Cantoni JOLLY 2010 Manual

Jolly Rev.05 Ed. Sett.2010(I) 1/24
WARRANTY
(ART. 6 GENERAL TERMS OF SALE)
The dump body is covered by a 12 (twelve) month warranty starting from the date of delivery
of the vehicle. Any repairs or maintenance interventions that become necessary during the
warranty period must be carried out exclusively at our plant or at the premises of one of our
authorised service centres. The warranty is limited to the replacement of parts that develop
faults due to defective workmanship or materials, and the relative labour costs. Inspection of
defective parts or identification of possible causes of faults must be carried out exclusively at
the headquarters of Cantoni & C. or on the premises of its authorised service centres.
The Warranty does not cover parts subject to normal wear and tear and will lapse if the dump
body is modified, tampered with, or disassembled, even partially, by non-authorised repair
shops. The Warranty will also be automatically invalidated if the dump body is loaded in
excess of the rated loading capacity specified in the vehicle's logbook.
The Warranty does not cover faults caused by incorrect use, negligence, or due to failure to
perform routine servicing. The Warranty does not cover the cost of transporting the vehicle to
our plant or to our authorised service centres, nor does it cover any losses arising through
unavailability of the vehicle or any whatsoever other costs and expenses. Any replaced parts
that are not covered by the terms of the Warranty will be charged on the basis of the Price List
in force at the time the work is carried out.
Warranty Certificate
VEHICLE TYPE
...........................................................................................................
DUMP BODY TYPE
CHASSIS N°
DELIVERY DATE
__________________
This Certificate must be rigorously retained together with the other vehicle documents and
produced at the time of any warranty claims.

2/24 Jolly Rev.05 Ed. Sett.2010(I)
USER AND MAINTENANCE HANDBOOK
ORIGINAL INSTRUCTION - revision: 05 Edition: September 2010
Tipper structure JOLLY type
READ THE CONTENTS OF THIS HANDBOOK
CAREFULLY BEFORE USING THE DUMP TRUCK !
INTRODUCTION
This user and maintenance handbook contains all the information needed
to get the best use out of your CANTONI dump truck in conditions of the
maximum safety.
The handbook is addressed to vehicle operators and the persons
responsible for maintenance and repair work.
Before using the dump truck you must read the information in this manual
carefully in order to gain familiarity with the exact operation of the
equipment and the relative manoeuvring procedures.
Incorrect manoeuvres or insufficient maintenance can cause serious
damage to the dump truck and impair the overall level of safety.
This handbook must be kept in a safe place and placed at the disposal of
the operator at all times. The information in this handbook defines the
Manufacturer's Conditions of Intended Use.
This handbook reflects the current state of the art in the construction of the
dump body. The manufacturer reserves the right to make improvements
whenever it deems appropriate with no obligation of prior notification. The
dump truck you have purchased may incorporate updated features with
respect to the features described in the latest revision of this manual.
S.p.A.
Via Roma, 9
20010 Boffalora sopra Ticino (MI)
ITALIA

Jolly Rev.05 Ed. Sett.2010(I) 3/24
C O N T ENT S
1. DUMP BODY
1.1 Identification
1.2 Description
1.3 Basic safety requirements
2. OPERATING PRESCRIPTIONS –Conditions of use
2.1 Configuration of the vehicle
2.2 Configuration of the load
2.3 Unloading conditions
3. OPERATING PRESCRIPTIONS –Manoeuvring instructions
3.1 Opening of side boards –Position of the pivot pins
3.2 Body tipping controls.
4. MAINTENANCE PRESCRIPTIONS
4.1 Preventive maintenance
4.2 Washing and greasing
4.3 Checking the hydraulic oil
4.4 Torquing of threaded fasteners
4.5 Functions of controls and safety devices
4.6 Conditions of use of tipping equipment
5. TROUBLESHOOTING
5.1 Problem
5.2 Cause
5.3 Corrective action

