code 57.0100.4200 - rev. 0 07/2005 self-loading dumper mixer mariner 25g...

Self-loading dumper mixer

MARINER 25G - 35G

OPERATOR HANDBOOKCode 57.0100.4200 - Rev. 0 07/2005

CAUTION: THOROUGHLY READ AND UNDERSTAND THIS HANDBOOK BEFORE OPERATING THE MACHINECAUTION: KEEP THIS HANDBOOK IN THE MACHINE AT ALL TIMES

English Edition

Mariner 25G Mariner 35GFrom s-n 11748 11743

To s-n 19060 18653

Operator handbook 57.0100.4200 - MARINER 25G - 35G

No part of this publication may be reproduced, stored in a retrieval system or transmitted in any formor by any means without prior written permission from TEREXLIFT srl.In pursuing a policy of constant quality improvement, TEREXLIFT srl reserves the right to makechanges at any time and without undertaking to give prior notice; therefore, also this publicationmay be subject to modifications.Some photos or drawings have been used to illustrate a specific function; as a result, they may notrefer to the machine treated in this manual.

© Copyright 2005 TEREXLIFT srl - All rights reserved.

Produced by:

DEALER’S OR ASSISTANCE CENTRE STAMP

ZONA INDUSTRIALE I-06019 UMBERTIDE (PG) - ITALIATel. +39 075 941811 - Fax +39 075 9415382

Technical Assistance ServiceTel.: +39 075 9418129Tel.: +39 075 9418171

e-mail: [email protected]

LIST OF REVISED PAGES

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Document 57.0100.4200 - 07/2005

Self-loading dumper mixer MARINER 25G - 35G

■ INTRODUCTION

This handbook provides information for a safe andproper operation and maintenance of the machine.

STRICTLY COMPLY WITH THE INSTRUCTIONSGIVEN IN THIS HANDBOOK!

READ AND UNDERSTAND THIS HANDBOOKBEFORE STARTING, USING AND CARRYING

OUT ANY OPERATION WITH AND ON THEMACHINE.

The handbook is divided into seven sections:

Sect. A GENERAL INFORMATIONSect. B SAFETYSect. C OPERATING INSTRUCTIONSSect. D MAINTENANCESect. E TROUBLESHOOTINGSect. F OPTIONAL ACCESSORIESSect. G TABLES AND ENCLOSURES

Section A contains general concepts that are decisivefor the knowledge of the main parts of the machine.It also contains all necessary data for a correctidentification of the machine, the technical features ofthe machine, etc.

Section B is especially addressed to the personnel,who shall operate, repair and service the machine, and,in case of companies with a wide fleet of machines, tothe safety responsible.It describes the essential compulsory qualities of thepersonnel in charge and other important informationfor the safety of persons and things.

Section C is mainly addressed to the operators whooperate the machine. This section illustrates all controldevices.Additionally, it contains the main use instructions -i.e.engine starting, machine parking, machine storing.

Section D is addressed to the maintenance responsibleand the servicemen.The section describes the maintenance schedule andthe relevant intervals.

Section E deals with the failure diagnostics.

Section F makes a list of the optional accessories whichcan be installed on the machine, their functions,characteristics, application field and limits.

Section G contains tables and various encloseddocuments like load charts, wiring diagrams, hydraulicschemes, torque wrench setting table, etc.

Sections are subdivided into chapters and paragraphsthat are numbered progressively.

The quickest way to look for an information is thereference to the general index or the titles of the singlechapters and paragraphs that represent keys for aneasy consultation.

Take care of this handbook and keep it in anaccessible place within the machine, evenafter its reading, so that it will always bewithin reach if in doubt.

If you are unsure about anything, please address toTEREXLIFT Assistance Service or to your agent/dealer: addresses, phone and fax numbers areprinted in the cover and in the title-page of thismanual.

IMPORTANTAny difference between the contents of this manualand the real functional character of the machinecan be attributed to either a machine manufacturedbefore the issue of this manual or to a manual goingto be updated after some changed effected on themachine.Always contact Terexlift Assistance Service for anyupdated version of this manual and any additionalinformation.Before contacting the Technical Assistance Service,take note of the machine model and serial number.

INTRODUCTION

Document 57.0100.4200 - 07/2005


■ SYMBOLS

When using the machine, operators could have to facesome situations requiring special care and particularknowledge.

When these situations involve the safety of operatorsor bystanders, the machine efficiency and properutilisation, this handbook stresses these specificinstructions by means of SPECIAL SYMBOLS.

There are six special (or safety) symbols in this manual,always combined with keywords that class the situationsaccording to their danger degree.

The symbols are always followed by a text explainingthe situation taken into account, the attention to bepaid to such situation, the method and the behaviour tobe adopted. When necessary, it stresses prohibitionsor supplies instructions to prevent dangers.

Sometimes, it can be followed by illustrations.

We list below the special (or safety) symbols accordingto the relative seriousness of the hazard situation:

DANGERDraws the attention to situations that involve yourown as well as the others’ safety and that can resultin serious or lethal injury.

ELECTRICALDANGER

Draws the attention to situations that involve yourown as well as the others’ safety and that can resultin serious injury or lethal injury.

CAUTIONDraws the attention either to situations that involveyour own as well as the others’ safety and that canresult in minor or moderate injury or to situationsthat involve the machine efficiency.

ATTENTIONDraws the attention to situations that involve themachine efficiency.

IMPORTANTDraws the attention to important technicalinformation or practical advice that allows for asafer and more efficient use of the machine.

PROTECT THEENVIRONMENT

Draws the attention to important environment-related information.

WHEN READING THIS MANUAL, PAY THEGREATEST ATTENTION TO THESE SPECIALSYMBOLS AND THE EXPLANATION OF THE

SITUATIONS THEY EMPHASIZE.

The manual in electronic format also contains thefollowing symbol:

which enables the user to return to thetable of contents

INTRODUCTION

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GENERAL INDEX

GENERAL INFORMATION Sect. A

SAFETY Sect. B

OPERATING INSTRUCTIONS Sect. C

MAINTENANCE Sect. D

TROUBLESHOOTING Sect. E

OPTIONAL ACCESSORIES Sect. F

TABLES AND DOCUMENTS ENCLOSED Sect. G

GENERAL INDEX

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GENERAL INFORMATION

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Section A

GENERAL INFORMATION

TABLE OF CONTENTS

A-1 CONVENTIONAL REFERENCES................................................................................ A-2

A-1.1 Machine position ........................................................................................................ A-2

A-1.2 Labels and warning plates applied on the machine ................................................... A-3

A-1.3 Explanation of the different symbols used on the machine ....................................... A-5

A-2 MACHINE IDENTIFICATION....................................................................................... A-7

A-2.1 Machine model and type ............................................................................................ A-7

A-2.2 Manufacturer .............................................................................................................. A-7

A-2.3 Machine identification plates...................................................................................... A-8

A-2.4 CE marking ................................................................................................................. A-8

A-2.5 Chassis serial number ................................................................................................ A-8

A-2.6 Identification plates of the main parts ........................................................................ A-8

A-3 ALLOWED USE .......................................................................................................... A-9

A-3.1 Allowed use ................................................................................................................ A-9

A-3.2 Improper use .............................................................................................................. A-9

A-3.3 Residual hazards ........................................................................................................ A-9

A-3.4 Applicable standards.................................................................................................. A-10

A-3.5 Safety devices ............................................................................................................ A-10

A-4 GENERAL DESCRIPTION .......................................................................................... A-11

A-4.1 List of the main components ...................................................................................... A-11

A-4.2 Description of the main components ......................................................................... A-12

A-4.3 Optional accessories .................................................................................................. A-12

A-5 TECHNICAL DATA AND PERFORMANCE ................................................................. A-13

A-5.1 Main dimensions ........................................................................................................ A-13

A-5.2 Weight ........................................................................................................................ A-14

A-5.3 Speed ......................................................................................................................... A-14

A-5.4 Dumper mixer perfomances ....................................................................................... A-14

A-5.5 Diesel engine .............................................................................................................. A-14

A-5.6 Electrical system ........................................................................................................ A-14

A-5.7 Machine sound levels ................................................................................................. A-14

A-5.8 Vibration levels ........................................................................................................... A-14

A-6 LIFETIME .................................................................................................................... A-15

A-7 ITEMS SUPPLIED....................................................................................................... A-15

A-7.1 Literature supplied ...................................................................................................... A-15

GENERAL INFORMATION

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A-1 CONVENTIONAL REFERENCES

■ A-1.1 MACHINE POSITION

Conventionally the machine should be consideredpositioned as shown in the figure.This convention is necessary to make any reference ofthis handbook to different machine parts (front, rear,etc.) clear and unmistakable.Any exception to this rule will always be specified.

UPPER PART

REAR PART

LEFT SIDE

FRONT PART

RIGHT SIDE

LOWER PART

CLOCKWISECOUNTER-FRAME ROTATION

ANTICLOCKWISECOUNTER-FRAME ROTATION

ANTICLOCKWISEDISCHARGE CHUTE

ROTATION

CLOCKWISE DISCHARGECHUTE ROTATION

GENERAL INFORMATION

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■ A-1.2 LABELS AND WARNING PLATESAPPLIED ON THE MACHINE

We list below the labels and warning plates which arenormally applied on standard machines or which couldbe applied when special optional accessories aremounted on the machine.

IMPORTANTThe familiarisation with these labels is never awaste of time.Make sure they are easy to read. For this purpose,clean them or replace those that becomeunreadable (either graphic or text).To clean labels, use of a soft cloth, water and soap.Never use solvents, petrol, etc.When a label is applied on a part to be replaced,make sure that the replaced part is already labelledas required or apply a new label.

KEEP OUT OFWORKING RANGE

VIETATO APRIRE CON MOTORE IN MOTODO NOT OPEN WHILE ENGINE IS RUNNINGN'OUVRIR QU'A L'ARRET DU MOTEURÖFFNEN NUR BEI STILLSTEHENDEM MOTORABRIR SOLO CON MOTOR PARADOPROIBIDO ABRIR COM O MOTOR LIGADO

VERBODEN KOFFERBAK TE OPENEN WANNEER DE MOTOR DRAAIT.

C H A N G E M E C H A N I C A LGEAR ONLY WHEN THEMACHINE IS STATIONARY

Description:red/white label “Keep out of the working range ofthe machine”.

Meaning:when the machine is running, entering the workingrange of the machine is prohibited.

Location:on the hopper.

Description:label on yellow background “Do not open whileengine is running”.

Meaning:do not open the engine bonnet when engine is running,since this may result in serious injury due to movingparts or hot components.

Location:on the engine bonnet.

Description:label on yellow background "Do not changemechanical gear when the machine is running".

Meaning:changing mechanical gears when the machine is runningmay result in serious damage to the gearbox.

Location:in the cab, on the top strut.

GENERAL INFORMATION

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WARNINGBEFORE OPERATING THE PUMP, MAKE SURE THE WASH

DOWN GUN IS OPEN.09.4618.0344

Description:label on yellow background withblack drawing "Hot surfaces. Riskof burns".

Meaning:Applied on those surfaces which during operation canbecome hot and cause burns.

Location:In all parts involved such as exhaust silencer, thermalengine, heat exchanger.

Description:label on yellow background withblack drawing "Unscrew the plugwith extreme caution: hot water.Risk of burns!".

Meaning:Warns the operator of the risk of burns when unscrewingthe plug of the compensation tank of the heat exchanger.

Location:Applied on the compensation tank of the fluid of theheat exchanger.

XXDescription:label with yellow background and black inscriptionshowing the “Guaranteed sound power level".

Meaning:it indicates the guaranteed sound power level measuredin accordance with the Directive 2000/14/EC.

Location:on the glass, inside the driving place.

Description:label on yellow background.

Meaning:Open the cock of the washing gun before putting thepump into operation.

Location:in the cab, on the top strut.

GENERAL INFORMATION

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■ A-1.3 EXPLANATION OF THE DIFFERENTSYMBOLS USED ON THE MACHINE

This paragraph illustrates those symbols that arenormally applied on the main control devices andinstruments of a standard machine, and those that canbe applied on accessories or optional attachments.They are mainly (ISO) standardised symbols that arenow part of the common life. But we consider useful toexplain them once again.

Symbol Description

Hazard warning lights

Windscreen wiper

Windscreen washer

Cab ventilation fan

Engine coolant temperature indicator

Position lights

High beam

Beacon

Low beam

Turn signals

Parking brake

Battery charge

Fuel level

Stop lights

Symbol Description

Back-up horn cutoff

Brake pressure

Steering mode switch

Differential locking

1st mechanical gear

2nd mechanical gear

Transmission disengaged

High hydraulic gear

Counter-frame rotation lock

Counter-frame rotation release

Drum charging

Drum discharge

Engine oil pressure

Hydraulic oil temperature

IMPORTANTSpend the necessary time to become familiar withthese symbols and to learn their meaning.

GENERAL INFORMATION

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Symbol Description

ASPIRAZIONE

SUCTIONSUCTION

ASPIRAZIONE

SUCTION

MANDATA

DELIVERY

MANDATA

DELIVERY

MANDATA

DELIVERY

Water intake from external source

Water delivery to wash down gun

Water intake from machine tank

Water delivery to machine tank

Water delivery to drum

Symbol Description

GENERAL INFORMATION

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A-2 MACHINE IDENTIFICATION

IMPORTANTCheck that the operator handbook refers to thedelivered machine.When asking for information or technicalassistance, always specify model, type and serialnumber of the machine.

■ A-2.1 MACHINE MODEL AND TYPEOff-road self-loading mobile mixer:

❑ model MARINER 25G

❑ model MARINER 35G

■ A-2.2 MANUFACTURERTEREXLIFT srlZona Industriale (Ind. Estate) - I-06019 UMBERTIDE(PG) - ITALY

Enrolled in the register of companies at the Court ofPerugia under no. 4823

C.C.I.A.A. n° 102886

Fiscal Code/V.A.T. no. 00249210543

GENERAL INFORMATION

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■ A-2.3 MACHINE IDENTIFICATION PLATES

� Machine data plate and road traffic data plateThe data plate of the machine is located in thedriving cab, on the seat supporting frame to theaccess door side.

The data plate contains the main identification dataof the machine like model, serial number and yearof manufacture.

On the machines destined for the Italian market,this plate also contains the road traffic related dataand the weights of the specific model of the machine.

■ A-2.4 CE MARKING

This machine fulfils the safety requirements of theMachinery Directive.The conformity has been certifiedand the placing of the CE marking on the machinedemonstrates compliance with the regulatoryrequirements.The CE marking is placed directly on the identificationplate of the machine �.

■ A-2.5 CHASSIS SERIAL NUMBER

The chassis serial number � is punched on the rightside of the machine, above the front wheel.

■ A-2.6 IDENTIFICATION PLATES OF THE MAINPARTS

The plates of the main components, not directlymanufactured by TEREXLIFT srl (for instance, engines,pumps, etc.), are located where originally applied bythe manufacturers.

200

kgkg

kg

kg

ZONA INDUSTRIALE - 06019 UMBERTIDE (PG) - ITALYTel. +39 075 941.811 Fax +39 075 941.53.82

MODELLO - MODEL - MODELE - TYP - MODELO

ANNO DI COSTRUZIONE - YEAR OF CONSTRUCTION - ANNEE DE CONSTRUCTIONBAUJAHR - AÑO DE FABRICACIÓN

MATRICOLA - SERIAL N. - N. DE SERIE - FZ.-IDENT NR. - NO. DE SERIE

OMOLOGAZIONE

FABBRICATO IN ITALIA - MADE IN ITALY

PESO MAX ASSALE ANT. - MAX FRONT AXLE WEIGHT - POIDS MAX ESSIEU AVANTZUL. ACHSLAST VO. N. ST VZO - PESO MAX EJE ANTERIOR

PESO MAX ASSALE POST. - MAX REAR AXLE WEIGHT - POIDS MAX ESSIEU ARRIEREZUL. ACHSLAST HI. N. ST VZO - PESO MAX EJE POSTERIOR

PESO TOTALE - TOTAL WEIGHT - POIDS TOTAL - ZUL. GESAMTGEWICHT N. ST VZOPESO TOTAL

MATRICOLA MOTORE TERMICO - ENGINE SERIAL N. - N. MOTEUR THERMIQUEFABRIK NR. DIESEL MOTOR - NO. DE SERIE MOTOR TERMICO

POTENZA MOTORE TERMICO - ENGINE POWER - PUISSANCE MOTEURMOTORLEISTUNG - POTENCIA MOTOR

CARICO STATICO VERT. GANCIO DI TRAINO-MAX.VERTICAL LOAD ONTHE COUPLING HOOK-EFFORT VERTICAL MAXIMAL SUR LE CROCHET D'ATTELAGEMAXIMALE STUTZLASTBEANSPRUCHUNG DES ZUGHAKENS IN VERTIKALER RICHTUNG-ESFUERZO VERTICAL SOBRE EL GANCHO DE TRACCION

MASSA MAX. RIMORCHIABILE - MAX.DRAWBAR PULL AT THE COUPLING HOOKEFFORT THE TRACTION - MAXI AU CROCHET D'ATTELAGE-MAXIMALEZUGBEANSPRUCHUNG AM ZUGHAKEN-MAXIMO ESFUERZO DE TRACCION EN ELGANCHO DE TRACCION

kW

kg

kg

�

�

GENERAL INFORMATION

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A-3 ALLOWED USE

■ A-3.1 ALLOWED USE

The self-loading dumper mixers of the MARINER series,models 25G-35G, have been designed andmanufactured for producing, transporting and layingconcrete.

