AUSA D 1000 AP Operator's Manual
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AUSA D 1000 AP Operator's Manual

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D 900 AP
D 1000 AP
D 1000 APG
OPERATOR'S
MANUAL
ENGLISH
ORIGINAL MANUAL

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Summary of Contents for AUSA D 1000 AP

  • Page 1 D 900 AP D 1000 AP D 1000 APG OPERATOR’S MANUAL ENGLISH ORIGINAL MANUAL...
  • Page 3 D 900 AP D 1000 AP D 1000 APG Above chassis number 63163011 ORIGINAL MANUAL...
  • Page 5 D 900 AP / D 1000 AP / D 1000 APG Foreword  Thank you for choosing this AUSA dumper model which offers the best levels of performance, safety and working comfort. Remember that you are the key to maintaining these characteristics.

  • Page 6: Table Of Contents

    D 900 AP / D 1000 AP / D 1000 APG Index Designed use of the dumpers ................Special safety messages ..................Identification plates and labels ................Specifications ......................How to identify your dumper ................... Controls instruments equipment ................Operating the dumper .....................
  • Page 7 Current legislation must be adhered to (Highway Code) when driving on public roads. AUSA shall not be responsible for any possible harm caused by any modification carried out on the dumper without their express authorisation.

  • Page 8: Special Safety Messages

    AUSA. This section gives instructions on how the dumper must be used as per that contained in the 2004/42/EC Machine Safety Directive.
  • Page 9 D 900 AP / D 1000 AP / D 1000 APG • Check the correct functioning of alarms and signalling devices (for example: Special acoustic warning, obstruction indicator for the air admission filter, etc.) safety • Check that all the information and safety advice plates on the dumper are clean and in good condition.
  • Page 10 D 900 AP / D 1000 AP / D 1000 APG • Check that the resistance of the ground on which you are driving is sufficient for the Special loaded dumper, in particular on access to bridges, embankments, slabbed areas, safety loading areas, etc (fig.
  • Page 11 D 900 AP / D 1000 AP / D 1000 APG  When leaving the vehicle..Special • Turn the engine off and switch off the ignition. Place the cargo box in the horizontal safety resting position (fig. 2). • Place all controls in the neutral standby position.
  • Page 12 D 900 AP / D 1000 AP / D 1000 APG • If the dumper needs to be towed, use a tow bar whenever possible, or if none is Special available, a cable that is strong enough for the job. In either case, it should be fixed...

  • Page 13: Identification Plates And Labels

    D 900 AP / D 1000 AP / D 1000 APG Identification plates and labels...

  • Page 14: Specifications

    A 25cc gear pump coupled to the engine. Control valves for bucket actuation: D 900 AP / D 1000 AP models: Single spool monoblock control valve. D 1000 APG models: Two spools monoblock control valve. The pressure limit valve is set to 170 bar.
  • Page 15 D 900 AP / D 1000 AP / D 1000 APG Specifications  Electrical Equipment - Electrical starting motor of 3.0 Kw - Battery 12V and 90 Ah. / 760 A - 12 V / 60 A alternator - Diesel preheating plugs...
  • Page 16 D 900 AP / D 1000 AP / D 1000 APG Specifications  External turning radius 5.950 mm.  Bucket box capacities (litres) D 900 AP D 1000 AP D 1000 APG WATER 2240 2440 2491 LEVEL 3665 3750 3941...
  • Page 17 D 900 AP / D 1000 AP / D 1000 APG Specifications  Machine Measurements (in mm) D 900 AP D 1000 AP D 1000 APG 2480 2480 2480 2190 2380 2385 2440 2440 2440 1860 1820 1950 3530 3560...
  • Page 18 D 900 AP / D 1000 AP / D 1000 APG How to identify IMPORTANT! Please indicate model number, date of purchase and frame and serial number when your dumper consulting AUSA or your dealer for any matter Model, purchase date, chassis number and engine number. These details are marked on the identification plate.