4/24 Jolly Rev.05 Ed. Sett.2010(I)
1. DUMP BODY
1.1 Identification
1.1.1 The dump body is identified in terms of Type and Serial Number as
punched on the dataplate shown below, complete with the Year of
Manufacture, Technical Payload, and chassis number of the vehicle on
which the dump body is installed.
1.1.2 The dataplate, which complies with the requirements of the EC
"Machinery Directive", bears the CE marking. The dataplate is located
on the outside of the left-hand subframe side member, in the forward
section.
1.1.3 Dump bodies installed on vehicles registered in Italy are identified also by
a dataplate complete with: Type and Serial number of the dump body,
Type and chassis number of the vehicle and, when specified, Type
approval number of the converted vehicle. The dataplate is located on the
outside of the right-hand subframe side member, in the forward section.
=======
XX0000
1234
XXXXXXXXXXX
XXX00000000000000
Telaio n°
Boffalora Ticino (MI)
S.p.A.
I
Autotelaio
Struttura
Omologazione
RIBALTABILE
XX0000
1234
20. . 00000
XXX00000000000000
Tipo e
Matric.
Portata
Tecnica kg
Matric.
Anno
N° Telaio veicolo
Via Roma, 9
Boffalora Ticino (MI)
S.p.A.
I

Jolly Rev.05 Ed. Sett.2010(I) 5/24
1.2. Description
The dump body is made up of the following units: :
1.2.1 Subframe:
The subframe is composed of welded steel profiles; its function is to
reinforcethe chassis of the vehicle to which it is bolted. The
subframe accommodates the lifting gear and relative hydraulic
system.
1.2.2 Load body:
The body is composed of a load floor complete with side boards and
a tailgate of various different types in accordance with the specific
type of dump truck. The load-bearing frame is fabricated from
pressed steel profiles. The panels making up the load floor and the
sides are in different gauges and materials in relation to the specific
type of use for which the dump truck is designed.
Example of a subframe
for tripartite body
Example of a tripartite
body

6/24 Jolly Rev.05 Ed. Sett.2010(I)
Lifting system:
The lifting system is composed of a telescopic cylinder that tips the
dump body, which is articulated on specially designed spherical or
cylindrical pivots.
1.2.3 The hydraulic system, made up of the following parts:
▪Power take off:: the power take off is fitted to the vehicle gearbox,
which provides the necessary drive. The power take off is engaged
by a pneumatically-operated clutch controlled from the vehicle cab.
▪Pump: the pump is driven by the power take off to which it is
mounted by means of a flange coupling. The pump draws in oil from
the hydraulic tank and delivers it under pressure to the directional
control valve.

Jolly Rev.05 Ed. Sett.2010(I) 7/24
▪Directional control valve: the directional control valve distributes the
pressurised oil to the services in accordance with the required
operations of lifting or lowering of the load body. The directional
control valve is composed of an open-centre spool valve, a load-
holding check valve that serves to hold the body in its raised
position, and a pressure relief valve that protects the various parts
of the system from possible overpressure conditions.
▪Power unit: in alternative to the mechanical plant above mentioned,
is actuated by a tele-control located in the cab.
▪Piping: suction (from tank to pump);
delivery (from pump to directional control valve);
delivery/return (from directional control valve to lift
cylinder);
delivery/return (from power unit to lift cylinder).

8/24 Jolly Rev.05 Ed. Sett.2010(I)
1.2.4 Controls and indications:the operating controls for the dump truck,
engagement of the power takeoff, and lifting and lowering of the load
body, are installed in the operator cab in such a way as to eliminate the
risk of inadvertent activation. Engagement of the power take off is
signalled by the illumination of a warning light in the cab, while the load
body raised condition is signalled by an acoustic sounder that is audible in
the immediate area of operation of the dump truck. If necessary, the
emergency stop function can be activated by stopping the vehicle
engine.

Jolly Rev.05 Ed. Sett.2010(I) 9/24
1.3. Essential safety requirements (ESR)
1.3.1 The dump body is constructed in compliance with the "Machinery
Directive" 2006/42/EC and subsequent amendments.
1.3.2 The equipment complies with the following Italian standards: UNI 10691,
UNI 10692, UNI 10693, UNI 10694, UNI 10695, which regulate the risk
analysis of the dump truck and determine the relative ESR.
1.3.3 Construction criteria
▪The members of the load-bearing structure are designed in
accordance with the rules of calculation issued by the Motorizzazione
Civile Italiana (Italian vehicles authority), to ensure adequate
resistance and safety in relation to the intended Conditions of Use.
▪The dump body and relative systems are installed on the vehicle in
accordance with best workmanship practices and in strict compliance
with the instructions of the vehicle manufacturer.
▪The installation does not affect the value of the sound level
detected by EC in the process of approval of the vehicle cab.
▪The dump body controls, featuring "maintained action" type operation,
are safe, reliable, and designed in accordance with basic logic criteria.
Controls are clearly visible and marked in such a way as to assure
coherent, practical, and safe manoeuvres.
▪The high pressure fluid pipelines are designed to withstand the
calculated stresses with an ample safety margin in conditions of the
maximum permissible load as specified in the project.
▪The hydraulic, pneumatic, and electrical systems are fully tested and
checked.
▪
1.3.4 Safety devices
▪A pressure relief valve incorporated in the directional control valve or
in the power unit serves to safeguard the various elements of the
hydraulic system from excess stress caused by overpressure.
▪A 175 A electrical fuse protects the electrical system of the power unit.
▪A stroke limiting device determines the maximum tipping angle of the
body.
▪In the standard version the tailgate is released automatically when the
body starts tipping; the latch engages only with the body in its rest
position.
▪These structures are equipped with removable journals that link the
pivots of the tipping movement and determine rear or side lifting of the