Any other use is considered contrary to that establishedand, therefore, improper.

The compliance with and the strict respect of theoperation, maintenance and repair conditions, indicatedby the Manufacturer, represent an essential part of theallowed use.

The use, maintenance and repair of the self-loadingdumper mixer shall be carried out by skilled operatorsonly, who have the necessary knowledge of the machinespecial features and the safety precautions to be taken.

It is also essential to comply with the safety at worklegislation, the precautions concerning safety andindustrial medicine as well as the local and nationalroad traffic regulations.

ATTENTIONEffecting changes or carrying out interventions onthe machine other than those of routinemaintenance is expressly forbidden. Anymodification of the machine not carried out byTEREXLIFT or an authorised assistance centreinvolves the automatic invalidation of theconformity of the machine to the Directive 98/37/EC.

■ A-3.2 IMPROPER USE

By improper use we mean a utilization of the MARINER25G-35G self-loading dumper mixers following workingcriteria which do not comply with the instructions ofthis manual, and, in general, which jeopardize yourown’s as well as the others’ safety.

DANGERWe list below some of the most frequent andhazardous situations of improper use:- Carrying passengers on the dumper mixer- Not strictly complying with the operation and

maintenance instructions of this handbook- Working beyond the dumper mixer utilization limits- Working on unstable edges of a ditch, on

excavation borders or on extremely soft grounds- Driving crosswise on slopes or hills- Working during a storm- Working on steep slopes- Using the bucket to level the ground or lift materials- Using the bucket to lift passengers- Using optional accessories for other utilizations

than those recommended- Using optional accessories which are not

approved or manufactured by TEREXLIFT- Working in potentially explosive areas- Working in confined and non-ventilated

environments.

■ A-3.3 RESIDUAL HAZARDSAlthough the machine has been designed andmanufactured according to the latest technology andall expected hazards have been eliminated, someoperations performed by the machine operator canresult in potentially hazardous situations. Among them:• Hazards deriving from a too high work or transfer

speed in relation to the load handled or the groundcondition of the jobsite.

• Hazards deriving from work procedures adoptedduring the check or replacement of a block valve(residual pressure - uncontrolled movements).

• Hazards deriving from work procedures adoptedwhile disassembling parts of the machine -e.g. thecylinders, without supporting mobile parts suitably(risk of uncontrolled fall of the mobile part).

GENERAL INFORMATION

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■ A-3.4 APPLICABLE STANDARDS

For the operator’s safety, the following standards wereobeyed during the risk assessment of the handler fittedwith telescopic boom:

Directive Title

98/37/CE Machinery Directive

89/336/CEE Electromagnetic compatibility

2000/14/CE Environment Acoustic Emissions

Standard Title

ISO 3449:1992 Earth-moving machinery - Falling-objectprotective structures - Laboratory testsand performance requirements.

EN 13510: 2002 Earth-moving machinery - Roll-overprotective structures - Laboratory testsand performance requirements.

ISO 3776:1989 Tractors for agriculture - Seat beltanchorages.

ISO 3795:1989 Road vehicles, tractors and machineryfor agriculture and forestry -Determination of burning behaviour ofinterior materials.

EN 13059:2002 Safety of industrial trucks - Test methodsfor measuring vibration

EN 50081-1: 1997 Electromagnetic compatibility – Genericrequirements on emissions - Part 1

EN 50082-1: 1997 Electromagnetic compatibility – Genericrequirements on immunity - Part 1

EN 60204-1:1998 Safety of machinery - Electricalequipment of machines - Part 1

UNI 10929: 05/2001 Self-loading mobile mixers - Definitions,terminology and classification

UNI 11023: 03/2003 Self-loading mobile mixers - Safetyrequirements

■ A-3.5 SAFETY DEVICES

• Block valves fitted to all cylinders:- Block valve on lifting cylinder

• Proximity switches:� Sensor on the parking brake which prevents the

machine from starting if the brake is not put.

�

GENERAL INFORMATION

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A-4 GENERAL DESCRIPTION

■ A-4.1 LIST OF THE MAIN COMPONENTS

11 14 1 13 4 6

8 9 23 7

14 4

5 3

12

2

10

15 16 17

18 19 20 21 22

1 - Drum2 - Water tank3 - Bucket lifting booms4 - Beacon5 - Driving cab6 - Engine compartment7 - Rear axle8 - Access step9 - Front axle

10 - Bucket11 - Hopper12 - Discharge chute13 - Rotating counter-frame14 - Rearview mirror15 - Water control lever16 - Drum rotation reduction gear17 - Fuel tank cap18 - Water intake pipe union19 - Water filter20 - Water tank21 - Sliding roller22 - Wash down gun23 - Water pump

GENERAL INFORMATION

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■ A-4.2 DESCRIPTION OF THE MAIN COMPONENTS

Hydrostatic transmission unitThis unit consists of parts which drive the machineshifting, and namely:- variable displacement pump connected to the

thermal engine by an elastic joint- variable displacement engine applied on the

gearbox and allowing to select two differenthydraulic gears

- hydraulic oil filter, placed on the suction line of thepump

- heat exchanger for the circuit cooling

Two-speed gearbox/reduction gearThe reduction gear/gearbox is fitted with two speeds(a working speed and a travel speed) to be selectedby the appropriate pushbutton in the cab; theircombination with the two hydraulic gears enables theoperator to select among four gears. The mechanicalgear can be selected only when the machine isstationary. From the gearbox through two cardanshafts, the motion is transmitted to the front and rearaxles, fitted with differential gear.

Steering axles/(front and rear) differential gearsThe differential axles transmit the motion to the wheels.Thanks to a locking device acting on the front axle,the vehicle can move also on grounds with low grip.

TyresThe machine is fitted with tyres suitably dimensionedfor the maximum load allowable on the dumper mixer.When worn, they should be replaced with new tyreshaving the same dimensions and payload.

Drum rotation hydraulic circuitIt consists of a closed-circuit hydrostatic transmission.A variable displacement pump operates the flangedengine to the drum reduction gear through two deliverybranches.

Hydraulic steering circuitA single gear pump feeds a Load-Sensing valve. Whenrequired, this valve feeds oil to the hydraulic steering.Otherwise, it feeds oil to the service distributor.

Brake hydraulic circuitA gear pump feeds the braking circuit. When notrequired by this system, oil is diverted to the servicecircuit. The brake discs, in oil bath, are located insideboth axles.

Service hydraulic systemThe same pump feeding the hydraulic steering circuitfeeds a distributor for the following functions:- loading bucket lifting and lowering- bucket rotation- discharge chute rotation and lifting- water pumping

Mixing drumIt consists of a container fitted inside with doublewearproof steel propellers for the ingredient mixing.Outside, it is equipped with a manhole used forinspections and emergency discharges.It is secured to a steel profile frame fitted with flewring, negative hydraulic brake and mechanical lockingdevice.

Loading bucketArticulated, hydraulically driven.

Discharge chuteThe hydraulically rotating and tilting main chute ismounted on the frame. It is equipped with twoadditional chutes housed in the lower part of the frame.

Water systemSide communicating tanks with self-priming pumphaving 200 lt/min delivery; litre-counter up to 500 ltinside the cab; wash down gun.

■ A-4.3 OPTIONAL ACCESSORIES

The machine can be fitted with a wide range of optionalaccessories: please address to TEREXLIFT salesnetwork.

IMPORTANTPlease check the accessories available for yourmachine.

GENERAL INFORMATION

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A-5 TECHNICAL DATA AND PERFORMANCE

■ A-5.1 MAIN DIMENSIONS MARINER 25G MARINER 35G

A Height with raised bucket mm 3950 3960B Minimum height with lowered bucket mm 3080 3150C Width at wheels mm 2000 2250D Height at discharging chute mm 1535 1700E Rear overhang mm 1350 1400F Wheelbase mm 2200 2400G Length with raised bucket mm 4900 5400H Length with lowered bucket mm 6565 7050I Ground clearance mm 380 400L Overall width mm 2370 2440M Front overhang mm 1350 1600N Side discharging overhang mm 1080 1170

R1 Internal steering radius mm 1350 1055R2 External steering radius mm 3500 3540R3 Maximum steering radius mm 4160 4480

D

I

C

L N

E F M

G

H

B

A

R3

R2R1

GENERAL INFORMATION

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■ A-5.2 WEIGHT MARINER 25G MARINER 35G

- Working weight kg 5800 7100

■ A-5.3 SPEED- Travel speed km/h 0÷28 0÷28- Max. slope with full load % 41 38- Maximum lateral stability % 30 35

■ A-5.4 DUMPER MIXER PERFOMANCES- Drum geometric volume lt 4000 5050- Concrete yield m3 2,5 3,5- Filling coefficient 0,62 0,69- Drum inclination 14° 14°- Drum rotation speed g/m' 19 18- Minimum cycle time m' 13 15- Loading bucket capacity lt 420 450- Water tank capacity lt 550 650

■ A-5.5 DIESEL ENGINE Aspirated version Turbo version- Make PERKINS PERKINS- Model / Type 1004.42 1104C-44T- Features: Diesel Diesel

4 cylinders in line 4 cylinders in line4 strokes 4 strokes

direct injection direct injection- Bore x Stroke mm 103 x 127 105 x 127- Total displacement cc 4232 4400- Power at 2300 r.p.m. kW 63 74,4

■ A-5.6 ELECTRICAL SYSTEM- Voltage V 12 12- Battery Ah 155 155

■ A-5.7 MACHINE SOUND LEVELS- Guaranteed sound power level

(in accordance with the Directive 2000/14/CE) dB Lwa = 114 Lwa = 112

- Measured sound pressure level(in accordance with the Directive 98/37/CE) dB Lpa = 80 Lpa = 77

■ A-5.8 VIBRATION LEVELS- Mean assessed vibration level transmitted to arms m/s2 < 2.5 < 2.5- Mean assessed vibration level transmitted to body m/s2 < 0.5 < 0.5

IMPORTANTThis is a Class A device. In a residential environment, such device can cause radio disturbance. In suchcases, the operator is required to take suitable measures

GENERAL INFORMATION

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A-6 LIFETIME

The lifetime of the machine is 10000 hours providedall checks, service jobs and overhauls are done at thetimes scheduled.

DANGERAfter this time, the machine must compulsorily beinspected and tested by the Manufacturer beforebeing used again.

A-7 ITEMS SUPPLIED

Following items are supplied together with themachine:

Description MARINER 25G 35G- 12 V lamps ✘ ✘

■ A-7.1 LITERATURE SUPPLIED

The machines comes with the following literature:

- Warranty and handing over certificate

- Machine operator's handbook

- Spare parts catalogue

- Engine use and maintenance manual

GENERAL INFORMATION

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SAFETY

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Section B

SAFETY

TABLE OF CONTENTS

B-1 GENERAL REMARKS ................................................................................................. B-2

B-2 PREREQUISITES OF THE PERSONNEL IN CHARGE ............................................... B-2

B-2.1 Requisites of the machine operators ......................................................................... B-2

B-2.2 Requisites of the servicemen ..................................................................................... B-3

B-2.3 Working clothes.......................................................................................................... B-3

B-2.4 Personal protective equipment .................................................................................. B-3

B-3 SAFETY PRECAUTIONS ............................................................................................ B-4

B-3.1 Job site ....................................................................................................................... B-4

B-3.2 Getting ready to work ................................................................................................. B-5

B-3.3 During work or maintenance ...................................................................................... B-5

B-4 SAFETY DEVICES ...................................................................................................... B-7

SAFETY

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B-1 GENERAL REMARKS

Most accidents occurring while working, repairing ormaintaining operation machines, are caused by notcomplying with the basic safety precautions.Therefore, it is necessary to pay steady attention tothe potential hazards and the effects that may comeof operations carried out on the machine.

IMPORTANTIf you recognise hazardous situations, you canprevent accidents!

For instance, this handbook makes use of specialsafety symbols to stress any potentially hazardoussituation.

CAUTIONThe instructions given in this handbook are theones established by TEREXLIFT. They do not excludeother safe and most convenient ways for themachine installation, operation and maintenancethat take into account the available spaces andmeans.

If you decide to follow instructions other than thosegiven in this manual, you shall absolutely:• be sure that the operations you are going to carry

out are not explicitly forbidden;• be sure that the methods are safe, say, in

compliance with the rules and provisions given inthis section;

• be sure that the methods cannot damage themachine directly or indirectly or make it unsafe;

• contact TEREXLIFT Assistance Service for anysuggestion and the necessary written permission.

IMPORTANTIf in doubt, it is always better to ask! For thispurpose, contact TEREXLIFT: the assistance serviceis at your disposal. Addresses, phone and faxnumbers are given in the cover and in the title-pageof this manual.

B-2 REQUISITES OF THEPERSONNEL IN CHARGE

■ B-2.1 REQUISITES OF THE MACHINEOPERATORS

The operators who use the machine regularly oroccasionally (i.e. for transport reasons) shall have thefollowing prerequisites:health:before and during any operation, operators shall nevertake alcoholic beverages, medicines or othersubstances that may alter their psycho-physicalconditions and, consequently, their working abilities.physical:good eyesight, acute hearing, good co-ordination andability to carry out all required operations in a safe way,according to the instructions of this manual.mental:ability to understand and apply the enforced rules,regulations and safety precautions. They shall becareful and sensible for their own as well as for theothers’ safety and shall desire to carry out the workcorrectly and in a responsible way.emotional:they shall keep calm and always be able to evaluatetheir own physical and mental conditions.training:they shall read and familiarise with this handbook, itsenclosed graphs and diagrams, the identification andhazard warning plates. They shall be skilled and trainedabout the machine use.

IMPORTANTThe operator shall have a licence (or a drivinglicence) when provided for by the laws enforced inthe country where the machine works. Please, askthe competent bodies. In Italy the operator mustbe at least 18 year old.

SAFETY

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■ B-2.2 REQUISITES OF THE SERVICEMENThe personnel charged with the machine maintenanceshall be qualified, specialised in the maintenance ofpublic works machines, and shall have the followingrequisites:physical:good eyesight, acute hearing, good co-ordination andability to carry out all required maintenance operationsin a safe way, according to this manual.mental:ability to understand and apply the enforced rules,regulations and safety precautions. They shall becareful and sensible for their own as well as for theothers’ safety and shall desire to carry out the workcorrectly and in a responsible waytraining:they shall read and familiarise with this handbook, itsenclosed graphs and diagrams, the identification andwarning plates. They shall be skilled and trained aboutthe machine functioning.

IMPORTANTFrom a technical point of view, the ordinarymaintenance of the machine is not a complexintervention and can be carried out by the machineoperator, too, provided he has a basic knowledgeof mechanics.

■ B-2.3 WORKING CLOTHESDuring work, but especially when maintaining orrepairing the machine, operators must wear suitableprotective clothing:• Overalls or any other comfortable garments.

Operators should wear neither clothes with largesleeves nor objects that can get stuck in movingparts of the machine.

• Protective helmet.• Protective gloves.• Working shoes.

IMPORTANTUse only type-approved working clothing in goodcondition.

■ B-2.4 PERSONAL PROTECTIVE EQUIPMENTUnder special working conditions, the followingpersonal protective equipment should be used:• Breathing set (or dust mask).• Ear-protectors or equivalent equipment.• Goggles or facial masks.

IMPORTANTUse only type-approved protective equipment ingood condition.

SAFETY

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B-3 SAFETY PRECAUTIONS

■ B-3.1 JOB SITEAlways take into account the features of the job sitewhere you are going to work:• Always examine the working area and compare it

with the machine dimensions in the differentworking phases.

ELECTRICALDANGER

Pay the greatest attention to overhead electriclines.Always stay a minimum safe distance of at least 6meters either from the drum upper part and fromthe raised loading bucket. Danger of electrocution.

CAUTIONMake sure the machine rests on a firm ground toprevent hazardous unstable conditions.If the ground is not firm enough, position somesupporting planks under the wheels. These platesmust grant a specific pressure of 1.2 to 1.5 kg/cm2

(500x500mm plates are sufficient).

• If you shall change the accessories of the machineor part of it on site, you need a fitted area of suitabledimensions. The surface shall be level, compactand stable.

• Look for the best route to the job site.• When the machine is running, nobody can enter its

working range.• While working, keep the working area in order. Never

leave objects scattered: they could hinder themachine movements and represent a danger forpersonnel.

• In presence of trenches, space the wheels to keepat a safe distance from the trench edge.

DANGERDo not at any time use the machine during a storm.

A ≥ B

A

B

SAFETY

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■ B-3.2 GETTING READY TO WORKBefore any operation, following precautions should betaken:

• First of all, make sure that the maintenanceinterventions have been carried out with careaccording to the established schedule (see sectionD - Maintenance).

• Ensure you have enough fuel to avoid a suddenstop of the engine, especially during a crucialmanoeuvre.

• Clean instruments, data plates, lights and the cabwindscreen thoroughly.

• Check the correct functioning of all the safetydevices installed on the machine and in the job site.

• In case of troubles or difficulties, inform the foremanat once. Never start working under unsafeconditions.

• Do not carry out any repair work in a makeshift wayto start working!

• Make sure the back-up horn has been activated.

IMPORTANTIn some countries, the back-up horn must bedeactivated. Strictly abide by any local and nationalregulations.

■ B-3.3 DURING WORK OR MAINTENANCEDuring work, and especially maintenance, always paythe greatest attention:• Do not walk or stop under raised loads or machine

parts supported by hydraulic cylinders or ropes only.• Keep the machine handholds and access steps

always clean from oil, grease or dirt to prevent fallsor slips.

