DYNAPAC Vibratory roller CA362 Engine Cummins QSB 6.7C. Operation & Maintenance (2010)

Instructions manual

Driving & Maintenance

Vibratory roller

CA362

Engine

Cummins QSB 6.7C

Serial number

*72X11155*-*72X11170*

CA362 is one of Dynapac's medium-heavy soil compaction rollers. It is

available in a D (smooth drum) and PD (padfoot) version. The main

applications for the PD version are on cohesive material and weathered

stone material.

All types of base courses and subbase courses can be compacted deeper

and the interchangeable drums, D to PD, and vice versa, facilitate even

greater variety in the range of application.

The cab and safety-related accessories are described in this manual.

Other accessories, such as compaction meter, tachograph and field

computer, are described in separate instructions.

Reservation for changes

Printed in Sweden

Table of Contents

Introduction

Safety - General instructions

Safety - when operating

Safety (Optional)

Special instructions

Technical specifications - Noise/Vibrations/Electrical

Technical specifications - Dimensions

Technical specifications - Weights and volumes

Technical specifications - Working capacity

Technical specifications - General

Machine plate - Identification

Machine description - Instruments/Controls

Machine description - Electrical system

Operation - Starting

Operation - Driving

Operation - Vibration

Operating - Stopping

Long-term parking

Miscellaneous

Operating instructions - Summary

Maintenance - Lubricants and symbols

Maintenance - Maintenance schedule

Maintenance - 10h

Maintenance - 50h

Maintenance - 250h

Maintenance - 500h

Maintenance - 1000h

Maintenance - 2000h

105

Introduction

Warning symbols

WARNING ! Marks a danger or a hazardous

procedure that can result in life threatening or

serious injury if the warning is ignored.

CAUTION ! Marks a danger or hazardous

procedure that can result in damage to the

machine or property if the warning is ignored.

Safety information

The safety manual supplied with the machine

must be read by all roller operators. Always

follow the safety instructions. Do not remove

the manual from the machine.

We recommend that the operator reads the

safety instructions in this manual carefully.

Always follow the safety instructions. Ensure

that this manual is always easily accessible.

Read the entire manual before starting the

machine and before carrying out any

maintenance.

Ensure good ventilation (extraction of air by fan)

where the engine is run indoors.

CALIFORNIA

Proposition 65 Warning

Diesel engine exhaust and some of its constituents are

known to the State of California to cause cancer, birth

defects, and other reproductive harm.

General

This manual contains instructions for machine

operation and maintenance.

Introduction

The machine must be correctly maintained for

maximal performance.

The machine should be kept clean so that any

leakages, loose bolts and loose connections are

discovered at as early a point in time as possible.

Inspect the machine every day, before starting.

Inspect the entire machine so that any leakages or

other faults are detected.

Check the ground under the machine. Leakages are

more easily detected on the ground than on the

machine itself.

THINK ENVIRONMENT ! Do not release oil,

fuel and other environmentally hazardous

substances into the environment. Always send

used filters, drain oil and fuel remnants to

environmentally correct disposal.

This manual contains instructions for periodic

maintenance normally carried out by the operator.

Additional instructions for the engine can be

found in the manufactuer's engine manual.

Safety - General instructions

(Also read the safety manual)

The operator must be familiar with the contents of the OPERATION section

before starting the roller.

Ensure that all instructions in the MAINTENANCE section are followed.

Only trained and/or experienced operators are to operate the roller.

Passengers are not permitted on the roller. Remain seated at all times when

operating the roller.

Never use the roller if it is in need of adjustment or repair.

Only mount and dismount the roller when it is stationary. Use the intended

grips and rails. Always use the three-point grip (both feet and one hand, or

one foot and both hands) when mounting or dismounting the machine.

Never jump down from the machine.

The ROPS (Roll Over Protective Structure) should always be used when the

machine is operated on unsafe ground.

Drive slowly in sharp bends.

Avoid driving across slopes. Drive straight up or straight down the slope.

When driving close to edges, ditches or holes, make sure that at least 2/3 of

the drum width is on previously compacted material (solid surface).

10.

Make sure that there are no obstacles in the direction of travel, on the

ground, in front of or behind the roller, or overhead.

11.

Drive particularly carefully on uneven ground.

12.

Use the safety equipment provided. The seat belt must be worn on machines

fitted with ROPS.

13.