  • Page 19: Controls Instruments Equipment

    D 900 AP / D 1000 AP / D 1000 APG Controls  Terms such are right, left, front and rear, used in this Manual indicate the sides of the vehicle from the driver’s seat looking forward. instruments equipment  Identification of the components Protector arch Operator’s seat with seatbelt...
  • Page 20 D 900 AP / D 1000 AP / D 1000 APG Controls  Pedals (fig.. 1) instruments a- Service brake pedal b- Accelerator pedal equipment  Acoustic warning for reverse gear This sounds when the machine moves in reverse gear.
  • Page 21  Skip's controls (fig. 2, 3, 4, 5) D 900 AP and D1000 AP models (fig. 2, 3). Skip operations are done with the joystick. By pushing lever (b) to the front, the skip tips forward and by pulling (b) back the skip tips backwards up to its rest position.
  • Page 22 D 900 AP / D 1000 AP / D 1000 APG Controls  Control panel and controls These are situated on the front operator protector and on the joystick. instruments Engine contact, preheating and stop switch (fig. 1) equipment This is located on the right side of the front protector.
  • Page 23 D 900 AP / D 1000 AP / D 1000 APG Controls  Multifunction switch (fig. 1, 2) Located on the steering column. instruments Direction indicators. Moving the lever (a) from its neutral position towards the driver, equipment the left direction indicator is selected and pushing the lever forwards, the right direction indicator is selected.

  • Page 24: Operating The Dumper

    D 900 AP / D 1000 AP / D 1000 APG Operating  Entering and exiting the operator’s cab. Do not grab and pull the steering wheel in order to enter the operator’s cab, hold the the dumper handles provided for this purpose and always support your foot on the step in order to avoid slipping both when entering and exiting the cab.
  • Page 25 D 900 AP / D 1000 AP / D 1000 APG Operating  Loading the dumper When the dumper is loaded, respect the maximum allowed load. the dumper See the SPECIFICATIONS section in this manual  Load capacity (see dumper identification plate) The nominal load is the load which the dumper can safely transport, it is determined by the weight of the load.
  • Page 26 D 900 AP / D 1000 AP / D 1000 APG Operating Emergency start If the engine cannot start due to a flat battery, another 12V booster battery can be used the dumper together with the corresponding jump leads to connect the two batteries. If you use the battery of another machine or dumper, avoid the two machines touching.
  • Page 27 D 900 AP / D 1000 AP / D 1000 APG Operating  Procedure for folding the ROPS protector arch (fig. 1, 2, 3, 4) The ROPS folding protector arch is comprised of two sections (h) and (i) can pivot to...

  • Page 28: Break In Period

    30 days from purchase, whichever is reached first, the dumper is inspected by an authorised AUSA dealer. This inspection will give you the opportunity to discuss the unanswered questions you may have encountered during the first hours of operations.

  • Page 29: Before Starting The Dumper

    D 900 AP / D 1000 AP / D 1000 APG Before starting WARNING the dumper The pre-operation check is very important prior to operating the vehicle. Always check the proper operation of critical controls, safety systems and mechanical components before starting. If the pre-check operations are not done as specified here, severe injury or even death might occur.

  • Page 30: Transporting The Dumper

    D 900 AP / D 1000 AP / D 1000 APG Transporting  Securing/immobilising the dumper on the truck bed (fig. 1, 2) When transporting the dumper on a truck bed or low loader, carefully follow the advice the dumper...
  • Page 31 D 900 AP / D 1000 AP / D 1000 APG Transporting  Loading the dumper with a crane (fig. 1, 2, 3, 4) When the dumper is loaded onto a truck using a crane and a cable or sling: the dumper •...
  • Page 32 D 900 AP / D 1000 AP / D 1000 APG Transporting  Towing the dumper (fig. 1) Towing dumpers is only recommended in cases of breakdown when there is no the dumper alternative. Whenever possible, we recommend repairing the vehicle without moving it.

  • Page 33: Liquids And Lubricants

    D 900 AP / D 1000 AP / D 1000 APG Liquids and This section specifies the recommended liquid and lubricants. See the “MAINTENANCE CHART” on this Manual for the recommended change / lubricants service intervals. FLUID OR CAPACITY SPECIFICATION...
  • Page 34 D 900 AP / D 1000 AP / D 1000 APG Liquids and  Fuel Use automotive clean diesel (class A), which preferably meets 98/70/CEE standard lubricants amended by standard 2003/17 or the equivalent EN 590 standard. In Spain RD 1728/1999 applies.
  • Page 35 D 900 AP / D 1000 AP / D 1000 APG Liquids and  Reduction a wheel Front axle oil SAE 90 Oil as per API GL5 LS / MIL-L-2105D SPECIFICATIONS lubricants Oil AUSA COMPEN EFFICIENT p/n 461.00099.09 with the following characteristics: Friction coefficient modifying additives “Extreme pressure”...