• When entering/leaving the cab or other raised parts,always face the machine; never turn the back.

• When carrying out operations at hazardous heights(over 1.5 meters from the ground), always use type-approved safety belts or fall preventing devices.

• Do not get into or off the machine when it is running.

• Do not leave the driving place when the machine isrunning, unless expressly foreseen in this manual.

• Neither stop nor carry out interventions under orbetween the machine wheels when engine isrunning. When maintenance in this area is required,stop the engine.

• Do not carry out maintenance or repair works

without a sufficient lighting.• When using the machine lights, the beam should

be oriented in order not to blind the personnel atwork.

• Before applying voltage to electric cables orcomponents, check their connection and properfunctioning.

• Do not carry out interventions on electriccomponents with voltage over 48V.

• Do not connect wet plugs or sockets.• Plates and hazard warning stickers shall never be

removed, hidden or become unreadable.

SAFETY

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• Except for maintenance purposes, do not removesafety devices, shields, protection cases, etc.Should their removal be necessary, stop the engine,remove them with the greatest care and alwaysremember to refit them before starting the engineand using the machine again.

• Before any maintenance or repair work, stop theengine and disconnect the batteries.

• Do not lubricate, clean or adjust moving parts.• Do not carry out operations manually when specific

tools are provided for this purpose.• Absolutely avoid to use tools in bad conditions or

in an improper way i.e. pliers instead of adjustablewrenches, etc.

• Before carrying out operations on hydraulic linesunder pressure or disconnecting hydrauliccomponents, ensure the relevant line has beenpreviously depressurised and does not contain anyhot fluid.

DANGERAny intervention on the hydraulic circuit must becarried out by authorised personnel.The hydraulic circuit of this machine is fitted withpressure accumulators. You and others could beseriously injured if accumulators are not completelydepressurised.For this purpose, shut the engine down and stepon the brake pedal 8÷10 times.

• Neither smoke nor use open flames in areas subjectto fire dangers and in presence of fuel, oil orbatteries.

SAFETY

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• Do not leave fuel cans or bottles in unsuitableplaces.

• Do not empty catalytic mufflers or other vesselscontaining burning materials without taking thenecessary precautions.

• Carefully handle all flammable or dangeroussubstances.

• Do not tamper with fire-extinguishers or pressureaccumulators: explosion hazard!

• After any maintenance or repair work, make surethat no tool, cloth or other object has been left withinmachine compartments, fitted with moving parts,or where suction and cooling air circulates.

• When working, do not give instructions or signs toseveral people at the same time. Instructions andsigns must be given by one person only.

• Always pay the due attention to the instructionsgiven by the foreman.

• Never distract the operator during working phasesor crucial manoeuvres.

• Do not call an operator suddenly, if unnecessary.• Do not frighten an operator or throw objects by no

means.• After work, never leave the machine under

potentially dangerous conditions.

B-4 SAFETY DEVICES

DANGERSeveral safety devices have been fitted to themachine. They must never be tampered with orremoved (see chap. A-3.5).

Regularly check the efficiency of such devices (seecheck card, chap. G-5).

In case of faults, stop working immediately andproceed in replacing the defective device.

For the checking procedures, read chap. D-3.19.

SAFETY

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OPERATING INSTRUCTIONS

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Section C


TABLE OF CONTENTS

C-1 BEFORE ENTERING THE MACHINE ........ C-2C-2 ENTERING THE MACHINE ....................... C-3C-2.1 Entering the cab ........................................ C-3C-2.2 Emergency exit-way ................................. C-4C-2.3 Adjusting the seat ..................................... C-4C-2.4 Adjusting the rear view mirrors ................. C-5C-2.5 Switching on the cab interior lamp ........... C-5C-3 DRIVING PLACE ....................................... C-6C-3.1 Controls and instruments ......................... C-6C-3.1.1 Controls and instruments inside the cab .. C-6C-3.1.2 Outside controls ....................................... C-8C-3.2 Engine controls and instruments .............. C-9C-3.2.1 Ignition switch ........................................... C-9C-3.2.2 Forward/reverse gear switch .................... C-9C-3.2.3 Brakes ..................................................... C-10C-3.2.4 Accelerator control ................................. C-10C-3.2.5 Lights - horn switch ................................ C-11C-3.2.6 Steering mode selection ......................... C-12C-3.2.7 Turn signals switch ................................. C-12C-3.2.8 Mechanical gearbox controls ................. C-12C-3.2.9 Hydraulic gear changeover switch ......... C-13C-3.2.10 Differential locking pushbutton ............... C-13C-3.2.11 Drum loading/unloading pushbutton ...... C-13C-3.2.12 Counter-frame locking button ............. C-14C-3.2.13 Auxiliary drive controls ............................ C-14C-3.3 Instruments and light indicators ............. C-16C-3.3.1 Instruments ............................................. C-16C-3.3.2 Light indicators ....................................... C-16C-3.4 Outside controls ..................................... C-17C-3.5 Control lever............................................ C-18C-3.5.1 Function selection ................................... C-19C-4 SETUP..................................................... C-20C-4.1 Before starting the engine ...................... C-20C-4.1.1 Checks at the machine start-up ............. C-20C-4.2 Starting the engine .................................. C-20C-4.3 Jump-starting the engine ........................ C-21

C-4.3.1 Low temperature starting ........................ C-22C-4.4 Disconnecting the battery ....................... C-22C-4.5 Starting the machine ............................... C-23C-4.6 Stopping and parking the machine ......... C-23C-5 USING THE DUMPER MIXER ................. C-24C-5.1 Water circuit ............................................ C-25C-5.1.1 Refilling the water pump ......................... C-26C-5.1.2 Draining the water circuit ........................ C-26C-5.1.3 Refilling the tanks ................................... C-27C-5.1.4 Charging the drum with water ................ C-28C-5.2 Working cycle ......................................... C-29C-5.2.1 Charging aggregates .............................. C-29C-5.2.2 Charging cement .................................... C-31C-5.2.3 Checking the consistency and fluidity

of the mix ................................................ C-32C-5.2.4 Charging the remaining quantity of water C-32C-5.3 Trasportation ........................................... C-33C-5.4 Laying the mix ......................................... C-33C-5.4.1 Mounting the additional chutes .............. C-34C-5.4.2 Rotating the counter-frame ................. C-35C-5.5 End of the working cycle ........................ C-35C-6 TRANSPORTING THE MACHINE ........... C-36C-6.1 Moving a disabled machine .................... C-36C-6.1.1 Gearbox in neutral .................................. C-36C-6.2 Road or work site transfer ...................... C-36C-6.3 Lifting the machine ................................. C-37C-6.4 Transport on other vehicles .................... C-37C-6.5 Parking and storage ................................ C-38C-6.5.1 Short inactivity ........................................ C-38C-6.5.2 Machine storage ..................................... C-38C-6.6 Cleaning and washing the machine ........ C-39C-6.6.1 Cleaning instructions .............................. C-39C-6.6.2 Washing instructions .............................. C-39C-6.7 Machine disposal .................................... C-39C-6.7.1 Battery disposal ...................................... C-39


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INTRODUCTION

This section provides the operator a practical guidefor the gradual learning of the machine use.The operator should get into the driving cab and carryout the preliminary adjustments, then memorise theposition of the different controls and instruments.The familiarisation with the controls ensures not only acorrect use during the working phases, but also aprompt and timely intervention of the operator, whenhe shall carry out sudden manoeuvres to safeguardhis safety and the machine integrity.It is necessary to learn how to use and foresee themachine reactions. Learn how to operate the machinecontrols in a safe and open place, without obstaclesand anybody standing around. Do not ram the controls.Operate them slowly to understand their effect on themachine.

C-1 BEFORE ENTERING THEMACHINE

Checks and cleaning• Clean glasses, lights and rear view mirrors.• Check that pins, joints and bolts are well tightened

in position.• Check for oil, water, fuel or coolant leaks.

Checking the tyres• Check the correct inflation of the tyres; see par.

“Tyre inflation” in the Maintenance section.• Make sure that the tyre plies are not cut or worn.

DANGERA tyre burst may result in serious injury; never usethe machine if tyres are worn, wrongly inflated ordamaged.


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C-2 ENTERING THE MACHINE

■ C-2.1 ENTERING THE CAB

CAUTIONAlways make sure that your hands and shoe solesare clean and dry before getting into the drivingcab. Always face the machine when entering andleaving it and hold to the suitable handles.

The access door of the dumper mixer cab is locatedon the right side.

Door opening from outside:• Insert the key and release lock �.• Open the door by the built-in handle.

Door closing from inside:• Turn knob � counter-clockwise to unlatch the door.• Pull the door with force: it locks automatically.

Door opening from inside:• Lift lever � and release the lock to open the door

completely.

To open the upper door section:• Rotate handle � to open only the upper section of

the door; rotate it completely until it locks againstthe catch.

�

�

�

�

CAUTIONIf the upper door section is not latched onto thelower section, swing it fully open and latch it ontothe special safety catch.


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■ C-2.2 LEAVING THE CAB IN ANEMERGENCY

In an emergency, use the rear window of the cab assafety exit-way.This window has special locking handles with a redplastic pin that, once broken, allow opening the glass.

■ C-2.3 ADJUSTING THE SEAT

A correct adjustment of the seat assures the operatora safe and comfortable driving. The seat of the dumpermixer is fitted with two devices which allow to adjustthe distance from the controls and the springing.

• Seat distance from the controlsTo slide the seat forward or back, lift lever � andpush the seat to the desired direction. Then releasethe lever and make sure the seat is locked inposition.

• Seat springingRotate knob � clockwise or anticlockwise untilachieving the required springing. Rotate the knobclockwise to increase the seat springing;anticlockwise to reduce the seat springing.

DANGER• The seat is for one person only.• Don't adjust the seat when the machine is

moving.

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�


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■ C-2.4 ADJUSTING THE REAR VIEW MIRRORS

The machine is fitted with two rear view mirrors:

• Mirror � is located on a special supporting bracketin advanced position and enables the operator tocheck the area behind the machine, on the left. Toadjust the mirror, manually turn the joint it is fittedwith.

• Mirror � is placed on the right upper post of thewindscreen and allows to check the area behindthe machine, on the right. To adjust its position,manually turn the joint it is fitted with.

��

■ C-2.5 SWITCHING ON THE CAB INTERIORLAMP

The ceiling light fixture of the cab has an internal lampand a courtesy lamp.

To switch on the cab interior lights:• Switch � in pos. A cab interior lights OFF

• Switch � in pos. B cab interior lights ON

• Switch � in pos. C courtesy lamp ON

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�

�

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C-3 DRIVING PLACE

■ C-3.1 CONTROLS AND INSTRUMENTS

■ C-3.1.1 Controls and instruments inside the cab

1 Ignition switch

2 Forward/reverse gear selector

3 Lights switch

4 Steering mode switch

5 Turn signals switch

6 Warning lights - 1st and 2nd gear engaged

7 Mechanical gear change pushbutton

8 Hydraulic gear switch

9 Differential locking pushbutton

10 Drum charge/discharge pushbutton

11 Counter-frame rotation locking/release pushbutton

12 Hazard warning lights switch

13 Beacon switch

14 Back-up horn switch

15 Fuse box

16 Hydraulic oil temperature gauge

17 Coolant temperature gauge

18 Fuel gauge

19 Hourmeter

20 Warning light - battery discharge

21 Warning light - low engine oil pressure

22 Warning light - turn signals

23 Warning light - position lights

24 Warning light - high beam

25 Warning light - parking brake engaged

26 Warning light - low brake pressure

27 Warning light - low engine coolant temperature

28 Wiper switch

29 Windscreen washer pushbutton

30 Fan switch

31 Gas pedal

32 Brake pedal

33 Parking brake

34 Service pressure gauge

35 Drum pressure gauge

36 Manual accelerator

37 Seat position adjustment

38 Seat springing adjustment

39 Bucket control lever

40 Discharge chute lifting/lowering lever

41 Discharge chute rotation lever

42 Counter-frame rotation

43 Water pump and safety cylinder release lever

44 Litre-counter

45 Warning light - air filter clogged

46 Cab heater control cock


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4080

120

°C

4080

120

°C

01/2

4/4

R

N

R

F

44

1

3

7

9

10

11

13 14 45 15 16 17 18

19 20 21

22 23 24 25 26

2712

24

5

68

2829

30

313234 35 37

39

33

36

38

40

41

42

43

46


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■ C-3.1.2 Outside controls

50 Selection lever for water intake from externalsource

51 Selection lever for water utilization

52 Wash down gun

53 Battery cutout switch

MANDATA

DELIVERY

MANDATA

DELIVERY

ASPIRAZIONE

SUCTIONSUCTION

MANDATA

DELIVERY

ASPIRAZIONE

SUCTION

50 51

53

52


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■ C-3.2 ENGINE CONTROLS AND INSTRUMENTS

■ C-3.2.1 Ignition switch (ref. 1)Four-position switch:

No circuit under voltage (except for hazardwarning lights and stop lights which are alwayspowered); key can be removed and engine isstopped

Thermostarter for cold climates. Turn the key tothis position and hold it for 10÷15 seconds, thenturn it to pos. I to start the engine.

Circuits under voltage, presetting for the enginestarting. Board controls and instruments are on.

Engine starting; when released, key springs backautomatically to pos. I.

■ C-3.2.2 Forward/reverse gear selector switch(ref. 2)

Three-position switch:

N Neutral position; no speed engaged

F Shifting the lever to pos. F selects the forwardspeed

R Shifting the lever to pos. R selecst the reversespeed

1

N

R

F

2


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■ C-3.2.3 Brakes

Brake pedal (ref. 32)Push down on the brake pedal to decelerate or stopthe machine. It operates on the axle shafts of bothaxles.

Parking brake (ref. 33)To engage the brake, pull upward while pushing therelease button. When the light 25 is ON, release thebutton. It operates on the axle shafts of the rear axleand, when engaged, it cuts off both forward and reversegear.

ATTENTIONNever use the parking brake to slow down themachine, unless in an emergency, since this wouldreduce the brake efficiency.

■ C-3.2.4 Accelerator control

Gas pedal (ref. 31)Its pressure controls the engine rpm and, coupled tothe gearbox, the machine speed.

Gas lever (ref. 36)Pull the lever upward to increase the engine r.p.m.gradually. The handle rotation allows to lock it inposition.

3233

31

36


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■ C-3.2.5 Lights - horn switch (ref. 3)

Lights are selected by rotating the switch to one of the five positionsprovided:

stop lights

Allows to switch the position lights on,independently from the position of the ignitionswitch 1 (therefore, also when key is removed)

lights off

position lights on

low beam on

high beam on

by pressing the switch, the horn switches on,independently from other preset functions.

0

A

B

C

D

E

A

B

C

D

E


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■ C-3.2.6 Steering mode selection (ref. 4)

Three-position switch for the selection of the steeringmode:

� Crab steering

� Two-wheel steering

� Four-wheel steering

ATTENTIONTo prevent any wheel misalignment between frontand rear axle, steer when the wheels of both axlesare straight.If necessary, re-align the wheels according to theinstructions of chapter D-3.17.

■ C-3.2.7 Turn signals switch (ref. 5)

Set lever to the left to indicate a leftturn; or to the right to indicate a rightturn.

■ C-3.2.8 Mechanical gearbox controls

Mechanical gearbox pushbutton (ref. 7)For changing between 1st and 2nd gear.Press the button to select the requiredspeed. Each pressure corresponds to theselection of a new gear and, when shifting,the red warning light on the button lightsand indicates that the transmission isdisengaged.

Warning lights - 1st and 2nd gear engaged (ref. 6)

They show the gear selected throughbutton 7.The light under the glass corresponding tothe selected speed lights up.

ATTENTIONDo not change mechanical gears when the machineis running.

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�

N

R

F

45 6

7

9

8

10


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■ C-3.2.9 Hydraulic gear changeover switch (ref. 8)

Two-position switch for selecting therequired hydraulic speed. The speedselection is signalled by the switch built-inwarning light.It is possible to change hydraulic speedalso when the machine is running, whichis not possible with mechanical gears.

The two hydraulic speeds are used in combination withthe mechanical gears.It is advisable to select the 1st mechanical gear forworking operations and the 2nd gear for transfers, byengaging the low or high hydraulic speed accordingto the needs.

■ C-3.2.10 Differential locking pushbutton (ref. 9)

Push and hold this button pushed to lockthe differential. The locking is signalled bythe warning light on the button.

ATTENTIONThe differential locking control shall be used onlyon rectilinear routes and before an excessiveskidding of a wheel. Before operating this control,slow down the engine r.p.m.

■ C-3.2.11 Drum loading/unloading pushbutton(ref. 10)

It allows to check the speed and rotation direction ofthe mixing drum:

Position �: rotation for loadingoperations

Position �: rotation for unloadingoperations

Push the button to start the drum rotation in one of thetwo directions. The rotation speed increases graduallyuntil the button is hold down; release the button whenthe drum rotates at the desired speed.

ATTENTIONThe drum speed depends on the Diesel enginer.p.m.

To increase the drum speed, push the button in theposition corresponding to the present rotation direction(for instance: in pos. �, if the drum is rotating incharging direction).To decrease the drum speed, push the button in theposition opposite to the present rotation direction (forinstance: in pos. �, if the drum is rotating in chargingdirection).In the same way, it is possible to stop the drum rotationand reverse the rotation direction.

6

7

9

8

10

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■ C-3.2.12 Counter-frame locking button (rif. 11)

Fitted with two positions, itallows to couple/release thecounter-frame rotation block.

To couple or release the block:

• Shift lever 43 to position �.