10/24 Jolly Rev.05 Ed. Sett.2010(I)
body in an unequivocal manner, preventing lifting in the direction of the
cab and providing the facility to inhibit body lifting.
▪All points of the dump body requiring periodic servicing are easily
accessible. The equipment is supplied with a safety prop to support
the raised body during maintenance work.
(See Maintenance Prescriptions, point 4.1.3).
▪Residual risks are highlighted by a series of dedicated warning plates
as specified on the next page.
1.3.5 Guarantee of risk-free operation
▪Observation of the instructions given in this handbook, in particular,
observance of the Prescriptions for Use and Prescriptions for
Servicing given in the following chapters.
▪Warning plates for residual risks:
5N49/1
Do no occupy work area during tipping
operations.
Do not insert any part of your body in the area
under the dump body.
5N49/2
Always fit the safety prop during maintenance
work with the load body in its raised position.
5N49/3
Do not occupy the load dumping area.
Adopt the maximum caution during the
opening of the side board.

Jolly Rev.05 Ed. Sett.2010(I) 11/24
OPERATING PRESCRIPTIONS –Conditions of use
2.1 Configuration of the vehicle
2.1.1 Before loading/unloading the body take steps to ensure:
▪your personal safety;
▪that you have an adequate view of the working area (construction site)
such as to ensure the absence of persons, animals, or property exposed
to the risk posed by projected objects and material;
▪that the lifting movement of the load body can be performed without
encountering any obstructions such as scaffolding, bridges, balconies,
and –in particular –overhead electrical power lines;
▪that the vehicle is at a standstill with the gear lever set to neutral;
▪that the vehicle's parking brake is applied;
2.1.2 While tipping the body, in normal circumstances do not exceed an
engine speed of 1000 rpm;
2.1.3 After dumping the material and before pulling away with the vehicle, check
that:
▪the dumped material is not in a position where it may obstruct the return
of the load body to its rest position;
▪the power take off has been disengaged (a warning light illuminates in
the cab when the power take off is engaged);
▪the load body has been fully lowered (the load body raised condition is
signalled by an audible warning signal);
2.1.4 To avoid the risk of damaging the lift cylinder, the body must not be
left in the raised position –even when the vehicle is at a standstill.
IMPROPER USE OF THE DUMP BODY IS STRICTLYPROHIBITED !

12/24 Jolly Rev.05 Ed. Sett.2010(I)
2.2 Unloading conditions
2.2.1 The weight of the load must never exceed the Payload value specified
in the vehicle logbook. (Overloads will compromise the correct
operation of the dump body and increase the risk of accidents and the
dangers associated with road circulation of the vehicle).
2.2.2 Ensure the side boards and tailgate are closed.
2.2.3 When loading the body, bulk material must be dropped into the body from
the minimum possible height.
2.2.4 Heavy materials such as boulders or demolition blocks must be placed
carefully on the load floor; never allow heavy blocks or boulders to fall into
the body.
2.2.5 Distribute the payload uniformly in the body both lengthwise and crosswise.
DO NOT OVERLOAD THE VEHICLE !
ENSURE THE SIDE BOARDS AND TAILGATE ARE CLOSED !
LOAD THE VEHICLE CORRECTILY !
YES
NO

Jolly Rev.05 Ed. Sett.2010(I) 13/24
2.3 Unloading conditions
2.3.1 Before dumping the load, check the condition of the ground:
▪the vehicle must be standing on stable terrain that does not allow
the tyres to become embedded;
▪the tyres must be in contact with a flat area of ground;
▪when dumping loads on uneven terrain make sure the body is
horizontal before proceeding.
2.3.2 Before tipping and at the start of the tipping movement make sure that
the material does not adhere to the inside walls of the body,
particularly with:
▪soil with high clay contents (agricultural soil);
▪sand with high contents of binder material;
▪frozen material due to low ambient temperatures.
2.3.3 It is extremely hazardous to agitate the load body in the attempt to
facilitate unloading of the material.
2.3.4 Do not tip the load body in positions exposed to strong winds.
DUMP LOADS EXCLUSIVELY ON FLAT,STABLE GROUND!
SUPERVISE CORRECT EMPTYING OF THE BODY DURING
LOAD DUMPING
DO NOT AGITATE THE LOAD BODY DURING TIPPING!
NO
YES