  • Page 36: Special Procedures

    When the dumper is overturned or stays tilted on one side, replace the vehicle in its normal operating position (on all four wheels). WARNING!! DO NOT TRY TO START UP THE DUMPER without first speaking with an AUSA dealer. - Remove the glow lamps.
  • Page 37 DO NOT START THE ENGINE! Immersion of the dumper can cause serious damage if the correct re-start procedures are not followed before starting the engine. WARNING Ask an authorised AUSA Utility dealer to fully inspect the fuel system as stated in the LUBRICATION AND MAINTENANCE CHART. 5.- Storage and pre-season preparation When a dumper is not in use for more than one month, proper storage is necessary.
  • Page 38 D 900 AP / D 1000 AP / D 1000 APG Periodic  In maintenance operations only use original AUSA spare parts. This is the only way to guarantee that your dumper will remain as technically maintenance efficient as when it was purchased.

  • Page 39: Periodic Maintenance Operations

    D 900 AP / D 1000 AP / D 1000 APG Periodic  Access for maintenance (fig. 1, 2, 3) The engine, the transmission and the filters are located under the side covers at the maintenance rear of the machine (fig. 1) and underneath the maintenance access panel, located to the side of the operator’s seat.

  • Page 40: Maintenance Chart

    D 900 AP / D 1000 AP / D 1000 APG Periodic 1.- Engine maintenance For operation instructions, a list of spare parts and for general maintenance consult the engine manual or the LUBRICATION AND MAINTENANCE CHART of this Manual.
  • Page 41 D 900 AP / D 1000 AP / D 1000 APG Periodic WARNING maintenance operations Always stop the engine before refuelling. Open the cap slowly. If you notice internal pressure (whistling sound heard when removing the fuel tank cap) the dumper must be inspected and/or repaired before further operation.
  • Page 42 D 900 AP / D 1000 AP / D 1000 APG Periodic  Draining the fuel tank (fig. 1) maintenance d. Fuel tank drainage cap operations Draining fuel is done via the cap situated on the lower part of the tank.
  • Page 43 D 900 AP / D 1000 AP / D 1000 APG Periodic 3.- Engine oil maintenance  Engine oil level (fig. 1, 2, 3) operations CAUTION: Frequently check the level and refill if necessary. Do not exceed the maximum level.
  • Page 44 D 900 AP / D 1000 AP / D 1000 APG Periodic  Changing the oil and the oil filter (fig.1, 2) Changing the oil and the oil filter should be carried out at the intervals indicated in the maintenance LUBRICATION AND MAINTENANCE CHART in this Manual.
  • Page 45 D 900 AP / D 1000 AP / D 1000 APG Periodic 4.- Engine cooling system maintenance Consult the LIQUIDS AND LUBRICANTS section of this Manual for the SPECIFICATIONS of the coolant liquid to be used. operations WARNING!! Never remove the reservoir cap if the engine is hot. Wait until the engine is cold. Wait for approximately 20 minutes.
  • Page 46 Be careful not to damage the radiator when cleaning the fins. Do not use any object or tool that could damage the fins. The fins are thin parts which therefore allow the radiator to cool correctly. See an authorised AUSA dealer to check the correct performance of the cooling system.
  • Page 47 D 900 AP / D 1000 AP / D 1000 APG Periodic 5.- Air intake system maintenance  Cleaning the air filter (fig. 1) The air intake to the engine is done via a double element dry filter. operations The life and performance of the engine largely depends on the correct maintenance of this filter.
  • Page 48 D 900 AP / D 1000 AP / D 1000 APG Periodic 6.- Gearbox and converter maintenance  Gearbox and converter oil level (fig.1, 2) Remove the dumper floor panel and access the upper part of the gearbox and the operations converter.
  • Page 49 D 900 AP / D 1000 AP / D 1000 APG Periodic  Changing the oil and the filter cartridge of the gearbox and converter. (fig.1, 2) maintenance WARNING!! operations The first replacement of oil and filter cartridge for the gearbox and converter should take place after 50 hours of service.
  • Page 50 D 900 AP / D 1000 AP / D 1000 APG Periodic 7.- Transfer box maintenance  Transfer box oil level (fig. 1) operations a. Level cap With the dumper on a level surface, check the oil level in the following way: - Unscrew the level cap.