Keep the roller clean. Clean any dirt or grease that accumulates on the

operator platform immediately. Keep all signs and decals clean and legible.

14.

Safety measures before refueling:

- Shut off the engine

- Do not smoke

- No naked flame in the vicinity of the machine

- Ground the filling device nozzle to the tank to avoid sparks

15.

Before repairs or service:

- Chock the drums/wheels and under the strike-off blade.

- Lock the articulation if necessary

Safety - General instructions

16. Hearing protection is recommended if the noise level exceeds 85 dB(A). The

noise level can vary depending on the equipment on the machine and the

surface the machine is being used on.

17. Do not make any changes or modifications to the roller that could affect

safety. Changes are only to be made after written approval has been given

by Dynapac.

18. Avoid using the roller before the hydraulic fluid has reached its normal

working temperature. Braking distances can be longer than normal when the

fluid is cold. See instructions in the STOP section.

19. For your own protection always wear:

- helmet

- working boots with steel toecaps

- ear protectors

- reflecting clothing/high visibility jacket

- working gloves

Safety - when operating

Driving near edges

When driving near an edge, minimum 2/3 of the drum

width must be on solid ground.

Keep in mind that the machine's center of gravity

moves outwards when steering. For example, the

center of gravity moves to the right when you

steer to the left.

Minimum

2/3

Fig. Position of drum when driving near

an edge

Slopes

This angle has been measured on a hard, flat surface

with the machine stationary.

The steering angle was zero, the vibration was

switched OFF and all tanks were full.

Always take into consideration that loose ground,

steering the machine, vibration on, machine speed

across the ground and raising the center of gravity can

all cause the machine to topple at smaller slope

angles than those specified here.

To exit the cab in an emergency, release the

Max 20° or 36%

hammer on the rear right post and break the

rear window.

It is recommended that ROPS (Roll Over

Protective Structure) or a ROPS-approved cab is

Fig. Operating on slopes

always used when driving on slopes or unsafe

ground. Always wear a safety belt.

Where possible, avoid driving across slopes.

Drive instead straight up and down sloping

ground.

Safety (Optional)

Strike-off blade

The operator must make sure that nobody is in

the area of operation while the machine is in

use.

Ensure always that the strike-off blade is

secured by the locking pin (1) when driving

with the blade in its raised position. Always

lower the blade to the ground before leaving or

parking the roller.

Fig.Strike-off blade

The strike-off blade must be retracted to the

1. Locking pin

transport position (1) at the end of each

working period.

Safety (Optional)

Air conditioning

The system described in this manual is type ACC

(Automatic Climate Control)

The system contains pressurized refrigerant. It

is forbidden to release refrigerants into the

atmosphere.

The cooling system is pressurized. Incorrect

handling can result in serious personal injury.

Do not disconnect or undo the hose couplings.

Fig. Cab

The system must be refilled with an approved

refrigerant by authorized personnel when

necessary.

Fig. Air conditioning

Special instructions

Standard lubricants and other recommended

oils and fluids

Before leaving the factory, the systems and

components are filled with the oils and fluids specified

in the lubricant specification. These are suitable for

ambient temperatures in the range -15°C to +40°C

(5°F - 104°F).

The maximum temperature for biological

hydraulic fluid is +35°C (95°F).

Higher ambient temperatures, above +40°C

(104°F)

For operation of the machine at higher ambient

temperatures, however maximum +50°C (122°F), the

following recommendations apply:

The diesel engine can be run at this temperature using

normal oil. However, the following fluids must be used

for other components:

Hydraulic system - mineral oil Shell Tellus T100 or

similar.

Other components that use transmission oil: Shell

Spirax AX 85W/140 or equivalent.

Temperatures

The temperature limits apply to standard versions of

rollers.

Rollers equipped with additional equipment, such as

noise suppression, may need to be more carefully

monitored in the higher temperature ranges.

High pressure cleaning

Do not spray directly onto electrical components.

Special instructions

High-pressure washing must not be used on the

instrument panel.

Detergent that can destroy electrical parts, or

which is conductive, must not be used.

In certain cases there is an electric operating

lever and an attendant program box in the engine

compartment, which must not be washed with

high-pressure washing or otherwise washed with

water. It is sufficient to wipe them clean.

Place a plastic bag over the fuel filler cap and secure

with a rubber band. This is to avoid high pressure

water entering the vent hole in the filler cap. This could

cause malfunctions, such as the blocking of filters.