• Hold the button down for about 3 seconds to couple(pos. �) or release (pos. �) il blocco the rotationblock.

• Shift lever 43 to position 0.

ATTENTIONThe counter-frame rotation block shall always becoupled when the counter-frame is in rest position.

■ C-3.2.13 Auxiliary drive controls

12 Hazard warning lights switchFitted with on-off position, it switches on theturn signals simultaneously

13 Beacon switchPress to switch on the beacons installed onthe machine. The warning light on the buttonlights when beacons are ON.

14 Back-up horn switchIt controls the back-up horn functioning. Thewarning light on the button lights when hornis ON.

15 Fuse boxBefore replacing the fuses, see par. “Fuses” in theMaintenance section.

28 Wiper switchThree-position switch:

0 Off1 Single speed2 Double speed

29 Windscreen washer buttonWhen pushed, it sprays a jet of detergentsolution on the windscreen and makes thewiper functioning easier.

30 Cab fan switchThree-position switch:

0 Off1 Low speed2 High speed.

R

N

R

F

F1

F2

F3

F4

F5

F1

0F

11

F1

2F

13

F1

4

F6

F7

F8

F9

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43

1412

11

15

13

30

2928

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34 Services pressure gaugeShows the pressure of the services hydraulic circuit.

35 Drum pressure gaugeIndicates the pressure of the rotation hydraulic circuitof the mixing drum.

37 Seat position adjustmentSee relevant preliminary description, par. C-2.2.

38 Seat springing adjustmentSee relevant preliminary description, par. C-2.2.

44 Litre-counterMeasures the water amount introduced into the drum.It is fitted with:

• variable reference index S• draining cock T• reset lever U.

46 Cab heater control cockLocated on the left side of the driving seat base.• Turn the cock clockwise to switch off heated air..• Turn the cock clockwise to switch on the cab

heater.• Adjust the flow of heated air in the cab operating

the A/C fan switch 30.

S

U

T

34 35

38

37

44

46

46


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■ C-3.3 INSTRUMENTS AND LIGHT INDICATORS

■ C-3.3.1 Instruments

16 Hydraulic oil temperature gaugeSignals the oil temperature in the hydraulic circuits. Ifthe temperature rises above the maximum threshold,stop the machine and find and rectify the problem.

17 Engine coolant temperature indicatorSignals the engine coolant temperature. If the fingerreaches the red zone and the warning light 27 comeson, stop the machine and find and rectify the problem.

18 Fuel gaugeSignals the fuel level within the tank.If the finger reaches the red zone, refuel within shorttimes.

ATTENTIONDo not use up all the fuel in the tank; air could enterthe suction pipeline.

19 Hour-meterSignals the total operating hours of the machine. Usethe hour-meter to gauge the routine maintenance jobs.

■ C-3.3.2 Light indicators

20 Warning light - low battery chargeSignals a low charge by the alternator

21 Warning light - low engine oil pressureIt lights when the engine oil pressure is too low.

22 Warning light - turn signalsGreen indicator light that signals when turnsignals are ON.

23 Warning light - position lightsGreen warning light which signals when positionlights are switched on.

24 Warning light - high beamBlue indicator light that signals when high beamis ON

25 Warning light- parking brake engagedWarning light which indicates when parkingbrake is engaged (it blinks when lever is pulledto stroke end).

26 Warning light - low brake pressureIt lights when the pressure of the braking circuitis too low for a correct functioning.

27 Warning light - coolant temperatureWhen this warning light and the indicator 17 areon, the engine coolant is getting overheated inan anomalous way.

45 Air filter cloggedThis lights comes ont to warn that the engineair filter is clogged. Clean or change the filterelements.

4080

120

°C

4080

120

°C

01/2

4/4

R

18 1916 17

22

23

2021

2627

24

25

45


Page C - 17Document 57.0100.4200 - 07/2005


■ C-3.4 OUTSIDE CONTROLS

The controls used for refilling water are located outside the drivingcab, on the right side of the machine (see photo).

50 Lever for selecting the water intake sourceTwo-position lever:

A When the lever is shifted to this position, water is takenfrom the two communicating tanks the machine is fittedwith.

B When the lever is shifted to this position, water is takenfrom an external source.

51 Selection lever for water utilizationThree-position lever:

C Delivers water to the mixing drum.

D Delivers water to the machine tanks.

E Delivers water to the wash down gun.

52 Wash down gunUsed for cleaning the machine external body: it distributes water athigh flowrate and low pressure. It is controlled by lever 43 (waterpump) and is fitted with an ON/OFF cock.

53 Battery disconnect switchDisconnects the battery from the electrical system (for any furtherinformation see paragraph C-4.4).

B

A

D

E

C

50

51

52

53

ASPIRAZIONE

SUCTION

ASPIRAZIONE

SUCTIONSUCTION

MANDATA

DELIVERY

MANDATA

DELIVERY

MANDATA

DELIVERY


Page C - 18Document 57.0100.4200 - 07/2005


■ C-3.5 CONTROL LEVER

The machine is equipped with a control joystick foroperating the different movements of the bucket.

On the control board, there are other four levers foroperating the discharge chute, the water pump andthe safety cylinder for the counter-frame rotation.

IMPORTANTSeize the control lever correctly and move it gently.The motion speed of the actuators depends on thelever position: a small motion results in a slowmotion of the actuators; vice versa, a full rangemotion of the lever corresponds to the max. speedof the actuator.

CAUTIONThe control lever shall be operated only whencorrectly seated in the driving place.

CAUTIONBefore operating the control lever, make sure thatnobody is within the working range of the machine.


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■ C-3.5.1 Function selection

Control levers can perform the following functions:

39 Bucket control leverOne-lever four-function distributor which controls allthe bucket movements:

A Raises the bucket booms

B Lowers the bucket booms

C Retracts the bucket

D Opens the bucket

40 Discharge chute tilting leverTwo-function distributor driving the discharge chutelifting/lowering:

1 Lifts the main chute

2 Lowers the main chute

41 Discharge chute rotation leverTwo-function distributor operating the discharge chuterotation:

3 Rotates the main chute anticlockwise

4 Rotates the main chute clockwise

42 Counter-frame rotationTwo-functions distributor operating the counter-framerotation which is integral with the drum:

5 Rotates the counter-frame anticlockwise

6 Rotates the counter-frame clockwise

ATTENTIONThe counter-frame rotation can be operated onlywhen the rotation block is released.

43 Water pump and safety cylinder release leverTwo-functions distributor which controls the waterpump operation and the safety cylinder release:

7 Starts the water pumping, after the selection ofthe feeding source and the water destination (seepar. C-3.4).

0 Neutral inactivity position.

8 Operates the rotation locking/releasing circuit forthe following switching by means of button 11(see par. C-3.2.12).

39

40

41

42

43

DC

B

A

1

3

5

2

4

6

56

12

43

7 80

A

DC

B 39

11


Page C - 20Document 57.0100.4200 - 07/2005


C-4 SETUP

■ C-4.1 BEFORE STARTING THE ENGINE

• To ensure safe conditions to the operators and thebystanders, and a longer life to your machine,perform a walk-around inspection before startingthe engine.

• Remove any dirt or rubbish from the cab interior,and especially from pedals and control levers.

• Remove oil, grease and mud from pedals andcontrol levers.

• Make sure that your hands and shoe soles are cleanand dry.

• Check that lights, indicators, side/tail lights, hazardindicator lights, wipers and horn are in workingorder.

• Adjust the driving seat so that you can reach allcontrol levers comfortably and fully depress thebrake pedal without moving your back from thedriving seat.

• Adjust the rear view mirrors to give you a good viewclose behind the machine when you are correctlyseated.

• Ensure the battery cutout switch is set to position (ON) (see par. C-4.4).

• Check the parking brake is engaged.

■ C-4.1.1 Checks at the machine start-up

At the machine starting check the efficiency of thesafety devices as described in chap. D-3.19, namely:• Machine start control• Parking brake proximity switch

■ C-4.2 STARTING THE ENGINE

• Thoroughly read chapt. C-4.1 before starting theengine.

• Set the forward/reverse gear switch to the neutralposition N.

• Engage the parking brake and ensure that warninglight 25 comes on.

IMPORTANTThe engine cannot be started if the parking brakeis not engaged.

• Rotate the ignition switch toposition : beacons and back-up horn switch on for about 3÷4seconds signalling the enginestarting, then starter is operated.Release the ignition switch assoon as the engine starts. .

IMPORTANTWhile the starter is functioning, the board is notpowered (except for parking and hazard warninglights).

If the engine does not started within 20 seconds,release the key and wait at least 2 minutes beforeattempting again.

• When the engine starts, slow down the enginer.p.m. and wait some seconds before selecting thegear; this allows a gradual warm up of the engine oiland a better lubrication.

• In case of engine jump-starting, remove theconnecting cables (see following chapter).

CAUTIONWarning lights 20 and 21must switch off within a fewseconds from the enginestarting. If they dot notswitch off/on when engine isrunning, immediately stopthe machine and check thefault.

DANGEROnce it has been started, the engine continues torun even if you leave the driving place. DO NOTLEAVE THE DRIVING PLACE BEFORE HAVINGSHUT THE ENGINE DOWN, LOWERED THE BOOMTO THE GROUND AND ENGAGED THE PARKINGBRAKE.

20

21


Page C - 21Document 57.0100.4200 - 07/2005


■ C-4.3 JUMP-STARTING THE ENGINE

DANGERWhen jump-starting the engine through the batteryof another machine, make sure that the two vehiclescannot collide to prevent formation of sparks.Batteries give off a flammable gas and sparks mayburn it and cause an explosionDo not smoke when checking the electrolyte level.Keep any metal object like buckles, watch straps,etc. clear of the battery positive (+) terminal. Theseelements can short between the terminal andnearby metal work and the operator can getburned.The booster supply must have the same ratedvoltage and the same number of elements of thebattery installed on the machine.

To jump-start the engine:

• Turn any users off by the special control levers.

• Set the forward/reverse gear selector to neutralposition and engage the parking brake.

• Ensure the machine battery A is connected to theframe earth, the terminals are well tightened andthe electrolyte level is regular.

• Connect the two batteries as shown in the figure.Connect first the positive terminals of the twobatteries, then the negative terminal of the boostersupply B to the machine frame earth.

• If the booster supply is installed on a second vehicle,make sure that the latter does not touch the handler;then start the vehicle and reach an rpmcorresponding to 1/4 of full throttle.

• Start the dumper mixer by means of the ignitionswitch, following the procedure given in chapt. C-4.2 “Starting the engine”.

• Disconnect the cables. Remove first the negativeterminal from the frame earth, then from the boostersupply. Disconnect the positive terminal from themachine battery, then from the booster supply.

ELECTRICALDANGER

Use only a 12V battery; other devices like batterychargers, etc. may cause an explosion of the batteryor result in damage to the electrical system.

A

B


Page C - 22Document 57.0100.4200 - 07/2005


■ C-4.3.1 Low temperature starting

In case of cold starting, use an oil with a SAE viscosityadequate to the ambient temperature.Please refer to the engine use and maintenance manual.The machine is supplied with oil SAE 15W/40.

To start the engine from cold, proceed as follows:

• Set the forward/reverse gear switch to the neutralposition N.

• Engage the parking brake and ensure that warninglight 25 comes on.

• Hold the ignition switch to position for some 10-

15 seconds, then turn the same to position I to start

the engine. Turn the switch to position and

release as soon as the engine fires.

• Let the engine run at idle for a few seconds beforeputting a gear; this allows for a gradual warm up ofthe engine oil and a better lubrication.

■ C-4.4 DISCONNECTING THE BATTERY

Every time the machine stands still or before anymaintenance or repair, and especially before startingwelding, turn off the battery main switch located behindthe rear left wheel compartment.

Two-position switch:

ON Battery connected to the mains

OFF Battery disconnected from themains.

IMPORTANTThis switch cuts out the hazard warning lights andthe stop lights, as well.

ATTENTIONDisconnect the battery only when the ignitionswitch is set to position 0. Disconnecting thebattery while the Diesel engine is running mayresult in damages to the electric system.


Page C - 23Document 57.0100.4200 - 07/2005


■ C-4.5 STARTING THE MACHINE

When the engine reaches the running temperature,ensure that both drum and loading bucket are intransfer position and the forward/reverse gear selectoris set to neutral position. Then:

• Select a gear to suit the job you will be doing and theconditions of the working site.

• Select the required steering mode.

• Select the required gear (forward or reverse).

• Release the parking brake.

• Slowly step on the gas pedal to start moving off.

DANGERDo not operate the forward/reverse gear selectinglever when the machine is running. The hydrostatictransmission could be seriously damaged.

■ C-4.6 STOPPING AND PARKING THE MACHINE

Where possible, stop the machine on a dry, level andsolid ground. Then:

• Bring the machine to a smooth stop by easing upthe gas pedal and down on the brake pedal.

• Set the forward/reverse gear selector to neutralposition (N).

• Engage the parking brake and check its indicatorlights up.

• Release the brake pedal.

• Rotate the ignition switch key to “0” and remove thekey.

• Get off the driving cab and lock the cab door.

• Set the battery cutout switch to (OFF).

DANGERAlways face the machine when getting off thedriving cab; make sure your hands are dry andclean, and hold to the handles to avoid falls or slips.

DANGERAlways engage the parking brake after stoppingthe machine to prevent possible accidental motionsof the vehicle.


Page C - 24Document 57.0100.4200 - 07/2005


C-5 USING THE DUMPER MIXER

This chapter supplies the instructions for a safe use ofthe standard machine. Before using any optionalaccessories, read chapter “Optional accessories”.

CAUTIONTake into account any possible hazardousconditions of the working area before using themachine. Make sure there are no holes, foundationexcavations, moving banks or debris which cancause you to lose the control of the machine.

ELECTRICALDANGER

Pay the greatest attention when working close toelectric lines. Check their position and ensure thatno part of the machine operates at less than 6meters from the power lines.

ATTENTIONUnless expressly stated, the machine is consideredoperating with 1st gear both forward and in reverse.


Page C - 25Document 57.0100.4200 - 07/2005


■ C-5.1 WATER CIRCUIT

The water circuit of the dumper mixer consists of:

1 Water communicating tanks

2 Filling cock

3 Pump filling hose

4 Drum

5 Cock 506 Filter

7 Self-priming pump

8 Cock 519 Wash down gun

10 Pump empyting hose with cock

11 External refilling tank

12 Liter-counter

13 Emptying cock

14 Emptying cock

15 Filter

16 Suction hose

17 Mouth

• By means of valve 5 it is possible to take water fromtanks 1 or from an external source 11.

• Valve 8 delivers water to the drum (passing throughthe liter-counter 12), the wash down gun 9 or tanks1.

1 1

8

75

11

4

2 3

15

10

6

9

17

16

14

12

13


Page C - 26Document 57.0100.4200 - 07/2005


■ C-5.1.1 Refilling the water pump

To refill the water pump, operate as follows:

• Remove the cap from the water tank.

• Close cocks 10, 13 and 14 and open cock 2.

• Pour about 4÷5 litres of water through hose �, then closecock 2.

• Refit the tank cap.

■ C-5.1.2 Draining the water circuit

In case of long inactivity of the machine under weather conditionsclose to zero, it is necessary to remove any mix/water residuesfrom the drum and the water supplying circuits.

To discharge any residual mix, follow the instructions provided inpar. C-5.4 - “Laying the concrete”.• To drain out any residual water from the tanks, open cock 14

located under the right-hand tank.

• To drain out any residual water from the pump, open cock �.

• To drain out the water from the litre-counter, open cock 13.

IMPORTANTAfter emptying, the pump must be refilled with water beforeuse.

2

14

�

�

13


Page C - 27Document 57.0100.4200 - 07/2005


■ C-5.1.3 Refilling the tanksTanks may be refilled by the pump by sucking the water from anexternal source or by pouring water through the filling plug of oneof the two tanks.

Refilling by an external source through the pumpApproach to the water intake source with the machine andremember that the filling union is located in the rear part of thevehicle, on the right side.

• Connect the suction hose 16 to the filling union 17.

• Shift the selecting lever 50 to position B.

• Shift the selecting lever 51 to position D to deliver water to themachine tanks.

• Shift lever 43 to position 7: the self-priming pump startsfunctioning and the refilling operation begins.

• Stop pumping as soon as tanks are full (water flows out fromthe tank drains).

ATTENTION- Do not connect the filling union to sources of pressurized

water. Pump may get damage.- Avoid any pump idling.- If water flow is irregular, check the tightness of the filling

circuit and remove any possible air suction.- Use water without suspended particles to prevent filter

cloggings.

43

1

3

5

2

4

6

56

12

43

7 80

16

17

B

A

D

E

C

50

51


Page C - 28Document 57.0100.4200 - 07/2005


Refilling through the fillerUnscrew the filler of one of the two tanks and pour water using amax 1” duct.As soon as tanks are full, refit and tighten the plug.

ATTENTIONDo not use ducts having a higher diameter and make sureair may comes out from the opening. A pressure increasemay result in damages to the tanks.

■ C-5.1.4 Charging the drum with waterStart the drum rotation in charging direction using the specialbutton 10 on the dashboard, then:

• By means of the selecting lever 50, choose the water intakesource:- position B for taking water from external sources- position A for taking water from the machine tank

• Shift the selecting lever 51 to position C to deliver water to themixing drum.

• Shift lever 43 to position 7: the self-priming pump startsfunctioning and the refilling operation begins. The amount ofwater delivered to the tank is displayed by the liter-counter 44.

• Stop refilling when reaching 80% of the maximum allowedwater amount.

