MDB MP100 Plus User manual

USE AND MAINTENANCE MANUAL

MP100 Plus

MDB004AEN

COMPANY WITH QUALITY MANAGEMENT SYSTEM CERTIFIED BY DNV GL ISO 9001:2015

00 01/2022

ENGLISH

Instructions

To be completed with the actual details of the machine concerned.

NOTICE See chapter 3 for an explanation of the fields shown on the machine

nameplate.

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MDB004AEN_00

MP100 Plus CONTENTS

CONTENTS

1 SAFETY 11

1.1 GENERAL SAFETY REGULATIONS........................................................................................................................................................................................................ 11

1.1.1 Safety procedures............................................................................................................................................................................................................................................. 1-1

1.1.2 Emergency prevention .................................................................................................................................................................................................................................. 1-2

1.1.3 Preparing the work area.............................................................................................................................................................................................................................. 1-2

1.1.4 Notice of maintenance work in progress............................................................................................................................................................................................ 1-2

1.1.5 Lightning precautions ................................................................................................................................................................................................................................... 1-2

1.1.6 Parking the machine safely........................................................................................................................................................................................................................ 1-2

1.1.7 Safe handling of fluids and fire prevention...................................................................................................................................................................................... 1-3

1.1.8 Burn hazard safety precautions.............................................................................................................................................................................................................. 1-3

1.1.9 Precautions against contact with high-pressure liquids .......................................................................................................................................................... 1-4

1.1.10 Fire prevention................................................................................................................................................................................................................................................... 1-4

1.1.11 Prevention of short circuits or electrical faults................................................................................................................................................................................ 1-4

1.1.12 Precautions for use of flammable liquids.......................................................................................................................................................................................... 1-5

1.1.13 Removing traces of flammable materials......................................................................................................................................................................................... 1-5

1.1.14 Abandoning the machine in the event of fire................................................................................................................................................................................. 1-5

1.1.15 Precautions against exposure to exhaust gases............................................................................................................................................................................1-6

1.1.16 Prevention of battery explosions............................................................................................................................................................................................................ 1-6

1.1.17 Precautions for use of coolant.................................................................................................................................................................................................................. 1-7

1.1.18 Safe handling of chemicals ........................................................................................................................................................................................................................ 1-7

1.1.19 Proper waste disposal.................................................................................................................................................................................................................................... 1-8

1.2 SAFETY PICTOGRAM LEGEND ...............................................................................................................................................................................................................19

1.2.1 Warning pictograms ...................................................................................................................................................................................................................................... 1-9

1.2.2 Prohibition pictograms...............................................................................................................................................................................................................................1-10

1.2.3 Requirement pictograms........................................................................................................................................................................................................................... 1-11

1.2.4 Additional pictograms ................................................................................................................................................................................................................................ 1-11

1.3 HAND SIGNALS..............................................................................................................................................................................................................................................112

2 GENERAL INFORMATION 21

2.1 MANUFACTURER IDENTIFICATION DATA....................................................................................................................................................................................... 21

2.1.1 Technical support............................................................................................................................................................................................................................................. 2-1

2.2 WARRANTY........................................................................................................................................................................................................................................................23

2.3 PRESERVATION OF THE MANUAL ......................................................................................................................................................................................................24

2.4 RECIPIENTS OF THE MANUAL................................................................................................................................................................................................................24

2.5 SEARCH CRITERIA AND USE OF THE MANUAL...........................................................................................................................................................................24

2.6 ENVIRONMENTAL REQUIREMENTS ..................................................................................................................................................................................................24

3 MACHINE FEATURES 31

3.1 NAMEPL ATE ...................................................................................................................................................................................................................................................... 31

3.2 DESCRIPTION .................................................................................................................................................................................................................................................... 32

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CONTENTS MP100 Plus

3.2.1 List of units...........................................................................................................................................................................................................................................................3-3

3.3 TECHNICAL SPECIFICATIONS..................................................................................................................................................................................................................34

3.3.1 Dimensions...........................................................................................................................................................................................................................................................3-4

3.3.2 Weight ....................................................................................................................................................................................................................................................................3-5

3.3.3 Flow rate................................................................................................................................................................................................................................................................3-5

3.3.4 Other technical specifications...................................................................................................................................................................................................................3-5

3.3.5 Engine specifications .....................................................................................................................................................................................................................................3-5

3.4 WORK AREA.......................................................................................................................................................................................................................................................36

3.4.1 Operator position.............................................................................................................................................................................................................................................3-6

3.4.2 Machine directional points......................................................................................................................................................................................................................... 3-7

3.5 RUNNING IN....................................................................................................................................................................................................................................................... 37

3.6 MACHINE CONFIGURATIONS..................................................................................................................................................................................................................38