Never aim the water jet directly at the fuel tank

cap. This is particularly important when using a

high-pressure cleaner.

Fire fighting

If the machine catches fire, use an ABE-class powder

fire extinguisher.

A BE-class carbon dioxide fire extinguisher can also

be used.

Roll Over Protective Structure (ROPS), ROPS

approved cab

If the machine is fitted with a Roll Over

Protective Structure (ROPS, or ROPS approved

cab) never carry out any welding or drilling in

the structure or cab.

Never attempt to repair a damaged ROPS

structure or cab. These must be replaced with

new ROPS structure or cabs.

Battery handling

When removing batteries, always disconnect the

negative cable first.

Special instructions

When fitting batteries, always connect the

positive cable first.

Dispose of old batteries in an environmentally

friendly way. Batteries contain toxic lead.

Do not use a quick-charger for charging the

battery. This may shorten battery life.

Jump starting

Do not connect the negative cable to the

negative terminal on the dead battery. A spark

can ignite the oxy-hydrogen gas formed

around the battery.

Check that the battery used for jump starting

has the same voltage as the dead battery.

Turn the ignition and all power consuming equipment

off. Switch off the engine on the machine which is

providing jump start power.

First connect the jump start battery's positive terminal

(1) to the flat battery's positive terminal (2).Then

connect the jump start battery's negative terminal (3)

to, for example, a bolt (4) or the lifjting eye on the

machine with the flat battery.

Start the engine on the power providing machine. Let it

run for a while. Now try to start the other machine.

Disconnect the cables in the reverse order.

Fig. Jump starting

Technical specifications - Noise/Vibrations/Electrical

Technical specifications -

Noise/Vibrations/Electrical

Vibrations - Operator station

(ISO 2631)

The vibration levels are measured in accordance with the operational cycle described in

EU directive 2004/14/EC on machines equipped for the EU market, with vibration switched

on, on soft polymer material and with the operator’s seat in the transport position.

Measured whole-body vibrations are below the action value of 0.5 m/s² as specified in Directive

2002/44/EC. (Limit is 1.15 m/s²)

Measured hand/arm vibrations also were below the action level of 2.5 m/s² specified in the same

directive. (Limit is 5 m/s²)

Noise level

The noise level is measured in accordance with the operational cycle described in EU

directive 2004/14/EC on machines equipped for the EU market, on soft polymer material

with vibration switched on and the operator's seat in the transport position.

Guaranteed sound power level, LwA

108 dB (A)

Sound pressure level at the operator's ear (platform), LpA

84 dB (A)

Sound pressure level at the operator's ear (cab), LpA

77 dB (A)

Electrical system

Machines are EMC tested in accordance with EN

13309:2000 'Construction machinery'

Technical specifications - Dimensions

Dimensions, side view

Dimensions

Wheelbase, drum and wheel

2879

113.3

Length, standard equipped roller

5758

226,7

Height, with ROPS (D)

2980

117,3

Height, with ROPS (PD)

2996

117,9

Height, with cab (D)

2980

117,3

Height, with cab (PD)

2996

117,9

Height, without ROPS (D)

2190

Height, without ROPS (PD)

2212

87,08

Diameter, drum (D)

1543

60,75

Diameter, drum (PD)

1523

59.96

Thickness, drum sweep, nominal (D)

1,378

Thickness, drum sweep, nominal (PD)

0.984

Height, pads (PD)

100

3.94

Clearance, tractor frame (D/PD)

453

17.83

Clearance, drum frame (D)

400

15.74

Clearance, drum frame (PD)

495

19.48

Technical specifications - Weights and volumes

Technical specifications - Weights and

volumes

Weights

Service weight with ROPS (EN500)

13050 kg

28775 lbs

(D)

Service weight with ROPS (EN500)

12950 kg

28555 lbs

(PD)

Service weight without ROPS (D)

12550 kg

27672 lbs

Service weight without ROPS (PD)

12450 kg

27452 lbs

Service weight with cab (D)

13050 kg

28775 lbs

Service weight with cab (PD)

12950 kg

28555 lbs

Fluid volumes

Rear axle

- Differential

12 liter

12.7 qts

- Planetary gear (standard

2.0 liters/side

2.1 qts/side

axel)

- Planetary gear (optional

1.85 liter/side

1.9 qts/side

shaft)

