine Operation .................................................. 31

Engine Stopping ................................................... 32

Cold Weather Operation ....................................... 33

Maintenance Section
Refill Capacities .................................................... 37

Maintenance Interval Schedule ............................ 51

Warranty Section
Warranty Information ............................................ 79

Index Section
Index ..................................................................... 80
4 SEBU7833-03
Foreword
Foreword
Literature Information
This manual contains safety, operation instructions,
lubrication and maintenance information. This
manual should be stored in or near the engine area
in a literature holder or literature storage area. Read,
study and keep it with the literature and engine
information.
English is the primary language for all Perkins
publications. The English used facilitates translation
and consistency.
Some photographs or illustrations in this manual
show details or attachments that may be different
from your engine. Guards and covers may have
been removed for illustrative purposes. Continuing
improvement and advancement of product design
may have caused changes to your engine which are
not included in this manual. Whenever a question
arises regarding your engine, or this manual, please
consult with your Perkins dealer or your Perkins
distributor for the latest available information.
Safety
This safety section lists basic safety precautions.
In addition, this section identifies hazardous,
warning situations. Read and understand the basic
precautions listed in the safety section before
operating or performing lubrication, maintenance and
repair on this product.
Operation
Operating techniques outlined in this manual are
basic. They assist with developing the skills and
techniques required to operate the engine more
efficiently and economically. Skill and techniques
develop as the operator gains knowledge of the
engine and its capabilities.
The operation section is a reference for operators.
Photographs and illustrations guide the operator
through procedures of inspecting, starting, operating
and stopping the engine. This section also includes a
discussion of electronic diagnostic information.
Maintenance
The maintenance section is a guide to engine care.
The illustrated, step-by-step instructions are grouped
by service hours and/or calendar time maintenance
intervals. Items in the maintenance schedule are
referenced to detailed instructions that follow.
Recommended service should be performed at the
appropriate intervals as indicated in the Maintenance
Interval Schedule. The actual operating environment
of the engine also governs the Maintenance Interval
Schedule. Therefore, under extremely severe,
dusty, wet or freezing cold operating conditions,
more frequent lubrication and maintenance than is
specified in the Maintenance Interval Schedule may
be necessary.
The maintenance schedule items are organized for
a preventive maintenance management program. If
the preventive maintenance program is followed, a
periodic tune-up is not required. The implementation
of a preventive maintenance management program
should minimize operating costs through cost
avoidances resulting from reductions in unscheduled
downtime and failures.
Maintenance Intervals
Perform maintenance on items at multiples of
the original requirement. We recommend that the
maintenance schedules be reproduced and displayed
near the engine as a convenient reminder. We also
recommend that a maintenance record be maintained
as part of the engine’s permanent record.
Your authorized Perkins dealer or your Perkins
distributor can assist you in adjusting your
maintenance schedule to meet the needs of your
operating environment.
Overhaul
Major engine overhaul details are not covered in
the Operation and Maintenance Manual except
for the interval and the maintenance items in that
interval. Major repairs should only be carried out by
Perkins authorized personnel. Your Perkins dealer
or your Perkins distributor offers a variety of options
regarding overhaul programs. If you experience
a major engine failure, there are also numerous
after failure overhaul options available. Consult with
your Perkins dealer or your Perkins distributor for
information regarding these options.
California Proposition 65 Warning
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer,
birth defects, and other reproductive harm. Battery
posts, terminals and related accessories contain lead
and lead compounds. Wash hands after handling.
SEBU7833-03 5
Safety Section
Safety Messages

Safety Section
i03299360

Safety Messages

There may be several specific warning signs on

an engine. The exact location of the hazards and
the description of the hazards are reviewed in this
section. Please become familiar with all warning
signs.
g01154807
Ensure that all of the warning signs are legible. Clean Illustration 1
the warning signs or replace the warning signs if Typical example
the words cannot be read or if the pictures are not
visible. When the warning signs are cleaned, use a The Universal Warning label (1) may be located on
cloth, water, and soap. Do not use solvent, gasoline, the valve mechanism cover or the inlet manifold.
or other harsh chemicals to clean the warning signs. Refer to illustration 2.
Solvents, gasoline, or harsh chemicals could loosen
the adhesive that secures the warning signs. The Note: The location of this label will depend on the
warning signs that are loosened could drop off of application of the engine.
the engine.

Replace any damaged warning signs or missing

warning signs. If a warning sign is attached to a part
of the engine that is replaced, install a new warning
sign on the replacement part. Perkins dealers or
Perkins distributors can provide new warning signs.

Do not work on the engine and do not operate the

engine unless the instructions and warnings in the
Operation and Maintenance Manual are understood.
Correct care is your responsibility. Failure to follow
the instructions or failure to heed the warnings could
result in injury or in death.

(1) Universal Warning

Do not operate or work on this equipment unless

you have read and understand the instructions Illustration 2
g01682734
and warnings in the Operation and Maintenance
Typical example
Manuals. Failure to follow the instructions or
heed the warnings could result in serious injury
or death. (2) Ether

Do not use aerosol types of starting aids such as

ether. Such use could result in an explosion and
personal injury.
6 SEBU7833-03
Safety Section
General Hazard Information

i02328435

General Hazard Information

g01682820
Illustration 3

The ether warning label (2) is located on the cover of

the inlet manifold. Refer to illustration 4.
g00104545
Illustration 5

Attach a “Do Not Operate” warning tag or a similar

warning tag to the start switch or to the controls
before you service the equipment or before you
repair the equipment.

g01682833
Illustration 4 g00702020
Illustration 6
Typical example
Wear a hard hat, protective glasses, and other
protective equipment, as required.

Do not wear loose clothing or jewelry that can snag

on controls or on other parts of the engine.

Make sure that all protective guards and all covers

are secured in place on the engine.

Keep the engine free from foreign material. Remove

debris, oil, tools, and other items from the deck, from
walkways, and from steps.

Never put maintenance fluids into glass containers.

Drain all liquids into a suitable container.

Obey all local regulations for the disposal of liquids.

Use all cleaning solutions with care.

SEBU7833-03
Report all necessary repairs.
Do not allow unauthorized personnel on the
equipment.
Ensure that the power supply is disconnected before
you work on the bus bar or the glow plugs.
Perform maintenance on the engine with the
equipment in the servicing position. Refer to the
OEM information for the procedure for placing the
equipment in the servicing position.
Pressure Air and Water
Pressurized air and/or water can cause debris
and/or hot water to be blown out. This could result in
personal injury.
The direct application of pressurized air or
pressurized water to the body could result in personal
injury.
When pressurized air and/or water is used for
cleaning, wear protective clothing, protective shoes,
and eye protection. Eye protection includes goggles
or a protective face shield.
The maximum air pressure for cleaning purposes
must be below 205 kPa (30 psi). The maximum
water pressure for cleaning purposes must be below
275 kPa (40 psi).
Fluid Penetration
Pressure can be trapped in the hydraulic circuit long
after the engine has been stopped. The pressure can
cause hydraulic fluid or items such as pipe plugs to
escape rapidly if the pressure is not relieved correctly.
Do not remove any hydraulic components or parts
until pressure has been relieved or personal injury
may occur. Do not disassemble any hydraulic
components or parts until pressure has been relieved
or personal injury may occur. Refer to the OEM
information for any procedures that are required to
relieve the hydraulic pressure.
7
Safety Section
Burn Prevention
g00687600
Illustration 7
Always use a board or cardboard when you check
for a leak. Leaking fluid that is under pressure can
penetrate body tissue. Fluid penetration can cause
serious injury and possible death. A pin hole leak can
cause severe injury. If fluid is injected into your skin,
you must get treatment immediately. Seek treatment
from a doctor that is familiar with this type of injury.
Containing Fluid Spillage
Care must be taken in order to ensure that fluids
are contained during performance of inspection,
maintenance, testing, adjusting and repair of the
engine. Make provision to collect the fluid with a
suitable container before any compartment is opened
or before any component is disassembled.
• Only use the tools that are suitable for collecting
fluids and equipment that is suitable for collecting
fluids.
• Only use the tools that are suitable for containing
fluids and equipment that is suitable for containing
fluids.
Obey all local regulations for the disposal of liquids.
i02143195
Burn Prevention
Do not touch any part of an operating engine.
Allow the engine to cool before any maintenance
is performed on the engine. Relieve all pressure
in the air system, in the hydraulic system, in the
lubrication system, in the fuel system, or in the
cooling system before any lines, fittings or related
items are disconnected.
8 SEBU7833-03
Safety Section
Fire Prevention and Explosion Prevention
Coolant
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant.
Any contact with hot coolant or with steam can cause
severe burns. Allow cooling system components to
cool before the cooling system is drained.
Check the coolant level after the engine has stopped
and the engine has been allowed to cool.
Ensure that the filler cap is cool before removing the
filler cap. The filler cap must be cool enough to touch
with a bare hand. Remove the filler cap slowly in
order to relieve pressure.
Cooling system conditioner contains alkali. Alkali can
cause personal injury. Do not allow alkali to contact
the skin, the eyes, or the mouth.
Oils
Hot oil and hot lubricating components can cause
personal injury. Do not allow hot oil to contact the
skin. Also, do not allow hot components to contact
the skin.
Batteries
Electrolyte is an acid. Electrolyte can cause personal
injury. Do not allow electrolyte to contact the skin or
the eyes. Always wear protective glasses for servicing
batteries. Wash hands after touching the batteries
and connectors. Use of gloves is recommended.
i02813488
Fire Prevention and Explosion
Prevention
g00704000
Illustration 8
All fuels, most lubricants, and some coolant mixtures
are flammable.
Flammable fluids that are leaking or spilled onto hot
surfaces or onto electrical components can cause
a fire. Fire may cause personal injury and property
damage.
A flash fire may result if the covers for the engine
crankcase are removed within fifteen minutes after
an emergency shutdown.
Determine whether the engine will be operated in an
environment that allows combustible gases to be
drawn into the air inlet system. These gases could
cause the engine to overspeed. Personal injury,
property damage, or engine damage could result.
If the application involves the presence of combustible
gases, consult your Perkins dealer and/or your
Perkins distributor for additional information about
suitable protection devices.
Remove all flammable combustible materials or
conductive materials such as fuel, oil, and debris from
the engine. Do not allow any flammable combustible
materials or conductive materials to accumulate on
the engine.
Store fuels and lubricants in correctly marked
containers away from unauthorized persons. Store
oily rags and any flammable materials in protective
containers. Do not smoke in areas that are used for
storing flammable materials.
Do not expose the engine to any flame.
Exhaust shields (if equipped) protect hot exhaust
components from oil or fuel spray in case of a line,
a tube, or a seal failure. Exhaust shields must be
installed correctly.
Do not weld on lines or tanks that contain flammable
fluids. Do not flame cut lines or tanks that contain
flammable fluid. Clean any such lines or tanks
thoroughly with a nonflammable solvent prior to
welding or flame cutting.
Wiring must be kept in good condition. All electrical
wires must be correctly routed and securely attached.
Check all electrical wires daily. Repair any wires
that are loose or frayed before you operate the
engine. Clean all electrical connections and tighten
all electrical connections.
Eliminate all wiring that is unattached or unnecessary.
Do not use any wires or cables that are smaller than
the recommended gauge. Do not bypass any fuses
and/or circuit breakers.
SEBU7833-03
Arcing or sparking could cause a fire. Secure
connections, recommended wiring, and correctly
maintained battery cables will help to prevent arcing
or sparking.
Inspect all lines and hoses for wear or for
deterioration. The hoses must be correctly routed.
The lines and hoses must have adequate support
and secure clamps. Tighten all connections to the
recommended torque. Leaks can cause fires.
Oil filters and fuel filters must be correctly installed.
The filter housings must be tightened to the correct
torque.
g00704059
Illustration 9
Use caution when you are refueling an engine. Do
not smoke while you are refueling an engine. Do not
refuel an engine near open flames or sparks. Always
stop the engine before refueling.
9
Safety Section
Fire Prevention and Explosion Prevention
g00704135
Illustration 10
Gases from a battery can explode. Keep any open
flames or sparks away from the top of a battery. Do
not smoke in battery charging areas.
Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter or
a hydrometer.
Incorrect jumper cable connections can cause
an explosion that can result in injury. Refer to
the Operation Section of this manual for specific
instructions.
Do not charge a frozen battery. This may cause an
explosion.
The batteries must be kept clean. The covers
(if equipped) must be kept on the cells. Use the
recommended cables, connections, and battery box
covers when the engine is operated.
Fire Extinguisher
Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations
on the instruction plate.
Lines, Tubes and Hoses
Do not bend high pressure lines. Do not strike high
pressure lines. Do not install any lines that are bent
or damaged. Do not clip any other items to the high
pressure lines.
10
Safety Section
Crushing Prevention and Cutting Prevention
Repair any lines that are loose or damaged. Leaks
can cause fires. Consult your Perkins dealer or your
Perkins distributor for repair or for replacement parts.
Check lines, tubes and hoses carefully. Do not use
your bare hand to check for leaks. Use a board or
cardboard to check for leaks. Tighten all connections
to the recommended torque.
Replace the parts if any of the following conditions
are present:
• End fittings are damaged or leaking.
• Outer coverings are chafed or cut.
• Wires are exposed.
• Outer coverings are ballooning.
• Flexible part of the hoses are kinked.
• Outer covers have embedded armoring.
• End fittings are displaced.
Make sure that all clamps, guards, and heat shields
are installed correctly. During engine operation, this
will help to prevent vibration, rubbing against other
parts, and excessive heat.
i02143194
Crushing Prevention and
Cutting Prevention
Support the component correctly when work beneath
the component is performed.
Unless other maintenance instructions are provided,
never attempt adjustments while the engine is
running.
Stay clear of all rotating parts and of all moving
parts. Leave the guards in place until maintenance
is performed. After the maintenance is performed,
reinstall the guards.
Keep objects away from moving fan blades. The fan
blades will throw objects or cut objects.
When objects are struck, wear protective glasses in
order to avoid injury to the eyes.
Chips or other debris may fly off objects when objects
are struck. Before objects are struck, ensure that no
one will be injured by flying debris.
SEBU7833-03
i01372247
Mounting and Dismounting
Inspect the steps, the handholds, and the work area
before mounting the engine. Keep these items clean
and keep these items in good repair.
Mount the engine and dismount the engine only at
locations that have steps and/or handholds. Do not
climb on the engine, and do not jump off the engine.
Face the engine in order to mount the engine or
dismount the engine. Maintain a three-point contact
with the steps and handholds. Use two feet and one
hand or use one foot and two hands. Do not use any
controls as handholds.
Do not stand on components which cannot support
your weight. Use an adequate ladder or use a work
platform. Secure the climbing equipment so that the
equipment will not move.
Do not carry tools or supplies when you mount the
engine or when you dismount the engine. Use a hand
line to raise and lower tools or supplies.
i02813489
Before Starting Engine
Before the initial start-up of an engine that is new,
serviced or repaired, make provision to shut the
engine off, in order to stop an overspeed. This may
be accomplished by shutting off the air and/or fuel
supply to the engine.
Overspeed shutdown should occur automatically for
engines that are controlled electronically. If automatic
shutdown does not occur, press the emergency stop
button in order to cut the fuel and/or air to the engine.
Inspect the engine for potential hazards.
Before starting the engine, ensure that no one is on,
underneath, or close to the engine. Ensure that the
area is free of personnel.
If equipped, ensure that the lighting system for the
engine is suitable for the conditions. Ensure that all
lights work correctly, if equipped.
All protective guards and all protective covers must
be installed if the engine must be started in order
to perform service procedures. To help prevent an
accident that is caused by parts in rotation, work
around the parts carefully.
SEBU7833-03
Do not bypass the automatic shutoff circuits. Do not
disable the automatic shutoff circuits. The circuits are
provided in order to help prevent personal injury. The
circuits are also provided in order to help prevent
engine damage.
See the Service Manual for repairs and for
adjustments.
i02207232
Engine Starting
Do not use aerosol types of starting aids such as
ether. Such use could result in an explosion and
personal injury.
If a warning tag is attached to the engine start switch
or to the controls, DO NOT start the engine or move
the controls. Consult with the person that attached
the warning tag before the engine is started.
All protective guards and all protective covers must
be installed if the engine must be started in order
to perform service procedures. To help prevent an
accident that is caused by parts in rotation, work
around the parts carefully.
Start the engine from the operator’s compartment or
from the engine start switch.
Always start the engine according to the procedure
that is described in the Operation and Maintenance
Manual, “Engine Starting” topic in the Operation
Section. Knowing the correct procedure will help to
prevent major damage to the engine components.
Knowing the procedure will also help to prevent
personal injury.
To ensure that the jacket water heater (if equipped)
and/or the lube oil heater (if equipped) is working
correctly, check the water temperature gauge and the
oil temperature gauge during the heater operation.
Engine exhaust contains products of combustion
which can be harmful to your health. Always start the
engine and operate the engine in a well ventilated
area. If the engine is started in an enclosed area,
vent the engine exhaust to the outside.
11
Safety Section
Engine Starting
Note: The engine is equipped with an automatic
device for cold starting for normal conditions of
operation. If the engine will be operated in very cold
conditions, then an extra cold starting aid may be
required. Normally, the engine will be equipped with
the correct type of starting aid for your region of
operation.
The engines are equipped with a glow plug starting
aid in each individual cylinder that heats the intake
air in order to improve starting.
i01928905
Engine Stopping
Stop the engine according to the procedure in
the Operation and Maintenance Manual, “Engine
Stopping (Operation Section)” in order to avoid
overheating of the engine and accelerated wear of
the engine components.
Use the Emergency Stop Button (if equipped) ONLY
in an emergency situation. Do not use the Emergency
Stop Button for normal engine stopping. After an
emergency stop, DO NOT start the engine until the
problem that caused the emergency stop has been
corrected.
Stop the engine if an overspeed condition occurs
during the initial start-up of a new engine or an engine
that has been overhauled. This may be accomplished
by shutting off the fuel supply to the engine and/or
shutting off the air supply to the engine.
i02176668
Electrical System
Never disconnect any charging unit circuit or battery
circuit cable from the battery when the charging unit
is operating. A spark can cause the combustible
gases that are produced by some batteries to ignite.
To help prevent sparks from igniting combustible
gases that are produced by some batteries, the
negative “−” jump start cable should be connected
last from the external power source to the negative
“−” terminal of the starting motor. If the starting motor
is not equipped with a negative “−” terminal, connect
the jump start cable to the engine block.
12 SEBU7833-03
Safety Section
Electrical System

Check the electrical wires daily for wires that are

loose or frayed. Tighten all loose electrical wires
before the engine is started. Repair all frayed
electrical wires before the engine is started. See
the Operation and Maintenance Manual for specific
starting instructions.

Grounding Practices
Correct grounding for the engine electrical system
is necessary for optimum engine performance
and reliability. Incorrect grounding will result in
uncontrolled electrical circuit paths and in unreliable
electrical circuit paths.

Uncontrolled electrical circuit paths can result in

damage to main bearings, to crankshaft bearing
journal surfaces, and to aluminum components.

Engines that are installed without engine-to-frame

ground straps can be damaged by electrical
discharge.

To ensure that the engine and the engine electrical

systems function correctly, an engine-to-frame
ground strap with a direct path to the battery must be
used. This path may be provided by way of a direct
engine ground to the frame.

All grounds should be tight and free of corrosion. The

engine alternator must be grounded to the negative
“-” battery terminal with a wire that is adequate to
handle the full charging current of the alternator.
SEBU7833-03 13
Product Information Section
Model Views

Product Information
Section

Model Views
i01928892

Model View Illustrations

1104 Engine Model Views

g01012280
Illustration 11
(1) Valve mechanism cover (4) Fuel injection pump (7) Water pump
(2) Crankcase breather (5) Engine oil filter (8) Fan pulley
(3) Fuel filter (6) Crankshaft pulley (9) Water temperature regulator housing
14 SEBU7833-03
Product Information Section
Model Views

Illustration 12
(1) Oil filler cap
(2) Exhaust manifold
(3) Alternator
g01012281
(4) Turbocharger (7) Flywheel
(5) Starter motor (8) Air intake
(6) Flywheel housing
SEBU7833-03 15
Product Information Section
Model Views

1103 Engine Model Views

g01011348
Illustration 13
(1) Alternator (3) Turbocharger oil supply (5) Turbocharger
(2) Fan pulley (4) Turbocharger oil drain (6) exhaust manifold
16 SEBU7833-03
Product Information Section
Model Views

g01011349
Illustration 14
(1) Fuel transfer pump (5) Dipstick (9) Water pump
(2) Oil filler cap (6) Oil filter (10) Water temperature regulator housing
(3) Fuel filter (7) Oil pan
(4) Starter motor (8) Crankshaft pulley

i02196981 • Naturally aspirated

Engine Description
Perkins Engines are designed for the following
applications: machine, genset, and industrial mobile
equipment. The engines are available in the following
types of aspiration:
Engine Specifications
Note: The front end of the engine is opposite the
flywheel end of the engine. The left and the right
sides of the engine are determined from the flywheel
end. The number 1 cylinder is the front cylinder.