ATTENTIONWhen operating under weather conditions close to zerodegrees, do not leave any water inside the tanks and therelevant refilling and check circuits after refilling.

B

A

50

D

E

C

51

43

1

3

5

2

4

6

56

12

43

7 80

44

10


Page C - 29Document 57.0100.4200 - 07/2005


■ C-5.2 WORKING CYCLE

The recommended working cycle is the following:

• Water supply

• Charging 80% of the total required water

• Charging cement

• Charging aggregates (in the following order: sand,fine aggregate, coarse aggregate)

• Checking the consistency and fluidity of the mix(only for the first time, to check the water amountrequired for the mix type)

• Charging the remaining water quantity

• Transportation

• Discharge

■ C-5.2.1 Charging aggregates

Start the drum rotation in the charging direction usingthe special button 10 on the dashboard, and frontlyapproach the aggregate loading point; then:

10

D

A

DC

B 39��B• Rotate the bucket and set it in horizontal position.

IMPORTANTThe boom lifting device allows to keep the bucketinitial inclination unaltered with respect to theground. To adjust the bucket inclination, set lever39 to position D (retraction) or C (unloading).

• Lower the boom by shifting lever 39 to position B,until the loading bucket is level with the ground.


Page C - 30Document 57.0100.4200 - 07/2005


• Enter the heap with the bucket by slowly movingthe machine forward, and ensure that the machinewheels are straight and not steered.��

C A

A

C

ATTENTIONMoving toward the heap with steered wheels mayresult in serious damages to the lifting arms or themachine structure.

• Retract the bucket to its stroke end by setting lever39 to position C and move back from the heap.

• Lift the bucket to the maximum height by shiftinglever 39 to position A.

• Rotate the bucket and unload the content into thedrum by setting lever 39 to position C.


Page C - 31Document 57.0100.4200 - 07/2005


• Unload any aggregates in excess.

• Repeat the charging operations till loading theamount of aggregates required for the mix.

��D ■ C-5.2.2 Charging cementStart the drum rotation in the charging direction usingthe special button 10 on the dashboard, and approachthe cement loading point; then:

• Rotate the bucket and set it by 45° with respect tothe ground..

IMPORTANTThe boom lifting device allows to keep the bucketinitial inclination unaltered with respect to theground. To adjust the bucket inclination, operatelever 39 to position D (retraction) or C (unloading).

• Lower the boom on the ground by shifting lever 39to position B, until the loading bucket is level withthe ground.

• Charge the bucket with about 200÷250 kg of cement:break and empty the bags of cement into thebucket.

• Lift the bucket by setting lever 39 to position A, andposition it onto the hopper.

• Slowly discharge the content into the drum bysetting lever 39 to position C.

IMPORTANTIt is of the utmost importance that cement comesout very slowly to prevent it from flowing over thehopper and creating dust. During this phase, it isadvisable to increase the drum rotation speed tomaximum by accelerating the Diesel engine.

• Repeat the charging operations till loading theamount of cement required for the mix.

A

DC

B 39


Page C - 32Document 57.0100.4200 - 07/2005


■ C-5.2.3 Checking the consistency and fluidityof the mix

Before introducing the remaining 20% of water, it isrecommended to check the mix consistency:

• Move to the unloading point and set the chute to therequired position by operating lever 40 to adjust thetilting and lever 41 to adjust the rotation.

1

3

5

2

4

6

56

12

43

7 80

40

41

10

• Reverse the rotation direction of the drum by meansof button 10 on the dashboard, then discharge asmall amount of mix and visually check its fluidity.

• If necessary, repeat the water refilling operation bycompletely or partially introducing the remainingquantity of water to obtain the required density ofthe mix.

The consistency of the mix may be checked as wellthrough the pressure gauge 35 (see par. C-3.2.13):

• A pressure of about 70÷90 bar on the pressuregauge corresponds to a fluid mix

• A pressure of about 120÷130 bar on the pressuregauge corresponds to an average mix

• A pressure of about 150÷170 bar on the pressuregauge corresponds to a thick mix.

C-5.2.4 Charging the remaining quantity ofwater

To charge the remaining quantity of water and achievethe correct fluidity of the mix, proceed according to theinstructions given in chapter C-5.1.4.


Page C - 33Document 57.0100.4200 - 07/2005


■ C-5.3 TRASPORTATION

For road transfers, refer to the pertinent laws andregulations, and comply with the instructions below:

• Before travelling on roads, ensure the warningdevices are efficient.

• Switch the beacons on.

• Select 2-wheel steer.

• Reduce the rotation speed of the drum, so that thehydrostatic transmission has more power availableand, in case of long transfers, the concrete does notrisk to weaken.

IMPORTANTIt is recommended to discharge the concrete within30 minutes from its preparation.

It is not advisable to transport concrete for over 10km, to reduce the time between preparation andlaying and, especially when travelling at full loadand high speed, not to stress the hydrostatictransmission.

• During travel, booms andbucket must be raised andthe drum shall be incharging position; rotatethe counter-frame to restposition and lock it.

• Always select the 2nd gear. When travelling onslopes, stop the machine, engage the 1st speedand restart.

DANGERIt is absolutely forbidden to drive on slopes sideways;this wrong manoeuvre is one of the main reasonsfor vehicle overturnings.• Avoid abrupt startings or brakings.

• Drive to the unloading point with the greatestattention and ensure the machine speed suits theground condition to avoid dangerous jumps or sideskids of the vehicle.

CAUTIONDo not change mechanical gear when the vehicleis running.When travelling on public roads, strictly obey theroad traffic regulations of the country. In Italy, themax. allowed weight at full load is 18,000 kg.

■ C-5.4 LAYING THE MIX

Reach the unloading point, then:

• Stop the machine in the most suitable position.

• If necessary, rotate thecounter-frame to dischargethe concrete sideways.

DANGERThe drum rotation on the horizontal plane may becarried out only when the machine is level; on thecontrary, the machine stability could be seriouslyjeopardized.• Mount the additional chutes to reach the unloading

point of the concrete easily (see par. C-5.4.1).

• Position the unloading chute by operating levers 40(lifting-lowering) and 41 (rotation).

1

3

5

2

4

6

56

12

43

7 80

40

41 10


Page C - 34Document 57.0100.4200 - 07/2005


• By means of button 10 on the dashboard, reverse therotation direction of the drum and start unloading themix.

IMPORTANTThe discharge speed of the mix depends on therotation speed of the drum.

C-5.4.1 Mounting the additional chutes

If the discharge chute cannot reach the mix unloding pointeasily, it is possible to mount special additional chutes.For this operation, stop the machine on a solid and levelground and engage the parking brake, then:

• Unhook the safety chain � which locks the additionalchutes.

• Take out the additional element by lifting it with bothhands so that the slots come out from the locking pins�.

• Position the additional chute as shown in fig. C62 sothat the two slots enter the locking pins � on thedischarge chute perfectly.

DANGERSeize the additional chute correctly to prevent injuryto your hands.• Slowly release the additional chute so that it lays on the

discharge chute end.

• If necessary, repeat the above operations using asecond additional element; otherwise, hook the safetychain again.

ATTENTIONSet the forward/reverse gear selector to neutral,engage the parking brake and stop the Diesel enginebefore leaving the driving place unattended.

�

�

�

YES

NO


Page C - 35Document 57.0100.4200 - 07/2005


C-5.4.2 Rotating the counter-frame

The counter-frame rotation allows to discharge theconcrete sideways.The bucket can be used regularly when the counter-frame finds in the rest position C or in area A. Thebucket shall be laid on the ground before rotating thecounter-frame to the interference area B to avoid anycontact between drum and bucket booms.

To rotate the counter-frame:

• Release the counter-frame rotation block by meansof button 11. No counter-frame rotation is allowedwhen the block is not released.

• Set the bucket horizontally by operating lever 39,then lower it to the ground to avoid any contactbetween drum and bucket booms. The bucket canbe raised again when the counter-frame is out of theinterference area B shown in fig.

CAUTIONThe counter-frame rotation block shall always becoupled when the counter-frame is in rest positionC (aligned with the machine).

• Rotate the counter-frame by means of the distributorlever 42 until reaching the required position.REMARK: A safety device locks the counter-frameinside the interference area B if the bucket is notlowered; to restart the counter-frame rotation, thebucket must lay on the ground. When lowered, it isnot possible to raise the bucket until the counter-frame is not out of the interference area B.

• Reset the counter-frame to rest position andremember to lower the booms before it reaches theinterference area B. Reach the rest position C andlock the rotation block by means of button 11.

■ C-5.5 END OF THE WORKING CYCLE

After every discharge:

• To avoid the formation of deposits, introduce 10-20% of the normal amount of water into the rotatingdrum. During the following mixing, this water residuemust be taken into account.

• After a working day, in addition to the water amountmentioned above, introduce also a bucket ofaggregate (fine or coarse gravel). Rotate the drumfor some minutes, then empty the drum.

BC

A


Page C - 36Document 57.0100.4200 - 07/2005


C-6 TRANSPORTING THE MACHINE

■ C-6.1 MOVING A DISABLED MACHINE

Tow the machine only when no alternative is possible,since this operation may result in serious damages tothe transmission. Where possible, repair the machineon site.

When the machine shall absolutely be towed:

• Tow the machine for short distances and at a lowspeed only.

• Use a rigid drawbar.


• Set the gear lever to neutral.

• Remove the Cardan shaft of the transmission.

• Where possible, start the engine and use thehydraulic steering and the braking system.

C-6.1.1 Gearbox in neutral

CAUTIONIt is absolutely forbidden to tow the machine if themechanical gearbox has not been set to neutralpreviously.

To set a gear lever to neutral:

• Set the first pin A which stops the gear levercentrally.

• Change the gear electrically by means of the button.

• Engage the second pin to lock the gear lever inneutral position.

If engine does not start, move the lever halfway andset the gear to neutral. For this purpose:

• Release the two lines from the gearbox cylinder.

• By a mechanical lever, manually set the gear leverto neutral.

C-6.2 ROAD OR WORK SITE TRANSFER (withunloaded machine)

When travelling on public roads, stricly obey thepertinent laws and regulations.Additionally, take into account following generalprecautions:


• Set booms and loading bucket to transfer position(raised).

A

• Rotate the counter-frame in rest position and lock it.

• Switch the beacon on.

• Make sure that lights, horn and turn signals are inworking order.

• Engage a high hydraulic speed.

CAUTIONDo not change mechanical gear when the machineis running.


Page C - 37Document 57.0100.4200 - 07/2005


■ C-6.3 LIFTING THE MACHINE

When the machine shall be lifted, use only meanshaving a suitable capacity. The characteristic data aredetailed in the relevant chapter of this manual and onthe identification plate.For the machine lifting, anchor the chains to the speciallugs on the machine.

C-6.4 TRANSPORT ON OTHER VEHICLES

When the machine shall be transferred on anothervehicle, follow the procedure below:

• Put chocks at the wheels of the transporting mean.

• Ensure ramps are correctly positioned.

• Carefully drive the machine onto the vehicle.

• Ensure the overall dimensions do not exceed theallowed limits.

• Lay the bucket on the vehicle platform.

• Engage the parking brake.

• Stop the machine engine and lock up the drivingcab.

• Secure the machine to the vehicle platform bywheel-chocks.

• Anchor the machine to the transporting mean withsuitable chains.


Page C - 38Document 57.0100.4200 - 07/2005


■ C-6.5 PARKING AND STORAGE

■ C-6.5.1 Short inactivity

After a working day, a shift and at night, park themachine in a safe way.

Take all precautions to prevent damages to those whowill approach the machine:

• Park the machine so that it does not hinder otheroperations.

• Set the forward/reverse gear switch to neutralposition and engage the parking brake.

• Remove the key from the ignition switch and lockthe cab door.

• Disconnect the battery by the special cutout switch(see par. C-4.4).

■ C-6.5.2 Machine storageIn case of extended inactivity of the machine, follow theabove precautions. Additionally:

• Wash the drum inside and drain out any water.

• Thoroughly wash the machine. To this end, removethe protection grilles and covers for a better cleaning.

• Carefully dry all machine parts by means of drycompressed air.

• Thoroughly lubricate the machine.

• Perform a walk-around inspection and replace anyworn or damaged part.

• Re-paint any worn or damaged part.

• Remove the battery, smear its terminals with vase-line and store it in a dry place. Battery can be usedfor other purposes. Otherwise, periodically checkthe charge level.

• Refuel the tank to prevent internal oxidation.

• Store the machine in a dry and ventilated place.

• Once a month, start the engine for about 10 minutes.

• When the weather is particularly cold, empty thewater tanks and the connecting circuits.

IMPORTANTAlways remember that the ordinary maintenancemust be carried out even during the machineinactivity. Pay particular attention to the fluid levelsand to those parts which are subject to ageing.Before re-starting the machine, carry out anextraordinary maintenance and carefully check allmechanical, hydraulic and electric components.


Page C - 39Document 57.0100.4200 - 07/2005


■ C-6.6 CLEANING AND WASHING THEMACHINE

■ C-6.6.1 Cleaning instructions

Clean the machine in accordance with the followinginstructions:

• Remove any oil or grease traces with a dry solventor a volatile mineral alcohol

• Before assembling a new part, remove anyprotection product (rust-preventer, grease, waxetc.).

• Remove any trace of rust from metal parts withsome emery cloth before smearing the part with aprotection product (rust-preventer, paint, oil etc.).

■ C-6.6.2 Washing instructions

IMPORTANTDo not use water at high pressure for washing themachine and especially the distributor, the solenoidvalves and electrical parts.

External washingBefore washing the machine, check that the engine isshut down and the doors and windows are closed.Do not, at any times, use fuel to clean the machine. Usewater or some steam. In cold climates, dry the locksafter washing or smear them with an antifreeze.Before using the machine again, check its conditions.

Internal washingWash the machine interior with some water and asponge. Do not use water at high pressure. Afterwashing, dry with a clean cloth.

Washing the engineBefore washing the engine, protect the air intake filterto prevent water from entering the circuit.

■ C-6.7 MACHINE DISPOSAL

When the machine efficiency gets reduced because ofits long operation life, dispose of it in a proper way. Forthis purpose, call in a specialized firm which will do thejob in compliance with the local regulations.


At the end of the machine life, call in a specialisedfirm to dispose of it in compliance with the local ornational regulations.

■ C-6.7.1 Battery disposal


Used lead-acid batteries cannot be disposed of asnormal industrial solid wastes. Because of thepresence of harmful substances, they must becollected, eliminated and/or recycled in accordancewith the laws of the UE.In Italy, used or discarded batteries have beenclassified as “Toxic wastes” in accordance withPresidential decree n. 397 of 09/09/1988 and Law n.475 O.G. n. 18 of 09/11/1988 because they containlead and sulphuric acid. Their disposal throughrecycling must be done only through companiesauthorised and belonging to the “Consorzio Obbli-gatorio Batterie Esauste e dei rifiuti piombosi”(Cobat) which collect and dispose of used lead-acidbatteries throughout the national territory.Used batteries must be kept in a dry and confinedplace. Make sure the battery is dry and the cellplugs are tight. Place a sign on the battery to warnof not using it. If before disposal the battery is leftin the open air, it will be necessary to dry, smear thebox and the elements with a coat of grease andtighten the plugs. Do not rest the battery on theground; it is always advisable to rest it on a palletand cover it. The disposal of batteries shall be asrapid as possible.


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MAINTENANCE

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Section D

MAINTENANCE

TABLE OF CONTENTS

D-1 LUBRICANTS - HEALTH AND SAFETYPRECAUTIONS ..................................... D-2

D-2 ORDINARY MAINTENANCE ................. D-3

D-2.1 Oil change schedule ............................. D-4

D-2.2 Ordinary maintenance summaryscheme ................................................. D-5

D-3 MAINTENANCE INTERVENTIONS ....... D-6

D-3.1 Disconnecting the battery..................... D-6

D-3.2 Access to the engine compartment andthe drive and filters compartment......... D-7

D-3.3 Greasing ............................................... D-8

D-3.4 Tyres and wheels .................................. D-9

D-3.5 Brakes ................................................... D-9

D-3.6 Engine air filter .................................... D-10

D-3.7 Engine cooling system........................ D-11

D-3.8 Oil tank level ....................................... D-12

D-3.9 Substitution of the suctionfilter elements ..................................... D-13

D-3.9.1 Checking the filter clogging degree .... D-14

D-3.10 Cleaning the service oil filter ............... D-14

D-3.11 Water filter .......................................... D-14

D-3.12 Oil level in the differential gears .......... D-15

D-3.13 Oil level in the gearbox ....................... D-15

D-3.14 Oil level in the (front/rear) wheelreduction gears ................................... D-16

D-3.15 Oil level in the drum rotationreduction gear ..................................... D-16

D-3.16 Oil level in the counter-frame rotationreduction gear ..................................... D-17

D-3.17 Shafting alignment .............................. D-18

D-3.18 Adjusting the sensor distance ............ D-19

D-3.19 Checking the safety devices ............... D-20

D-3.20 Servicing the a/c system (if any) ......... D-21

D-4 EXTRAORDINARY MAINTENANCE.... D-22

D-4.1 Emptying the water tanks ................... D-22

D-4.2 Emptying the drum in an emergency.. D-23

D-4.3 Emergency control for the drumrotation................................................ D-24

D-4.4 Checking the alignment of thedrum sliding rollers ............................. D-24

D-4.5 Resetting the variabledisplacement pump ............................ D-24

D-5 ELECTRICAL SYSTEM ....................... D-25

D-5.1 Battery ................................................ D-25

D-5.2 Fuses and relays ................................. D-26

D-5.3 Lamps ................................................. D-28

D-6 REFUELLING ...................................... D-29

D-6.1 Refuelling ............................................ D-29

D-6.2 Product specifications ........................ D-29

D-6.2.1 Engine oil ............................................ D-29

D-6.2.2 Lubrication oils and relevant filteringelements ............................................. D-29

D-6.2.3 Fuel ..................................................... D-30

D-6.2.4 Grease ................................................ D-30

D-6.2.5 Engine coolant .................................... D-30

MAINTENANCE

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INTRODUCTION

A thorough and regular maintenance keeps themachine in a safe and efficient working condition.