  • Page 51 D 900 AP / D 1000 AP / D 1000 APG Periodic 8.- Differentials (fig.1, 2) maintenance  Differential oil level operations a. Filling cap and devaporizer b. Level cap With the dumper on a level surface, check the oil level in the following way: - Unscrew the filling cap.
  • Page 52 D 900 AP / D 1000 AP / D 1000 APG Periodic 9.- Service and parking brake maintenance Check the following to keep the brakes in good operating conditions. - System fluid leaks operations - Spongy feel to the pedal and no feeling of tightening...
  • Page 53 D 900 AP / D 1000 AP / D 1000 APG Periodic 10.- Hydraulic Circuit maintenance  Hydraulic oil level (fig. 1, 2, ) The hydraulic oil tank is located on the left side of the engine compartment. operations Place that the dumper is on a level surface.
  • Page 54 D 900 AP / D 1000 AP / D 1000 APG Periodic  Adjusting the safety valves (fig. 1, 2) There are two safety valves to avoid over pressures in the steering circuit and the load maintenance handling systems. operations a.
  • Page 55 D 900 AP / D 1000 AP / D 1000 APG Periodic  Fuses If a fuse is damaged, replace it with another fuse of the same amps. maintenance CAUTION: operations Do not use fuses with higher amps, this may cause important damage. The fuses are located in a box behind the battery and the instrument and control panel in front of the operator.
  • Page 56 D 900 AP / D 1000 AP / D 1000 APG Periodic 12.- Wheels maintenance Unless it is essential for the type of work to be carried out, the use of solid tyres is not recommended, as this increase the effects of impacts on the transmission and the operations operator.
  • Page 57 D 900 AP / D 1000 AP / D 1000 APG Periodic  Wheel/Tyre condition Check the tyres for possible damage or wear. Replace if necessary. maintenance Do not rotate the tyres if they are directional. For correct operation their rotation must maintain a specific direction.
  • Page 58 D 900 AP / D 1000 AP / D 1000 APG Periodic 13.- Cable lubrication (fig. 1) maintenance All cables must be lubricated with cable lubricant. operations WARNING!! Using another lubricant could cause the cable or control to malfunction (accelerator pedal, etc.).
  • Page 59 D 900 AP / D 1000 AP / D 1000 APG Maintenance chart EVERY I: Inspect, verify, clean, lubricate, replace if necessary C: Clean L: Lubricate R: Replace ENGINE Oil (1) USER Oil filter (1) USER Alternator Belt (1) DEALER...
  • Page 60 D 900 AP / D 1000 AP / D 1000 APG Maintenance chart EVERY I: Inspect, verify, clean, lubricate, replace if necessary C: Clean L: Lubricate R: Replace GREASING POINTS Central pivot USER Nipples (see section "Greasing points" in this Manual) USER Cables and articulations (throttle, lifting rams...)
  • Page 61 D 900 AP / D 1000 AP / D 1000 APG Greasing points  Greasing points (fig. 1, 2, 3, 4, 5, 6, 7, 8) 6 nipples (a) on the central chassis articulation and on the tipping frame. 2 nipples (b) on the steering cylinder 3 nipples (c) on the universal drive shaft joints, one on each cross and one on the groove.
  • Page 62 D 900 AP / D 1000 AP / D 1000 APG Electric diagram WIRE COLOURS Light Blue Withe Orange Yellow Gray Blue Brown Black Pink Green Violet Single color wire Two lengthways colors wire Two crossways colors wire NOTE: The colour of the two-coloured cables is indicated by the signals painted above them.
  • Page 63 D 900 AP / D 1000 AP / D 1000 APG Electric diagram...
  • Page 64 D 900 AP / D 1000 AP / D 1000 APG Electric diagram...
  • Page 65 D 900 AP / D 1000 AP / D 1000 APG Electric diagram...
  • Page 66 D 900 AP / D 1000 AP / D 1000 APG Electric diagram...
  • Page 67 D 900 AP / D 1000 AP / D 1000 APG Electric diagram Name Description Pag. Name Description Pag. Alternator Parking brake relay Engine oil minimum pressure switch Horn relay Coolant temperature warning switch Dashboard buzzer relay Horn Low beam light relay...

  • Page 68: Hydraulic Diagram D 900 Ap / D 1000 Ap

    D 900 AP / D 1000 AP / D 1000 APG Hydraulic diagram D 900 AP / D 1000 AP...

  • Page 69: Hydraulic Diagram D 1000 Apg

    D 900 AP / D 1000 AP / D 1000 APG Hydraulic diagram D 1000 APG...
  • Page 70 DECLARACIÓN DE CONFORMIDAD El fabricante AUSA Center, S.L.U. con dirección en ctra. de Vic, km 2.8, 08243 – Manresa – Barcelona Declara que la máquina asignada a continuación: DUMPER Denominación genérica : D 900 AP – D 1000 AP/G Modelo/Tipo: XXXXXXXX Número de serie :...

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