14/24 Jolly Rev.05 Ed. Sett.2010(I)
3 OPERATING PRESCRIPTIONS –Manoeuvring instructions
3.1 Opening of tailgate or side boards –Position of the pivot pins
3.1.1 In the standard configuration the tailgate is equipped with an
automatic release device that is activated as soon as the body starts
to tip.
3.1.2 In the standard version the side boards are opened manually by
means of the specific handle located at the end of the body.
3.1.3 Before starting the tipping movement, check the following:
▪pins correctly inserted in the pivot points for tilting, thereby
ensuring that the body lifts on the required side,
▪that the tailgate or side board on the side towards which the body
is to be tipped has been released.
ALWAYSCHECKTHATTHESIDEBOARDS/ TAILGATE OPEN
CORRECTLY!
OPEN THE SIDE BOARDS, KEEPING ALL PARTS OF YOUR BODY
WELL CLEAR OF THE AREA IN WHICH THE LOAD WILL BE DUMPED!
MAKE SURE THE PIVOT PINS ARE CORRECTLY POSITIONED !

Jolly Rev.05 Ed. Sett.2010(I) 15/24
3.2. Body tipping controls
THE CONTROLS FOR THE MECHANICAL ENGAGEMENT (WITH PTO) ARE
LOCATED ON THE DASHBOARD IN THE CAB IN POSITION CLEARLY VISIBLE
AND EASILY ACCESSIBLE.
THE KEYBOARD FOR THE ELECTRICAL ENGAGEMENT IS LOCATED IN THE
CAB, USUALLY BEHIND THE DRIVING SEAT, TO PREVENT ACCINTAL
CONTACT.
N.B. In the case of controls provided by the vehicle manufacturer,
consult the "Vehicle Owner's Handbook".
If it becomes necessary to perform an Emergency Stop, switch off
the vehicle engine.
THE BATTERY SWITCHES (RED KEY LOCATED
ON THE FRONT PART OF THE LEFT SIDE
MEMBER OF THE AUXILARY CHASSIS) MUST
BE INSERTED ONLY DURING THE TIPPING

16/24 Jolly Rev.05 Ed. Sett.2010(I)
3.1.1 Lifting
Lifting with mechanical plant
▪With the vehicle engine running (neutral gear selected) press the
clutch pedal fully down and wait a few seconds to allow all gears
currently spinning in the gearbox to coast to a stop.
▪For engage the Power Take-Off, push the button with indicated a
symbol in the shape of gear.
▪Engagement of the Power Take-Off is confirmed by illumination of
a red indicator light.
▪Release the clutch pedal.
▪Press the button indicated with an arrow pointing upwards. Begins
to tip the bucket until reaching the maximum lifting, determined by
the end of stroke device. The tailgate, in the standard version, it
opens automatically at the beginning of the lift.
▪Release the button, it will automatically return to the Stop position.
▪The body remains lifted.
▪During the step of tipping, releasing the button, the body stops the
lifting.
Lifting with electrical plant
▪Press the button of the keyboard with the arrow pointing upwards.
3.1.1 Lowering
▪Press the button indicated with an arrow pointing downward. The
body starting lowering.
During lowering, releasing the button, it stops running, and the
body remains in the required position.
During the entire duration of the tipping phase an Audible
Warning will sound warn that the body is raised.
MAKE SURE THE SIDE BOARDS / TAILGATE ARE CORRECTLY
CLOSED!
RESTARTONLY WHEN THE BODYIS IN ITSREST POSITION !
Note: The aesthetic aspect of the controls in the cab may be
different from that reported in previous drawings. The operating
logic remains the same.