• Turbocharged aftercooled
• Turbocharged
SEBU7833-03 17
Product Information Section
Model Views

Table 2
1103 Industrial Engine Specifications
Number of Cylinders 3 In-Line
Bore 105 mm (4.134 inch)
Stroke 127 mm (5.0 inch)
Aspiration Turbocharged
Naturally aspirated
Compression Ratio NA 19.25:1
T 18.25:1
Displacement 3.3 L (201 in3)
Firing Order 1 2 3
g00984281
Illustration 15
Rotation (flywheel end) Counterclockwise
A typical example of the layout of the valves
(A) Inlet valves Valve Lash Setting (Inlet) 0.20 mm (0.008 inch)
(B) Exhaust valves
Valve Lash Setting 0.45 mm (0.018 inch)
(Exhaust)
Table 1

1104 Industrial Engine Specifications Table 3

Number of Cylinders 4 In-Line 1104 Genset Specifications
Bore 105 mm (4.134 inch) Number of Cylinders 4 In-Line
Stroke 127 mm (5.0 inch) Bore 105 mm (4.134 inch)
Aspiration Turbocharged aftercooled Stroke 127 mm (5.0 inch)
Turbocharged
Naturally aspirated Aspiration Turbocharged aftercooled
Turbocharged
Compression Ratio NA 19.25:1 NA Naturally aspirated
T 18.23:1 T, TA
Compression Ratios NA 19.25:1
Displacement 4.4 L (268 in 3) T 17.25:1, T 18.23:1,
Firing Order 1 3 4 2 TA 18.23:1

Rotation (flywheel end) Counterclockwise Displacement 4.4 L (268 in 3)

Valve Lash Setting (Inlet) 0.20 mm (0.008 inch) Firing Order 1 3 4 2

Valve Lash Setting Rotation (flywheel end) Counterclockwise

0.45 mm (0.018 inch)
(Exhaust) Valve Lash Setting (Inlet) 0.20 mm (0.008 inch)
Valve Lash Setting
0.45 mm (0.018 inch)
(Exhaust)
18 SEBU7833-03
Product Information Section
Model Views

Table 4 Engine Service Life

1103 Genset Specifications
Engine efficiency and maximum utilization of engine
Number of Cylinders 3 In-Line performance depend on the adherence to proper
Bore 105 mm (4.134 inch) operation and maintenance recommendations. In
addition, use recommended fuels, coolants and
Stroke 127 mm (5.0 inch) lubricants. Use the Operation and Maintenance
Aspiration Turbocharged
Manual as a guide for required engine maintenance.
Naturally aspirated
Expected engine life is generally predicted by the
Compression Ratio NA 19.25:1 average power that is demanded. The average power
T 17.25:1 that is demanded is based on fuel consumption of
Displacement 3.3 L (201 in3) the engine over a period of time. Reduced hours of
operation at full throttle and/or operating at reduced
Firing Order 1 2 3 throttle settings result in a lower average power
Rotation (flywheel end) Counterclockwise demand. Reduced hours of operation will increase
the length of operating time before an engine
Valve Lash Setting (Inlet) 0.20 mm (0.008 inch) overhaul is required.
Valve Lash Setting 0.45 mm (0.018 inch)
(Exhaust)

Engine Cooling and Lubrication

The cooling system consists of the following
components:

• Gear-driven centrifugal water pump

• Water temperature regulator which regulates the
engine coolant temperature

• Gear-driven oil pump (gear type)

• Oil cooler
The engine lubricating oil is supplied by a gear
type pump. The engine lubricating oil is cooled and
the engine lubricating oil is filtered. Bypass valves
provide unrestricted flow of lubrication oil to the
engine parts when oil viscosity is high. Bypass valves
can also provide unrestricted flow of lubrication oil
to the engine parts if the oil cooler should become
plugged or if the oil filter element should become
plugged.

Engine efficiency, efficiency of emission controls, and

engine performance depend on adherence to proper
operation and maintenance recommendations.
Engine performance and efficiency also depend on
the use of recommended fuels, lubrication oils, and
coolants. Refer to the Operation and Maintenance
Manual, “Maintenance Interval Schedule” for more
information on maintenance items.
SEBU7833-03 19
Product Information Section
Product Identification Information

Product Identification i01940474

Information Serial Number Plate

i02280116

Engine Identification

Perkins engines are identified by a serial number.

This number is shown on a serial number plate that
is mounted on the left hand side of the engine block.

An example of an engine number is

RE12345U090001H.

RE __________________________________________Type of engine

RE12345____________________________Engine List Number

U ____________________________Built in the United Kingdom

090001 ___________________________Engine Serial Number

H _____________________________________Year of Manufacture g00994966

Illustration 16

Perkins dealers need these numbers in order to Typical serial number plate
determine the components that were included with (1) Temporary Parts List number
the engine. This permits accurate identification of (2) Type
(3) Serial number
replacement part numbers. (4) List number

The Serial Number Plate is located on the left side of

the cylinder block behind the high pressure pipes of
the Fuel injection pump.

The following information is stamped on the Serial

Number Plate: Engine serial number, Model, and
Arrangement number.

i02164876

Reference Numbers

Information for the following items may be needed to

order parts. Locate the information for your engine.
Record the information in the appropriate space.
Make a copy of this list for a record. Keep the
information for future reference.

Record for Reference

Engine Model _______________________________________________

Engine Serial number _____________________________________

Engine Low Idle rpm ______________________________________

20 SEBU7833-03
Product Information Section
Product Identification Information

Engine Full Load rpm _____________________________________

Primary Fuel Filter _________________________________________

Water Separator Element ________________________________

Secondary Fuel Filter Element __________________________

Lubrication Oil Filter Element ___________________________

Auxiliary Oil Filter Element _______________________________

Total Lubrication System Capacity _____________________

Total Cooling System Capacity _________________________

Air Cleaner Element _______________________________________

Fan Drive Belt ______________________________________________

Alternator Belt ______________________________________________

i02758852

Emissions Certification Film

Label for compliant engines

Typical examples of emissions labels
SEBU7833-03 21
Product Information Section
Product Identification Information

g01173630
Illustration 17
This typical example of a label is installed on engines that have electronic fuel injection systems and installed on engines that have electronic
fuel injection pumps.

g01156733
Illustration 18
This typical example of a label is installed on engines that have mechanical fuel injection pumps.
22 SEBU7833-03
Product Information Section
Product Identification Information

Label for engines that comply with

MSHA emissions

g01381316
Illustration 19
Typical example

The label that is shown in illustration 19 is for engines

that operate in underground coal mines in North
America. The label is installed on engines that comply
with the Mine Safety and Health Administration
(MSHA) emissions. Approved diesel engines shall
be identified by an approved mark that is legible
and permanent. The approved mark is scribed with
the approved MSHA number. The label should be
securely attached to the diesel engine.

Label for engines that do not

comply with emissions

g01156734
Illustration 20
This typical example of a label is installed on engines that do not comply with emissions.
SEBU7833-03 23
Product Information Section
Product Identification Information

g01157127
Illustration 21
This typical example of a label is installed on engines that are stationary engines.
24 SEBU7833-03
Operation Section
Lifting and Storage

Operation Section Some removals require lifting the fixtures in order to

obtain correct balance and safety.

To remove the engine ONLY, use the lifting eyes that

Lifting and Storage are on the engine.

Lifting eyes are designed and installed for specific

i02164186 engine arrangements. Alterations to the lifting eyes
and/or the engine make the lifting eyes and the lifting
Engine Lifting fixtures obsolete. If alterations are made, ensure
that correct lifting devices are provided. Consult
your Perkins dealer or your Perkins distributor for
information regarding fixtures for correct engine
lifting.

i01930351

Engine Storage

If the engine will not be started for several weeks, the

lubricating oil will drain from the cylinder walls and
from the piston rings. Rust can form on the cylinder
walls. Rust on the cylinder walls will cause increased
engine wear and a reduction in engine service life.

Lubrication System
To help prevent excessive engine wear, use the
following guidelines:

Complete all of the lubrication recommendations that

are listed in this Operation and Maintenance Manual,
“Maintenance Interval Schedule” (Maintenance
Section).

If an engine is out of operation and if use of the engine

g01097527
Illustration 22
NOTICE
Never bend the eyebolts and the brackets. Only load
the eyebolts and the brackets under tension. Remem-
ber that the capacity of an eyebolt is less as the angle
between the supporting members and the object be-
comes less than 90 degrees.
When it is necessary to remove a component at an
angle, only use a link bracket that is properly rated for
the weight.
is not planned, special precautions should be made.
If the engine will be stored for more than one month,
a complete protection procedure is recommended.
Use the following guidelines :
• Completely clean the outside of the engine.
• Drain the fuel system completely and refill
the system with preservative fuel.1772204
POWERPART Lay-Up 1 can be mixed with
the normal fuel in order to change the fuel into
preservative fuel.

• If preservative fuel is not available, the fuel system

Use a hoist to remove heavy components. Use
an adjustable lifting beam to lift the engine. All
supporting members (chains and cables) should be
parallel to each other. The chains and cables should
be perpendicular to the top of the object that is being
lifted.
can be filled with normal fuel. This fuel must be
discarded at the end of the storage period together
with the fuel filter elements.
• Operate the engine until the engine reaches normal
operating temperature. Stop any leaks from fuel,
lubricating oil or air systems. Stop the engine and
drain the lubricating oil from the oil pan.
SEBU7833-03
• Renew the canister(s) of the lubricating oil filter.
• Fill the oil pan to the Full Mark on the dipstick
with new, clean lubricating oil. Add 1762811
POWERPART Lay-Up 2 to the oil in order to
protect the engine against corrosion. If 1762811
POWERPART Lay-Up 2 is not available, use a
preservative of the correct specification instead
of the lubricating oil. If a preservative is used,
this must be drained completely at the end of the
storage period and the oil pan must be refilled to
the correct level with normal lubricating oil.
Cooling System
To help prevent excessive engine wear, use the
following guidelines:
NOTICE
Do not drain the coolant while the engine is still hot and
the system is under pressure because dangerous hot
coolant can be discharged.
If freezing temperatures are expected, check the
cooling system for adequate protection against
freezing. See this Operation and Maintenance
Manual, “General Coolant Information” (Maintenance
Section).
NOTICE
To prevent frost damage, ensure that all the coolant is
removed from the engine. This is important if the sys-
tem is drained after it has been flushed with water, or if
an antifreeze solution too weak to protect the system
from frost has been used.
g01003928
Illustration 23
1. Ensure that the vehicle is on level ground.
2. Remove the filler cap of the cooling system.
3. Remove the drain plug (1) from the side of the
cylinder block in order to drain the engine. Ensure
that the drain hole is not restricted.
25
Operation Section
Lifting and Storage
4. Open the tap or remove the drain plug at the
bottom of the radiator in order to drain the radiator.
If the radiator does not have a tap or a drain plug,
disconnect the hose at the bottom of the radiator.
5. Flush the cooling system with clean water.
6. Fit the drain plugs and the filler cap. Close the tap
or connect the radiator hose.
7. Fill the cooling system with an approved
antifreeze mixture because this gives protection
against corrosion. The maximum flow rate is 1 L
(0.2200 Imp gal) per minute in order to fill the
system.
Note: Certain corrosion inhibitors could cause
damage to some engine components. Contact the
Service Department of Perkins for advice.
8. Operate the engine for a short period in order to
circulate the lubricating oil and the coolant in the
engine.
9. Disconnect the battery. Put the battery into safe
storage in a fully charged condition. Before the
battery is put into storage, protect the terminals
against corrosion.1734115 POWERPART Lay-Up
3 can be used on the terminals.
10. Clean the crankcase breather if one is installed.
Seal the end of the pipe.
11. Remove the fuel injector nozzles and spray
1762811 POWERPART Lay-Up 2 for one or two
seconds into each cylinder bore with the piston
at BDC.
12. Slowly rotate the crankshaft for one complete
revolution and then replace the fuel injector
nozzles.
Induction System
• Remove the air filter assembly. If necessary,
remove the pipes that are installed between
the air filter assembly and the turbocharger.
Spray 1762811 POWERPART Lay-Up 2 into the
turbocharger. The duration of the spray is printed
on the container. Seal the turbocharger with
waterproof tape.
Exhaust System
• Remove the exhaust pipe. Spray 1762811
POWERPART Lay-Up 2 into the turbocharger. The
duration of the spray is printed on the container.
Seal the turbocharger with waterproof tape.
26 SEBU7833-03
Operation Section
Lifting and Storage

General Items
• If the lubricating oil filler is installed on the rocker
cover, remove the filler cap. If the lubricating oil filler
cap is not installed on the rocker cover, remove
the rocker cover. Spray 1762811 POWERPART
Lay-Up 2 around the rocker shaft assembly.
Replace the filler cap or the rocker cover.

• Seal the vent of the fuel tank or the fuel filler cap
with waterproof tape.

• Remove the alternator drive belts and put the drive

belts into storage.

• In order to prevent corrosion, spray the engine with

1734115 POWERPART Lay-Up 3. Do not spray
the area inside the alternator.

When the engine protection has been completed in

accordance with these instructions, this ensures that
no corrosion will occur. Perkins are not responsible
for damage which may occur when an engine is in
storage after a period in service.

Your Perkins dealer or your Perkins distributor can

assist in preparing the engine for extended storage
periods.
SEBU7833-03 27
Operation Section
Gauges and Indicators

Gauges and Indicators 1. Reduce the load and the engine rpm.

2. Inspect the cooling system for leaks.

i02164190
3. Determine if the engine must be shut down
Gauges and Indicators immediately or if the engine can be cooled by
reducing the load.

Tachometer – This gauge indicates engine

Your engine may not have the same gauges or all of
the gauges that are described. For more information
about the gauge package, see the OEM information.
Gauges provide indications of engine performance.
Ensure that the gauges are in good working order.
Determine the normal operating range by observing
the gauges over a period of time.
Noticeable changes in gauge readings indicate
potential gauge or engine problems. Problems may
also be indicated by gauge readings that change
even if the readings are within specifications.
Determine and correct the cause of any significant
change in the readings. Consult your Perkins dealer
or your Perkins distributor for assistance.
NOTICE
If no oil pressure is indicated, STOP the engine. If
maximum coolant temperature is exceeded, STOP
the engine. Engine damage can result.
Engine Oil Pressure – The oil pressure
should be greatest after a cold engine is
started. The typical engine oil pressure with
SAE10W30 is 207 to 413 kPa (30 to 60 psi) at rated
rpm.
speed (rpm). When the throttle control lever
is moved to the full throttle position without
load, the engine is running at high idle. The engine is
running at the full load rpm when the throttle control
lever is at the full throttle position with maximum
rated load.
NOTICE
To help prevent engine damage, never exceed the
high idle rpm. Overspeeding can result in serious
damage to the engine. The engine can be operated
at high idle without damage, but should never be
allowed to exceed high idle rpm.
Ammeter – This gauge indicates the
amount of charge or discharge in the
battery charging circuit. Operation of the
indicator should be to the right side of “0” (zero).
Fuel Level – This gauge indicates the fuel
level in the fuel tank. The fuel level gauge
operates when the “START/STOP” switch
is in the “ON” position.
Service Hour Meter – The gauge indicates
operating time of the engine.

A lower oil pressure is normal at low idle. If the load

is stable and the gauge reading changes, perform
the following procedure:

1. Remove the load.

2. Reduce engine speed to low idle.

3. Check and maintain the oil level.

Jacket Water Coolant Temperature –

Typical temperature range is 71 to 96°C
(160 to 205°F). The maximum allowable
temperature with the pressurized cooling system at
48 kPa (7 psi) is 110°C (230°F). Higher temperatures
may occur under certain conditions. The water
temperature reading may vary according to load. The
reading should never exceed the boiling point for the
pressurized system that is being used.

If the engine is operating above the normal range

and steam becomes apparent, perform the following
procedure:
28
Operation Section
Engine Starting
Engine Starting
i02194223
Before Starting Engine
Before the engine is started, perform the required
daily maintenance and any other periodic
maintenance that is due. Refer to the Operation
and Maintenance Manual, “Maintenance Interval
Schedule” for more information.
• For the maximum service life of the engine, make a
thorough inspection within the engine compartment
before the engine is started. Look for the following
items: oil leaks, coolant leaks, loose bolts, and
excessive dirt and/or grease. Remove any excess
dirt and/or grease buildup. Repair any faults that
were identified during the inspection.
• Inspect the cooling system hoses for cracks and
for loose clamps.
• Inspect the alternator and accessory drive belts for
cracks, breaks, and other damage.
• Inspect the wiring for loose connections and for
worn wires or frayed wires.
• Check the fuel supply. Drain water from the water
separator (if equipped). Open the fuel supply valve
(if equipped).
NOTICE
All valves in the fuel return line must be open before
and during engine operation to help prevent high fuel
pressure. High fuel pressure may cause filter housing
failure or other damage.
If the engine has not been started for several weeks,
fuel may have drained from the fuel system. Air
may have entered the filter housing. Also, when fuel
filters have been changed, some air pockets will be
trapped in the engine. In these instances, prime the
fuel system. Refer to the Operation and Maintenance
Manual, “Fuel System - Prime” for more information
on priming the fuel system.
Engine exhaust contains products of combustion
which may be harmful to your health. Always start
and operate the engine in a well ventilated area
and, if in an enclosed area, vent the exhaust to the
outside.
SEBU7833-03
• Do not start the engine or move any of the controls
if there is a “DO NOT OPERATE” warning tag or
similar warning tag attached to the start switch or
to the controls.
• Ensure that the areas around the rotating parts are
clear.
• All of the guards must be put in place. Check for
damaged guards or for missing guards. Repair
any damaged guards. Replace damaged guards
and/or missing guards.
• Disconnect any battery chargers that are not
protected against the high current drain that
is created when the electric starting motor is
engaged. Check electrical cables and check the
battery for poor connections and for corrosion.
• Reset all of the shutoffs or alarm components (if
equipped).
• Check the engine lubrication oil level. Maintain the
oil level between the “ADD” mark and the “FULL”
mark on the engine oil level gauge.
• Check the coolant level. Observe the coolant level
in the header tank (if equipped). Maintain the
coolant level to the “FULL” mark on the header
tank.
• If the engine is not equipped with a header tank
maintain the coolant level within 13 mm (0.5 inch)
of the bottom of the filler pipe. If the engine is
equipped with a sight glass, maintain the coolant
level in the sight glass.
• Observe the air cleaner service indicator (if
equipped). Service the air cleaner when the yellow
diaphragm enters the red zone, or when the red
piston locks in the visible position.
• Ensure that any equipment that is driven by the
engine has been disengaged from the engine.
Minimize electrical loads or remove any electrical
loads.
SEBU7833-03
i02198348
Starting the Engine
Do not use aerosol types of starting aids such as
ether. Such use could result in an explosion and
personal injury.
Refer to the OMM for your type of controls. Use the
following procedure to start the engine.
1. If equipped, move the throttle lever to the full
throttle position before you start the engine.
NOTICE
Do not crank the engine for more than 30 seconds.
Allow the electric starting motor to cool for two minutes
before cranking the engine again.
2. Turn the engine start switch to the START position.
Hold the engine start switch in the START position
and crank the engine.
3. When the engine starts, release the engine start
switch.
4. If equipped, slowly move the throttle lever to the
low idle position and allow the engine to idle. Refer
to the Operation and Maintenance Manual, “After
Starting Engine” topic.
5. If the engine does not start, release the engine
start switch and allow the electric starting motor to
cool. Then, repeat steps 2 through step 4.
6. Turn the engine start switch to the OFF position in
order to stop the engine.
i02198092
Cold Weather Starting
Do not use aerosol types of starting aids such as
ether. Such use could result in an explosion and
personal injury.
Startability will be improved at temperatures below
−18 °C (0 °F) from the use of a jacket water heater
or extra battery capacity.
29
Operation Section
Engine Starting
When Group 2 diesel fuel is used, the following items
provide a means of minimizing starting problems
and fuel problems in cold weather: engine oil pan
heaters, jacket water heaters, fuel heaters, and fuel
line insulation.
Use the procedure that follows for cold weather
starting.
1. If equipped, move the throttle lever to the full
throttle position before you start the engine.
2. If equipped, turn the engine start switch to the
HEAT position. Hold the engine start switch in the
HEAT position for 6 seconds until the glow plug
indicator light illuminates. This will activate the
glow plugs and aid in the starting of the engine.
NOTICE
Do not crank the engine for more than 30 seconds.
Allow the electric starting motor to cool for two minutes
before cranking the engine again.
3. While the glow plug indicator light is illuminated,
turn the engine start switch to the START position
and crank the engine.
Note: If the glow plug indicator light illuminates
rapidly for 2 to 3 seconds, or if the glow plug indicator
light fails to illuminate, a malfunction exists in the cold
start system. Do not use ether or other starting fluids
to start the engine.
4. When the engine starts, release the engine start
switch key.
5. If the engine does not start, release the engine
start switch and allow the starter motor to cool.
Then, repeat steps 2 through step 4.
6. If the engine is equipped with a throttle allow the
engine to idle for three to five minutes, or allow the
engine to idle until the water temperature indicator
begins to rise. The engine should run at low idle
smoothly until speed is gradually increased to high
idle. Allow the white smoke to disperse before
proceeding with normal operation.
7. Operate the engine at low load until all systems
reach operating temperature. Check the gauges
during the warm-up period.
8. Turn the engine start switch to the OFF position in
order to stop the engine.
30
Operation Section
Engine Starting
i02177935
Starting with Jump Start
Cables
Improper jump start cable connections can cause
an explosion resulting in personal injury.
Prevent sparks near the batteries. Sparks could
cause vapors to explode. Do not allow jump start
cable ends to contact each other or the engine.
Note: If it is possible, first diagnose the reason
for the starting failure. Make any necessary
repairs. If the engine will not start only due to
the condition of the battery, either charge the
battery, or start the engine with jump start cables.
The condition of the battery can be rechecked
after the engine has been switched OFF.
NOTICE
Using a battery source with the same voltage as the
electric starting motor. Use ONLY equal voltage for
jump starting. The use of higher voltage will damage
the electrical system.
Do not reverse the battery cables. The alternator can
be damaged. Attach ground cable last and remove
first.
When using an external electrical source to start the
engine, turn the generator set control switch to the
“OFF” position. Turn all electrical accessories OFF be-
fore attaching the jump start cables.
Ensure that the main power switch is in the OFF posi-
tion before attaching the jump start cables to the en-
gine being started.
1. Turn the start switch to the OFF position. Turn off
all the engine’s accessories.
2. Connect one positive end of the jump start cable
to the positive cable terminal of the discharged
battery. Connect the other positive end of the jump
start cable to the positive cable terminal of the
electrical source.
SEBU7833-03
3. Connect one negative end of the jump start cable
to the negative cable terminal of the electrical
source. Connect the other negative end of the
jump start cable to the engine block or to the
chassis ground. This procedure helps to prevent
potential sparks from igniting the combustible
gases that are produced by some batteries.
4. Start the engine.
5. Immediately after the stalled engine is started,
disconnect the jump start cables in reverse order.
After jump starting, the alternator may not be able to
fully recharge batteries that are severely discharged.
The batteries must be replaced or charged to the
correct voltage with a battery charger after the engine
is stopped. Many batteries which are considered
unusable are still rechargeable. Refer to Operation
and Maintenance Manual, “Battery - Replace” and
Testing and Adjusting Manual, “Battery - Test”.
i01903609
After Starting Engine
Note: In temperatures from 0 to 60°C (32 to 140°F),
the warm-up time is approximately three minutes. In
temperatures below 0°C (32°F), additional warm-up
time may be required.
When the engine idles during warm-up, observe the
following conditions:
• Check for any fluid or for any air leaks at idle rpm
and at one-half full rpm (no load on the engine)
before operating the engine under load. This is not
possible in some applications.
• Operate the engine at low idle until all systems
achieve operating temperatures. Check all gauges
during the warm-up period.
Note: Gauge readings should be observed and
the data should be recorded frequently while the
engine is operating. Comparing the data over time
will help to determine normal readings for each
gauge. Comparing data over time will also help
detect abnormal operating developments. Significant
changes in the readings should be investigated.
SEBU7833-03
Engine Operation
i02176671
Engine Operation
Correct operation and maintenance are key factors
in obtaining the maximum life and economy of
the engine. If the directions in the Operation and
Maintenance Manual are followed, costs can be
minimized and engine service life can be maximized.
The engine can be operated at the rated rpm after the
engine reaches operating temperature. The engine
will reach normal operating temperature sooner
during a low engine speed (rpm) and during a low
power demand. This procedure is more effective than
idling the engine at no load. The engine should reach
operating temperature in a few minutes.
Gauge readings should be observed and the data
should be recorded frequently while the engine
is operating. Comparing the data over time will
help to determine normal readings for each gauge.
Comparing data over time will also help detect
abnormal operating developments. Significant
changes in the readings should be investigated.
i01929404
Engine Warm-up
1. Run the engine at low idle for three to five minutes,
or run the engine at low idle until the jacket water
temperature starts to rise.
More time may be necessary when the
temperature is below −18°C (0°F).
2. Check all of the gauges during the warm-up
period.
3. Perform a walk-around inspection. Check the
engine for fluid leaks and air leaks.
4. Increase the rpm to the rated rpm. Check for
fluid leaks and air leaks. The engine may be
operated at full rated rpm and at full load when
the temperature of the water jacket reaches 60°C
(140°F).
31
Operation Section
Engine Operation
i02330149
Fuel Conservation Practices
The efficiency of the engine can affect the fuel
economy. Perkins design and technology in
manufacturing provides maximum fuel efficiency in
all applications. Follow the recommended procedures
in order to attain optimum performance for the life
of the engine.
• Avoid spilling fuel.
Fuel expands when the fuel is warmed up. The fuel
may overflow from the fuel tank. Inspect fuel lines for
leaks. Repair the fuel lines, as needed.
• Be aware of the properties of the different fuels.
Use only the recommended fuels.
• Avoid unnecessary idling.
Shut off the engine rather than idle for long periods of
time.
• Observe the air cleaner service indicator frequently.
Keep the air cleaner elements clean.
• Maintain the electrical systems.
One damaged battery cell will overwork the alternator.
This will consume excess power and excess fuel.
• Ensure that the drive belts are correctly adjusted.
The drive belts should be in good condition.
• Ensure that all of the connections of the hoses are
tight. The connections should not leak.
• Ensure that the driven equipment is in good
working order.
• Cold engines consume excess fuel. Utilize heat
from the jacket water system and the exhaust
system, when possible. Keep cooling system
components clean and keep cooling system
components in good repair. Never operate the
engine without water temperature regulators.
All of these items will help maintain operating
temperatures.
32 SEBU7833-03
Operation Section
Engine Stopping