3.7 SAFETY SIGNS...................................................................................................................................................................................................................................................39

3.8 SAFETY DEVICES.......................................................................................................................................................................................................................................... 310

3.9 PROFESSIONAL USER PROFILES........................................................................................................................................................................................................311

3.9.1 Operator...............................................................................................................................................................................................................................................................3-11

3.9.2 Maintenance technician.............................................................................................................................................................................................................................3-12

3.10 PERMITTED USES.........................................................................................................................................................................................................................................312

3.11 NONINTENDED USES ...............................................................................................................................................................................................................................312

3.12 NOISE LEVEL ....................................................................................................................................................................................................................................................312

3.13 PERSONAL PROTECTIVE EQUIPMENT .......................................................................................................................................................................................... 313

3.14 REMOTE CONTROL CASE, DOCUMENTATION AND EQUIPMENT................................................................................................................................. 314

3.15 ANNEXES........................................................................................................................................................................................................................................................... 314

3.16 RESIDUAL RISKS ......................................................................................................................................................................................................................................... 315

3.17 EMERGENCY DEVICES...............................................................................................................................................................................................................................317

4 UNPACKING, LIFTING AND TRANSPORT 41

4.1 UNPACKING........................................................................................................................................................................................................................................................42

4.2 LIFTING................................................................................................................................................................................................................................................................. 44

4.2.1 Lifting with a crane, hoist or bridge crane........................................................................................................................................................................................4-5

4.2.2 Lifting with a forklift......................................................................................................................................................................................................................................4-6

4.3 TRANSPORT........................................................................................................................................................................................................................................................47

5 OPERATION AND USE 51

5.1 CONTROL PANEL............................................................................................................................................................................................................................................. 51

5.1.1 Display ....................................................................................................................................................................................................................................................................5-2

5.1.2 Programming menu.......................................................................................................................................................................................................................................5-5

5.1.3 Alarms..................................................................................................................................................................................................................................................................... 5-7

5.2 REMOTE CONTROL.........................................................................................................................................................................................................................................58

5.2.1 Description of the remote control...........................................................................................................................................................................................................5-8

5.2.2 Remote control LEDs.................................................................................................................................................................................................................................... 5 -10

5.3 CONTROLS ON THE MACHINE..............................................................................................................................................................................................................511

5.4 PRESTART CHECKS................................................................................................................................................................................................................................... 512

5.4.1 Refuelling............................................................................................................................................................................................................................................................5-13

5.4.2 Engine oil refill................................................................................................................................................................................................................................................ 5-14

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MP100 Plus CONTENTS

5.4.3 Coolant refill..................................................................................................................................................................................................................................................... 5-14

5.4.4 Hydraulic oil refill.......................................................................................................................................................................................................................................... 5-14

5.4.5 Battery connection/presence check.................................................................................................................................................................................................... 5-14

5.5 STARTUP.......................................................................................................................................................................................................................................................... 515

5.5.1 Manual start.................................................................................................................................................................................................................................................... 5 -15

5.5.2 Remote control start.................................................................................................................................................................................................................................... 5-16

5.6 USE ....................................................................................................................................................................................................................................................................... 517

5.6.1 Main controls....................................................................................................................................................................................................................................................5-17

5.6.2 Safety guidelines for use........................................................................................................................................................................................................................... 5-21

5.6.3 Picking up and depositing the load.................................................................................................................................................................................................... 5-24

5.7 PARKING............................................................................................................................................................................................................................................................ 527

5.8 REMOVING/FITTING THE BLADE...................................................................................................................................................................................................... 528

5.8.1 Removing the blade..................................................................................................................................................................................................................................... 5-28

5.8.2 Fitting the blade.............................................................................................................................................................................................................................................5-29

5.9 SHUTDOWN.....................................................................................................................................................................................................................................................530

5.9.1 Manual shutdown........................................................................................................................................................................................................................................5-30

5.9.2 Shutdown by remote control..................................................................................................................................................................................................................5-31

5.10 HYDRAULIC CONNECTION OF TOOLS............................................................................................................................................................................................ 532

6 MAINTENANCE 61

6.1 PREPARING FOR MAINTENANCE......................................................................................................................................................................................................... 61

6.1.1 Arm raised position safety bracket - Engine compartment bonnet...................................................................................................................................6-2

6.2 EQUIPMENT SUPPLIED...............................................................................................................................................................................................................................63

6.3 SCHEDULED MAINTENANCE TABLE.................................................................................................................................................................................................. 64

6.3.1 Check list...............................................................................................................................................................................................................................................................6-5

6.4 ROUTINE MAINTENANCE..........................................................................................................................................................................................................................67

6.4.1 General checks................................................................................................................................................................................................................................................... 6-7