For this reason, it is advisable to wash, grease andservice the machine properly, especially after havingworked under particular conditions (muddy or dustyenvironments, heavy operations, etc.).

Always ensure all machine components are in goodcondition. Check for oil leaks or loosening of guards,and make sure that the safety devices are efficient. Incase of defects, find and rectify them before using themachine again.

The maintenance interventions are based on themachine working hours. Regularly check the hour-meter and keep it in good condition to define themaintenance intervals correctly.

Not respecting the ordinary maintenance schedule ofthis manual automatically voids TEREXLIFT warranty.

IMPORTANTFor the engine maintenance, please refer to thespecific Operator handbook supplied with themachine.

D-1 LUBRICANTS - HEALTH ANDSAFETY PRECAUTIONS

HealthA prolonged skin contact with oil can cause irritation.Use rubber gloves and protective goggles. Afterhandling oil, carefully wash your hands with soap andwater.

StorageAlways keep lubricants in a closed place, out of thechildren’s reach. Never store lubricants on the openair and without a label indicating their contents.

DisposalNew or exhausted oil is always polluting! Never drainoil on the ground. Store new oil in a suitable warehouse.Pour exhausted oil into cans and deliver them tospecialised firms for disposal.

Oil leaksIn case of accidental oil leaks, cover with sand or type-approved granulate. Then scrape off and dispose of itas chemical waste.

First aidEyes : In case of accidental contact with the

eyes, wash with fresh water. If theirritation persists, seek medical advice.

Intake : In case of oil intake, do not inducevomiting, but seek medical advice.

Skin : In case of a prolonged contact, washwith soap and water

FireIn case of fire, use carbon dioxide, dry chemical orfoam extinguishers. Do not use water.

MAINTENANCE

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D-2 ORDINARY MAINTENANCE

A wrong or neglected maintenance can result in possiblerisks for both operator and bystanders. Make suremaintenance and lubrication are carried out accordingto the manufacturer’s instructions to keep the machinesafe and efficient.

The maintenance interventions are based on themachine working hours. Regularly check the hour-meter and keep it in good conditions to define themaintenance intervals correctly. Make sure any defectdetected during the maintenance is promptly rectifiedbefore using the machine.

ATTENTIONAll " ▲ " marked operations must be carried out bya skilled technician.

During the first 10 working hours1 Replace the hydraulic oil filtering elements2 Check the oil level within reduction and differential

gears3 Regularly check the tightening of the wheel bolts4 Check the tightening of all bolts and nuts5 Check the couplings for oil leaks

Every 10 working hours or daily1 Check the engine oil level2 Clean the outer element of the air suction filter3 Check the engine coolant level4 Clean the radiator, where necessary5 Check the hydraulic oil level in the tank6 Grease all joints of boom and bucket, the articulation

of the rear axle, the transmission shafts, the frontand rear axles and the sliding rollers

7 Check the functioning of the drum rotation system8 Check the efficiency of the lighting electric system9 Check the efficiency of braking system and parking

brake10 Check the efficiency of the differential locking11 Check the efficiency of the steering selection system12 Check the efficiency of the hydraulic gear selection

system13 Check the efficiency of the mechanical gear selector

switch (1st-2nd gear)14 Check the integrity of the air suction hose between

engine and filter15 Make sure the safety devices installed are in efficient

working order - see procedure in chap. D-3.19.

Every 50 working hours or weeklyOperations to be carried out in addition to the dailymaintenance interventions.

1 Check the oil level in the gearbox2 Check the oil level in both front and rear differential

gears3 Check the oil level in the four wheel reduction gears4 Check the oil level in the drum rotation reduction

gear5 Check the oil level in the counter-frame rotation

reduction gear6 Check the level of the battery electrolyte7 Check the tension of the alternator belt8 Check for water or deposits within the transparent

pan of the Diesel-fuel filter9 Check the tyre inflation10 Check the tightening of the wheel nuts11 Check the tightening of the Cardan shaft screws12 Change the engine oil13 Clean the water filter14 Clean the drum sliding track15 Grease the counter-frame rotation flew ring16 Check the outer element of the air engine filter;

replace, where necessary17 Check the clamping of the cableheads to the

battery terminals18 Check for cloggings of the hydraulic oil filters using

the vacuometers

Every 250 working hours or monthlyJobs to be done in addition to those above.

1 Change engine oil and filter2 Check the conditions of the cylinder chrome-plated

rods3 Check the hydraulic lines are not worn because of

rubbing against the frame or other mechanicalcomponents

4 Check the electric cables do not rub against theframe or other mechanical components

5 ▲ Adjust the parking brake6 Check the alignment of the sliding rollers7 Change the engine Diesel-oil filter

Every 3 working months1 Check the efficiency of the block valves - see

chap. D-3.19

Every 500 working hours or every six monthsJobs to be done in addition to those above.

1 Visually check the smoke quantity from the engineexhaust

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2 Check the tightening of the engine fixing screws3 Check the tightening of the cab fixing screws4 Check the backlash between pins and bushings in

all joints5 Change the drum rotation oil filter6 Change the hydraulic oil filter of the transmission7 Change the inner element of the engine air filter8 Clean the hydraulic oil filter of the services9 ▲ Check the Diesel engine idling/peak r.p.m.10 ▲ Check the Diesel engine pressure11 ▲ Check the transmission pump setting12 ▲ Check the calibration of the max. pressure valve

within the bucket lifting distributor13 ▲ Check the calibration of the max. pressure valve

within the bucket rotation distributor14 ▲ Have the hydraulic circuit be checked by a

specialized technician

Every 1000 working hours or yearlyJobs to be done in addition to those above.

1 Change the engine coolant2 Change the oil in both front and rear differential

gears3 Change the oil in the gearbox4 Change the oil in the four wheel reduction gears5 Change the hydraulic oil6 Change the oil in the drum rotation reduction gear7 Change oil of the counter-frame rotation reduction

gear8 ▲ Check the end float of the engine valves9 ▲ Check the starting motor10 ▲ Check the alternator11 Change the outer element of the engine air filter

■ D-2.1 OIL CHANGE SCHEDULE

Job operating service Oil typehours* interval*

Oil level check 10 daily SHELL RIMULA 15W-40

First change 50 - (API CH-4/CG-4/CF-4/CF; ACEA E3;

Subsequent changes 250 monthly MB228.3)

Oil level check 50 weekly FUCHS TITAN GEAR LS 85 W-90

First change - - API GL-5 LS / GL-5

Subsequent changes 1000 yearly

Oil level check 10 daily SHELL TELLUS T 46

First change - - DENISON HF-1, DIN 51524 part 2 & 3

Subsequent changes 1000 yearly

Engine

Axles andpowerdivider

Hydraulicoil

* whichever occurs first.

MAINTENANCE

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■ D-2.2 ORDINARY MAINTENANCE SUMMARY SCHEME

Motor oil

Hydraulic oil

Reduction gear oil

Grease

Oil filter cartridge

Air filter cartridge

Coolant

Battery electrolyte

Control

Cleaning

1000 h (or 1 year)* 500 h (or 6 months)* 250 h (or 1 month)* 50 h (or weekly)* 10 h (or daily)*Within the first 10 hours

* According to which occurs first

MAINTENANCE

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D-3 MAINTENANCE INTERVENTIONS

DANGERAll maintenance interventions must be carried outwith engine stopped,forward/reverse gear selectorswitch in neutral, parking brake engaged andworking attachments on the ground.

CAUTIONWhen raising a component for maintenancepurposes, secure it in a safe way before anymaintenance intervention.

CAUTIONAny intervention on the hydraulic circuit must becarried out by skilled personnel.The hydraulic circuit of this machine is fitted withpressure accumulators. You and others could beseriously injured if accumulators are not completelydepressurised.For this purpose, shut the engine down and stepon the brake pedal 8÷10 times.

CAUTIONBefore any operation on hydraulic lines orcomponents, make sure there is no residualpressure. For this purpose, stop the engine, engagethe parking brake and operate the control levers ofthe distributors in both working directions(alternately) to depressurise the hydraulic circuit.

ATTENTIONHigh pressure lines must be replaced by qualifiedpersonnel only.Any foreign matters entering the closed circuit mayresult in a sudden deterioration of the transmission.

ATTENTIONThe qualified staff charged with the maintenanceof the hydraulic circuit must clean all areas aroundwith care before any intervention.


The handling and disposing of used oils can beruled by local or national regulations. Address toauthorised centres.

■ D-3.1 DISCONNECTING THE BATTERYIn case of maintenance or repair works, and especiallyof weldings, turn off the battery main switch, located inthe left rear wheel compartment (see par. C-4.4).

MAINTENANCE

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■ D-3.2 ACCESS TO THE ENGINECOMPARTMENT AND THE DRIVEAND FILTERS COMPARTMENT

For any operation within the engine compartment � orthe drive and filters compartment �, you shall open theprotection cover.

From the engine compartment �, you reach:• Thermal engine• Water radiator

From the drive and filters compartment �, you reach:• Oil filters• Engine air filter• Battery

To reach the inside of these compartments:• Shut the engine down and put the parking brake• Open the cover latches �• Turn to fully open the cover.

DANGERTake all precautions when approachingthe engine compartment. Some parts ofthe engine may be very hot.Always use protective gloves.

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■ D-3.3 GREASING

ATTENTIONBefore injecting grease into the greasers, thoroughlyclean them to avoid that mud, dust or other matterscan mix with the lubricant and reduce or annihilatethe lubrication effect.

Regularly grease the machine to grant it efficientconditions and a long life.

By means of a pump, inject grease into the specialgreasers.

As the fresh grease comes out, stop the operation.

Follow the instructions of chapter D-2 and the summaryscheme D-2.2.

SERVICE INTERVAL

Running-in ____________________________ None

Ordinary ____________________Every 10 hours

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■ D-3.4 TYRES AND WHEELS

DANGEROver-inflated or overheated tyres can burst. Do notflame-cut or weld the wheel rims. For any repairwork, call in a qualified technician.

For the tyre inflation or substitution, please refer to thetable below:

On new machines, and when a wheel has beendisassembled or replaced, check the nut torque of thewheels every 2 hours until they stay correct.

ATTENTIONAlways use tyres having the dimensions indicatedin the vehicle registration card.

■ D-3.5 BRAKES

• For any intervention on the braking system(adjustment and/or substitution of the brake discs)address to the TEREXLIFT Technical AssistanceService or the nearest TEREXLIFT authorisedworkshop.

RIGHT WAY WRONG WAYOKAY WRONG

MARINER 25G MARINER 35G

Tyre Front and rear Front and rear

Dimensions 12,5-20 16/70-20

P.R. (or load index) 12 pr 14 pr

Rim 11 x 20 13 x 20

Pressure bar 5 5Psi 72,5 72,5

SERVICE INTERVAL

Running-in _________ Within the first 10 hours


MAINTENANCE

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■ D-3.6 ENGINE AIR FILTER

Clean the engine air filter; replace the filtering element, if necessary.1 Cleaning and substitution of the outer element:

- Stop the engine and engage the parking brake.- Unscrew wingnut � and remove cover �.- Unscrew wingnut � and remove the outer element �.- Clean the filter bowl.- Dry clean the cartridge (at max. 6 bar pressure) and direct

the air jet from inside to outside.- Check for cracks in the filtering element by introducing a

lamp inside.- Smear the seal with grease, then set the element in position.- Tighten wingnut �, then close the cover � and tighten

wingnut �.

ATTENTIONWhen the clogging indicator � of the filter is on the red zoneor the warning light 45 in the cab switches on, immediatelyreplace the outer element.

2 Substitution of the inner element- See instructions 1 above for removing the outer element.- Loosen wingnut � and remove the inner element.- Clean the filter bowl.- Smear the seal with grease, then mount the new element

and make sure it is correctly positioned.- To refit the outer element and the cover, see paragraph 1.

ATTENTIONThe inner element should be replaced every two times theouter element is replaced.Daily remove any dust collected in the filter by pressing therubber cap �.

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SERVICE INTERVAL

Running-in ____________________________ None

Cleaning ___________________ Every 50 hours

Outer element change ______ Every 500 hours

Inner element change _____ Every 1000 hours

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■ D-3.7 ENGINE COOLING SYSTEM

DANGERWhen the coolant is hot, the cooling system is under pressure.With warm engine, slowly and carefully loosen the radiatorplug, without removing it, so that pressure can release. Useprotection gloves and keep at a safe distance.

• Check the coolant level within pan � before starting working(when coolant is cold).

• Where necessary, top-up with clean water or an antifreezemixture through cap �.

• Change the antifreeze mixture every two years.

To drain the antifreeze:

- Let the engine cool down.

- Unscrew the plug � at the bottom of the rubber hose ordisconnect the rubber hose, if no plug is present. Drain themixture into a container of suitable size.

- Refit the hose and pour fresh antifreeze (proportion: 50%water-50% antifreeze). This proportion will provide protectionup to -38°C.

• Daily clean the radiator grille.

SERVICE INTERVAL

Running-in ____________________________ None


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■ D-3.8 OIL TANK LEVEL

DANGERFine jets of pressurized hydraulic oil can penetratethe skin. Do not use your fingers, but a piece ofcardboard to detect oil leaks.Check the hydraulic oil level (visually) through thespecial level � fitted into the tank.Ensure that oil has not emulsified with water (oil tendsto be whitish).

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When necessary, add new oil through filler.

CAUTIONOil level shall be checked with the engine stopped,the speed selector in neutral, the parking brakeengaged and the working attachment on the ground.

To change the oil:1 Stop the machine on a level ground and make sure

the parking brake is engaged.2 Release the pressure from the hydraulic circuit.3 Place a container of suitable size under the drain

plug, placed in the lower part of the reservoir, andcollect any oil leaks.

4 Remove the drain plug and allow oil to flow out intothe container.

5 Remove the inspection cover of tank.6 Carefully wash the tank with Diesel oil and blow a

jet of compressed air.7 Refit the drain plug and the inspection cover.8 Add new oil by making sure that it matches the

recommended type indicated in paragraph D-6.2.2.until it is level with �.


The handling and disposing of used oils can beruled by local or national regulations. Address toauthorised centres

SERVICE INTERVAL



SERVICE INTERVAL

Running-in ____________________________ None

Ordinary ________________ Every 1000 hours

MAINTENANCE

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■ D-3.9 SUBSTITUTION OF THE SUCTIONFILTER ELEMENTS

Travel circuitEvery 500 working hours and within the first 10 workinghours, replace the hydraulic oil filtering element of thetravel circuit.For this operation:1 Stop the machine on a level ground and engage the

parking brake.2 Place a container of suitable size under the filter to

collect any oil leaks, then close the cock.3 By a small wrench, loosen element �.4 Replace the element, thoroughly clean and grease

the seat and the seal.5 Hand-tighten the filtering element � and re-open

the cock.

Drum rotation circuitEvery 500 working hours and within the first 10 workinghours, replace the hydraulic oil filtering element of thedrum rotation circuit.For this operation:1 Stop the machine on a level ground and engage the

parking brake.2 Place a container of suitable size under the filter to

collect any oil leaks, then close the cock.3 By a small wrench, loosen element �.4 Replace the element, thoroughly clean and grease

the seat and the seal.5 Hand-tighten the filtering element � and re-open

the cock.

IMPORTANTWhen changing the oil, drain it when it is still hotand the polluting substances are in suspension.

IMPORTANTHydraulic oil filter canisters cannot be cleaned orwashed and refitted.They must be replaced with new ones of the typerecommended by the manufacturer (see par. D-6.2.2).


The handling and disposing of used oils may beruled by local or national regulations. Address toauthorised centres.

SERVICE INTERVAL

Running-in ____________________________ None

Ordinary __________________ Every 500 hours

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■ D-3.9.1 Checking the filter clogging degree

Every 50 working hours, check if the oil filters areclogged using the vacuometers �.

The indexed scale of the vacuometer is divided into 3areas:1 - Green area: Normal running.

2 - Yellow area: Change the filter as soon as possible.

3 - Red area: Immediately stop the engine toprevent any damages to the hydraulicsystem. Change the filter and/or findthe trouble (for instance: the gatevalve of the hydraulic tank is closed).

in Hgcm Hg

10

20

3040

50

60

70

76 0

5

1015

20

25

30

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■ D-3.10 CLEANING THE SERVICE OIL FILTER

Every 500 working hours, clean the hydraulic oil filtercartridge of the services:

1 Stop the machine on a level ground and engagethe parking brake.

2 Remove the inspection cover on the oil tank andthe filtering element.

3 Clean the cartridge with compressed air (max.pressure: 6 bar).

4 Check for cracks (if any, replace).5 Refit the filtering element and the inspection cover.

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SERVICE INTERVAL

Running-in ____________________________ None


■ D-3.11 WATER FILTER

Clean the filter every 50 hours; for this operation:

• Loosen the ring nut �

• Remove and clean the filter

• Refit the filter and re-tighten the ring nut �.