Engine Stopping i01903608

After Stopping Engine

i01929389

Stopping the Engine

NOTICE
Stopping the engine immediately after it has been
working under load can result in overheating and ac-
celerated wear of the engine components.
Note: Before you check the engine oil, do not operate
the engine for at least 10 minutes in order to allow
the engine oil to return to the oil pan.
• Check the crankcase oil level. Maintain the oil level
between the “ADD” mark and the “FULL” mark on
the oil level dipstick.

If the engine has been operating at high rpm and/or
high loads, run at low idle for at least three minutes
to reduce and stabilize internal engine temperature
before stopping the engine.
Avoiding hot engine shutdowns will maximize tur-
bocharger shaft and bearing life.
• If necessary, perform minor adjustments. Repair
any leaks and tighten any loose bolts.
• Note the required service interval. Perform
the maintenance that is in the Operation and
Maintenance Manual, “Maintenance Interval
Schedule”.

• Fill the fuel tank in order to help prevent

Prior to stopping an engine that is being operated
at low loads, operate the engine at low idle for 30
seconds before stopping. If the engine has been
operating at highway speeds and/or at high loads,
operate the engine at low idle for at least three
minutes. This procedure will cause the internal
engine temperature to be reduced and stabilized.
Ensure that the engine stopping procedure is
understood. Stop the engine according to the shutoff
system on the engine or refer to the instructions that
are provided by the OEM.
• To stop the engine, turn the ignition key switch to
the OFF position.
i01903586
accumulation of moisture in the fuel. Do not overfill
the fuel tank.
NOTICE
Only use antifreeze/coolant mixtures recommended in
the Coolant Specifications that are in the Operation
and Maintenance Manual. Failure to do so can cause
engine damage.
• Allow the engine to cool. Check the coolant level.
• If freezing temperatures are expected, check the
coolant for the correct antifreeze protection. The
cooling system must be protected against freezing
to the lowest expected outside temperature. Add
the correct coolant/water mixture, if necessary.

Emergency Stopping • Perform all required periodic maintenance on all

driven equipment. This maintenance is outlined in
the instructions from the OEM.

NOTICE
Emergency shutoff controls are for EMERGENCY use
ONLY. DO NOT use emergency shutoff devices or
controls for normal stopping procedure.

The OEM may have equipped the application with

an emergency stop button. For more information
about the emergency stop button, refer to the OEM
information.

Ensure that any components for the external system

that support the engine operation are secured after
the engine is stopped.
SEBU7833-03
Cold Weather Operation
i02717265
Cold Weather Operation
Perkins Diesel Engines can operate effectively in
cold weather. During cold weather, the starting and
the operation of the diesel engine is dependent on
the following items:
• The type of fuel that is used
• The viscosity of the engine oil
• The operation of the glow plugs
• Optional Cold starting aid
• Battery condition
This section will cover the following information:
• Potential problems that are caused by cold weather
operation
• Suggest steps which can be taken in order to
minimize starting problems and operating problems
when the ambient air temperature is between
0° to−40 °C (32° to 40 °F).
The operation and maintenance of an engine in
freezing temperatures is complex . This is because
of the following conditions:
• Weather conditions
• Engine applications
Recommendations from your Perkins dealer or
your Perkins distributor are based on past proven
practices. The information that is contained in
this section provides guidelines for cold weather
operation.
Hints for Cold Weather Operation
• If the engine will start, operate the engine until a
minimum operating temperature of 81 °C (177.8 °F)
is achieved. Achieving operating temperature will
help prevent the intake valves and exhaust valves
from sticking.
• The cooling system and the lubrication system
for the engine do not lose heat immediately upon
shutdown. This means that an engine can be shut
down for a period of time and the engine can still
have the ability to start readily.
33
Operation Section
Cold Weather Operation
• Install the correct specification of engine lubricant
before the beginning of cold weather.
• Check all rubber parts (hoses, fan drive belts, etc)
weekly.
• Check all electrical wiring and connections for any
fraying or damaged insulation.
• Keep all batteries fully charged and warm.
• Fill the fuel tank at the end of each shift.
• Check the air cleaners and the air intake daily.
Check the air intake more often when you operate
in snow.
• Ensure that the glow plugs are in working order.
Refer to Testing and Adjusting Manual, “Glow Plug
- Test”.
Personal injury or property damage can result
from alcohol or starting fluids.
Alcohol or starting fluids are highly flammable and
toxic and if improperly stored could result in injury
or property damage.
Do not use aerosol types of starting aids such as
ether. Such use could result in an explosion and
personal injury.
• For jump starting with cables in cold weather,
refer to the Operation and Maintenance Manual,
“Starting with Jump Start Cables.” for instructions.
Viscosity of the Engine Lubrication
Oil
Correct engine oil viscosity is essential. Oil viscosity
affects the amount of torque that is needed to
crank the engine. Refer to this Operation and
Maintenance Manual, “Fluid Recommendations” for
the recommended viscosity of oil.
Recommendations for the Coolant
Provide cooling system protection for the lowest
expected outside temperature. Refer to this Operation
and Maintenance Manual, “Fluid Recommendations”
for the recommended coolant mixture.
34
Operation Section
Cold Weather Operation
In cold weather, check the coolant often for the
correct glycol concentration in order to ensure
adequate freeze protection.
Engine Block Heaters
Engine block heaters (if equipped) heat the
engine jacket water that surrounds the combustion
chambers. This provides the following functions:
• Startability is improved.
• Warm up time is reduced.
An electric block heater can be activated once
the engine is stopped. An effective block heater
is typically a 1250/1500 W unit. Consult your
Perkins dealer or your Perkins distributor for more
information.
Idling the Engine
When idling after the engine is started in cold
weather, increase the engine rpm from 1000 to 1200
rpm. This will warm up the engine more quickly.
Maintaining an elevated low idle speed for extended
periods will be easier with the installation of a hand
throttle. The engine should not be “raced” in order to
speed up the warm up process.
While the engine is idling, the application of a light
load (parasitic load) will assist in achieving the
minimum operating temperature. The minimum
operating temperature is 82 °C (179.6 °F).
Recommendations for Coolant
Warm Up
Warm up an engine that has cooled below normal
operating temperatures due to inactivity. This should
be performed before the engine is returned to full
operation. During operation in very cold temperature
conditions, damage to engine valve mechanisms can
result from engine operation for short intervals. This
can happen if the engine is started and the engine is
stopped many times without being operated in order
to warm up completely.
When the engine is operated below normal operating
temperatures, fuel and oil are not completely burned
in the combustion chamber. This fuel and oil causes
soft carbon deposits to form on the valve stems.
Generally, the deposits do not cause problems and
the deposits are burned off during operation at
normal engine operating temperatures.
When the engine is started and the engine is stopped
many times without being operated in order to warm
up completely, the carbon deposits become thicker.
This can cause the following problems:
SEBU7833-03
• Free operation of the valves is prevented.
• Valves become stuck.
• Pushrods may become bent.
• Other damage to valve train components can
result.
For this reason, when the engine is started,
the engine must be operated until the coolant
temperature is 71 °C (160 °F) minimum. Carbon
deposits on the valve stems will be kept at a minimum
and the free operation of the valves and the valve
components will be maintained.
In addition, the engine must be thoroughly warmed in
order to keep other engine parts in better condition
and the service life of the engine will be generally
extended. Lubrication will be improved. There will be
less acid and less sludge in the oil. This will provide
longer service life for the engine bearings, the piston
rings, and other parts. However, limit unnecessary
idle time to ten minutes in order to reduce wear and
unnecessary fuel consumption.
The Water Temperature Regulator and
Insulated Heater Lines
The engine is equipped with a water temperature
regulator. When the engine coolant is below the
correct operating temperature jacket water circulates
through the engine cylinder block and into the
engine cylinder head. The coolant then returns to the
cylinder block via an internal passage that bypasses
the valve of the coolant temperature regulator. This
ensures that coolant flows around the engine under
cold operating conditions. The water temperature
regulator begins to open when the engine jacket
water has reached the correct minimum operating
temperature. As the jacket water coolant temperature
rises above the minimum operating temperature the
water temperature regulator opens further allowing
more coolant through the radiator to dissipate excess
heat.
The progressive opening of the water temperature
regulator operates the progressive closing of the
bypass passage between the cylinder block and
head. This ensures maximum coolant flow to
the radiator in order to achieve maximum heat
dissipation.
Note: Perkins discourages the use of all air flow
restriction devices such as radiator shutters.
Restriction of the air flow can result in the following:
high exhaust temperatures, power loss, excessive
fan usage, and reduction in fuel economy.
SEBU7833-03
A cab heater is beneficial in very cold weather. The
feed from the engine and the return lines from the
cab should be insulated in order to reduce heat loss
to the outside air.
Insulating the Air Inlet and Engine
Compartment
When temperatures below −18 °C (−0 °F) will be
frequently encountered, an air cleaner inlet that
is located in the engine compartment may be
specified. An air cleaner that is located in the engine
compartment may also minimize the entry of snow
into the air cleaner. Also, heat that is rejected by the
engine helps to warm the intake air.
Additional heat can be retained around the engine by
insulating the engine compartment.
i02322217
Fuel and the Effect from Cold
Weather
Note: Only use grades of fuel that are recommended
by Perkins. Refer to this Operation and Maintenance
Manual, “Fluid Recommendations”.
The following fuels can be used in this series of
engine.
• Group 1
• Group 2
• Group 3
• Special Fuels
Perkins prefer only Group 1 and Group 2 fuels for
use in this series of engines.
Group 1 fuels are the preferred Group of Fuels for
general use by Perkins. Group 1 fuels maximize
engine life and engine performance. Group 1 fuels
are usually less available than Group 2 fuels.
Frequently, Group 1 fuels are not available in colder
climates during the winter.
Note: Group 2 fuels must have a maximum wear
scar of 650 micrometers (HFRR to ISO 12156-1).
Group 2 fuels are considered acceptable for issues
of warranty. This group of fuels may reduce the life
of the engine, the engine’s maximum power, and the
engine’s fuel efficiency.
35
Operation Section
Cold Weather Operation
When Group 2 diesel fuels are used the following
components provide a means of minimizing problems
in cold weather:
• Glow plugs (if equipped)
• Engine coolant heaters, which may be an OEM
option
• Fuel heaters, which may be an OEM option
• Fuel line insulation, which may be an OEM option
There are three major differences between Group
1 fuels and Group 2 fuels. Group 1 fuels have the
following different characteristics to Group 2 fuels.
• A lower cloud point
• A lower pour point
• A higher energy per unit volume of fuel
Note: Group 3 fuels reduce the life of the engine. The
use of Group 3 fuels is not covered by the Perkins
warranty.
Group 3 fuels include Low Temperature Fuels and
Aviation Kerosene Fuels.
Special fuels include Biofuel.
The cloud point is a temperature that allows wax
crystals to form in the fuel. These crystals can cause
the fuel filters to plug.
The pour point is the temperature when diesel fuel
will thicken. The diesel fuel becomes more resistant
to flow through fuel lines, fuel filters,and fuel pumps.
Be aware of these facts when diesel fuel is
purchased. Consider the average ambient air
temperature for the engine’s application. Engines
that are fueled in one climate may not operate well if
the engines are moved to another climate. Problems
can result due to changes in temperature.
Before troubleshooting for low power or for poor
performance in the winter, check the fuel for waxing.
Low temperature fuels may be available for engine
operation at temperatures below 0 °C (32 °F). These
fuels limit the formation of wax in the fuel at low
temperatures.
For more information on cold weather operation, refer
to the Operation and Maintenance Manual, “Cold
Weather Operation and Fuel Related Components in
Cold Weather”.
36 SEBU7833-03
Operation Section
Cold Weather Operation

i01903588

Fuel Related Components in

Cold Weather

Fuel Tanks
Condensation can form in partially filled fuel tanks.
Top off the fuel tanks after you operate the engine.

Fuel tanks should contain some provision for draining

water and sediment from the bottom of the tanks.
Some fuel tanks use supply pipes that allow water
and sediment to settle below the end of the fuel
supply pipe.

Some fuel tanks use supply lines that take fuel

directly from the bottom of the tank. If the engine is
equipped with this system, regular maintenance of
the fuel system filter is important.

Drain the water and sediment from any fuel storage

tank at the following intervals: weekly, oil changes,
and refueling of the fuel tank. This will help prevent
water and/or sediment from being pumped from the
fuel storage tank and into the engine fuel tank.

Fuel Filters
It is possible that a primary fuel filter is installed
between the fuel tank and the engine fuel inlet. After
you change the fuel filter, always prime the fuel
system in order to remove air bubbles from the fuel
system. Refer to the Operation and Maintenance
Manual in the Maintenance Section for more
information on priming the fuel system.

The micron rating and the location of a primary fuel

filter is important in cold weather operation. The
primary fuel filter and the fuel supply line are the most
common components that are affected by cold fuel.

Fuel Heaters
Note: The OEM may equip the application with fuel
heaters. If this is the case, disconnect an electric type
of fuel heater in warm weather in order to prevent
overheating of the fuel. If the type of fuel heater is a
heat exchanger, the OEM should have included a
bypass for warm weather. Ensure that the bypass is
operational during warm weather in order to prevent
overheating of the fuel.

For more information about fuel heaters (if equipped),

refer to the OEM information.
SEBU7833-03 37
Maintenance Section
Refill Capacities

Maintenance Section Cooling System

To maintain the cooling system, the Total Cooling
System capacity must be known. The approximate
Refill Capacities capacity for the engine cooling system is listed
below. External System capacities will vary among
applications. Refer to the OEM specifications for the
i02198350 External System capacity. This capacity information
will be needed in order to determine the amount
Refill Capacities of coolant/antifreeze that is required for the Total
Cooling System.

1104 Engine
Lubrication System
Table 7
The refill capacities for the engine crankcase 1104 Naturally Aspirated Engine
reflect the approximate capacity of the crankcase
or sump plus standard oil filters. Auxiliary oil filter Compartment or System Liters Quarts
systems will require additional oil. Refer to the OEM
Engine Only 10.4 11
specifications for the capacity of the auxiliary oil filter.
Refer to the Operation and Maintenance Manual, External cooling system capacity
“Maintenance Section” for more information on (OEM recommendation) (1)
Lubricant Specifications. Total Cooling System (2)

(1) The external cooling system includes a radiator or an

1104 Engine expansion tank with the following components: heat exchanger,
aftercooler, and piping. Refer to the OEM specifications. Enter
Table 5 the value for the external system capacity in this row.
(2) The Total Cooling System includes the capacity for the engine
1104 Engine
cooling system plus the capacity for the external cooling
Compartment or System Liters Quarts system. Enter the total in this row.

Standard Oil Sump for the Engine Table 8

6.5 7
Crankcase (1)
1104 Turbocharged Engine
(1) These values are the approximate capacities for the crankcase
oil sump which include the standard factory installed oil filters. Compartment or System Liters Quarts
Engines with auxiliary oil filters will require additional oil. Refer
to the OEM specifications for the capacity of the auxiliary oil Engine Only 11.4 12
filter.
External cooling System capacity
(OEM recommendation) (1)
1103 Engine
Total Cooling System (2)

Table 6 (1) The external cooling system includes a radiator or an

expansion tank with the following components: heat exchanger,
1103 Engine aftercooler, and piping. Refer to the OEM specifications. Enter
Compartment or System Liters Quarts the value for the external cooling system capacity in this row.
(2) The Total Cooling System includes the capacity for the engine

Standard Oil Sump for the Engine cooling system plus the capacity for the external cooling
6.5 7 system. Enter the total in this row.
Crankcase (1)
(1) These values are the approximate capacities for the crankcase
oil sump which include the standard factory installed oil filters.
Engines with auxiliary oil filters will require additional oil. Refer
to the OEM specifications for the capacity of the auxiliary oil
filter.
38 SEBU7833-03
Maintenance Section
Refill Capacities

1103 Engine API Oils

Table 9 The Engine Oil Licensing and Certification System by
1103 Naturally Aspirated Engine without an oil cooler the American Petroleum Institute (API) is recognized
by Perkins. For detailed information about this
Compartment or System Liters Quarts system, see the latest edition of the “API publication
Engine Only 4.21 4 No. 1509”. Engine oils that bear the API symbol are
authorized by API.
External cooling system capacity
(OEM recommendation) (1)
Total Cooling System (2)
(1) The external cooling system includes a radiator or an
expansion tank with the following components: heat exchanger,
aftercooler, and piping. Refer to the OEM specifications. Enter
the value for the external system capacity in this row.
(2) The Total Cooling System includes the capacity for the engine
cooling system plus the capacity for the external cooling
system. Enter the total in this row.