Drum gearbox

3.0 liter

3,2 qts

Drum cartridge

2.3 liters/side

2.4 qts/side

Hydraulic reservoir

52 liters

13.7 gal

Oil in hydraulic system

23 liters

6 gal

Lubrication oil, diesel

14 liter

14,8 qts

engine

Coolant, diesel engine

29 liter

7,7 gal

Fuel tank

320 liters

84,5 gal

Technical specifications - Working capacity

Technical specifications - Working

capacity

Compaction data

Static linear load (D)

37,5 kg/cm

210 pli

Static linear load (PD)

Static linear load with ROPS (D)

37,9 kg/cm

212 pli

Static linear load with ROPS (PD)

Static linear load with cab (D)

38,3 kg/cm

214 pli

Static linear load with cab (PD)

Amplitude, high (D)

1.7 mm

0.066 in

Amplitude, high (PD)

1.6 mm

0,062 in

Amplitude, low (D/PD)

0.8 mm

0.031 in

Vibration frequency, high amplitude (D/PD)

33 Hz

1980 vpm

Vibration frequency, low amplitude (D/PD)

33 Hz

1980 vpm

Centrifugal force, high amplitude (D/PD)

300 kN

67500 lb

Centrifugal force, low amplitude (D/PD)

146 kN

32850 lb

Note: The frequency is measured at high revs. The

amplitude is measured as the real value and not

the nominal.

Technical specifications - General

Engine

Manufacturer/Model

Cummins QSB 6.7C

Water cooled turbo diesel

with after cooler

Power (SAE J1995)

112 kW

150 hp

Engine speed, idling

900 rpm

Engine speed, loading/unloading

1,500 rpm

Engine speed, working/transport

2,200 rpm

Electrical system

Battery

12V 170Ah

Alternator

12V 95A

Fuses

See the Electrical system section - fuses

Tire

Tire dimensions

Tire pressure

Std-type

23.1 x 26.0 12 ply

110 kPa (1.1 kp/cm) (16 psi)

Tractor type

23.1 x 26.0 12 ply

110 kPa (1.1 kp/cm) (16 psi)

The tires can be optionally filled with fluid, (extra

weight up to 700 kg/tire) (1,543 lbs/tire). When

servicing, bear this extra weight in mind.

Technical specifications - General

Tightening torque

Tightening torque in Nm (lbf.ft) for oiled or dry bolts

tightened with a torque wrench.

Metric coarse screw thread, bright galvanized (fzb):

STRENGTH CLASS:

M -

8.8, Oiled

8.8, Dry

10.9, Oiled

10.9, Dry

12.9, Oiled

12.9, Dry

thread

8,4

9,4

13,4

14,6

16,3

M10

M12

110

117

131

M14

110

123

156

174

187

208

M16

169

190

240

270

290

320

M20

330

370

470

520

560

620

M22

446

497

626

699

752

839

M24

570

640

800

900

960

1080

M30

1130

1260

1580

1770

1900

2100

Metric coarse thread, zinc-treated

(Dacromet/GEOMET):

STRENGTH CLASS:

M - thread

10.9, Oiled

10.9, Dry

12.9, Oiled

12.9, Dry

12,0

15,0

14,6

18,3

M10

M12

124

117

147

M14

156

196

187

234

M16

240

304

290

360

M20

470

585

560

698

M22

626

786

752

944

M24

800

1010

960

1215

M30

1580

1990

1900

2360

Technical specifications - General

ROPS-bolts which are to be torque tightened

must be dry.

ROPS - bolts

Bolt dimensions :

M24 (PN 904562)

Strength class :

10.9

Tightening torque :

800 Nm (Dacromet

treated)

Hydraulic system

Opening pressure

MPa

Drive system

38,0

Supply system

2.0

Vibration system

40,0

Control systems

18,0

Brake release

1,4

Automatic Climate Control (ACC) (Optional)

The system described in this manual is type ACC

(Automatic Climate Control), i.e. a system which

maintains the set temperature in the cab provided the

windows and doors are kept closed.

Coolant designation: HFC-R134:A

Coolant weight when full: 1600 gram (3.53 lbs)

Machine plate - Identification

Product identification number on the frame

The machine PIN (product identification number) (1) is

punched on the right edge of the front frame.