6.4.2 General machine cleaning.......................................................................................................................................................................................................................... 6-7

6.4.3 Checking engine oil.........................................................................................................................................................................................................................................6-8

6.4.4 Topping up engine oil....................................................................................................................................................................................................................................6-8

6.4.5 Changing the engine oil and replacing the oil filter....................................................................................................................................................................6-8

6.4.6 Checking coolant ..............................................................................................................................................................................................................................................6-9

6.4.7 Topping up coolant...................................................................................................................................................................................................................................... 6-10

6.4.8 Coolant change............................................................................................................................................................................................................................................... 6-10

6.4.9 Hydraulic oil level check.............................................................................................................................................................................................................................6-11

6.4.10 Topping up hydraulic oil.............................................................................................................................................................................................................................6-12

6.4.11 Hydraulic oil change.....................................................................................................................................................................................................................................6 -12

6.4.12 Air filter check ................................................................................................................................................................................................................................................. 6-13

6.4.13 Cleaning the air filters ............................................................................................................................................................................................................................... 6-14

6.4.14 Replacing the air filters ............................................................................................................................................................................................................................ 6 -14

6.4.15 Hydraulic oil filter check............................................................................................................................................................................................................................ 6-15

6.4.16 Replacing the hydraulic oil filter.......................................................................................................................................................................................................... 6-15

6.4.17 Fuel filter check .............................................................................................................................................................................................................................................. 6 -16

6.4.18 Cleaning the fuel filters ............................................................................................................................................................................................................................ 6-16

6.4.19 Replacing the fuel filters .......................................................................................................................................................................................................................... 6-16

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CONTENTS MP100 Plus

6.4.20 Track check and tensioning ..................................................................................................................................................................................................................... 6 -17

6.4.21 Periodic lubrication...................................................................................................................................................................................................................................... 6-18

6.4.22 Checking tightening elements............................................................................................................................................................................................................... 6-19

6.4.23 Checking lifting elements......................................................................................................................................................................................................................... 6-19

6.4.24 Cooling system check .................................................................................................................................................................................................................................. 6-19

6.4.25 Hydraulic system check.............................................................................................................................................................................................................................. 6-19

6.4.26 Electrical system check............................................................................................................................................................................................................................... 6 -19

6.5 SPECIAL MAINTENANCE......................................................................................................................................................................................................................... 622

6.5.1 Track replacement.........................................................................................................................................................................................................................................6-22

6.6 PERIODIC CHECK AND INSPECTION LOG..................................................................................................................................................................................... 624

7 TROUBLESHOOTING 71

7.1 TROUBLESHOOTING GUIDE..................................................................................................................................................................................................................... 71

7.1.1 Remote control....................................................................................................................................................................................................................................................7-1

7.1.2 Engine ..................................................................................................................................................................................................................................................................... 7-2

7.1.3 Tracks....................................................................................................................................................................................................................................................................... 7-3

7.1.4 Audible signal device ..................................................................................................................................................................................................................................... 7-3

7.1.5 Indicator lights................................................................................................................................................................................................................................................... 7-3

7.1.6 Movement devices........................................................................................................................................................................................................................................... 7-4

8 DISMANTLING 81

8.1 TEMPORARY DECOMMISSIONING...................................................................................................................................................................................................... 81

8.2 PERMANENT DECOMMISSIONING  DISMANTLING............................................................................................................................................................... 81

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MDB004AEN_01

MP100 Plus 1 - SAFETY

1 SAFETY

1.1 GENERAL SAFETY REGULATIONS

1.1.1 SAFETY PROCEDURES

›Carefully read the safety information contained in this manual and follow the safety signs on the machine.

›Safety signs must be affixed, periodically maintained (cleaned) and, if damaged, replaced.

›Only allow authorised, qualified and trained personnel to operate the machine.

›Acquire the necessary training and skill, with the correct procedures for use and maintenance of the machine.

›The machine must always be kept in optimal operating conditions and must be used in ways and for purposes consistent with

the its technical specifications.

›Changes to its components or their replacement with non-original components, or any other modifications not authorised in

writing by the Manufacturer, affect safety and operation, and reduce the operating life of the machine, and thus invalidate

the warranty.

›The Manufacturer bears no liability in the event of:

›improper use of the machine;

›Modification of machine components not authorised in writing by the manufacturer;

›Personal injury, machine failure and/or damage to materials and/or third parties that is direct, connected and

consequential

›Damage resulting from the use of tools and/or optional components or accessories not authorised in writing by the

manufacturer.

›The use of the machine and its equipment in complete safety requires maximum concentration by the operator.