Table 10
1103 Naturally Aspirated Engines and Turbocharged
Engines with an oil cooler
Compartment or System Liters Quarts g00546535
Illustration 24
Engine Only 4.43 4.02
Typical API symbol
External cooling system capacity
(OEM recommendation) (1) Diesel engine oils CC, CD, CD-2, and CE have
not been API authorized classifications since 1
Total Cooling System (2)
January 1996. Table 11 summarizes the status of the
(1) The external cooling system includes a radiator or an classifications.
expansion tank with the following components: heat exchanger,
aftercooler, and piping. Refer to the OEM specifications. Enter Table 11
the value for the external system capacity in this row.
(2) The Total Cooling System includes the capacity for the engine API Classifications
cooling system plus the capacity for the external cooling
system. Enter the total in this row. Current Obsolete
CF-4, CG-4, CH-4 CE
i02280119 CF CC, CD
Fluid Recommendations CF-2(1) CD-2(1)
(1) The classifications CD-2 and American Petroleum Institute
CF-2 are for two-cycle diesel engines. Perkins does not sell
engines that utilize CD-2 and API CF-2 oils.
General Lubricant Information
Terminology
Because of government regulations regarding the
certification of exhaust emissions from the engine, Certain abbreviations follow the nomenclature of
the lubricant recommendations must be followed. “SAE J754”. Some classifications follow “SAE J183”
abbreviations, and some classifications follow the
Engine Manufacturers Association (EMA) “EMA Recommended Guideline on Diesel Engine
Oil”. In addition to Perkins definitions, there are other
Oils definitions that will be of assistance in purchasing
lubricants. Recommended oil viscosities can be found
The “Engine Manufacturers Association in this publication, “Fluid Recommendations/Engine
Recommended Guideline on Diesel Engine Oil” is Oil” topic (Maintenance Section).
recognized by Perkins. For detailed information
about this guideline, see the latest edition of EMA
publication, “EMA DHD -1”.
SEBU7833-03
Engine Oil
Commercial Oils
The performance of commercial diesel engine
oils is based on American Petroleum Institute
(API) classifications. These API classifications are
developed in order to provide commercial lubricants
for a broad range of diesel engines that operate at
various conditions.
Only use commercial oils that meet the following
classifications:
• EMA DHD-1 multigrade oil (preferred oil)
• API CH-4 multigrade oil (preferred oil)
• ACEAE3
In order to make the correct choice of a commercial
oil, refer to the following explanations:
EMA DHD-1 – The Engine Manufacturers
Association (EMA) has developed lubricant
recommendations as an alternative to the API oil
classification system. DHD-1 is a Recommended
Guideline that defines a level of oil performance for
these types of diesel engines: high speed, four stroke
cycle, heavy-duty, and light duty. DHD-1 oils may
be used in Perkins engines when the following oils
are recommended: API CH-4, API CG-4, and API
CF-4. DHD-1 oils are intended to provide superior
performance in comparison to API CG-4 and API
CF-4.
DHD-1 oils will meet the needs of high performance
Perkins diesel engines that are operating in many
applications. The tests and the test limits that are
used to define DHD-1 are similar to the new API
CH-4 classification. Therefore, these oils will also
meet the requirements for diesel engines that require
low emissions. DHD-1 oils are designed to control the
harmful effects of soot with improved wear resistance
and improved resistance to plugging of the oil filter.
These oils will also provide superior piston deposit
control for engines with either two-piece steel pistons
or aluminum pistons.
All DHD-1 oils must complete a full test program
with the base stock and with the viscosity grade of
the finished commercial oil. The use of “API Base
Oil Interchange Guidelines” are not appropriate for
DHD-1 oils. This feature reduces the variation in
performance that can occur when base stocks are
changed in commercial oil formulations.
39
Maintenance Section
Refill Capacities
DHD-1 oils are recommended for use in extended oil
change interval programs that optimize the life of the
oil. These oil change interval programs are based
on oil analysis. DHD-1 oils are recommended for
conditions that demand a premium oil. Your Perkins
dealer or your Perkins distributor has the specific
guidelines for optimizing oil change intervals.
API CH-4 – API CH-4 oils were developed in order to
meet the requirements of the new high performance
diesel engines. Also, the oil was designed to
meet the requirements of the low emissions diesel
engines. API CH-4 oils are also acceptable for use
in older diesel engines and in diesel engines that
use high sulfur diesel fuel. API CH-4 oils may be
used in Perkins engines that use API CG-4 and API
CF-4 oils. API CH-4 oils will generally exceed the
performance of API CG-4 oils in the following criteria:
deposits on pistons, control of oil consumption, wear
of piston rings, valve train wear, viscosity control,
and corrosion.
Three new engine tests were developed for the API
CH-4 oil. The first test specifically evaluates deposits
on pistons for engines with the two-piece steel piston.
This test (piston deposit) also measures the control
of oil consumption. A second test is conducted
with moderate oil soot. The second test measures
the following criteria: wear of piston rings, wear of
cylinder liners, and resistance to corrosion. A third
new test measures the following characteristics with
high levels of soot in the oil: wear of the valve train,
resistance of the oil in plugging the oil filter, and
control of sludge.
In addition to the new tests, API CH-4 oils have
tougher limits for viscosity control in applications that
generate high soot. The oils also have improved
oxidation resistance. API CH-4 oils must pass an
additional test (piston deposit) for engines that use
aluminum pistons (single piece). Oil performance is
also established for engines that operate in areas
with high sulfur diesel fuel.
All of these improvements allow the API CH-4
oil to achieve optimum oil change intervals. API
CH-4 oils are recommended for use in extended oil
change intervals. API CH-4 oils are recommended
for conditions that demand a premium oil. Your
Perkins dealer or your Perkins distributor has specific
guidelines for optimizing oil change intervals.
Some commercial oils that meet the API
classifications may require reduced oil change
intervals. To determine the oil change interval, closely
monitor the condition of the oil and perform a wear
metal analysis.
40 SEBU7833-03
Maintenance Section
Refill Capacities

Table 12
NOTICE Percentage of Sulfur in Oil change interval
Failure to follow these oil recommendations can cause the fuel
shortened engine service life due to deposits and/or
excessive wear. Lower than 0.5 Normal
0.5 to 1.0 0.75 of normal
Total Base Number (TBN) and Fuel Sulfur Greater than 1.0 0.50 of normal
Levels for Direct Injection (DI) Diesel
Engines Lubricant Viscosity Recommendations
for Direct Injection (DI) Diesel Engines
The Total Base Number (TBN) for an oil depends on
the fuel sulfur level. For direct injection engines that The correct SAE viscosity grade of oil is determined
use distillate fuel, the minimum TBN of the new oil by the minimum ambient temperature during
must be 10 times the fuel sulfur level. The TBN is cold engine start-up, and the maximum ambient
defined by “ASTM D2896”. The minimum TBN of the temperature during engine operation.
oil is 5 regardless of fuel sulfur level. Illustration 25
demonstrates the TBN. Refer to Table 13 (minimum temperature) in order
to determine the required oil viscosity for starting a
cold engine.

Refer to Table 13 (maximum temperature) in order

to select the oil viscosity for engine operation at the
highest ambient temperature that is anticipated.

Generally, use the highest oil viscosity that is

available to meet the requirement for the temperature
at start-up.

Table 13

Engine Oil Viscosity

g00799818 EMA LRG-1 Ambient Temperature

Illustration 25 API CH-4
(Y) TBN by “ASTM D2896” Viscosity Grade Minimum Maximum
(X) Percentage of fuel sulfur by weight
(1) TBN of new oil SAE 0W20 −40 °C (−40 °F) 10 °C (50 °F)
(2) Change the oil when the TBN deteriorates to 50 percent of
the original TBN. SAE 0W30 −40 °C (−40 °F) 30 °C (86 °F)
SAE 0W40 −40 °C (−40 °F) 40 °C (104 °F)
Use the following guidelines for fuel sulfur levels that
exceed 1.5 percent: SAE 5W30 −30 °C (−22 °F) 30 °C (86 °F)
SAE 5W40 −30 °C (−22 °F) 40 °C (104 °F)
• Choose an oil with the highest TBN that meets one
of these classifications: EMA DHD-1 and API CH-4. SAE 10W30 −20 °C (−4 °F) 40 °C (104 °F)
SAE 15W40 −10 °C (14 °F) 50 °C (122 °F)
• Reduce the oil change interval. Base the oil
change interval on the oil analysis. Ensure that the
oil analysis includes the condition of the oil and a Synthetic Base Stock Oil
wear metal analysis.
Synthetic base oils are acceptable for use in
Excessive piston deposits can be produced by an oil these engines if these oils meet the performance
with a high TBN. These deposits can lead to a loss requirements that are specified for the engine.
of control of the oil consumption and to the polishing
of the cylinder bore. Synthetic base oils generally perform better than
conventional oils in the following two areas:
NOTICE
Operating Direct Injection (DI) diesel engines with fuel • Synthetic base oils have improved flow at low
sulphur levels over 0.5 percent will require shortened temperatures especially in arctic conditions.
oil change intervals in order to help maintain adequate
wear protection. • Synthetic base oils have improved oxidation
stability especially at high operating temperatures.
SEBU7833-03
Some synthetic base oils have performance
characteristics that enhance the service life of the
oil. Perkins does not recommend the automatic
extending of the oil change intervals for any type of
oil.
Re-refined base stock oil
Re-refined base stock oil are acceptable for use in
Perkins engines if these oils meet the performance
requirements that are specified by Perkins.Re-refined
base stock oil can be used exclusively in finished oil
or in a combination with new base stock oil . The US
military specifications and the specifications of other
heavy equipment manufacturers also allow the use of
re-refined base stock oil that meet the same criteria.
The process that is used to make re-refined base
stock oil should adequately remove all wear metals
that are in the used oil and all the additives that
are in the used oil. The process that is used to
make re-refined base stock oil generally involves the
process of vacuum distillation and hydrotreating the
used oil. Filtering is adequate for the production of
high quality, re-refined base stock oil.
Lubricants for Cold Weather
When an engine is started and an engine is operated
in ambient temperatures below −20 °C (−4 °F), use
multigrade oils that are capable of flowing in low
temperatures.
These oils have lubricant viscosity grades of SAE
0W or SAE 5W.
When an engine is started and operated in ambient
temperatures below −30 °C (−22 °F), use a synthetic
base stock multigrade oil with an 0W viscosity grade
or with a 5W viscosity grade. Use an oil with a pour
point that is lower than −50 °C (−58 °F).
The number of acceptable lubricants is limited in
cold weather conditions. Perkins recommends the
following lubricants for use in cold weather conditions:
First Choice – Use oil with an EMA DHD-1
Recommended Guideline. Use a CH-4 oil that has
an API license. The oil should be either SAE 0W20,
SAE 0W30, SAE 0W40, SAE 5W30, or SAE 5W40
lubricant viscosity grade.
Second Choice – Use an oil that has a CH-4
additive package. Although the oil has not been
tested for the requirements of the API license, the oil
must be either SAE 0W20, SAE 0W30, SAE 0W40,
SAE 5W30, or SAE 5W40.
41
Maintenance Section
Refill Capacities
NOTICE
Shortened engine service life could result if second
choice oils are used.
Aftermarket Oil Additives
Perkins does not recommend the use of aftermarket
additives in oil. It is not necessary to use aftermarket
additives in order to achieve the engine’s maximum
service life or rated performance. Fully formulated,
finished oils consist of base oils and of commercial
additive packages. These additive packages are
blended into the base oils at precise percentages in
order to help provide finished oils with performance
characteristics that meet industry standards.
There are no industry standard tests that evaluate
the performance or the compatibility of aftermarket
additives in finished oil. Aftermarket additives may
not be compatible with the finished oil’s additive
package, which could lower the performance of the
finished oil. The aftermarket additive could fail to
mix with the finished oil. This could produce sludge
in the crankcase. Perkins discourages the use of
aftermarket additives in finished oils.
To achieve the best performance from a Perkins
engine, conform to the following guidelines:
• Select the correct oil, or a commercial oil that meets
the “EMA Recommended Guideline on Diesel
Engine Oil” or the recommended API classification.
• See the appropriate “Lubricant Viscosities” table in
order to find the correct oil viscosity grade for your
engine.
• At the specified interval, service the engine. Use
new oil and install a new oil filter.
• Perform maintenance at the intervals that are
specified in the Operation and Maintenance
Manual, “Maintenance Interval Schedule”.
S·O·S Oil analysis
Some engines may be equipped with an oil sampling
valve. If S·O·S oil analysis is required the oil sampling
valve is used to obtain samples of the engine oil. The
S·O·S oil analysis will complement the preventive
maintenance program.
The S·O·S oil analysis is a diagnostic tool that is used
to determine oil performance and component wear
rates. Contamination can be identified and measured
through the use of the S·O·S oil analysis. The S·O·S
oil analysis includes the following tests:
42
Maintenance Section
Refill Capacities
• The Wear Rate Analysis monitors the wear of the
engine’s metals. The amount of wear metal and
type of wear metal that is in the oil is analyzed. The
increase in the rate of engine wear metal in the
oil is as important as the quantity of engine wear
metal in the oil.
• Tests are conducted in order to detect
contamination of the oil by water, glycol or fuel.
• The Oil Condition Analysis determines the loss of
the oil’s lubricating properties. An infrared analysis
is used to compare the properties of new oil to the
properties of the used oil sample. This analysis
allows technicians to determine the amount of
deterioration of the oil during use. This analysis
also allows technicians to verify the performance
of the oil according to the specification during the
entire oil change interval.
Fuel Specifications
Fuel Recommendations
To get the correct power and performance from
the engine, use a fuel of the correct quality. The
recommended fuel specification for Perkins engines
is shown below:
• Cetane number___________________________45 minimum
• Viscosity___________ 2,0 to 4.5 cSt at 40 °C (104 °F)
• Density________________________0.835 to 0.855 Kg/liter
• Sulfur_______________________0.2% of mass, maximum
• Distillation___________________85% at 350 °C (662 °F)
• Lubricity______________________________460 micrometers
maximum wear scar on “ISO 12156 - 1”
Cetane number
This indicates the properties of ignition of the fuel.
Fuel with a low cetane number can be the root
cause of problems during cold start. This will affect
combustion.
Viscosity
This is the resistance to flow of a fluid. If this
resistance is outside the limits, the engine and the
engine starting performance in particular can be
affected.
Sulfur
SEBU7833-03
High sulfur content of the fuel is not normally found
in Europe, North America or Australasia. This can
cause engine wear. When only high sulfur fuels
are available, it will be necessary that high alkaline
lubricating oil is used in the engine or that the
lubricating oil change interval is reduced.
Distillation
This is an indication of the mixture of different
hydrocarbons in the fuel. A high ratio of light weight
hydrocarbons can affect the characteristics of
combustion.
Lubricity
This is the capability of the fuel to prevent pump wear.
Diesel engines have the ability to burn a wide variety
of fuels. These fuels are divided into four general
groups:
• Group 1 (preferred fuels)
• Group 2 (permissible fuels)
• Group 3 (aviation kerosene fuels)
• Other fuels
Group 1 (preferred fuels): Specification
“DERV to EN590”
Note: Only use Arctic fuels when the temperature is
below 0 °C (32 °F). Do not use Arctic fuels when the
ambient temperature is above 0 °C (32 °F). To ensure
that the time period between cranking the engine and
first fire is kept to a minimum, only use fuel of the
correct viscosity and at the correct temperature.
Gas oil to “BS2869 Class A2”
“ASTM D975 - 91 Class 2D” This can only be used if
the fuel has the correct specification of lubricity.
“JIS K2204 (1992) Grades 1,2,3 and Special Grade
3” This can only be used if the fuel has the correct
specification of lubricity.
Note: If low sulfur or low sulfur aromatic fuels are
used, then fuel additives can be used to increase
lubricity.
Group 2 (permissible fuels): Specification
These fuel specifications are considered acceptable
for issues of warranty. However,these fuels may
reduce the life of the engine, the engine’s maximum
power and the engine’s fuel efficiency.
SEBU7833-03 43
Maintenance Section
Refill Capacities

“ASTM D975 - 91 Class 1D” The preferred fuels provide maximum engine service
life and performance. The preferred fuels are distillate
“JP7, Mil T38219” fuels. These fuels are commonly called diesel fuel
or gas oil.
“NATO F63”
The permissible fuels are crude oils or blended fuels.
NOTICE Use of these fuels can result in higher maintenance
These fuels should have a wear scar value of 650 costs and in reduced engine service life.
micrometers maximum *HFRR to ISO 12156 - 1.*
Diesel fuels that meet the specifications in Table
14 will help to provide maximum engine service life
Group 3 (aviation kerosene fuels): Specification and performance. In North America, diesel fuel that
is identified as No. 2-D in “ASTM D975” generally
These fuels need additives to achieve lubricity of 650 meets the specifications. Table 14 is for diesel fuels
micrometers wear scar and the reliability of the fuel that are distilled from crude oil. Diesel fuels from
injection pump will be reduced. The fuel injection other sources could exhibit detrimental properties
pump is not covered by a warranty, even when the that are not defined or controlled by this specification.
additives are included.
Table 14
“JP5 MIL T5624 (Avcat FSII, NATO F44”
Perkins Specifications for Distillate Diesel Fuel
“JP8 T83133 (Avtur FSII, NATO F34” Specifications Requirements ASTM Test
Aromatics 35% maximum “D1319”
“Jet A”
0.02% maximum
Ash “D482”
“Jet A1, NATO F35, XF63” (weight)
Carbon Residue 0.35% maximum
Low temperature fuels on 10% Bottoms (weight)
“D524”

Special fuels for use in cold weather may be available 40 minimum (DI
Cetane Number engines) “D613”
for engine operation at temperatures below 0 °C
(32 °F). These fuels limit the formation of wax in the
fuel oil at low temperatures. If wax forms in the fuel The cloud
point must not
oil, this could stop the flow of fuel oil through the filter.
exceed the -
Cloud Point
lowest expected
Note: These fuels that lack lubricity may cause the ambient
following problems: temperature.
(continued)
• Low engine power
• Difficult starting in hot conditions or in cold
conditions

• White smoke
• Deterioration of emissions and misfire at certain
operating conditions

Biofuel: Specification

Biofuel: A 5% mix of RME to EN14214 in conventional

fuel is permitted.

NOTICE
Water emulsion fuels: These fuels are not permitted

Refer to the following fuel specifications for

North America.
44 SEBU7833-03
Maintenance Section
Refill Capacities

(Table 14, contd)

Copper Strip No. 3 maximum NOTICE
“D130” Operating with fuels that do not meet the Perkins rec-
Corrosion
ommendations can cause the following effects: Start-
10% at 282 °C
ing difficulty, poor combustion, deposits in the fuel in-
(540 °F)
maximum jectors, reduced service life of the fuel system, de-
Distillation “D86” posits in the combustion chamber, and reduced ser-
90% at 360 °C vice life of the engine.
(680 °F)
maximum
Flash Point legal limit “D93” NOTICE
Heavy Fuel Oil (HFO), Residual fuel, or Blended fuel
30 minimum must NOT be used in Perkins diesel engines. Severe
API Gravity “D287” component wear and component failures will result if
45 maximum
HFO type fuels are used in engines that are configured
6 °C (10 °F) to use distillate fuel.
minimum
Pour Point “D97”
below ambient
temperature In extreme cold ambient conditions, you may use the
distillate fuels that are specified in Table 15. However,
0.2% maximum “D3605” the fuel that is selected must meet the requirements
Sulfur (1) or that are specified in Table 14. These fuels are
“D1552”
intended to be used in operating temperatures that
2.0 cSt minimum are down to −54 °C (−65 °F).
Kinematic and 4.5 cSt
“D445”
Viscosity (2) maximum at Table 15
40 °C (104 °F)
Distillate Fuels (1)

Water and 0.1% maximum

“D1796”
Sediment
Water 0.1% maximum “D1744”
0.05% maximum
Sediment “D473”
(weight)
Gum and Resins 10 mg per 100
“D381”
(3) mL maximum
0.38 mm
(0.015 inch)
Lubricity (4) “D6079”
maximum at
25 °C (77 °F)
(1) Perkins fuel systems and engine components can operate
on high sulfur fuels. Fuel sulfur levels affect exhaust
emissions. High sulfur fuels also increase the potential
for corrosion of internal components. Fuel sulfur levels
above 0.5 percent may significantly shorten the oil change
interval. For additional information, see this publication, “Fluid
Recommendations/Engine Oil” topic (Maintenance Section).
(2) The values of the fuel viscosity are the values as the fuel
is delivered to the fuel injection pumps. If a fuel with a low
viscosity is used, cooling of the fuel may be required to maintain
a 1.4 cSt viscosity at the fuel injection pump. Fuels with a high
viscosity might require fuel heaters in order to bring down the
viscosity to a 20 cSt viscosity.
(3) Follow the test conditions and procedures for gasoline (motor).
(4) The lubricity of a fuel is a concern with low sulfur fuel. To
determine the lubricity of the fuel, use either the “ASTM D6078
Scuffing Load Wear Test (SBOCLE)” or the “ASTM D6079 High
Frequency Reciprocating Rig (HFRR)” test. If the lubricity of a
fuel does not meet the minimum requirements, consult your
fuel supplier. Do not treat the fuel without consulting the fuel
supplier. Some additives are not compatible. These additives
can cause problems in the fuel system.
Specification Grade
“MIL-T-5624R” JP-5
“ASTM D1655” Jet-A-1
“MIL-T-83133D” JP-8
(1) The fuels that are listed in this Table may not meet the
requirements that are specified in the “Perkins Specifications
for Distillate Diesel Fuel” Table. Consult the supplier for the
recommended additives in order to maintain the correct fuel
lubricity.
These fuels are lighter than the No. 2 grades of fuel.
The cetane number of the fuels in Table 15 must be
at least 40. If the viscosity is below 1.4 cSt at 38 °C
(100 °F), use the fuel only in temperatures below
0 °C (32 °F). Do not use any fuels with a viscosity
of less than 1.2 cSt at 38 °C (100 °F). Fuel cooling
may be required in order to maintain the minimum
viscosity of 1.4 cSt at the fuel injection pump.
There are many other diesel fuel specifications that
are published by governments and by technological
societies. Usually, those specifications do not
review all the requirements that are addressed
in this specification. To ensure optimum engine
performance, a complete fuel analysis should be
obtained before engine operation. The fuel analysis
should include all of the properties that are listed in
Table 14.
SEBU7833-03 45
Maintenance Section
Refill Capacities

Cooling System Specifications DO NOT use the following types of water in cooling
systems: Hard water, softened water that has been
General Coolant Information conditioned with salt, and sea water.