Jolly Rev.05 Ed. Sett.2010(I) 17/24
4 MAINTENANCE PRESCRIPTIONS
Use of the equipment in accordance with the designated Prescriptions for
Use together with properly executed maintenance constitute the best
possible guarantee of lasting efficiency of the dump truck and the
minimum possible need for repairs.
To facilitate maintenance operations, all parts subject to adjustment,
lubrication, or cleaning can be easily accessed in such a way as to allow
the operator to work with the minimum fatigue and in conditions of safety.
4.1 Preventive maintenance
4.1.1 Observe general accident prevention regulations. Italian Law 626 / 94
4.1.2 Work only when the vehicle is parked with the parking brake applied
and disconnected from sources of power (switch off the ignition and, if
necessary, open the battery disconnect switch).
4.1.3 When work must be performed with the body in its raised position, it is
absolutely mandatory to use the SAFETY PROP which is normally
stowed in its housing under the body. The prop is pivoted to the
subframe and identified by a specific warning plate.
4.1.4 Even though the prop must be used, it is still strictly prohibited to work
under the body when this latter is fully or partially loaded.
4.1.5 Compile the register of inspections and repairs (see the attached table
II).
4.2 Washing and Greasing
4.2.1 Wash the dump body every month, carefully removing all dust and
remains of materials that could otherwise attack the paintwork and
compromise the proper operation of the various devices.
4.2.2 Wash using cold or lukewarm water. Do not wash any parts of the
system with high pressure washers.
4.2.3 Grease parts in contact with each other and the pivots by way of the
dedicated grease nipples (if present). Specifically:
▪Supports of the lift cylinder and cradle.
▪Tipping pivots.
▪Side board and tailgate hinges and latches.
▪Return springs
▪Winches, safety prop, and other accessories supplied with
the dump body.
4.2.4 Grease the parts once a month and, in any event, after each time the
dump body has been washed and following work performed in
demanding conditions with particularly aggressive and/or abrasive

18/24 Jolly Rev.05 Ed. Sett.2010(I)
materials such as, for example, very high concentrations of dust,
humidity, substances with high salt contents.
4.2.5 Use Grease with a high pour point (180°C) featuring elevated
resistance to mechanical stress. Do not use grease containing acid,
naphtha, or solid particulate.
4.3 Checking the Hydraulic Oil
4.3.1 Once a week check the hydraulic system for possible external or
internal leakage of oil in the Power Take-Off –pump assemblies.
4.3.2 Each month (or after 200 working hours) check for possible leakage of
oil from the unions of the hydraulic system, which may have worked
loose due to vibration generated when the vehicle is travelling. If
necessary, tighten ringnuts, hose clamps, and screws.
4.3.3 With the same frequency check for leakage from between the
extensions of the lift cylinder due to wear of the relative seals. If you
notice signs of leakage take the vehicle to an authorised service
centre.
4.3.4 Check also that the oil tank filler plug vent line is not obstructed and
that the oil level in the tank is correct (see point 1.2.4. under the
heading Oil tank).
4.3.5 If necessary, top up the oil or change the oil if the characteristics of
the original oil contents have altered due to ageing. Use Hydraulic Oil
viscosity class 32/46 (ISO 3448) and viscosity index 106/110 (ASTM
D2270).
WARNING! DO NOT DISPERSE SPENT OIL IN THE
ENVIRONMENT!

Jolly Rev.05 Ed. Sett.2010(I) 19/24
4.4 Torquing of Threaded Fasteners
Once a month check the torque of the Subframe to Vehicle chassis fixing
bolts.
4.4.1 Fixing:
Braket type Plate type
BOLT DIAMETER
(mm)
TIGHTENING
TORQUE (Nm)
Ø10
55
Ø12
100
4.4.2 In the event of replacement use fasteners with resistance class 10.9

20/24 Jolly Rev.05 Ed. Sett.2010(I)
4.4 Functions of controls and safety devices
Check the following aspects during normal use of the dump body and at
least one a month:
4.4.1 That the indicator symbols and warning plates are present and legible.
4.4.2 That the dump truck controls are working correctly, checking also that there
are no leaks from the pneumatic circuit.
4.4.3 That the indicator light illuminates to signal engagement of the power
takeoff.
4.4.4 Efficiency ofthe sounder signaling the"Body raised" condition
4.4.5 That the safety cables are not frayed and that the relative attachment points
are in good condition.
4.4.6 The efficiency of the stroke limiting device. On structures incorporating this
solution, check the cable as per the previous point.
4.4.7 Functionality of the devices for insertion of the pivot pins to ensure the
correct direction of tipping.
4.4.8 Perfect condition and functionality of the check valve and the pressurerelief
valve. Do not tamper with the parts!
4.4.9 If necessary, have the system checked by an authorised repair shop.
BEFORE WORKING UNDER THE RAISED LOAD BODY:
MAKE SURE THE BODY IS COMPLETELY EMPTY !
INSTALL THE SAFETY PROP !