›Do not use headphones to listen to music or the radio while operating the machine

NOTICE For more details, please refer to the GENERAL CONDITIONS OF SALE on the

website (URL landing page general conditions of sale).

CAUTION

The safety information in this chapter is intended to illustrate the main

safety procedures to be adopted during the use and operation of the

machine.

If in doubt or for further information on safety procedures, contact your

supervisor and/or your authorised dealer before using the machine or

carrying out maintenance operations.

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1 - SAFETY MP100 Plus

1.1.2 EMERGENCY PREVENTION

›It is necessary to be prepared in the event of fire or accidents.

›Establish general emergency procedures to be implemented in the event of fires and/or accidents.

›Always keep a first aid kit and fire extinguisher within reach.

›For correct use of the fire extinguisher, carefully read the information printed on the label attached to it.

›Have the extinguisher periodically inspected and maintained, in accordance with the schedule given in the manual

supplied with it, to always ensure perfect efficiency and correct operation when need arises.

CAUTION

Check your location and ensure that it has adequate phone coverage, in

order to communicate it if need arises.

Always carry a mobile phone with emergency numbers for doctors,

ambulance service, hospitals and fire-fighters.

1.1.3 PREPARING THE WORK AREA

›Carry out an inspection in the work area before starting activities.

›Move people away and remove objects within the range of action and movement of the machine.

›Do not allow people or vehicles to enter and transit the work area.

›Make sure that the surface of the work area is sufficiently solid to support the weight of the machine.

1.1.4 NOTICE OF MAINTENANCE WORK IN PROGRESS

›The ignition key must be removed from the control panel and kept by the maintenance technician.

›Before carrying out work on the machine, put the "Maintenance in progress” sign in position.

›Never operate the machine when the “Maintenance in progress" sign is present.

1.1.5 LIGHTNING PRECAUTIONS

›If lightning strikes the machine, or a point close to it, check the proper integrity of all the components and devices on the

machine, particularly the machine’s safety devices.

›If any fault is found, do not operate the machine and contact the support service for repairs.

1.1.6 PARKING THE MACHINE SAFELY

›When not in use, the machine at must be parked on a solid and flat surface.

›Once the machine is parked, shut it down as indicated in chapter 5.

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MP100 Plus 1 - SAFETY

1.1.7 SAFE HANDLING OF FLUIDS AND FIRE PREVENTION

DANGER Handle fuel with extreme care because it is highly flammable. In the

event of combustion, explosions and fires can occur with the risk of serious

injuries.

All fuel types and most lubricants are flammable

›Refuelling must be performed outdoors

›Always switch off the engine before refuelling.

›Do not refuel the machine in the vicinity of open flames or sparks

›Store flammable liquids away from potential sources of fire

›Do not burn or puncture the containers.

1.1.8 BURN HAZARD SAFETY PRECAUTIONS

›When the machine is in use, the engine coolant is hot and under pressure.

›When the machine is in use, the engine oil and hydraulic oil reach high temperatures.

›The cooling system pipes contain hot water or steam, which can cause scalding in the event of accidental skin contact.

›The hydraulic oil system pipes contain hot oil, which can cause scalding in the event of accidental skin contact.

WARNING To avoid scalding caused by hot liquids, perform work on the machine only

after all the hot parts on the machine have cooled down.

The operator must wear the following personal protective equipment:

›Safety footwear

›Protective gloves

›Protective clothing

›Safety goggles

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1 - SAFETY MP100 Plus

1.1.9 PRECAUTIONS AGAINST CONTACT WITH HIGHPRESSURE LIQUIDS

›Pressurised liquids can penetrate the skin and eyes, causing serious injury.

›To avoid this risk, the residual pressure must be discharged.

WARNING

The operator must wear the following personal protective equipment:

›Safety footwear

›Protective gloves

›Protective clothing

›Safety goggles

›Use a strip of cardboard to detect any leaks.

›In the case of injury from contact with pressurised fluids, seek medical attention immediately.

1.1.10 FIRE PREVENTION

DANGER

The presence of any leakage of fuel, hydraulic oil and/or lubricant can lead

to fires, with the consequent risk of serious injury.

›Make sure there are no missing or loose clamps, bent hoses or rubbing between rigid and/or flexible hoses.

›If necessary, tighten, repair or replace the radiator, clamps, pipes and flexible hoses if loose or damaged.

›Do not bend or hit high-pressure pipes.

›Never install bent or damaged pipes or flexible hoses.

1.1.11 PREVENTION OF SHORT CIRCUITS OR ELECTRICAL FAULTS

›Clean and tighten all electrical connections.

›Check that the electrical cables and wires are not loose, bent, hardened, worn or damaged.

WARNING

Short circuits can cause fires.

Do not use the machine if it has loose, bent and/or damaged cables or wires.

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