If distilled water or deionized water is not available,

NOTICE
use water with the properties that are listed in Table
Never add coolant to an overheated engine. Engine
16.
damage could result. Allow the engine to cool first.
Table 16

NOTICE Perkins Minimum Acceptable Water Requirements

If the engine is to be stored in, or shipped to an area Property Maximum Limit
with below freezing temperatures, the cooling system
must be either protected to the lowest outside temper- Chloride (Cl) 40 mg/L
ature or drained completely to prevent damage. Sulfate (SO4) 100 mg/L
Total Hardness 170 mg/L
NOTICE
Total Solids 340 mg/L
Frequently check the specific gravity of the coolant for
proper freeze protection or for anti-boil protection. Acidity pH of 5.5 to 9.0

Clean the cooling system for the following reasons: For a water analysis, consult one of the following
sources:
• Contamination of the cooling system
• Local water utility company
• Overheating of the engine
• Agricultural agent
• Foaming of the coolant
• Independent laboratory
NOTICE
Never operate an engine without water temperature Additives
regulators in the cooling system. Water temperature
regulators help to maintain the engine coolant at the Additives help to protect the metal surfaces of
proper operating temperature. Cooling system prob- the cooling system. A lack of coolant additives or
lems can develop without water temperature regula- insufficient amounts of additives enable the following
tors. conditions to occur:

Many engine failures are related to the cooling

system. The following problems are related to cooling
system failures: Overheating, leakage of the water
pump, and plugged radiators or heat exchangers.
These failures can be avoided with correct cooling
system maintenance. Cooling system maintenance is
as important as maintenance of the fuel system and
the lubrication system. Quality of the coolant is as
important as the quality of the fuel and the lubricating
oil.
Coolant is normally composed of three elements:
Water, additives, and glycol.
Water
• Corrosion
• Formation of mineral deposits
• Rust
• Scale
• Foaming of the coolant
Many additives are depleted during engine operation.
These additives must be replaced periodically.
Additives must be added at the correct concentration.
Overconcentration of additives can cause the
inhibitors to drop out-of-solution. The deposits can
enable the following problems to occur:

Water is used in the cooling system in order to • Formation of gel compounds

transfer heat.
Distilled water or deionized water is
recommended for use in engine cooling systems.
• Reduction of heat transfer
• Leakage of the water pump seal
• Plugging of radiators, coolers, and small passages
46 SEBU7833-03
Maintenance Section
Refill Capacities

Glycol Acceptable – A commercial heavy-duty

Glycol in the coolant helps to provide protection
against the following conditions:
• Boiling
• Freezing
• Cavitation of the water pump
For optimum performance, Perkins recommends a
1:1 mixture of a water/glycol solution.
Note: Use a mixture that will provide protection
against the lowest ambient temperature.
coolant/antifreeze that meets “ASTM D4985”
specifications
NOTICE
Do not use a commercial coolant/antifreeze that on-
ly meets the ASTM D3306 specification. This type of
coolant/antifreeze is made for light automotive appli-
cations.
Perkins recommends a 1:1 mixture of water
and glycol. This mixture of water and glycol will
provide optimum heavy-duty performance as a
coolant/antifreeze. This ratio may be increased to 1:2
water to glycol if extra freezing protection is required.

Note: 100 percent pure glycol will freeze at a Note: A commercial heavy-duty coolant/antifreeze
temperature of −23 °C (−9 °F). that meets “ASTM D4985” specifications MAY require
a treatment with an SCA at the initial fill. Read the
Most conventional coolant/antifreezes use ethylene label or the instructions that are provided by the OEM
glycol. Propylene glycol may also be used. In a 1:1 of the product.
mixture with water, ethylene and propylene glycol
provide similar protection against freezing and In stationary engine applications and marine engine
boiling. See Tables 17 and 18. applications that do not require anti-boil protection
or freeze protection, a mixture of SCA and water
Table 17 is acceptable. Perkins recommends a six percent
Ethylene Glycol to eight percent concentration of SCA in those
cooling systems. Distilled water or deionized water
Freeze Boil is preferred. Water which has the recommended
Concentration
Protection Protection properties may be used.
50 Percent −36 °C (−33 °F) 106 °C (223 °F)
Engines that are operating in an ambient temperature
60 Percent −51 °C (−60 °F) 111 °C (232 °F) above 43 °C (109.4 °F) must use SCA and water.
Engines that operate in an ambient temperature
above 43 °C (109.4 °F) and below 0 °C (32 °F) due
NOTICE
to seasonal variations consult your Perkins dealer
Do not use propylene glycol in concentrations that ex-
or your Perkins distributor for the correct level of
ceed 50 percent glycol because of propylene glycol’s
protection.
reduced heat transfer capability. Use ethylene glycol
in conditions that require additional protection against Table 19
boiling or freezing.
Coolant Service Life

Table 18 Coolant Type Service Life

Propylene Glycol 12,000 Service Hours
Perkins ELC
or Six Years
Freeze Anti-Boil
Concentration Commercial Heavy-Duty
Protection Protection 3000 Service Hours or
Coolant/Antifreeze that
50 Percent −29 °C (−20 °F) 106 °C (223 °F) Two Years
meets “ASTM D4985”
Perkins POWERPART 3000 Service Hours or
To check the concentration of glycol in the coolant, SCA Two Years
measure the specific gravity of the coolant.
Commercial SCA and 3000 Service Hours or
Water Two Years
Coolant Recommendations
The following two coolants are used in Perkins diesel Extended Life Coolant (ELC)
engines:
Perkins provides Extended Life Coolant (ELC) for
Preferred – Perkins Extended Life Coolant (ELC) use in the following applications:

• Heavy-duty spark ignited gas engines

SEBU7833-03 47
Maintenance Section
Refill Capacities

• Heavy-duty diesel engines

• Automotive applications
The anti-corrosion package for ELC is different from
the anti-corrosion package for other coolants. ELC
is an ethylene glycol base coolant. However, ELC
contains organic corrosion inhibitors and antifoam
agents with low amounts of nitrite. Perkins ELC
has been formulated with the correct amount of
these additives in order to provide superior corrosion
protection for all metals in engine cooling systems.
ELC extends the service life of the coolant to 12000
service hours or six years. ELC does not require
a frequent addition of a Supplemental Coolant
Additive (SCA). An Extender is the only additional
maintenance that is needed at 6000 service hours or
one half of the ELC service life.
ELC is available in a 1:1 premixed cooling solution
with distilled water. The Premixed ELC provides
freeze protection to −36 °C (−33 °F). The Premixed
ELC is recommended for the initial fill of the cooling
system. The Premixed ELC is also recommended for
topping off the cooling system.
ELC Concentrate is also available. ELC Concentrate
can be used to lower the freezing point to −51 °C
(−60 °F) for arctic conditions.
NOTICE
Do not use a conventional coolant to top-off a cooling
system that is filled with Extended Life Coolant (ELC).
Do not use standard supplemental coolant additive
(SCA). Only use ELC Extender in cooling systems that
are filled with ELC.
Perkins ELC Extender
ELC Extender is added to the cooling system halfway
through the ELC service life. Treat the cooling system
with ELC Extender at 6000 hours or three years. Use
Table 20 in order to determine the correct amount of
ELC Extender that is required.
Containers of several sizes are available. Consult
your Perkins dealer or your Perkins distributor for the
part numbers.
Use the formula in Table 20 to determine the correct
amount of ELC Extender for your cooling system.
Refer to Operation and Maintenance Manual, “Refill
Capacities” in order to determine the capacity of the
cooling system.
Table 20
Formula For Adding ELC Extender To ELC

Containers of several sizes are available. Consult V × 0.02 = X

your Perkins dealer or your Perkins distributor for the V is the total capacity of the cooling system.
part numbers.
X is the amount of ELC Extender that is required.

ELC Cooling System Maintenance Table 21 is an example for using the formula that is
in Table 20.
Correct additions to the Extended Life
Coolant Table 21
Example Of The Equation For Adding ELC
NOTICE Extender To ELC
Use only Perkins products for pre-mixed or concen-
Total Volume Multiplication Amount of ELC
trated coolants. of the Cooling Factor Extender that is
System (V) Required (X)
Use only Perkins Extender with Extended Life
Coolant. 0.18 L
9 L (2.4 US gal) × 0.02 (0.05 US gal)
Mixing Extended Life Coolant with other products re- or (6 fl oz)
duces the Extended Life Coolant service life. Failure to
follow the recommendations can reduce cooling sys- NOTICE
tem components life unless appropriate corrective ac- When using Perkins ELC, do not use standard SCA’s
tion is performed. or SCA filters.

In order to maintain the correct balance between

the antifreeze and the additives, you must maintain
the recommended concentration of Extended Life
Coolant (ELC). Lowering the proportion of antifreeze
lowers the proportion of additive. This will lower the
ability of the coolant to protect the system from pitting,
from cavitation, from erosion, and from deposits.
48
Maintenance Section
Refill Capacities
ELC Cooling System Cleaning
Note: If the cooling system is already using ELC,
cleaning agents are not required to be used at
the specified coolant change interval. Cleaning
agents are only required if the system has been
contaminated by the addition of some other type of
coolant or by cooling system damage.
Clean water is the only cleaning agent that is required
when ELC is drained from the cooling system.
After the cooling system is drained and after the
cooling system is refilled, operate the engine while
the cooling system filler cap is removed. Operate
the engine until the coolant level reaches the normal
operating temperature and until the coolant level
stabilizes. As needed, add the coolant mixture in
order to fill the system to the specified level.
Changing to Perkins ELC
To change from heavy-duty coolant/antifreeze to the
Perkins ELC, perform the following steps:
NOTICE
Care must be taken to ensure that all fluids are
contained during performance of inspection, main-
tenance, testing, adjusting and the repair of the
product. Be prepared to collect the fluid with suitable
containers before opening any compartment or dis-
assembling any component containing fluids.
Dispose of all fluids according to local regulations and
mandates.
1. Drain the coolant into a suitable container.
2. Dispose of the coolant according to local
regulations.
3. Flush the system with clean water in order to
remove any debris.
4. Use Perkins cleaner to clean the system. Follow
the instruction on the label.
5. Drain the cleaner into a suitable container. Flush
the cooling system with clean water.
6. Fill the cooling system with clean water and
operate the engine until the engine is warmed to
49° to 66°C (120° to 150°F).
SEBU7833-03
NOTICE
Incorrect or incomplete flushing of the cooling system
can result in damage to copper and other metal com-
ponents.
To avoid damage to the cooling system, make sure to
completely flush the cooling system with clear water.
Continue to flush the system until all the signs of the
cleaning agent are gone.
7. Drain the cooling system into a suitable container
and flush the cooling system with clean water.
Note: The cooling system cleaner must be thoroughly
flushed from the cooling system. Cooling system
cleaner that is left in the system will contaminate the
coolant. The cleaner may also corrode the cooling
system.
8. Repeat Steps 6 and 7 until the system is
completely clean.
9. Fill the cooling system with the Perkins Premixed
ELC.
ELC Cooling System Contamination
NOTICE
Mixing ELC with other products reduces the effective-
ness of the ELC and shortens the ELC service life.
Use only Perkins Products for premixed or concen-
trate coolants. Use only Perkins ELC extender with
Perkins ELC. Failure to follow these recommenda-
tions can result in shortened cooling system compo-
nent life.
ELC cooling systems can withstand contamination to
a maximum of ten percent of conventional heavy-duty
coolant/antifreeze or SCA. If the contamination
exceeds ten percent of the total system capacity,
perform ONE of the following procedures:
• Drain the cooling system into a suitable container.
Dispose of the coolant according to local
regulations. Flush the system with clean water. Fill
the system with the Perkins ELC.
• Drain a portion of the cooling system into a suitable
container according to local regulations. Then, fill
the cooling system with premixed ELC. This should
lower the contamination to less than 10 percent.
• Maintain the system as a conventional Heavy-Duty
Coolant. Treat the system with an SCA. Change
the coolant at the interval that is recommended for
the conventional Heavy-Duty Coolant.
SEBU7833-03 49
Maintenance Section
Refill Capacities

Commercial Heavy-Duty Coolant/ Table 24 is an example for using the equation that
Antifreeze and SCA is in Table 23.

Table 24
NOTICE
Commercial Heavy-Duty Coolant which contains Example Of The Equation For Adding The SCA To
Amine as part of the corrision protection system must The Heavy-Duty Coolant At The Initial Fill
not be used. Total Volume Multiplication Amount of SCA
of the Cooling Factor that is Required
System (V) (X)
NOTICE
Never operate an engine without water temperature 15 L (4 US gal) × 0.045 0.7 L (24 oz)
regulators in the cooling system. Water temperature
regulators help to maintain the engine coolant at the
correct operating temperature. Cooling system prob-
Adding The SCA to The Heavy-Duty
lems can develop without water temperature regula- Coolant For Maintenance
tors.
Heavy-duty coolant/antifreeze of all types REQUIRE
periodic additions of an SCA.
Check the coolant/antifreeze (glycol concentration)
in order to ensure adequate protection against Test the coolant/antifreeze periodically for the
boiling or freezing. Perkins recommends the use of a concentration of SCA. For the interval, refer to the
refractometer for checking the glycol concentration. Operation and Maintenance Manual, “Maintenance
Interval Schedule” (Maintenance Section). Test the
Perkins engine cooling systems should be tested concentration of SCA.
at 500 hour intervals for the concentration of
Supplemental Coolant Additive (SCA). Additions of SCA are based on the results of the
test. The size of the cooling system determines the
Additions of SCA are based on the results of the test. amount of SCA that is needed.
An SCA that is liquid may be needed at 500 hour
intervals. Use the equation that is in Table 25 to determine the
amount of Perkins SCA that is required, if necessary:
Refer to Table 22 for part numbers and for quantities
of SCA. Table 25

Table 22 Equation For Adding The SCA To The Heavy-Duty

Coolant For Maintenance
Perkins Liquid SCA
V × 0.014 = X
Part Number Quantity
V is the total volume of the cooling system.
21825735
X is the amount of SCA that is required.

Adding the SCA to Heavy-Duty Coolant Table 26 is an example for using the equation that
at the Initial Fill is in Table 25.
Commercial heavy-duty coolant/antifreeze that Table 26
meets “ASTM D4985” specifications MAY require
Example Of The Equation For Adding The SCA To
an addition of SCA at the initial fill. Read the label The Heavy-Duty Coolant For Maintenance
or the instructions that are provided by the OEM of
the product. Total Volume Multiplication Amount of SCA
of the Cooling Factor that is Required
Use the equation that is in Table 23 to determine the System (V) (X)
amount of Perkins SCA that is required when the 15 L (4 US gal) × 0.014 0.2 L (7 oz)
cooling system is initially filled.

Table 23
Equation For Adding The SCA To The Heavy-Duty
Coolant At The Initial Fill
V × 0.045 = X
V is the total volume of the cooling system.
X is the amount of SCA that is required.
50 SEBU7833-03
Maintenance Section
Refill Capacities

Cleaning the System of Heavy-Duty

Coolant/Antifreeze
Perkins cooling system cleaners are designed
to clean the cooling system of harmful scale
and corrosion. Perkins cooling system cleaners
dissolve mineral scale, corrosion products, light oil
contamination and sludge.

• Clean the cooling system after used coolant is

drained or before the cooling system is filled with
new coolant.

• Clean the cooling system whenever the coolant is

contaminated or whenever the coolant is foaming.
SEBU7833-03 51
Maintenance Section
Maintenance Interval Schedule

i03302982 Every 2 Years

Maintenance Interval Schedule Cooling System Coolant - Change ....................... 58

Every 3000 Service Hours

When Required Fuel Injector - Test/Change ................................... 68

Battery - Replace .................................................. 54 Every 3000 Service Hours or 2 Years

Battery or Battery Cable - Disconnect .................. 55
Engine - Clean ...................................................... 60 Cooling System Coolant (Commercial Heavy-Duty) -
Engine Air Cleaner Element (Dual Element) - Change ............................................................... 55
Clean/Replace .................................................... 61
Engine Air Cleaner Element (Single Element) - Every 4000 Service Hours
Inspect/Replace .................................................. 63
Engine Oil Sample - Obtain .................................. 64 Aftercooler Core - Clean/Test ............................... 52
Fuel Injector - Test/Change ................................... 68
Fuel System - Prime ............................................. 69 Every 6000 Service Hours or 3 Years
Severe Service Application - Check ..................... 75
Cooling System Coolant Extender (ELC) - Add .... 59
Daily Every 12 000 Service Hours or 6 Years
Alternator and Fan Belts - Inspect/Adjust/
Cooling System Coolant (ELC) - Change ............. 57
Replace ............................................................... 53
Cooling System Coolant Level - Check ................ 59
Driven Equipment - Check .................................... 60
Engine Air Cleaner Service Indicator - Inspect ..... 63
Engine Oil Level - Check ...................................... 64
Fuel System Primary Filter/Water Separator -
Drain ................................................................... 70
Walk-Around Inspection ........................................ 77

Every 50 Service Hours or Weekly

Fuel Tank Water and Sediment - Drain ................. 73

Every 500 Service Hours or 1 Year

Battery Electrolyte Level - Check .......................... 54
Engine Air Cleaner Element (Dual Element) -
Clean/Replace .................................................... 61
Engine Air Cleaner Element (Single Element) -
Inspect/Replace .................................................. 63
Engine Ground - Inspect/Clean ............................ 64
Engine Oil and Filter - Change ............................. 65
Fuel System Primary Filter (Water Separator)
Element - Replace .............................................. 70
Fuel System Secondary Filter - Replace .............. 71
Hoses and Clamps - Inspect/Replace .................. 74
Radiator - Clean .................................................... 75

Every 1000 Service Hours

Engine Valve Lash - Inspect/Adjust ...................... 67

Every 2000 Service Hours

Aftercooler Core - Inspect ..................................... 52
Alternator - Inspect ............................................... 53
Engine Mounts - Inspect ....................................... 64
Starting Motor - Inspect ........................................ 76
Turbocharger - Inspect .......................................... 76
Water Pump - Inspect ........................................... 78
52
Maintenance Section
Aftercooler Core - Clean/Test
i02322260
Aftercooler Core - Clean/Test
1. Remove the core. Refer to the OEM information
for the correct procedure.
2. Turn the aftercooler core upside-down in order to
remove debris.
Personal injury can result from air pressure.
Personal injury can result without following prop-
er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing.
Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.
3. Pressurized air is the preferred method for
removing loose debris. Direct the air in the
opposite direction of the fan’s air flow. Hold the
nozzle approximately 6 mm (.25 inch) away from
the fins. Slowly move the air nozzle in a direction
that is parallel with the tubes. This will remove
debris that is between the tubes.
4. Pressurized water may also be used for cleaning.
The maximum water pressure for cleaning
purposes must be less than 275 kPa (40 psi). Use
pressurized water in order to soften mud. Clean
the core from both sides.
NOTICE
Do not use a high concentration of caustic cleaner to
clean the core. A high concentration of caustic cleaner
can attack the internal metals of the core and cause
leakage. Only use the recommended concentration of
cleaner.
5. Back flush the core with a suitable cleaner.
6. Steam clean the core in order to remove any
residue. Flush the fins of the aftercooler core.
Remove any other trapped debris.
7. Wash the core with hot, soapy water. Rinse the
core thoroughly with clean water.
SEBU7833-03
Personal injury can result from air pressure.
Personal injury can result without following prop-
er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing.
Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.
8. Dry the core with compressed air. Direct the air in
the reverse direction of the normal flow.
9. Inspect the core in order to ensure cleanliness.
Pressure test the core. If necessary, repair the
core.
10. Install the core. Refer to the OEM information for
the correct procedure.
11. After cleaning, start the engine and accelerate
the engine to high idle rpm. This will help in the
removal of debris and drying of the core. Stop the
engine. Use a light bulb behind the core in order
to inspect the core for cleanliness. Repeat the
cleaning, if necessary.
i02322295
Aftercooler Core - Inspect
Note: Adjust the frequency of cleaning according to
the effects of the operating environment.
Inspect the aftercooler for these items: damaged fins,
corrosion, dirt, grease, insects, leaves, oil, and other
debris. Clean the aftercooler, if necessary.
For air-to-air aftercoolers, use the same methods that
are used for cleaning radiators.
Personal injury can result from air pressure.
Personal injury can result without following prop-
er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing.
Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.
SEBU7833-03 53
Maintenance Section
Alternator - Inspect

After cleaning, start the engine and accelerate the
engine to high idle rpm. This will help in the removal
of debris and drying of the core. Stop the engine.
Use a light bulb behind the core in order to inspect
the core for cleanliness. Repeat the cleaning, if
necessary.
For applications that require multiple drive belts,
replace the belts in matched sets. Replacing only
one belt of a matched set will cause the new belt to
carry more load because the older belt is stretched.
The additional load on the new belt could cause the
new belt to break.