SERVICE INTERVAL

Running-in ____________________________ None

Ordinary __________________ Every 500 hours

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SERVICE INTERVAL

Running-in ____________________________ None

Ordinary ____________________ Every 50 hours

MAINTENANCE

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■ D-3.12 OIL LEVEL IN THE DIFFERENTIALGEARS

To check the oil level in the front and rear differentialgears:

• Stop the machine on a level ground and engage theparking brake.

• Loosen the level plug � and check if oil reaches thehole.

• If necessary, top-up from hole � until oil reacheshole �.

• Refit and tighten plugs � and �.

For the oil change:• Place a container of suitable size under the drain

plug, located at the differential gear bottom.• Loosen the drain plug, the level plug � and the filler

� and drain the oil from the reduction gear.• Refit and tighten the drain plug.• Top-up through the filling hole until achieving level

�.• Refit and tighten plugs � and �.

■ D-3.13 OIL LEVEL IN THE GEARBOX

To check the oil level within the gearbox:• Stop the machine on a level ground and ensure the

parking brake is engaged.• Clean the level plug � all around.• Loosen plug � and check oil is level with the hole.• Where necessary, top-up through the filling plug �

until oil comes out from plug �.• Refit and tighten plugs � and �.

For the oil change:• Remove plugs � and �.• Place a container of suitable size under the drain

plug at the gearbox bottom.• Loosen the drain plug � and drain the oil from the

gearbox.• Refit and tighten the drain plug �.• Pour fresh oil from the filling plug �, located at the

gearbox top until oil reaches hole �.• Refit and tighten plugs � and �.

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SERVICE INTERVAL



SERVICE INTERVAL



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■ D-3.14 OIL LEVEL IN THE (front/rear) WHEELREDUCTION GEARS

To check the oil level within the wheel reduction gears:• Stop the machine on a level ground and ensure the

parking brake is engaged. Check plug � finds onthe horizontal axis as shown in fig.

• Clean the plug all around, then remove it and checkif oil is level with the hole.

• If necessary, top-up through hole � until oil comesout from the hole itself.

• Refit and tighten the plug.

For the oil change:• Stop the machine and check if the plug is turned

toward the vertical axis as shown in fig.• Place a container of suitable size beneath the

reduction gear plug.• Unscrew plug � and drain any oil from the reduction

gear.• Rotate the wheel by 90° so that the cap sets on the

orizontal axis.• Top-up through hole �.• Refit and tighten plug �.

■ D-3.15 OIL LEVEL IN THE DRUM ROTATIONREDUCTION GEAR

To check the oil level within the drum rotation reductiongear:• Stop the machine on a level ground and ensure the

parking brake is engaged.• Slowly rotate the drum until plug A is in vertical

position.• Clean the level plug A all around and remove it to

check if the oil is level with the hole.• Slowly rotate the drum until plug A finds in horizontal

position: oil must flows out.On the contrary, rotate the drum and reset plug A invertical position, add new oil until, by setting theplug horizontally, it drains out.

• Refit the closing plug.

For the oil change:• Detect the drain plug located diametrally opposite

to the filler.• Place a container of suitable size under the drain

plug of the reduction gear.• Loosen the plug and drain the oil from the reduction

gear; then refit and tighten the plug.• Top-up with new oil through hole �.• Refit and tighten plug �.

SERVICE INTERVAL



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SERVICE INTERVAL

Running-in ____________________________ None


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■ D-3.16 OIL LEVEL IN THE COUNTER-FRAMEROTATION REDUCTION GEAR

Every 50 working hours, check the oil level within thecounter-frame rotation reduction gear which is locatedat the bottom under the supporting frame of the machine.

CAUTIONDue to the position of this access, the presence ofa second operator is required. He shall check themachine inactivity and assists the maintenanceoperator.• Stop the machine on a level ground and ensure the

parking brake is engaged.• Clean the plug all around and remove it to check if

the oil is level with the hole.• Top-up the oil through hole � until it comes out

from the hole itself.• Refit the closing plug.

For the oil change:• Detect the drain plug � which is located under the

filler.• Place a container of suitable size under the drain

plug � of the reduction gear.• Loosen the drain plug � and drain the oil from the

reduction gear; then refit and tighten the plug.• Top-up with new oil through hole �.• Refit and tighten plug �.

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SERVICE INTERVAL

Running-in ____________________________ None


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■ D-3.17 SHAFTING ALIGNMENT

During operation, the alignment of the front and rearaxles of the machine can be subject to variations. Thiscan depend on an oil blow-by from the steering controlcircuit, or on a steering of both axles when front andrear wheels are not perfectly aligned.

To fix this problem, rather than checking the alignmentvisually, follow the procedure below:

1) Move to a solid and level ground

2) Set the steering selection switch 25 to “four-wheelsteer” (pos. �)

3) Rotate the steering up to its stop (either to the rightor to the left)

4) Set the steering selection switch to “two-wheelsteer” (pos. �)

5) Rotate the steering up to its stop (turn in the samedirection as above)

6) Reset the steering selection switch to “four-wheelsteer” (pos. �)

7) Rotate the steering (to the side opposite to point 3)so that the rear axle reaches its stop

8) Reset the steering selection switch to “two-wheelsteer” (pos. �)

9) Rotate the steering (to the same side as in point 7)so that the front axle reaches its stop

10) Reset the steering selection switch to “four-wheelsteer” (pos. �)

Now the wheels should be re-aligned.

SERVICE INTERVAL

Running-in ____________________________ None

Ordinary ___________________ When necessary

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R

F

21 3

25

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■ D-3.18 ADJUSTING THE SENSOR DISTANCE

In case of a failure or complete malfunctioning of the sensors due toa loosening of their fixing ring nuts, re-adjust their position:

1 Loosen nuts � fixing sensor �.

2 Set the mobile part � of the machine, controlled by the sensor, asclose as possible to it.Near the sensor to the component until the LED indicator � lightsup.

3 Further near the sensor by 1÷2 mm. Smoothly tighten the sensorfixing nut and the relevant lock nut.

One proximity sensor is installed on the machine:

N° 1 parking brake proximity switch

SERVICE INTERVAL

Running-in ____________________________ None

Ordinary ___________________ When necessary

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■ D-3.19 CHECKING THE SAFETY DEVICES

■ Checking the machine start control(at every use)

Attempt to start the engine with the forward or reversegear put.

The engine must not start. If the engine starts, contactthe TEREXLIFT Technical Service.

Repeat the operation putting first one gear, then theother.

■ Parking brake proximity switch(at every use)

• To check the efficiency of the parking brake micro-switch, simply sit in the driving place, start theengine and attempt to move the machine with theparking brake engaged. The machine should notmove. Should that not be the case, adjust orreplace the proximity sensor on the parking brake.

■ Checking the block valves (every 3 months).

The piloted blocking valves allow to held the load inposition in case of burst of a flexible hose.

To check the efficiency of a valve, proceed as follows:• Load a weight near the maximum payload onto the

boom.• Raise the load some centimetres above the ground

(max 10 cm). To check the valve on the telescopeextension cylinder move the boom to maximumheight and extend it some centimetres.

• Loosen the oil hoses to the cylinder of which youare checking the valve with caution.

• To check the efficiency of the block valves of theoutriggers, lower them to the ground and unload theweight of the tyres without raising them. Loosen thecylinder hoses to check the efficiency of the valve.

During the check, the oil will flow out of the hoses andthe load shall remain blocked in position.Should that not be the case, the valve must be replaced.Contact TEREXLIFT Technical Service.

DANGERDo the check of the valves taking all the possibleprecautionary measures:- Wear safety glasses- Wear safety gloves- Wear safety shoes- Wear suitable working clothes- Use guards against leaks of oil at high pressure- Do the check in a free space with barriers all

around to keep non-authorised people away- Ensure that the part to be checked is in safe

condition and that the action generated doesnot result in an uncontrolled movement of themachine.

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For the adjustment of the proximity switches, readchap. D-3.18.If the trouble does not depend on the sensor adjustment,contact the Terexlift Technical Assistance Service.

MAINTENANCE

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TO REMOVE THE BLOCK VALVES OR THECYLINDERS- Lower the boom to the ground in a firm way

since the removal of the block valve or thecylinder can cause an uncontrolled down-movement.

- After refitting the valve or the cylinder, replenishthe circuit and eliminate any air before startingworking. To eliminate the air from the circuit,move the involved cylinders to end-of-stroke inthe two directions (opening/closing. To eliminatethe air from the fork balance cylinder, move theboom up and down and tilt the fork plateforwards/back.

■ D-3.20 SERVICING THE A/C SYSTEM(if any)

In order to maintain the A/C system in efficient workingorder:

• Every 10 hours check that the radiator grill is clean.Clean the heating core � with some compressedair if necessary.

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• Every 50 hours check the tension of the compressorbelt. Re-adjust using register � if necessary.

ATTENTIONYearly before the beginning of the hot season, havethe A/C system checked by an authorisedworkshop which, if necessary, will top up therefrigerating gas reservoir.

MAINTENANCE

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D-4 EXTRAORDINARYMAINTENANCE

■ D-4.1 EMPTYING THE WATER TANKSIn case of long inactivity of the machine under weatherconditions close to zero, it is necessary to remove anymix/water residues from the drum, the connectingcircuits and the tanks.

To discharge any residual mix, follow the instructionsprovided in par. C-5.4 - "Discharge". Adopt themeasures given in the following paragraph D-4.2 onlyin an emergency.

To drain out any residual water from the tanks, use thespecial cock � located under the right tank by rotatingit until water flows out.

Also remember to drain the water contained in the litre-counter using the special cock .

Drain the water out of the pump by loosening plug �.

After emptying, the pump must be refilled with waterbefore use: rotate lever 50 to position B and refill thefloating hose by holding it lifted over the pump level.

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MAINTENANCE

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■ D-4.2 EMPTYING THE DRUM IN ANEMERGENCY

When, due to force majeure or failure, the mix cannotbe discharged from the drum according to the standardprocedure, it is possible to unload it by opening thehatch � the drum is fitted with:

• Position the drum so that the hatch finds upwards.

ATTENTIONDo not loosen the fixing screws if the hatch is notcompletely upwards: you could be run over by thematerial contained in the drum.

• Unscrew the Allen screws � which fix the hatch tothe drum.

• Remove the hatch from its seat.

• Rotate the drum until the hatch opening finds in thelowest position and the mix can be unloaded.

• Remount the hatch and fix it using the screwsprovided.

ATTENTIONBefore starting a new working cycle, find and rectifythe fault which prevented the standard dischargeprocedure.

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MAINTENANCE

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■ D-4.3 EMERGENCY CONTROL FOR THEDRUM ROTATION

In case of need, it is possible to rotate the drum bydirectly operating the solenoid valve � located on therotation pump. Use a screwdriver to manually push thecursor (right in the middle of the solenoid valve) in onedirection or the other.

■ D-4.4 CHECKING THE ALIGNMENT OF THEDRUM SLIDING ROLLERS

Every 250 working hours, check the alignment of thedrum sliding rollers. In presence of iron dust (wear ofrollers or guides), call in a qualified technician.

■ D-4.5 RESETTING THE VARIABLEDISPLACEMENT PUMP

When the engine must be re-started after a suddenstop with drum full and Diesel-engine set to the max.r.p.m., some starting difficulties may occur.

To cope with this inconvenient, operate as follows:• Loosen screw � on the pump to bypass the drum

rotation.• Start the engine.• Re-tighten screw �.

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MAINTENANCE

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D-5 ELECTRICAL SYSTEM

DANGERAll maintenance interventions must be carried outwith engine stopped,forward/reverse gear selectorswitch in neutral, parking brake engaged andworking attachments on the ground.

DANGERWhen, for maintenance purposes, a componentshall be lifted, secure the raised component in asafe and stable way before carrying out anymaintenance.

D-5.1 BATTERY

• Check the electrolyte level; if necessary, top-upwith distilled water.

• Pay attention the fluid is 5÷6 mm above the platesand the cell level is correct.

• Check the cable clips are well fixed to the batteryterminals. To tighten the clips, always use a boxwrench, never pliers.

• Protect the terminals smearing them with purevaseline.

• Disconnect the battery and shelter it in a dry place,when the machine is not used for a long time.

DANGER• Battery electrolyte contains sulphuric acid. It

can burn you if it touches your skin and eyes.Always wear goggles and protective gloves, andhandle the battery with caution to preventspillage. Keep metal objects (watch straps, rings,necklaces) clear of the battery leads, since theycan short the terminals and burn you.

• Before disconnecting the battery, set all switcheswithin the cab to OFF.

• To disconnect the battery, disconnect thenegative (-) lead from the frame earth first.

• To connect the battery, connect the positive (+)lead first.

• Recharge the battery far from the machine, in awell-ventilated place.

• Keep out of items which can produce sparks, ofnaked flames or lit cigarettes.

• Do not rest metal objects onto the battery. Thiscan result in a dangerous short especially duringa recharge.

• Because the electrolyte is highly corrosive, itmust never come in contact with the frame ofthe handler or electric/electronic parts. If theelectrolyte comes in contact with these parts,contact the nearest authorised assistancecentre.

DANGERRisk of explosion or shorts. During the recharge,an explosive mixture with release of hydrogen gasforms.

DANGERDo not add sulphuric acid; add only distilled water.

MAINTENANCE

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D-5.2 FUSES AND RELAYS

The electric system is protected by fuses, located bothinside the cab and inside the engine compartmentwhere also relays are housed. Before replacing a blownfuse with a new one having the same amperage, findout why the fuse has blown.

■ Fuses inside the cab

Ref. Protected circuit Amp.

F1 Hazard warning lights 15

F2 Stop lights 10F3 Right side position lights

Dashboard lightsPosition lights warning light 7,5

F4 Left side position lightsLicense plate lights 7,5

F5 High beam - High beam warning light 10F6 Left low beam 7,5F7 Right low beam 7,5F8 Horn - Parking lights 7,5F9 Beacon - Work lights 20

F10 Interior lamps - Windscreen wiperWindscreen washerCab ventilation fan 20

F11 Turn signalsBack-up hornBack-up lampsDashboard power supply 15

F12 Solenoid valves: steering selection,differential locking,drum rotation 15

F13 Solenoid valves:forward/reverse gear,mechanical gears 10

F14 Solenoid valves: hydraulic gear,optional accessories, boom locking,counter-frame rotation block 20

F1F2

F3F4

F5

F10

F11

F12

F13

F14

F6F7

F8F9

Fuses inside the cab

ATTENTION• Never use fuses with a higher amperage than

that recommended, since they can damage theelectric system seriously.

• If the fuse blows after a short time, look for thefault source by checking the electric system.

• Always keep some spare fuses for anemergency.

• Never try to repair or short blown fuses.• Check the contacts of fuses and fuse-sockets

assure a good electric connection and are notoxidated.

MAINTENANCE

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■ Fuses inside the engine compartment

(*) 30 A when the hydraulic oil cooling fan is installed

■ Relays inside the engine compartment

Ref. Protected circuit Amp.

F101 Main power supply circuit 80F102 Starting motor 20F103 Fuel supply solenoid valve

Hydraulic oil solenoid valve (*) 10F104 Thermostarter 30F105 Air conditioning 30F106 Auxiliary power supply circuits 20F107 Electronic power supply 3

Ref. Involved circuit

RL101 Main power supply circuit

RL102 Starting motor

RL103 Fuel supply solenoid valve

RL104 Thermostarter

RL105 Hydraulic oil fan

ATTENTION• Do not use fuses having a higher amperage

than that recommended, since they candamage the electric system seriously.

• If the fuse blows after a short time, look for thefault source by checking the electric system.

• Always keep some spare fuses for anemergency.

• Never try to repair or short blown fuses.• Make sure the contacts of fuses and fuse-

sockets ensure a good electric connection andare not oxidised.

RL101

F101

F105

F106

F104

F103

F102

RL102 RL103

RL105 RL104

F107

Fuses and relays inside the engine compartment

MAINTENANCE

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■ D-5.3 12V DC LAMPS

Use Voltage Socket type Power

• Front high/low beam ............................................................ 12 V ....................... P45t ................. 45/40 W• Front position lights ............................................................. 12 V ..................... BA 9s ........................ 3 W• Side/tail lights ...................................................................... 12 V ................... BA 15s ...................... 21 W• Stop lights and rear position lights ...................................... 12 V .................BAY 15d ................... 21/5 W• Beacon - Work lights (OPTIONAL) ....................................... 12 V .......................... H3 ...................... 55 W• Dashboard and cab lights .................................................... 12 V ................W 2x4,6d ..................... 1,2 W• Interior lamp ......................................................................... 12 V ................. SV 8,5-8 ........................ 5 W• License plate lights .............................................................. 12 V ................... BA 15s ........................ 5 W• Back-up lamps..................................................................... 12 V ................... BA 15s ....................... 21W

CAUTIONWhen switched on, lamps become hot. Beforetouching a lamp with your fingers, let it cool down.

IMPORTANTNever touch the bulb of halogen lamps (socket typeH3) with your fingers: this may damage the lamp(make use of a clean cloth or a paper tissue). If youtouch it accidentally, thoroughly clean with a papertissue and some ethyl alcohol.

MAINTENANCE

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D-6 REFUELLING■ D-6.1 REFUELLING

Capacity (litres) Product specificationPart Product 25G 35G see par.