Inspect the fins for damage. Bent fins may be opened If the belts are too loose, vibration causes
with a “comb”. unnecessary wear on the belts and pulleys. Loose
belts may slip enough to cause overheating.
Note: If parts of the aftercooler system are repaired
or replaced, a leak test is highly recommended. To accurately check the belt tension, a suitable gauge
should be used.
Inspect these items for good condition: Welds,
mounting brackets, air lines, connections, clamps,
and seals. Make repairs, if necessary.

i02322311

Alternator - Inspect

Perkins recommends a scheduled inspection of

the alternator. Inspect the alternator for loose
connections and correct battery charging. Check the
ammeter (if equipped) during engine operation in
order to ensure correct battery performance and/or Illustration 26
g01003936
correct performance of the electrical system. Make
Typical example
repairs, as required.
(1) Burroughs Gauge
Check the alternator and the battery charger for
correct operation. If the batteries are correctly Fit the gauge (1) at the center of the longest free
charged, the ammeter reading should be very near length and check the tension. The correct tension
zero. All batteries should be kept charged. The is 535 N (120 lb). If the tension of the belt is below
batteries should be kept warm because temperature 250 N (56 lb) adjust the belt to 535 N (120 lb).
affects the cranking power. If the battery is too cold,
the battery will not crank the engine. When the If twin belts are installed, check and adjust the
engine is not run for long periods of time or if the tension on both belts.
engine is run for short periods, the batteries may not
fully charge. A battery with a low charge will freeze Adjustment
more easily than a battery with a full charge.

i01929797

Alternator and Fan Belts -

Inspect/Adjust/Replace

Inspection
To maximize the engine performance, inspect the
belts for wear and for cracking. Replace belts that are
worn or damaged. g01003939
Illustration 27

1. Loosen The alternator pivot bolt (2) and the bolt

(3).
54
Maintenance Section
Battery - Replace
2. Move the alternator in order to increase or
decrease the belt tension. Tighten the alternator
pivot bolt and the link bolt to 22 N·m (16 lb ft).(1).
Replacement
Refer to the Disassembly and Assembly Manual for
the installation procedure and the removal procedure
for the belt.
i02322315
Battery - Replace
Batteries give off combustible gases which can
explode. A spark can cause the combustible gas-
es to ignite. This can result in severe personal in-
jury or death.
Ensure proper ventilation for batteries that are in
an enclosure. Follow the proper procedures in or-
der to help prevent electrical arcs and/or sparks
near batteries. Do not smoke when batteries are
serviced.
The battery cables or the batteries should not be
removed with the battery cover in place. The bat-
tery cover should be removed before any servic-
ing is attempted.
Removing the battery cables or the batteries with
the cover in place may cause a battery explosion
resulting in personal injury.
1. Switch the engine to the OFF position. Remove
all electrical loads.
2. Turn off any battery chargers. Disconnect any
battery chargers.
3. The NEGATIVE “-” cable connects the NEGATIVE
“-” battery terminal to the NEGATIVE “-” terminal
on the starting motor. Disconnect the cable from
the NEGATIVE “-” battery terminal.
4. The POSITIVE “+” cable connects the POSITIVE
“+” battery terminal to the POSITIVE “+” terminal
on the starting motor. Disconnect the cable from
the POSITIVE “+” battery terminal.
Note: Always recycle a battery. Never discard a
battery. Dispose of used batteries to an appropriate
recycling facility.
SEBU7833-03
5. Remove the used battery.
6. Install the new battery.
Note: Before the cables are connected, ensure that
the engine start switch is OFF.
7. Connect the cable from the starting motor to the
POSITIVE “+” battery terminal.
8. Connect the NEGATIVE “-” cable to the NEGATIVE
“-” battery terminal.
i02747977
Battery Electrolyte Level -
Check
When the engine is not run for long periods of time or
when the engine is run for short periods, the batteries
may not fully recharge. Ensure a full charge in order
to help prevent the battery from freezing. If batteries
are correctly charged, the ammeter reading should
be very near zero, when the engine is in operation.
All lead-acid batteries contain sulfuric acid which
can burn the skin and clothing. Always wear a face
shield and protective clothing when working on or
near batteries.
1. Remove the filler caps. Maintain the electrolyte
level to the “FULL” mark on the battery.
If the addition of water is necessary, use distilled
water. If distilled water is not available use clean
water that is low in minerals. Do not use artificially
softened water.
2. Check the condition of the electrolyte with a
suitable battery tester.
3. Install the caps.
4. Keep the batteries clean.
Clean the battery case with one of the following
cleaning solutions:
• Use a solution of 0.1 kg (0.2 lb) baking soda
and 1 L (1 qt) of clean water.
• Use a solution of ammonium hydroxide.
Thoroughly rinse the battery case with clean water.
SEBU7833-03
i02323088
Battery or Battery Cable -
Disconnect
The battery cables or the batteries should not be
removed with the battery cover in place. The bat-
tery cover should be removed before any servic-
ing is attempted.
Removing the battery cables or the batteries with
the cover in place may cause a battery explosion
resulting in personal injury.
1. Turn the start switch to the OFF position. Turn the
ignition switch (if equipped) to the OFF position
and remove the key and all electrical loads.
2. Disconnect the negative battery terminal. Ensure
that the cable cannot contact the terminal. When
four 12 volt batteries are involved, two negative
connection must be disconnected.
3. Remove the positive connection.
4. Clean all disconnected connection and battery
terminals.
5. Use a fine grade of sandpaper to clean the
terminals and the cable clamps. Clean the items
until the surfaces are bright or shiny. DO NOT
remove material excessively. Excessive removal
of material can cause the clamps to not fit
correctly. Coat the clamps and the terminals with
a suitable silicone lubricant or petroleum jelly.
6. Tape the cable connections in order to help
prevent accidental starting.
7. Proceed with necessary system repairs.
8. In order to connect the battery, connect the
positive connection before the negative connector.
55
Maintenance Section
Battery or Battery Cable - Disconnect
i02203590
Cooling System Coolant
(Commercial Heavy-Duty) -
Change
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Dispose of all fluids according to Local regulations and
mandates.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Clean the cooling system and flush the cooling
system before the recommended maintenance
interval if the following conditions exist:
• The engine overheats frequently.
• Foaming is observed.
• The oil has entered the cooling system and the
coolant is contaminated.
• The fuel has entered the cooling system and the
coolant is contaminated.
Note: When the cooling system is cleaned, only
clean water is needed.
Note: Inspect the water pump and the water
temperature regulator after the cooling system has
been drained. This is a good opportunity to replace
the water pump, the water temperature regulator and
the hoses, if necessary.
Drain
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
sure.
56
Maintenance Section
Cooling System Coolant (Commercial Heavy-Duty) - Change
1. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system filler cap.
g01003928
Illustration 28
2. Open the drain cock or remove the drain plug (1)
on the engine. Open the drain cock or remove the
drain plug on the radiator.
Allow the coolant to drain.
NOTICE
Dispose of used engine coolant or recycle. Various
methods have been proposed to reclaim used coolant
for reuse in engine cooling systems. The full distillation
procedure is the only method acceptable by Perkins to
reclaim the coolant.
For information regarding the disposal and the
recycling of used coolant, consult your Perkins dealer
or your Perkins distributor.
Flush
1. Flush the cooling system with clean water in order
to remove any debris.
2. Close the drain cock or install the drain plug in the
engine. Close the drain cock or install the drain
plug on the radiator.
NOTICE
Do not fill the cooling system faster than 5 L
(1.3 US gal) per minute to avoid air locks.
Cooling system air locks may result in engine damage.
3. Fill the cooling system with clean water. Install the
cooling system filler cap.
4. Start and run the engine at low idle until the
temperature reaches 49 to 66 °C (120 to 150 °F).
SEBU7833-03
5. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system filler cap. Open the drain cock or remove
the drain plug on the engine. Open the drain cock
or remove the drain plug on the radiator. Allow
the water to drain. Flush the cooling system with
clean water.
Fill
1. Close the drain cock or install the drain plug on the
engine. Close the drain cock or install the drain
plug on the radiator.
NOTICE
Do not fill the cooling system faster than 5 L
(1.3 US gal) per minute to avoid air locks.
Cooling system air locks may result in engine damage.
2. Fill the cooling system with Commercial
Heavy-Duty Coolant. Add Supplemental Coolant
Additive to the coolant. For the correct amount,
refer to the Operation and Maintenance Manual,
“Fluid Recommendations” topic (Maintenance
Section) for more information on cooling system
specifications. Do not install the cooling system
filler cap.
3. Start and run the engine at low idle. Increase the
engine rpm to high idle. Run the engine at high
idle for one minute in order to purge the air from
the cavities of the engine block. Stop the engine.
4. Check the coolant level. Maintain the coolant level
within 13 mm (0.5 inch) below the bottom of the
pipe for filling. Maintain the coolant level in the
expansion bottle (if equipped) at the correct level.
5. Clean the cooling system filler cap. Inspect the
gasket that is on the cooling system filler cap. If
the gasket that is on the cooling system filler cap
is damaged, discard the old cooling system filler
cap and install a new cooling system filler cap. If
the gasket that is on the cooling system filler cap
is not damaged, use a suitable pressurizing pump
in order to pressure test the cooling system filler
cap. The correct pressure for the cooling system
filler cap is stamped on the face of the cooling
system filler cap. If the cooling system filler cap
does not retain the correct pressure, install a new
cooling system filler cap.
6. Start the engine. Inspect the cooling system for
leaks and for correct operating temperature.
SEBU7833-03
i02203595
Cooling System Coolant (ELC)
- Change
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Dispose of all fluids according to Local regulations and
mandates.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Clean the cooling system and flush the cooling
system before the recommended maintenance
interval if the following conditions exist:
• The engine overheats frequently.
• Foaming is observed.
• The oil has entered the cooling system and the
coolant is contaminated.
• The fuel has entered the cooling system and the
coolant is contaminated.
Note: When the cooling system is cleaned, only
clean water is needed when the ELC is drained and
replaced.
Note: Inspect the water pump and the water
temperature regulator after the cooling system has
been drained. This is a good opportunity to replace
the water pump, the water temperature regulator and
the hoses, if necessary.
Drain
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
sure.
57
Maintenance Section
Cooling System Coolant (ELC) - Change
1. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system filler cap.
g01003928
Illustration 29
Typical example
2. Open the drain cock or remove the drain plug (1)
on the engine. Open the drain cock or remove the
drain plug on the radiator.
Allow the coolant to drain.
NOTICE
Dispose of used engine coolant or recycle. Various
methods have been proposed to reclaim used coolant
for reuse in engine cooling systems. The full distillation
procedure is the only method acceptable by Perkins to
reclaim the coolant.
For information regarding the disposal and the
recycling of used coolant, consult your Perkins dealer
or your Perkins distributor.
Flush
1. Flush the cooling system with clean water in order
to remove any debris.
2. Close the drain cock or install the drain plug in the
engine. Close the drain cock or install the drain
plug on the radiator.
NOTICE
Do not fill the cooling system faster than 5 L
(1.3 US gal) per minute to avoid air locks.
Cooling system air locks may result in engine damage.
3. Fill the cooling system with clean water. Install the
cooling system filler cap.
4. Start and run the engine at low idle until the
temperature reaches 49 to 66 °C (120 to 150 °F).
58 SEBU7833-03
Maintenance Section
Cooling System Coolant - Change

5. Stop the engine and allow the engine to cool. i01929799

Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling Cooling System Coolant -
system filler cap. Open the drain cock or remove
the drain plug on the engine. Open the drain cock
Change
or remove the drain plug on the radiator. Allow
the water to drain. Flush the cooling system with
clean water.

Fill
1. Close the drain cock or install the drain plug on the
engine. Close the drain cock or install the drain
plug on the radiator.

NOTICE
Do not fill the cooling system faster than 5 L
(1.3 US gal) per minute to avoid air locks.

Cooling system air locks may result in engine damage.

2. Fill the cooling system with Extended Life
Coolant (ELC). Refer to the Operation and
Maintenance Manual, “Fluid Recommendations”
topic (Maintenance Section) for more information
on cooling system specifications. Do not install the
cooling system filler cap.
3. Start and run the engine at low idle. Increase the
engine rpm to high idle. Run the engine at high
idle for one minute in order to purge the air from
the cavities of the engine block. Stop the engine.
4. Check the coolant level. Maintain the coolant level
within 13 mm (0.5 inch) below the bottom of the
pipe for filling. Maintain the coolant level in the
expansion bottle (if equipped) at the correct level.
g01003928
Illustration 30
Drain plug
NOTICE
Do not drain the coolant while the engine is still hot and
the system is under pressure because dangerous hot
coolant can be discharged.
Note: The radiator may not have been provided by
Perkins. The following is a general procedure for
changing the coolant. Refer to the OEM information
for the correct procedure.
1. Ensure that the vehicle is on level ground.
2. Remove the filler cap of the cooling system.

5. Clean the cooling system filler cap. Inspect the
gasket that is on the cooling system filler cap. If
the gasket that is on the cooling system filler cap
is damaged, discard the old cooling system filler
cap and install a new cooling system filler cap. If
the gasket that is on the cooling system filler cap
is not damaged, use a suitable pressurizing pump
in order to pressure test the cooling system filler
cap. The correct pressure for the cooling system
filler cap is stamped on the face of the cooling
system filler cap. If the cooling system filler cap
does not retain the correct pressure, install a new
cooling system filler cap.
6. Start the engine. Inspect the cooling system for
leaks and for correct operating temperature.
3. Remove the drain plug (1) from the side of the
cylinder block in order to drain the engine. Ensure
that the drain hole is not restricted.
4. Open the radiator drain tap or remove the drain
plug at the bottom of the radiator in order to
drain the radiator. If the radiator does not have a
radiator drain tap or a drain plug, disconnect the
hose at the bottom of the radiator.
5. Flush the coolant system with clean water.
6. Install the drain plugs and close the radiator drain
tap. Install the radiator hose if the radiator hose
was previously removed.
7. Fill the system with an approved antifreeze
mixture. The maximum flow rate is 1 L
(0.2200 Imp gal) per minute in order to fill the
system. Install the filler cap.

8. Run the engine and check for coolant leaks.

SEBU7833-03 59
Maintenance Section
Cooling System Coolant Extender (ELC) - Add

i02335364 1. Observe the coolant level in the coolant recovery

tank. Maintain the coolant level to “COLD FULL”
Cooling System Coolant mark on the coolant recovery tank.
Extender (ELC) - Add

Pressurized System: Hot coolant can cause seri-

The Perkins Extended Life Coolant (ELC) does not
need the frequent addition of Supplemental Coolant
Additives (SCA) that are associated with conventional
coolants. The Extender only needs to be added once.
Check the cooling system only when the engine is
stopped and cool.
1. Loosen the cooling system filler cap slowly in
order to relieve pressure. Remove the cooling
system filler cap.
2. It may be necessary to drain enough coolant from
the cooling system in order to add the Extender.
3. Add Extender according to the requirements for
your engine’s cooling system capacity. Refer to
this Operation and Maintenance Manual, “Refill
Capacities” in the Maintenance Section for the
capacity of the cooling system for your engine.
Refer to this Operation and Maintenance Manual,
“Fluid Recommendations” information for the
Perkins ELC Extender.
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
sure.
2. Loosen filler cap slowly in order to relieve any
pressure. Remove the filler cap.
3. Pour the correct coolant mixture into the tank.
Refer to the Operation and Maintenance Manual,
“Refill Capacities and Recommendations” for
information on the correct mixture and type of
coolant. Refer to the Operation and Maintenance
Manual, “Refill Capacities and Recommendations”
for the cooling system capacity. Do not fill the
coolant recovery tank above “COLD FULL” mark.

4. Clean the cooling system filler cap and inspect the

gasket. If the gasket is damaged, discard the old
filler cap and install a new filler cap. If the gasket
is not damaged, use a suitable pressurizing pump
in order to pressure test the filler cap. The correct
pressure is stamped on the face of the filler cap. If
the filler cap does not retain the correct pressure,
install a new filler cap.
g00103639
Illustration 31
i02335378
4. Clean filler cap and the receptacle. Reinstall the
Cooling System Coolant Level filler cap and inspect the cooling system for leaks.
- Check
Note: The coolant will expand as the coolant heats
up during normal engine operation. The additional
volume will be forced into the coolant recovery tank
during engine operation. When the engine is stopped
Engines With a Coolant Recovery and cool, the coolant will return to the engine.
Tank
Note: The cooling system may not have been
Engines Without a Coolant
provided by Perkins. The procedure that follows Recovery Tank
is for typical cooling systems. Refer to the OEM
information for the correct procedures. Check the coolant level when the engine is stopped
and cool.
Check the coolant level when the engine is stopped
and cool.
60
Maintenance Section
Driven Equipment - Check
g00285520
Illustration 32
Cooling system filler cap
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
sure.
1. Remove the cooling system filler cap slowly in
order to relieve pressure.
2. Maintain the coolant level within 13 mm (0.5 inch)
of the bottom of the filler pipe. If the engine is
equipped with a sight glass, maintain the coolant
level to the correct level in the sight glass.
3. Clean the cooling system filler cap and inspect the
gasket. If the gasket is damaged, discard the old
filler cap and install a new filler cap. If the gasket
is not damaged, use a suitable pressurizing pump
in order to pressure test the filler cap. The correct
pressure is stamped on the face of the filler cap. If
the filler cap does not retain the correct pressure,
install a new filler cap.
4. Inspect the cooling system for leaks.
i00174798
Driven Equipment - Check
Refer to the OEM specifications for more information
on the following maintenance recommendations for
the driven equipment:
• Inspection
• Adjustment
SEBU7833-03
• Lubrication
• Other maintenance recommendations
Perform any maintenance for the driven equipment
which is recommended by the OEM.
i01930350
Engine - Clean
Personal injury or death can result from high volt-
age.
Moisture can create paths of electrical conductiv-
ity.
Make sure that the electrical system is OFF. Lock
out the starting controls and tag the controls “DO
NOT OPERATE”.
NOTICE
Accumulated grease and oil on an engine is a fire haz-
ard. Keep the engine clean. Remove debris and fluid
spills whenever a significant quantity accumulates on
the engine.
NOTICE
Failure to protect some engine components from
washing may make your engine warranty invalid.
Allow the engine to cool for one hour before washing
the engine.
Periodic cleaning of the engine is recommended.
Steam cleaning the engine will remove accumulated
oil and grease. A clean engine provides the following
benefits:
• Easy detection of fluid leaks
• Maximum heat transfer characteristics
• Ease of maintenance
Note: Caution must be used in order to prevent
electrical components from being damaged by
excessive water when the engine is cleaned.
Pressure washers and steam cleaners should not be
directed at any electrical connectors or the junction of
cables into the rear of the connectors. Avoid electrical
components such as the alternator and the starter.
Protect the fuel injection pump from fluids in order
to wash the engine.
SEBU7833-03
Engine Air Cleaner Element (Dual Element) - Clean/Replace
i01915869
Engine Air Cleaner Element
(Dual Element) - Clean/Replace
NOTICE
Never run the engine without an air cleaner element
installed. Never run the engine with a damaged air
cleaner element. Do not use air cleaner elements with
damaged pleats, gaskets or seals. Dirt entering the
engine causes premature wear and damage to engine
components. Air cleaner elements help to prevent air-
borne debris from entering the air inlet.
NOTICE
Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine.
Servicing the Air Cleaner Elements
Note: The air filter system may not have been
provided by Perkins. The procedure that follows
is for a typical air filter system. Refer to the OEM
information for the correct procedure.
If the air cleaner element becomes plugged, the air
can split the material of the air cleaner element.
Unfiltered air will drastically accelerate internal
engine wear. Refer to the OEM information for the
correct air cleaner elements for your application.
• Check the precleaner (if equipped) and the dust
bowl daily for accumulation of dirt and debris.
Remove any dirt and debris, as needed.
• Operating conditions (dust, dirt and debris) may
require more frequent service of the air cleaner
element.
• The air cleaner element should be replaced at least
one time per year. This replacement should be
performed regardless of the number of cleanings.
Replace the dirty air cleaner elements with clean air
cleaner elements. Before installation, the air cleaner
elements should be thoroughly checked for tears
and/or holes in the filter material. Inspect the gasket
or the seal of the air cleaner element for damage.
Maintain a supply of suitable air cleaner elements
for replacement purposes.
61
Maintenance Section
Dual Element Air Cleaners
The dual element air cleaner contains a primary air
cleaner element and a secondary air cleaner element.
The primary air cleaner element can be used up
to six times if the element is properly cleaned and
properly inspected. The primary air cleaner element
should be replaced at least one time per year. This
replacement should be performed regardless of the
number of cleanings.
The secondary air cleaner element is not serviceable
or washable. Refer to the OEM information for
instructions in order to replace the secondary air
cleaner element. When the engine is operating in
environments that are dusty or dirty, air cleaner
elements may require more frequent replacement.
Illustration 33
g00736431
(1) Cover
(2) Primary air cleaner element
(3) Secondary air cleaner element
(4) Air inlet
1. Remove the cover. Remove the primary air
cleaner element.
2. The secondary air cleaner element should be
removed and discarded for every three cleanings
of the primary air cleaner element.
Note: Refer to “Cleaning the Primary Air Cleaner
Elements”.
3. Cover the air inlet with tape in order to keep dirt
out.
4. Clean the inside of the air cleaner cover and body
with a clean, dry cloth.
5. Remove the tape for the air inlet. Install the
secondary air cleaner element. Install a primary
air cleaner element that is new or cleaned.
6. Install the air cleaner cover.
7. Reset the air cleaner service indicator.
62 SEBU7833-03
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Clean/Replace

Cleaning the Primary Air Cleaner

Elements
NOTICE
Observe the following guidelines if you attempt to
clean the filter element:

Do not tap or strike the filter element in order to re-

move dust.

Do not wash the filter element.

Use low pressure compressed air in order to remove

the dust from the filter element. Air pressure must not
exceed 207 kPa (30 psi). Direct the air flow up the
pleats and down the pleats from the inside of the filter
element. Take extreme care in order to avoid damage
to the pleats.
Do not use air filters with damaged pleats, gaskets, or
seals. Dirt entering the engine will cause damage to
engine components.
Refer to the OEM information in order to determine
the number of times that the primary filter element can
be cleaned. When the primary air cleaner element is
cleaned, check for rips or tears in the filter material.
The primary air cleaner element should be replaced
at least one time per year. This replacement should
be performed regardless of the number of cleanings.
NOTICE
Do not clean the air cleaner elements by bumping or
tapping. This could damage the seals. Do not use el-
ements with damaged pleats, gaskets or seals. Dam-
aged elements will allow dirt to pass through. Engine
damage could result.
g00281692
Illustration 34
Note: When the primary air cleaner elements are
cleaned, always begin with the clean side (inside)
in order to force dirt particles toward the dirty side
(outside).
Aim the hose so that the air flows inside the element
along the length of the filter in order to help prevent
damage to the paper pleats. Do not aim the stream
of air directly at the primary air cleaner element. Dirt
could be forced further into the pleats.
Note: Refer to “Inspecting the Primary Air Cleaner
Elements”.
Vacuum Cleaning
Vacuum cleaning is a good method for cleaning
primary air cleaner elements which require daily
cleaning because of a dry, dusty environment.
Cleaning with pressurized air is recommended prior
to vacuum cleaning. Vacuum cleaning will not remove
deposits of carbon and oil.

Visually inspect the primary air cleaner elements Note: Refer to “Inspecting the Primary Air Cleaner
before cleaning. Inspect the air cleaner elements for Elements”.
damage to the seal, the gaskets, and the outer cover.
Discard any damaged air cleaner elements. Inspecting the Primary Air Cleaner
Elements
There are two common methods that are used to
clean primary air cleaner elements:

• Pressurized air
• Vacuum cleaning

Pressurized Air
Pressurized air can be used to clean primary air
cleaner elements that have not been cleaned more
than two times. Pressurized air will not remove
deposits of carbon and oil. Use filtered, dry air with a
maximum pressure of 207 kPa (30 psi).
g00281693
Illustration 35
SEBU7833-03
Engine Air Cleaner Element (Single Element) - Inspect/Replace
Inspect the clean, dry primary air cleaner element.
Use a 60 watt blue light in a dark room or in a similar
facility. Place the blue light in the primary air cleaner
element. Rotate the primary air cleaner element.
Inspect the primary air cleaner element for tears
and/or holes. Inspect the primary air cleaner element
for light that may show through the filter material. If it
is necessary in order to confirm the result, compare
the primary air cleaner element to a new primary air
cleaner element that has the same part number.
Do not use a primary air cleaner element that has
any tears and/or holes in the filter material. Do not
use a primary air cleaner element with damaged
pleats, gaskets or seals. Discard damaged primary
air cleaner elements.
i02152042
Engine Air Cleaner
Element (Single Element) -
Inspect/Replace
Refer to Operation and Maintenance Manual, “Engine
Air Cleaner Service Indicator-Inspect”.
NOTICE
Never run the engine without an air cleaner element
installed. Never run the engine with a damaged air
cleaner element. Do not use air cleaner elements with
damaged pleats, gaskets or seals. Dirt entering the
engine causes premature wear and damage to engine
components. Air cleaner elements help to prevent air-
borne debris from entering the air inlet.
NOTICE
Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine.
A wide variety of air cleaners may be installed for use
with this engine. Consult the OEM information for the
correct procedure to replace the air cleaner.
i01909507
Engine Air Cleaner Service
Indicator - Inspect
Some engines may be equipped with a different
service indicator.
63
Maintenance Section
Some engines are equipped with a differential gauge
for inlet air pressure. The differential gauge for inlet
air pressure displays the difference in the pressure
that is measured before the air cleaner element and
the pressure that is measured after the air cleaner
element. As the air cleaner element becomes dirty,
the pressure differential rises. If your engine is
equipped with a different type of service indicator,
follow the OEM recommendations in order to service
the air cleaner service indicator.
The service indicator may be mounted on the air
cleaner element or in a remote location.
Illustration 36
g00103777
Typical service indicator
Observe the service indicator. The air cleaner
element should be cleaned or the air cleaner element
should be replaced when one of the following
conditions occur:
• The yellow diaphragm enters the red zone.
• The red piston locks in the visible position.
Test the Service Indicator
Service indicators are important instruments.
• Check for ease of resetting. The service indicator
should reset in less than three pushes.
• Check the movement of the yellow core when the
engine is accelerated to the engine rated speed.
The yellow core should latch approximately at the
greatest vacuum that is attained.
If the service indicator does not reset easily, or if the
yellow core does not latch at the greatest vacuum,
the service indicator should be replaced. If the new
service indicator will not reset, the hole for the service
indicator may be restricted.
The service indicator may need to be replaced
frequently in environments that are severely dusty.
64
Maintenance Section
Engine Ground - Inspect/Clean
i01941505
Engine Ground - Inspect/Clean
Inspect the wiring harness for good connections.
Perkins use the starter motor in order to ground the
engine. Check the connection on the starter motor at
every oil change. Ground wires and straps should be
combined at engine grounds. All grounds should be
tight and free of corrosion.
• Clean the grounding stud on the starter motor and
the terminals with a clean cloth.
• If the connections are corroded, clean the
connections with a solution of baking soda and
water.
• Keep the grounding stud and the strap clean and
coated with suitable grease or petroleum jelly.
i02323089
Engine Mounts - Inspect
Note: The engine mounts may not have been
supplied by Perkins. Refer to the OEM information
for further information on the engine mounts and the
correct bolt torque.
Inspect the engine mounts for deterioration and for
correct bolt torque. Engine vibration can be caused
by the following conditions:
• Incorrect mounting of the engine
• Deterioration of the engine mounts
• Loose engine mounts
Any engine mount that shows deterioration should
be replaced. Refer to the OEM information for the
recommended torques.
i02335785
Engine Oil Level - Check
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
SEBU7833-03
g01165836
Illustration 37
(Y) “Min” mark. (X) “Max” mark.
NOTICE
Perform this maintenance with the engine stopped.
Note: Ensure that the engine is either level or that
the engine is in the normal operating position in order
to obtain a true level indication.
Note: After the engine has been switched OFF, wait
for ten minutes in order to allow the engine oil to drain
to the oil pan before checking the oil level.
1. Maintain the oil level between the “ADD” mark (Y)
and the “FULL” mark (X) on the engine oil dipstick.
Do not fill the crankcase above the “FULL” mark
(X).
NOTICE
Operating your engine when the oil level is above the
“FULL” mark could cause your crankshaft to dip into
the oil. The air bubbles created from the crankshaft
dipping into the oil reduces the oil’s lubricating char-
acteristics and could result in the loss of power.
2. Remove the oil filler cap and add oil, if necessary.
Clean the oil filler cap. Install the oil filler cap.
i02202699
Engine Oil Sample - Obtain
The condition of the engine lubricating oil may be
checked at regular intervals as part of a preventive
maintenance program. Perkins include an oil
sampling valve as an option. The oil sampling valve
(if equipped) is included in order to regularly sample
the engine lubricating oil. The oil sampling valve is
positioned on the oil filter head or the oil sampling
valve is positioned on the cylinder block.
SEBU7833-03
Perkins recommends using a sampling valve in order
to obtain oil samples. The quality and the consistency
of the samples are better when a sampling valve is
used. The location of the sampling valve allows oil
that is flowing under pressure to be obtained during
normal engine operation.
Obtain the Sample and the Analysis
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
In order to help obtain the most accurate analysis,
record the following information before an oil sample
is taken:
• The date of the sample
• Engine model
• Engine number
• Service hours on the engine
• The number of hours that have accumulated since
the last oil change
• The amount of oil that has been added since the
last oil change
Ensure that the container for the sample is clean and
dry. Also ensure that the container for the sample is
clearly labelled.
To ensure that the sample is representative of the
oil in the crankcase, obtain a warm, well mixed oil
sample.
To avoid contamination of the oil samples, the tools
and the supplies that are used for obtaining oil
samples must be clean.
The sample can be checked for the following: the
quality of the oil, the existence of any coolant in the
oil, the existence of any ferrous metal particles in
the oil, and the existence of any nonferrous metal
particles in the oil.
65
Maintenance Section
Engine Oil and Filter - Change
i01929323
Engine Oil and Filter - Change
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
Do not drain the oil when the engine is cold. As the oil
cools, suspended waste particles settle on the bottom
of the oil pan. The waste particles are not removed
with the draining cold oil. Drain the crankcase with
the engine stopped. Drain the crankcase with the
oil warm. This draining method allows the waste
particles that are suspended in the oil to be drained
properly.
Failure to follow this recommended procedure will
cause the waste particles to be recirculated through
the engine lubrication system with the new oil.
Drain the Engine Oil
g01003623
Illustration 38
Oil drain plug
After the engine has been run at the normal operating
temperature, stop the engine. Use one of the
following methods to drain the engine crankcase oil:
• If the engine is equipped with a drain valve, turn the
drain valve knob counterclockwise in order to drain
the oil. After the oil has drained, turn the drain valve
knob clockwise in order to close the drain valve.
• If the engine is not equipped with a drain valve,
remove the oil drain plug (1) in order to allow the
oil to drain. If the engine is equipped with a shallow
sump, remove the bottom oil drain plugs from both
ends of the oil pan.
66 SEBU7833-03
Maintenance Section
Engine Oil and Filter - Change

After the oil has drained, the oil drain plugs should
be cleaned and installed. If necessary, renew the O
ring seal on the drain plug.

Some types of oil pans have oil drain plugs that are
on both sides of the oil pan, because of the shape of
the pan. This type of oil pan requires the engine oil to
be drained from both plugs.

Replace the Spin-on Oil Filter

NOTICE
Perkins oil filters are manufactured to Perkins speci-
fications. Use of an oil filter that is not recommended g01003628
by Perkins could result in severe damage to the en- Illustration 39
gine bearings, crankshaft, etc., as a result of the larger (2) Filter head
waste particles from unfiltered oil entering the engine (3) O ring seal
lubricating system. Only use oil filters recommended
by Perkins. 3. Clean the sealing surface of the oil filter head (2).
Ensure that the union (not shown) in the oil filter
head is secure.
1. Remove the oil filter with a suitable tool.
4. Apply clean engine oil to the O ring seal (3) on
Note: The following actions can be carried out as the oil filter.
part of the preventive maintenance program.
NOTICE
2. Cut the oil filter open with a suitable tool. Break Do not fill the oil filters with oil before installing them.
apart the pleats and inspect the oil filter for metal This oil would not be filtered and could be contaminat-
debris. An excessive amount of metal debris in ed. Contaminated oil can cause accelerated wear to
the oil filter may indicate early wear or a pending engine components.
failure.

Use a magnet to differentiate between the ferrous 5. Install the oil filter. Tighten the oil filter by hand
metals and the nonferrous metals that are found in according to the instructions that are shown on
the oil filter element. Ferrous metals may indicate the oil filter. Do not overtighten the oil filter.
wear on the steel and cast iron parts of the engine.

Nonferrous metals may indicate wear on the

Replace the Element for the Oil
aluminum parts, brass parts or bronze parts of Filter
the engine. Parts that may be affected include
the following items: main bearings, rod bearings,
turbocharger bearings, and cylinder heads.

Due to normal wear and friction, it is not

uncommon to find small amounts of debris in the
oil filter.

g01003662
Illustration 40
(1) Drain plug
(2) Square hole
(3) Filter bowl

1. Place a suitable container under the oil filter.

Remove the drain plug (1) and the seal, from the
oil filter.
SEBU7833-03
2. Locate a suitable wrench into the square hole (2)
in order to remove the filter bowl (3).
3. Remove the filter bowl (3) and remove the element
from the filter bowl. Clean the filter bowl.
g01003675
Illustration 41
(4) O ring seal
(5) Element
(6) Filter head
4. Install a new O ring (4) onto the filter bowl and
lubricate the O ring with clean engine oil. Install
the filter element (5) into the filter bowl.
5. Install the filter bowl into the oil filter head (6).
Tighten the filter bowl to the following torque
25 N·m (18 lb ft).
6. Install a new seal onto the drain plug (1) and
install the drain plug into the oil filter. Tighten the
drain plug to the following torque 12 N·m (8 lb ft).
Note: Some engines may have a horizontally
mounted oil filter. This oil filter has a drain plug that is
located in the oil filter head.
Fill the Engine Crankcase
1. Remove the oil filler cap. Refer to the Operation
and Maintenance Manual for more information on
lubricant specifications. Fill the crankcase with the
proper amount of oil. Refer to the Operation and
Maintenance Manual for more information on refill
capacities.
NOTICE
If equipped with an auxiliary oil filter system or a re-
mote oil filter system, follow the OEM or filter manu-
facturer’s recommendations. Under filling or overfilling
the crankcase with oil can cause engine damage.
67
Maintenance Section
Engine Valve Lash - Inspect/Adjust
NOTICE
To prevent crankshaft bearing damage, crank the en-
gine with the fuel OFF. This will fill the oil filters before
starting the engine. Do not crank the engine for more
than 30 seconds.
2. Start the engine and run the engine at “LOW
IDLE” for two minutes. Perform this procedure in
order to ensure that the lubrication system has
oil and that the oil filters are filled. Inspect the oil
filter for oil leaks.
3. Stop the engine and allow the oil to drain back to
the sump for a minimum of ten minutes.
g00998024
Illustration 42
(Y) “ADD” mark. (X) “FULL” mark.
4. Remove the oil level gauge in order to check the
oil level. Maintain the oil level between the “ADD”
and “FULL” marks on the engine oil dipstick.
i02171102
Engine Valve Lash -
Inspect/Adjust
This maintenance is recommended by Perkins as
part of a lubrication and preventive maintenance
schedule in order to help provide maximum engine
life.
NOTICE
Only qualified service personel should perform this
maintenance. Refer to the Service Manual or your au-
thorized Perkins dealer or your Perkins distributor for
the complete valve lash adjustment procedure.
Operation of Perkins engines with incorrect valve lash
can reduce engine efficiency, and also reduce engine
component life.
68 SEBU7833-03
Maintenance Section
Fuel Injector - Test/Change

Ensure that the engine can not be started while

this maintenance is being performed. To help pre-
vent possible injury, do not use the starting motor
to turn the flywheel.

Hot engine components can cause burns. Allow

additional time for the engine to cool before mea-
suring/adjusting valve lash clearance.

Ensure that the engine is stopped before measuring

the valve lash. The engine valve lash can be
inspected and adjusted when the temperature of the
engine is hot or cold.

Refer to Systems Operation/Testing and Adjusting,

“Engine Valve Lash - Inspect/Adjust” for more
information.

i02198352

Fuel Injector - Test/Change

Fuel leaked or spilled onto hot surfaces or electri-
cal components can cause a fire.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
nected fuel system component.
NOTICE
If a fuel injector is suspected of operating outside of
normal parameters it should be removed by a qualified
technician. The suspect fuel injector should be taken
to an authorised agent for inspection.
The fuel injector (1) in illustration 43 has no fuel
return. The fuel injector (2) has a fuel return.
g01110422
Illustration 43
Typical fuel Injectors
The fuel injector (1) will need to be removed and the
injector will need to be checked for performance.
The fuel injectors should not be cleaned as cleaning
with incorrect tools can damage the nozzle. The fuel
injectors should be renewed only if a fault with the
fuel injectors occurs. Some of the problems that may
indicate that new fuel injectors are needed are listed
below:
• The engine will not start or the engine is difficult
to start.
• Not enough power
• The engine misfires or the engine runs erratically.
• High fuel consumption
• Black exhaust smoke
• The engine knocks or there is vibration in the
engine.

• Excessive engine temperature

SEBU7833-03
Removal and Installation of the
Fuel Injectors
Work carefully around an engine that is running.
Engine parts that are hot, or parts that are moving,
can cause personal injury.
Make sure that you wear eye protection at all
times during testing. When fuel injection nozzles
are tested, test fluids travel through the orifices
of the nozzle tip with high pressure. Under this
amount of pressure, the test fluid can pierce the
skin and cause serious injury to the operator.
Always keep the tip of the fuel injection nozzle
pointed away from the operator and into the fuel
collector and extension.
NOTICE
If your skin comes into contact with high pressure fuel,
obtain medical assistence immediately.
Operate the engine at a fast idle speed in order to
identify the faulty fuel injector. Individually loosen and
tighten the union nut for the high pressure pipe to
each fuel injector. Do not loosen the union nut more
than half a turn. There will be little effect on the engine
speed when the union nut to the faulty fuel injection
nozzle is loosened. Refer to the Disassembly and
Assembly Manual for more information. Consult your
authorized Perkins dealer or your Perkins distributor
for assistance.
i02890360
Fuel System - Prime
If air enters the fuel system, the air must be purged
from the fuel system before the engine can be
started. Air can enter the fuel system when the
following events occur:
• The fuel tank is empty or the fuel tank has been
partially drained.
• The low pressure fuel lines are disconnected.
• A leak exists in the low pressure fuel system.
• The fuel filter is replaced.
• A new injection pump is installed.
69
Maintenance Section
Fuel System - Prime
Use the following procedure in order to remove air
from the fuel system:
1. Ensure that all low pressure fuel connections and
high pressure fuel lines are installed correctly.
2. Turn the ignition key to the RUN position. Leave
the ignition key in the RUN position for three
minutes. If a manual purging screw is installed,
the purging screw should be slackened during
priming the fuel system.
g01003929
Illustration 44
Typical example
3. Crank the engine with the throttle lever in the
CLOSED position until the engine starts.
Note: If necessary, loosen the union nuts (1) on the
fuel injection lines at the connection with the fuel
injector until fuel is evident. Stop cranking the engine.
Tighten the union nuts (1) to a torque of 30 N·m
(22 lb ft).
4. Start the engine and run the engine at idle for one
minute.
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
5. Cycle the throttle lever from the low idle position to
the high idle position three times. The cycle time
for the throttle lever is one second to six seconds
for one complete cycle.
Note: In order to purge air from the fuel injection
pump on Perkins engines with a fixed throttle, the
engine should be run at full load for thirty seconds.
The load should then be decreased until the engine
is at high idle. This should be repeated three times.
This will assist in removing trapped air from the fuel
injection pump.
6. Check for leaks in the fuel system.
70 SEBU7833-03
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace

i02206563 2. Place a suitable container under the water

separator. Clean the outside of the water
Fuel System Primary Filter separator.
(Water Separator) Element - 3. Open the drain (5). Allow the fluid to drain into
Replace the container.

4. Tighten the drain (5) by hand pressure only.

5. Hold the element (2) and remove the screw (1).

Fuel leaked or spilled onto hot surfaces or elec-
trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
nected fuel system component.
Remove the element and the glass bowl (3) from
the base. Discard the old element.
6. Clean the glass bowl (4). Clean the bottom cover
(6).
7. Install the new O ring seal. Install the bottom cover
onto the new element. Install the assembly onto
the base.
8. Install the screw (1) and tighten the screw to a
torque of 8 N·m (6 lb ft).
9. Remove the container and dispose of the fuel
safely.

10. Open the fuel supply valve.

11. Prime the fuel system. Refer to the Operation and

Maintenance Manual, “Fuel System - Prime” for
more information.

i02211066

Fuel System Primary

Filter/Water Separator - Drain

Fuel leaked or spilled onto hot surfaces or elec-

trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.

NOTICE
The water separator is not a filter. The water separa-
Illustration 45
g01118416 tor separates water from the fuel. The engine should
never be allowed to run with the water separator more
(1) Screw
(2) Element
than half full. Engine damage may result.
(3) Glass bowl
(4) Sensor connection
(5) Drain NOTICE
(6) Bottom cover The water separator is under suction during normal
engine operation. Ensure that the drain valve is tight-
1. Turn the fuel supply valve (if equipped) to the OFF ened securely to help prevent air from entering the fuel
position. system.
SEBU7833-03 71
Maintenance Section
Fuel System Secondary Filter - Replace

NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
nected fuel system component.

Element filter
Turn the valves for the fuel lines (if equipped) to the
OFF position before performing this maintenance.
Place a tray under the fuel filter in order to catch
any fuel that might spill. Clean up any spilled fuel
immediately.

g01118416
Illustration 46
(1) Screw
(2) Element
(3) Glass bowl
(4) Sensor connection
(5) Drain
(6) Bottom cover

1. Place a suitable container below the water

separator. g01010637
Illustration 47
2. Open the drain (5). Allow the fluid to drain into (1) Drain
(2) Filter bowl
the container.

3. When clean fuel drains from the water separator
close the drain (5). Tighten the drain by hand
pressure only. Dispose of the drained fluid
correctly.
1. Close the valves for the fuel lines (if equipped).
2. Clean the outside of the fuel filter assembly. Open
the fuel drain (1) and drain the fuel into a suitable
container.

i02469473

Fuel System Secondary Filter -

Replace

Fuel leaked or spilled onto hot surfaces or elec-

trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
72 SEBU7833-03
Maintenance Section
Fuel System Secondary Filter - Replace

g01010595
Illustration 48
(3) O ring seal
(4) Element
(5) Filter head

3. Remove the filter bowl (2) from the filter head

(5). Press on the element (4). Rotate the element
g01121396
counterclockwise in order to release the element Illustration 49
for the filter bowl and remove the element from the (1) Filter Head
bowl. Discard the used element. (2) Spin-on filter
(3) Drain
4. Remove the O ring (3) from the filter bowl and
clean the filter bowl. Check that the threads of the 1. Clean the outside of the fuel filter assembly. Open
filter bowl are not damaged. the fuel drain (3) and drain the fuel into a suitable
container.
5. Install a new O ring seal (3) to the filter bowl (2).
2. Use a suitable tool in order to remove the spin-on
6. Locate a new filter element (4) into the filter bowl. filter (2) from the filter head (1).
Press on the element and rotate the element
clockwise in order to lock the element into the 3. Ensure that the fuel drain (3) on the new spin-on
filter bowl. filter is closed.

7. Install the filter bowl (4) into the top of the filter
head (5).

8. Tighten the filter bowl by hand until the filter bowl

contacts the filter head. Rotate the filter bowl
through 90 degrees.

Note: Do not use a tool to tighten the filter bowl.