Diesel engine Engine oil 11,5 11,5 D-6.2.1

Engine cooling system Water + antifreeze 15 15 D-6.2.5

Fuel tank Diesel fuel 95 80 D-6.2.3

Hydraulic system tank A Hydraulic oil 115 140 D-6.2.2

Gearbox B Oil 2,7 2,7 D-6.2.2

Differential gears B Oil 8,5 8,5 D-6.2.2

Wheel reduction gears B Oil 0,6 0,6 D-6.2.2

Drum rotation reduction gear C Oil 1,5 1,5 D-6.2.2

Counter-frame rotation reduction gear C Oil 0,75 1 D-6.2.2

■ D-6.2 PRODUCT SPECIFICATIONS■ D-6.2.1 Engine oilUse the oil recommended by the Diesel engine Manufacturer. (Please refer to the relevant booklet delivered withthe machine).At the delivery, the machine is refilled with:

SHELL RIMULA SAE 15W-40 (API CH-4/ CG-4/ CF-4/CF, ACEA E3, MB 228.3)

■ D-6.2.2 Lubricants and relevant filtering elementsThe machine shall be refilled with following lubricants:

Products International definition Use

A SHELL TELLUS T 46 API GL-5 LS / GL-5 Hydraulic system and brakes

B FUCHS TITAN GEAR LS 85 W-90 DENISON HF-1 DIN 51524 part 2 & 3 Gearbox-Differential gears-Reduction gears

C AGIP BLASIA 150 / SHELL OMOLA 150 Drum rotation reduction gear

ATTENTIONNever mix oils of different type or features: this could result in troubles and component breakings.

Oils for hydraulic system:Arctic climates: Temperatures below -10°C Use SHELL Tellus T22Mild climates: Temperatures from -15°C to + 45°C Use SHELL Tellus T46Tropical climates: Temperatures above + 30°C Use SHELL Tellus T68

The machine is fitted with the following filtering elements:

Flow rate l/1' FilteringFilter 25G 35G 25G 35G Coupling

Transmission hydraulic circuit 150 150 10 μm 10 μm 1"1/4 B.S.P.

Drum rotation hydraulic circuit 100 100 10 μm 10 μm 1"1/4 B.S.P.

Service hydraulic circuit 100 100 10 μm 60 μm 2" B.S.P.

MAINTENANCE

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■ D-6.2.3 Fuel

Use only Diesel fuel with less than 0.5% sulphurcontent, according to the specifications of the dieselengine booklet.

ATTENTIONIn cold climates (temperature below - 20°C) use onlyDiesel fuel of “Arctic” type, or oil-diesel fuelmixtures. The composition of the latter can vary inrelation to the room temperature up to max. 80%oil.

Unscrew cap �, located on the right side of themachine, and refuel.

■ D-6.2.4 Grease

For the machine greasing, use:

ATTENTIONAvoid to mix greases of different type or features:this may result in troubles and componentbreakings.

■ D-6.2.5 Engine coolant

It is advisable to use an antifreeze mixture (50% water-50% antifreeze). The machine is delivered withfollowing mixture:

TEREX PRO COOL by VALVOLINE

The use of this product guarantees protection to thecircuit for 3 years or 7000 hours without having to addany dry coolant additive.

TEREX PRO COOLProtection against boiling / freezing

Product Freezing Boiling% point point

33 -17 °C 123 °C40 -24 °C 126 °C50 -36 °C 128 °C70 -67 °C 135 °C

ATTENTIONUse an antifreeze mixture in the proportionsrecommended by the manufacturer in relation tothe ambient temperature of the jobsite.

• Lithium-based VanguardLIKO grease, type EP2

When greasing by pump.

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FAULTS AND TROUBLESHOOTING

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E-1 FAULTS AND TROUBLESHOOTING .............................................................. E-2

E-1.1 Fault - Cause - Solution ................................................................................. E-2

Section E

FAULTS ANDTROUBLESHOOTING

TABLE OF CONTENTS


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E-1 FAULTS AND TROUBLESHOOTING

DANGERAny repair work, maintenance or troubleshootingmust be carried out with machine stopped, boomin rest position or laid on the ground, parking brakeengaged and ignition key removed.

This chapter represents a practical guide for theoperator for fixing the most common failures and, atthe same time, detecting those interventions that mustbe carried out by qualified technical engineers.If you are unsure about anything, do not carry outoperations on the machine, but call in a skilledtechnician.

E-1.1 Fault - Cause - Solution

DASHBOARD DOES NOT TURNON

BY STARTING THE ENGINE,DASHBOARD TURNS OFF

ENGINE DOES NOT STARTThe starting motor does not run

ENGINE DOES NOT STARTThe starter runs, but the enginedoes not start

• Battery disconnected

• Battery down• Fuse blown (F106)

• This is normal, while, during theengine starting, no power is supplied(except for hazard warning lights andstop lights)

• The forward/reverse gear selector isnot in neutral

• Battery down• Battery cut-out switch ON• Fuse blown (F102)

• Parking brake not engaged

• Ignition board defective

• Fuse blown (F102-F103-F104)

• No fuel• Diesel oil filter clogged• The Diesel oil hose is empty (due to a

fuel exhaustion)• Starting motor defective

• Connect the battery by means ofswitch 48

• Check the battery condition• Check fuse F106 in the engine

compartment and replace if necessary

• Set the selector to position N

• Recharge or replace the battery• Disconnect the battery• Check fuse F102 in the engine

compartment and replace if necessary• Engage the parking brake (lamp 25

must switch on) and repeat thestarting procedure

• Check and replace if necessary

• Check fuses F102-F103-F104 in theengine compartment and replace ifnecessary

• Refuel• See engine operator handbook• Refuel, then refer to engine operator

handbook• Check and replace if necessary

PROBLEM CAUSES SOLUTIONS


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• The forward/reverse gear selector isin neutral position (N)

• Forward/reverse selector defective• Fuse blown (F107)

• Fuse blown (F3)

• Filter clogged

• Parking brake engaged

• Mechanical gear disengaged

• Drive system pump defective

• Parking brake engaged• Filter clogged

• Difficult gear engagement

• Proximity switches inefficient

• Fuse blown (F13)




MACHINE DOES NOT MOVE

Is light 25 ON?

Is the disengaged transmission light(on the gear change button 7) ON?

THE MACHINE DRIVE IS NOTENOUGH

NO SHIFTING BETWEEN 1st AND2nd GEAR

Warning lights 6 are both OFF

NO SHIFTING BETWEEN LOWAND HIGH HYDRAULIC GEARThe warning light on the button doesnot turn on while pressing the button

THE DIFFERENTIAL LOCKINGCANNOT BE TURNED ONThe warning light on the button doesnot turn on while pressing the button

• Select the forward (F) or reverse (R)gear

• Check and replace if necessary• Check fuse F107 in the engine

compartment and replace if necessary• Check fuse F3 and replace if

necessary.• Check the vacuometer and filter (see

par. D-3.9)

• Disengage the parking brake

• Engage the gearFor further checks, see also “Noshifting between 1st and 2nd

mechanical gear"

• Check the efficiency of the controlspools and replace if necessary

• Disengage the parking brake• Check the vacuometer and filter (see

par. D-3.9)

• Operate the steering wheel andrepeat the gear selection operation

• Check and adjust the distance (seepar. D-3.18)

• Check fuse F13 and replace ifnecessary

• Check fuse F107 in the enginecompartment and replace ifnecessary





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NO SELECTION OF THESTEERING MODE

LOW PARKING BRAKE ACTION

THE COUNTER-FRAME BLOCKCANNOT BE COUPLED/RELEASED

COUNTER-FRAME DOES NOTROTATE

THE BUCKET BOOMS DO NOTMOVE

DRUM DOES NOT ROTATE

THE HYDRAULIC OILTHERMOMETER “16” DOESNOT WORK


• Steering selector defective

• Insufficient cable tensioning

• Lever 43 is wrongly positioned

• The counter-frame is in the interferencearea with the bucket booms


• Counter-frame rotation blockengaged








• Filter clogged

• Defective solenoid valve

• This is normal, when the outsidetemperature is low and/or themachine is used for short periods,since the hydraulic oil cannot warmup over 40÷50°C


• Check and replace if necessary

• Check and adjust the cable tensionby means of the hollow screws

• Check and adjust the lead tighteningon the cable heads

• Shift lever 43 to position 8 to enablebutton 11 and lock the counter-frame

• Further rotate the counter-frame


• Release the block

• Lay the bucket on the ground


• Check fuse F107 in the enginecompartment and replace if necessary

• Further rotate the counter-frame




• Check the vacuometer and filter (seepar. D-3.9)

• Address to an authorized workshop.The solenoid valve can be operatedmanually (see par. D-4.3)



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• Fuses damaged

• A/C system switch damaged

• Relay damaged

• A/C system motor M05 damaged

• Relay damaged

• Fan motor damaged



• Check the fuses are in efficientworking order or replace

• Check that the output voltage of theswitch is 12V; or change the switch

• Check the relays are in efficientworking order

• Check you have 12V at the motoroutput; or change the motor

• Check you have 12V on the relaycontact; or change the relay

• Check you have 12V on the contactof the connector placed on the fanmotor

ATTENTIONIn case of faults not listed in this chapter, address to the TEREXLIFT Technical Assistance, your nearestauthorised workshop or dealer.


THE PARKING BRAKE LIGHTDOES NOT TURN ON

THE A/C SYSTEM DOES NOTWORK

THE A/C SYSTEM FAN DOESNOT WORK


Page E - 6Document 57.0100.4200 - 07/2005


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OPTIONAL ACCESSORIES

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F-1.1 Additional straight chute ....................................................................... F-2

F-1.2 Additional curve chute .......................................................................... F-3

F-1.3 High-pressure wash down gun ............................................................. F-3

F-1.4 Oildynamic weighbatching system ....................................................... F-4

F-1.5 Additive volumetric proportioner ........................................................... F-5

F-1.6 Drum remote control pushbutton strip .................................................. F-5

Section F


TABLE OF CONTENTS


Page F - 2Document 57.0100.4200 - 07/2005


INTRODUCTION

This section is aimed at supplying the operator anyinformation on the optional accessories which can beinstalled on the MARINER 25G-35G self-loadingdumpers mixers.Use only the original accessories, described in thissection, after having read their features thoroughly andunderstood their use.

DANGERWhen replacing optional accessories, keep anyperson clear of the working area.

■ F-1.1 ADDITIONAL STRAIGHT CHUTE

Technical data

Length mm 800

Width mm 320

Height mm 200

Weight kg 14

ApplicationExtension of the main chute.

SafetyStrictly comply with the general safety precautionsgiven in section B “SAFETY”.

FunctioningAdjust the discharge rotation before mounting theadditional chute and visually check it is coupledcorrectly before using it.

MaintenanceVisually check the chute is not incrusted before usingit.


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■ F-1.2 ADDITIONAL CURVE CHUTE

Technical data

Length mm 750

Width mm 350

Height mm 300

Weight kg 14

ApplicationExtension of the main chute.


FunctioningMount the additional chute as first element below themain chute.

MaintenanceVisually check the chute is not incrusted before usingit.

■ F-1.3 HIGH-PRESSURE WASH DOWN GUN

ApplicationHydraulically driven appliance fitted with quick-coupling wash down gun which allows to direct thehigh-pressure water jet for washing the machine orparts of it.

It must be installed by qualified technicians.


DANGERDo not direct the water jet toward people: this mayresult in serious injury.Do not direct the water jet toward electric,mechanical or hydraulic components: the highpressure may damage them.

Functioning1 Start the engine at slow r.p.m.2 Operate the special hydraulic deviator and seize the

wash down gun3 Press the starting handle to allow the high-pressure

water jet to come out; release to stop

MaintenanceVisually check for damages before using it. Check foroil or water leaks from the hydraulic circuit.


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■ F-1.4 OILDYNAMIC WEIGHBATCHINGSYSTEM

D

C

B

A

ApplicationOildynamic device complete with reading instrumentwhich allows to weigh the material loaded with a ± 10%approximation.It must be installed by qualified technicians.


FunctioningBefore weighing the load, reset the reading manometerwithin the cab. Then:1 Start the engine at a reduced r.p.m.2 Open cocks A and B.3 Operate the steering wheel to bleed, then release it.4 Close cock B.5 Slightly operate the steering wheel to allow the

piston of the hydraulic cell and, consequenttly, theempty drum to lift. When the piston reaches itsstroke end, and the manometer shows a 20÷25 barpressure, close cock A.

6 Loosen the three screws C and rotate the ring nut D(fitted with holes and slot) until the “0” value of its kgindexed scale matches the minimum pressure value(about 20÷25 kg) which is necessary to lift theunloaded drum. Then tighten the three screws C.

MaintenanceVisually check for oil blow-by before using it. Wherenecessary, reset the manometer.


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■ F-1.5 ADDITIVE VOLUMETRICPROPORTIONER

ApplicationIndexed vessel, fitted with electropump, for introducingpreset additive amounts into the drum.


FunctioningIntroduce the necessary additive(s) amount within thevessel by checking it through the level gauge. Reachthe desired quantity, then connect the vessel to thedrum using the hose provided and operate theelectropump to transfer the product completely.

MaintenanceVisually check for damages before using it. Thoroughlywash the vessel with water after every proportioningcycle.

■ F-1.6 DRUM REMOTE CONTROLPUSHBUTTON STRIP

ApplicationDevice to be electrically connected to the machine forremote-controlling the drum functions.


FunctioningTo operate the drum, press the buttons marked withthe same symbols used on the cab dashboard.

MaintenanceVisually check for damages before using it.


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TABLES AND DOCUMENTS ENCLOSED

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G-1 TORQUE WRENCH SETTING ............................................................... G-3

G-5 ROUTINE CHECK SCHEDULE-SAFETY DEVICES............................... G-4

Section G

TABLES ANDDOCUMENTS ENCLOSED

TABLE OF CONTENTS


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Page G - 3Document 57.0100.4200 - 07/2005


D x p Pre-loading (N) Torque wrench setting (Nm)

4.8 8.8 10.9 12.9 4.8 8.8 10.9 12.9

M 4 x 0,7 1970 3930 5530 6640 1,5 3,1 4,3 5,2

M 5 x 0,8 3180 6360 8950 10700 3 6 8,5 10,1

M 6 x 1 4500 9000 12700 15200 5,2 10,4 14,6 17,5

M 8 x 1,25 8200 16400 23100 27700 12,3 24,6 34,7 41,6

M 8 x 1 8780 17600 24700 29600 13 26 36,6 43,9

M 10 x 1,5 13000 26000 36500 43900 25,1 50,1 70,5 84,6

M 10 x 1,25 13700 27400 38500 46300 26,2 52,4 73,6 88,4

M 12 x 1,75 18900 37800 53000 63700 42,4 84,8 119 143

M 12 x 1,25 20600 41300 58000 69600 45,3 90,6 127 153

M 14 x 2 25800 51500 72500 86900 67,4 135 190 228

M 14 x 1,5 28000 56000 78800 94500 71,7 143 202 242

M 16 x 2 35200 70300 98900 119000 102 205 288 346

M 16 x 1.5 37400 74800 105000 126000 107 214 302 362

M 18 x 2,5 43000 86000 121000 145000 142 283 398 478

M 18 x 1,5 48400 96800 136000 163000 154 308 434 520

M 20 x 2,5 54900 110000 154000 185000 200 400 562 674

M 20 x 1,5 60900 122000 171000 206000 216 431 607 728

M 22 x 2,5 67900 136000 191000 229000 266 532 748 897

M 22 x 1,5 74600 149000 210000 252000 286 571 803 964

M 24 x 3 79100 158000 222000 267000 345 691 971 1170

M 24 x 2 86000 172000 242000 290000 365 731 1030 1230

M 27 x 3 103000 206000 289000 347000 505 1010 1420 1700

M 27 x 2 111000 222000 312000 375000 534 1070 1500 1800

M 30 x 3,5 126000 251000 353000 424000 686 1370 1930 2310

M 30 x 2 139000 278000 391000 469000 738 1480 2080 2490

G-1 TORQUE WRENCH SETTINGS

IMPORTANTSensor maximum driving torque: 15 Nm.


Page G - 4Document 57.0100.4200 - 07/2005


G-5 ROUTINE CHECK SCHEDULE - SAFETY DEVICES

COMPONENT

Result/Notes

Date Positive Negative SignatureBlo

ck.V

alve

1

Blo

ck.V

alve

2

Blo

ck.V

alve

3

Blo

ck.V

alve

4

Blo

ck.V

alve

5

Blo

ck.V

alve

6

Blo

ck.V

alve

7

Blo

ck.V

alve

8

Blo

ck.V

alve

9

Mic

ro 1

Mic

ro 2

Mic

ro 3

Mic

ro 4

Mic

ro 5

❑ ❑

❑ ❑

❑ ❑

❑ ❑

❑ ❑

❑ ❑

❑ ❑

❑ ❑

❑ ❑

❑ ❑

❑ ❑

❑ ❑

❑ ❑

❑ ❑

❑ ❑

❑ ❑

❑ ❑

❑ ❑

❑ ❑

❑ ❑

❑ ❑

❑ ❑

❑ ❑

❑ ❑

❑ ❑

❑ ❑

❑ ❑

❑ ❑

❑ ❑

❑ ❑

❑ ❑

❑ ❑

❑ ❑


Page G - 5Document 57.0100.4200 - 07/2005


Table key explanation:

Block valve 1 Block valve on lifting cylinder

Block valve 2

Block valve 3

Block valve 4

Block valve 5

Block valve 6

Block valve 7

Block valve 8

Block valve 9

Micro 1 Presence micro-switch on parking brake

Micro 2

Micro 3

Micro 4

Micro 5


Page G - 6Document 57.0100.4200 - 07/2005



code 57.0100.4200 - rev. 0 07/2005 self-loading dumper mixer mariner 25g...

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