9. Open the valves for the fuel lines (if equipped).

Spin-on filter
Turn the valves for the fuel lines (if equipped) to the
OFF position before performing this maintenance.
Place a tray under the fuel filter in order to catch
any fuel that might spill. Clean up any spilled fuel
immediately.
SEBU7833-03
g01121723
Illustration 50
4. Lubricate the sealing ring (4) with clean fuel oil.
5. Install the spin-on filter (2) into the top of the filter
head (1).
6. Tighten the spin-on filter by hand until the sealing
ring contacts the filter head. Rotate the spin-on
filter through 90 degrees.
7. Prime the fuel system. Refer to Operation and
Maintenance Manual, “Fuel System - Prime”.
i02335436
Fuel Tank Water and Sediment
- Drain
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting, and repair of the product. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any com-
ponent containing fluids.
Dispose of all fluids according to local regulations and
mandates.
Fuel Tank
Fuel quality is critical to the performance and to the
service life of the engine. Water in the fuel can cause
excessive wear to the fuel system.
73
Maintenance Section
Fuel Tank Water and Sediment - Drain
Water can be introduced into the fuel tank when the
fuel tank is being filled.
Condensation occurs during the heating and cooling
of fuel. The condensation occurs as the fuel passes
through the fuel system and the fuel returns to the
fuel tank. This causes water to accumulate in fuel
tanks. Draining the fuel tank regularly and obtaining
fuel from reliable sources can help to eliminate water
in the fuel.
Drain the Water and the Sediment
Fuel tanks should contain some provision for draining
water and draining sediment from the bottom of the
fuel tanks.
Open the drain valve on the bottom of the fuel tank
in order to drain the water and the sediment. Close
the drain valve.
Check the fuel daily. Allow five minutes after the
fuel tank has been filled before draining water and
sediment from the fuel tank.
Fill the fuel tank after operating the engine in
order to drive out moist air. This will help prevent
condensation. Do not fill the tank to the top. The
fuel expands as the fuel gets warm. The tank may
overflow.
Some fuel tanks use supply pipes that allow water
and sediment to settle below the end of the fuel
supply pipe. Some fuel tanks use supply lines that
take fuel directly from the bottom of the tank. If
the engine is equipped with this system, regular
maintenance of the fuel system filter is important.
Fuel Storage Tanks
Drain the water and the sediment from the fuel
storage tank at the following intervals:
• Weekly
• Service intervals
• Refill of the tank
This will help prevent water or sediment from being
pumped from the storage tank into the engine fuel
tank.
If a bulk storage tank has been refilled or moved
recently, allow adequate time for the sediment to
settle before filling the engine fuel tank. Internal
baffles in the bulk storage tank will also help trap
sediment. Filtering fuel that is pumped from the
storage tank helps to ensure the quality of the fuel.
When possible, water separators should be used.
74
Maintenance Section
Hoses and Clamps - Inspect/Replace
i02813964
Hoses and Clamps -
Inspect/Replace
Inspect all hoses for leaks that are caused by the
following conditions:
• Cracking
• Softness
• Loose clamps
Replace hoses that are cracked or soft. Tighten any
loose clamps.
NOTICE
Do not bend or strike high pressure lines. Do not in-
stall bent or damaged lines, tubes or hoses. Repair
any loose or damaged fuel and oil lines, tubes and
hoses. Leaks can cause fires. Inspect all lines, tubes
and hoses carefully. Tighten all connections to the rec-
ommended torque. Do not clip any other item to the
high pressure lines.
Check for the following conditions:
• End fittings that are damaged or leaking
• Outer covering that is chafed or cut
• Exposed wire that is used for reinforcement
• Outer covering that is ballooning locally
• Flexible part of the hose that is kinked or crushed
• Armoring that is embedded in the outer covering
A constant torque hose clamp can be used in place
of any standard hose clamp. Ensure that the constant
torque hose clamp is the same size as the standard
clamp.
Due to extreme temperature changes, the hose will
harden. Hardening of the hoses will cause hose
clamps to loosen. This can result in leaks. A constant
torque hose clamp will help to prevent loose hose
clamps.
Each installation application can be different. The
differences depend on the following factors:
• Type of hose
• Type of fitting material
SEBU7833-03
• Anticipated expansion and contraction of the hose
• Anticipated expansion and contraction of the
fittings
Replace the Hoses and the Clamps
Refer to the OEM information for further information
on removing and replacing fuel hoses (if equipped).
The coolant system and the hoses for the coolant
system are not usually supplied by Perkins. The
following text describes a typical method of replacing
coolant hoses. Refer to the OEM information for
further information on the coolant system and the
hoses for the coolant system.
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
sure.
1. Stop the engine. Allow the engine to cool.
2. Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system filler cap.
Note: Drain the coolant into a suitable, clean
container. The coolant can be reused.
3. Drain the coolant from the cooling system to a
level that is below the hose that is being replaced.
4. Remove the hose clamps.
5. Disconnect the old hose.
6. Replace the old hose with a new hose.
7. Install the hose clamps with a torque wrench.
Note: For the correct coolant, see this Operation and
Maintenance Manual, “Fluid Recommendations”.
8. Refill the cooling system. Refer to the OEM
information for further information on refilling the
cooling system.
9. Clean the cooling system filler cap. Inspect the
cooling system filler cap’s seals. Replace the
cooling system filler cap if the seals are damaged.
Install the cooling system filler cap.
10. Start the engine. Inspect the cooling system for
leaks.
SEBU7833-03
i02335774
Radiator - Clean
The radiator is not usually supplied by Perkins. The
following text describes a typical cleaning procedure
for the radiator. Refer to the OEM information for
further information on cleaning the radiator.
Note: Adjust the frequency of cleaning according to
the effects of the operating environment.
Inspect the radiator for these items: Damaged fins,
corrosion, dirt, grease, insects, leaves, oil, and other
debris. Clean the radiator, if necessary.
Personal injury can result from air pressure.
Personal injury can result without following prop-
er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing.
Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.
Pressurized air is the preferred method for removing
loose debris. Direct the air in the opposite direction
to the fan’s air flow. Hold the nozzle approximately
6 mm (0.25 inch) away from the radiator fins. Slowly
move the air nozzle in a direction that is parallel with
the radiator tube assembly. This will remove debris
that is between the tubes.
Pressurized water may also be used for cleaning.
The maximum water pressure for cleaning purposes
must be less than 275 kPa (40 psi). Use pressurized
water in order to soften mud. Clean the core from
both sides.
Use a degreaser and steam for removal of oil and
grease. Clean both sides of the core. Wash the core
with detergent and hot water. Thoroughly rinse the
core with clean water.
If the radiator is blocked internally, refer to the OEM
Manual for information regarding flushing the cooling
system.
After cleaning the radiator, start the engine. Allow
the engine to operate at low idle speed for three to
five minutes. Accelerate the engine to high idle. This
will help in the removal of debris and the drying of
the core. Slowly reduce the engine speed to low idle
and then stop the engine. Use a light bulb behind
the core in order to inspect the core for cleanliness.
Repeat the cleaning, if necessary.
75
Maintenance Section
Radiator - Clean
Inspect the fins for damage. Bent fins may be opened
with a “comb”. Inspect these items for good condition:
Welds, mounting brackets, air lines, connections,
clamps, and seals. Make repairs, if necessary.
i02335775
Severe Service Application -
Check
Severe service is the application of an engine that
exceeds the current published standards for that
engine. Perkins maintains standards for the following
engine parameters:
• Performance such as power range, speed range,
and fuel consumption
• Fuel quality
• Operational Altitude
• Maintenance intervals
• Oil selection and maintenance
• Coolant type and maintenance
• Environmental qualities
• Installation
• The temperature of the fluid in the engine
Refer to the standards for the engine or consult your
Perkins dealer or your Perkins distributor in order to
determine if the engine is operating within the defined
parameters.
Severe service operation can accelerate component
wear. Engines that operate under severe conditions
may need more frequent maintenance intervals in
order to ensure maximum reliability and retention of
full service life.
Due to individual applications, it is not possible
to identify all of the factors which can contribute
to severe service operation. Consult your Perkins
dealer or your Perkins distributor for the unique
maintenance that is necessary for the engine.
The operating environment, incorrect operating
procedures and incorrect maintenance procedures
can be factors which contribute to a severe service
application.
76
Maintenance Section
Starting Motor - Inspect
Environmental Factors
Ambient temperatures – The engine may be
exposed to extended operation in extremely
cold environments or hot environments. Valve
components can be damaged by carbon buildup if
the engine is frequently started and stopped in very
cold temperatures. Extremely hot intake air reduces
engine performance.
Quality of the air – The engine may be exposed
to extended operation in an environment that is
dirty or dusty, unless the equipment is cleaned
regularly. Mud, dirt and dust can encase components.
Maintenance can be very difficult. The buildup can
contain corrosive chemicals.
Buildup – Compounds, elements, corrosive
chemicals and salt can damage some components.
Altitude – Problems can arise when the engine is
operated at altitudes that are higher than the intended
settings for that application. Necessary adjustments
should be made.
Incorrect Operating Procedures
• Extended operation at low idle
• Frequent hot shutdowns
• Operating at excessive loads
• Operating at excessive speeds
• Operating outside the intended application
Incorrect Maintenance Procedures
• Extending the maintenance intervals
• Failure to use recommended fuel, lubricants and
coolant/antifreeze
i02177969
Starting Motor - Inspect
Perkins recommends a scheduled inspection of the
starting motor. If the starting motor fails, the engine
may not start in an emergency situation.
SEBU7833-03
Check the starting motor for correct operation. Check
the electrical connections and clean the electrical
connections. Refer to the Systems Operation, Testing
and Adjusting Manual, “Electric Starting System -
Test” for more information on the checking procedure
and for specifications or consult your Perkins dealer
or your Perkins distributor for assistance.
i02184788
Turbocharger - Inspect
(If Equipped)
A regular visual inspection of the turbocharger is
recommended. Any fumes from the crankcase are
filtered through the air inlet system. Therefore,
by-products from oil and from combustion can collect
in the turbocharger compressor housing. Over time,
this buildup can contribute to loss of engine power,
increased black smoke and overall loss of engine
efficiency.
If the turbocharger fails during engine operation,
damage to the turbocharger compressor wheel
and/or to the engine may occur. Damage to the
turbocharger compressor wheel can cause additional
damage to the pistons, the valves, and the cylinder
head.
NOTICE
Turbocharger bearing failures can cause large quanti-
ties of oil to enter the air intake and exhaust systems.
Loss of engine lubricant can result in serious engine
damage.
Minor leakage of oil into a turbocharger under extend-
ed low idle operation should not cause problems as
long as a turbocharger bearing failure has not oc-
cured.
When a turbocharger bearing failure is accompanied
by a significant engine performance loss (exhaust
smoke or engine rpm up at no load), do not continue
engine operation until the turbocharger is renewed.
A visual inspection of the turbocharger can minimize
unscheduled downtime. A visual inspection of the
turbocharger can also reduce the chance for potential
damage to other engine parts.
Removal and Installation
Note: The turbochargers that are supplied are
nonserviceable.
SEBU7833-03
For options regarding the removal, installation, and
replacement, consult your Perkins dealer or your
Perkins distributor. Refer to the Disassembly and
Assembly Manual, “Turbocharger - Remove and
Turbocharger - Install” for further information.
Inspecting
NOTICE
The compressor housing for the turbocharger must
not be removed from the turbocharger for cleaning.
The actuator linkage is connected to the compressor
housing. If the actuator linkage is moved or disturbed
the engine may not comply with emmissions legisla-
tion.
1. Remove the pipe from the turbocharger exhaust
outlet and remove the air intake pipe to the
turbocharger. Visually inspect the piping for the
presence of oil. Clean the interior of the pipes
in order to prevent dirt from entering during
reassembly.
2. Check for the presence of oil. If oil is leaking from
the back side of the compressor wheel, there is a
possibility of a failed turbocharger oil seal.
The presence of oil may be the result of extended
engine operation at low idle. The presence of oil
may also be the result of a restriction of the line
for the intake air (clogged air filters), which causes
the turbocharger to slobber.
3. Inspect the bore of the housing of the turbine
outlet for corrosion.
4. Fasten the air intake pipe and the exhaust outlet
pipe to the turbocharger housing.
i02177973
Walk-Around Inspection
Inspect the Engine for Leaks and
for Loose Connections
A walk-around inspection should only take a few
minutes. When the time is taken to perform these
checks, costly repairs and accidents can be avoided.
For maximum engine service life, make a thorough
inspection of the engine compartment before starting
the engine. Look for items such as oil leaks or coolant
leaks, loose bolts, worn belts, loose connections and
trash buildup. Make repairs, as needed:
77
Maintenance Section
Walk-Around Inspection
• The guards must be in the correct place. Repair
damaged guards or replace missing guards.
• Wipe all caps and plugs before the engine is
serviced in order to reduce the chance of system
contamination.
NOTICE
For any type of leak (coolant, lube, or fuel) clean up the
fluid. If leaking is observed, find the source and correct
the leak. If leaking is suspected, check the fluid levels
more often than recommended until the leak is found
or fixed, or until the suspicion of a leak is proved to be
unwarranted.
NOTICE
Accumulated grease and/or oil on an engine is a fire
hazard. Remove the accumulated grease and oil. Re-
fer to this Operation and Maintenance Manual, “En-
gine - Clean” for more information.
• Ensure that the cooling system hoses are correctly
clamped and that the cooling system hoses are
tight. Check for leaks. Check the condition of all
pipes.
• Inspect the water pump for coolant leaks.
Note: The water pump seal is lubricated by the
coolant in the cooling system. It is normal for a small
amount of leakage to occur as the engine cools down
and the parts contract.
Excessive coolant leakage may indicate the need
to replace the water pump seal. For the removal of
the water pump and the installation of water pump
and/or seal, refer to the Disassembly and Assembly
Manual, “Water Pump - Remove and Install” for more
information or consult your Perkins dealer or your
Perkins distributor.
• Inspect the lubrication system for leaks at the front
crankshaft seal, the rear crankshaft seal, the oil
pan, the oil filters and the rocker cover.
• Inspect the fuel system for leaks. Look for loose
fuel line clamps and/or tie-wraps.
• Inspect the piping for the air intake system and the
elbows for cracks and for loose clamps. Ensure
that hoses and tubes are not contacting other
hoses, tubes, wiring harnesses, etc.
• Inspect the alternator belts and any accessory
drive belts for cracks, breaks or other damage.
78 SEBU7833-03
Maintenance Section
Water Pump - Inspect

Belts for multiple groove pulleys must be replaced as

matched sets. If only one belt is replaced, the belt will
carry more load than the belts that are not replaced.
The older belts are stretched. The additional load on
the new belt could cause the belt to break.

• Drain the water and the sediment from the fuel

tank on a daily basis in order to ensure that only
clean fuel enters the fuel system.

• Inspect the wiring and the wiring harnesses for

loose connections and for worn wires or frayed
wires.

• Inspect the ground strap for a good connection and

for good condition.

• Disconnect any battery chargers that are not

protected against the current drain of the starting
motor. Check the condition and the electrolyte level
of the batteries, unless the engine is equipped with
a maintenance free battery.

• Check the condition of the gauges. Replace any

gauges that are cracked. Replace any gauge that
can not be calibrated.

i01907756

Water Pump - Inspect

A failed water pump may cause severe engine

overheating problems that could result in the following
conditions:

• Cracks in the cylinder head

• A piston seizure
• Other potential damage to the engine
Note: The water pump seal is lubricated by the
coolant in the cooling system. It is normal for a small
amount of leakage to occur as the engine cools down
and parts contract.

Visually inspect the water pump for leaks. Renew

the water pump seal or the water pump if there
is an excessive leakage of coolant. Refer to the
Disassembly and Assembly Manual, “Water Pump
- Remove and Install” for the disassembly and
assembly procedure.
SEBU7833-03 79
Warranty Section
Warranty Information

Warranty Section

Warranty Information
i01903596

Emissions Warranty
Information

This engine may be certified to comply with exhaust

emission standards and gaseous emission standards
that are prescribed by the law at the time of
manufacture, and this engine may be covered by an
Emissions Warranty. Consult your authorized Perkins
dealer or your authorized Perkins distributor in order
to determine if your engine is emissions certified and
if your engine is subject to an Emissions Warranty.
80
Index Section
Index
A E
After Starting Engine ............................................. 30
After Stopping Engine............................................ 32
Aftercooler Core - Clean/Test ................................ 52
Aftercooler Core - Inspect...................................... 52
Alternator - Inspect ................................................ 53
Alternator and Fan Belts - Inspect/Adjust/
Replace................................................................ 53
Adjustment ......................................................... 53
Inspection........................................................... 53
Replacement...................................................... 54
B Clean/Replace ..................................................... 61
Battery - Replace................................................... 54
Battery Electrolyte Level - Check .......................... 54
Battery or Battery Cable - Disconnect ................... 55
Before Starting Engine .................................... 10, 28
Burn Prevention....................................................... 7
Batteries............................................................... 8
Coolant................................................................. 8
Oils....................................................................... 8
C Engine Identification .............................................. 19
Cold Weather Operation........................................ 33
Hints for Cold Weather Operation...................... 33
Idling the Engine ................................................ 34
Recommendations for Coolant Warm Up .......... 34
Recommendations for the Coolant .................... 33
Viscosity of the Engine Lubrication Oil............... 33
Cold Weather Starting ........................................... 29
Cooling System Coolant - Change ........................ 58
Cooling System Coolant (Commercial Heavy-Duty) -
Change ................................................................ 55
Drain .................................................................. 55
Fill ...................................................................... 56
Flush .................................................................. 56
Cooling System Coolant (ELC) - Change.............. 57
Drain .................................................................. 57
Fill ...................................................................... 58
Flush .................................................................. 57
Cooling System Coolant Extender (ELC) - Add..... 59
Cooling System Coolant Level - Check ................. 59
Engines With a Coolant Recovery Tank............. 59
Engines Without a Coolant Recovery Tank........ 59
Crushing Prevention and Cutting Prevention ........ 10
D Fire Prevention and Explosion Prevention .............. 8
Driven Equipment - Check..................................... 60
SEBU7833-03
Electrical System .................................................... 11
Grounding Practices .......................................... 12
Emergency Stopping ............................................. 32
Emissions Certification Film .................................. 20
Label for compliant engines ............................... 20
Label for engines that comply with MSHA
emissions ......................................................... 22
Label for engines that do not comply with
emissions ......................................................... 22
Emissions Warranty Information............................ 79
Engine - Clean....................................................... 60
Engine Air Cleaner Element (Dual Element) -
Cleaning the Primary Air Cleaner Elements ...... 62
Servicing the Air Cleaner Elements ................... 61
Engine Air Cleaner Element (Single Element) -
Inspect/Replace ................................................... 63
Engine Air Cleaner Service Indicator - Inspect...... 63
Test the Service Indicator................................... 63
Engine Description ................................................ 16
Engine Cooling and Lubrication ......................... 18
Engine Service Life ............................................ 18
Engine Specifications......................................... 16
Engine Ground - Inspect/Clean ............................. 64
Engine Lifting......................................................... 24
Engine Mounts - Inspect........................................ 64
Engine Oil and Filter - Change .............................. 65
Drain the Engine Oil........................................... 65
Fill the Engine Crankcase .................................. 67
Replace the Element for the Oil Filter ................ 66
Replace the Spin-on Oil Filter ........................... 66
Engine Oil Level - Check ....................................... 64
Engine Oil Sample - Obtain ................................... 64
Obtain the Sample and the Analysis.................. 65
Engine Operation................................................... 31
Engine Starting ................................................. 11, 28
Engine Stopping ............................................... 11, 32
Engine Storage...................................................... 24
Cooling System.................................................. 25
Exhaust System ................................................. 25
General Items .................................................... 26
Induction System ............................................... 25
Lubrication System ............................................ 24
Engine Valve Lash - Inspect/Adjust ....................... 67
Engine Warm-up.................................................... 31
F
Fire Extinguisher .................................................. 9
Lines, Tubes and Hoses ...................................... 9
SEBU7833-03
Fluid Recommendations........................................ 38
Cooling System Specifications........................... 45
ELC Cooling System Maintenance .................... 47
Engine Oil .......................................................... 39
Fuel Specifications............................................. 42
General Lubricant Information ........................... 38
Foreword ................................................................. 4
California Proposition 65 Warning ....................... 4
Literature Information........................................... 4
Maintenance ........................................................ 4
Maintenance Intervals.......................................... 4
Operation ............................................................. 4
Overhaul .............................................................. 4
Safety................................................................... 4
Fuel and the Effect from Cold Weather ................. 35
Fuel Conservation Practices.................................. 31
Fuel Injector - Test/Change ................................... 68
Removal and Installation of the Fuel Injectors ... 69
Fuel Related Components in Cold Weather .......... 36
Fuel Filters ......................................................... 36
Fuel Heaters ...................................................... 36
Fuel Tanks.......................................................... 36
Fuel System - Prime .............................................. 69
Fuel System Primary Filter (Water Separator)
Element - Replace ............................................... 70
Fuel System Primary Filter/Water Separator -
Drain .................................................................... 70
Fuel System Secondary Filter - Replace ............... 71
Element filter ...................................................... 71
Spin-on filter....................................................... 72
Fuel Tank Water and Sediment - Drain ................. 73
Drain the Water and the Sediment..................... 73
Fuel Storage Tanks ............................................ 73
Fuel Tank ........................................................... 73
G (2) Ether ............................................................... 5
Gauges and Indicators .......................................... 27
General Hazard Information .................................... 6
Containing Fluid Spillage ..................................... 7
Fluid Penetration.................................................. 7
Pressure Air and Water........................................ 7
H Starting with Jump Start Cables ............................ 30
Hoses and Clamps - Inspect/Replace ................... 74
Replace the Hoses and the Clamps .................. 74
I Table of Contents..................................................... 3
Important Safety Information ................................... 2
Lifting and Storage ................................................ 24
81
Index Section
M
Maintenance Interval Schedule ............................. 51
Maintenance Section ............................................. 37
Model View Illustrations......................................... 13
1103 Engine Model Views.................................. 15
1104 Engine Model Views.................................. 13
Model Views .......................................................... 13
Mounting and Dismounting.................................... 10
O
Operation Section.................................................. 24
P
Product Identification Information .......................... 19
Product Information Section .................................. 13
R
Radiator - Clean .................................................... 75
Reference Numbers .............................................. 19
Record for Reference......................................... 19
Refill Capacities..................................................... 37
Cooling System.................................................. 37
Lubrication System ............................................ 37
S
Safety Messages ..................................................... 5
(1) Universal Warning .......................................... 5
Safety Section ......................................................... 5
Serial Number Plate .............................................. 19
Severe Service Application - Check ...................... 75
Environmental Factors ....................................... 76
Incorrect Maintenance Procedures .................... 76
Incorrect Operating Procedures......................... 76
Starting Motor - Inspect ......................................... 76
Starting the Engine ................................................ 29
Stopping the Engine .............................................. 32
T
Turbocharger - Inspect (If Equipped)..................... 76
Inspecting........................................................... 77
Removal and Installation.................................... 76
82 SEBU7833-03
Index Section

Walk-Around Inspection ........................................ 77

Inspect the Engine for Leaks and for Loose
Connections ..................................................... 77
Warranty Information ............................................. 79
Warranty Section ................................................... 79
Water Pump - Inspect............................................ 78
Product and Dealer Information
Note: For product identification plate locations, see the section “Product Identification Information” in the Operation
and Maintenance Manual.

Delivery Date:

Product Information
Model:

Product Identification Number:

Engine Serial Number:

Transmission Serial Number:

Generator Serial Number:

Attachment Serial Numbers:

Attachment Information:

Customer Equipment Number:

Dealer Equipment Number:

Dealer Information
Name: Branch:

Address:

Dealer Contact Phone Number Hours

Sales:

Parts:

Service:
Copyright © 2008 Perkins Engines Company Limited Printed in U.K.
All Rights Reserved