Fig. Front frame

1. PIN

Machine plate

The machine type plate (1) is attached to the front left

side of the frame, beside the steering joint.

The plate specifies the manufacturer's name and

address, the type of machine, the PIN product

identification number (serial number), service weight,

engine power and year of manufacture. (If the

machine is delivered outside the EU there are no CE

markings, and on some machines the year of

manufacture may not be specified.)

Fig. Operator platform

1. Machine plate

Please state the machine's PIN when ordering

spares.

Machine plate - Identification

Decals

Location - decals

2, 3

Warning, Crush zone

Warning, Locking

13.

Sound power level

Warning, Rotating engine

Warning, Toxic gas

14.

Hydraulic

components

fluid/Biohydraulic fluid

Warning, Hot surfaces

Hoisting plate

15.

Tie down point

Warning, Ballasted tire.

10.

Tire pressure

16.

Handbook compartment

Emergency exit

11.

Diesel fuel

17.

Battery master switch

Warning, Read instructions manual 12.

Lift point

18.

Warning sign

Machine plate - Identification

Safety decals

4700903422

Warning - Crush zone, articulation/drum.

Maintain a safe distance from the crush zone.

(Two crush zones on machines fitted with pivotal steering)

4700903423

Warning - Rotating engine components.

Keep your hands at a safe distance from the

danger zone.

4700903424

Warning - Hot surfaces in the engine compartment.

Keep your hands at a safe distance from the

danger zone.

4700903985

Warning - Ballasted tire.

Read the instruction manual.

4700903590

-Emergency exit

4700903459

Warning - Instruction manual

The operator must read the safety, operation and

maintenance instructions before operating the

machine.

Machine description - Instruments/Controls

Machine description -

Instruments/Controls

Locations - Instruments and controls

Fig. Instruments and control panel

Starter switch

Rpm/Frequency selector

Working lights

Hazard beacon

Direction indicator switch

Hazard warning lights

Main beam switch

Parking/dipped beam switch

Anti-spin, fault indication

10.

Voltmeter

11.

Hydraulic temperature

12.

Engine temperature

13.

Engine revs/Vibration frequency

14.

Compaction meter/Speedometer (see pos. 21)

15.

Fuel gauge

16.

Preheating lamp

17.

Reserve

18.

Fault indicating lamp

19.

Diagnostics "ON"

20.

Browse in error codes

21.

Speedometer (if compaction meter is located in pos. 14)

22.

Fault indicating lamp

23.

Engine speed control

24.

Amplitude selector, High/0/Low

25.

CMV väljare

* = Optional equipment

Machine description - Instruments/Controls

Locations - Control panel and controls

Fig. Control panel

26.

Hourmeter

34.

Warning lamp, fuel level

27.

Brake warning lamp

35.

Speed selector, drum/wheels (Optional)

28.

Warning lamp, engine oil pressure

36.

Speed selector, wheels

29.

Warning lamp, hydraulic fluid filter

37.

Reserve/Parking brake knob

30.

Warning lamp, air filter

38.

Vibration ON/OFF

31.

Warning lamp, charging

39.

Forward/Reverse lever

32.

Warning lamp, hydraulic fluid temperature

40.

Horn

33.

Warning lamp, engine temperature

41.

Antispin function (Optional)

Function descriptions

Designation

Symbol

Function

Starter switch

The electric circuit is broken.

All instruments and electric controls are supplied with

power.

Starter motor activation.

Engine revs/Frequency selector

The current rpm is shown in this position

(Optional)

The vibration frequency is shown in this position (Left

position has no function.

Rear working lights switch

Turn right to switch on the working lights.

(Optional).

Hazard beacon, switch

Turn right to switch on the hazard beacon.

(Optional).

Direction indicator, switch

Turn to the left to switch on the left direction indicators

(Optional).

etc.

The direction indicators are off in the middle position.

Machine description - Instruments/Controls

Designation

Symbol

Function

Hazard flashers, switch

Turn to the right to switch on the hazard flashers.

(Optional).

Main/dipped beam, switch with

In the right position, the switch lights and the main

control lamp (Optional).

beam is on.

In the left position, the dipped beam is on.

Driving lighting, switch

Lights off.

(Optional).

Parking lights on.

Front working lights on.

Warning lamp, malfunctioning

The hydraulic propulsion system is not working

anti-spin function (Optional)

satisfactorily if the lamp flashes. Locate and remedy

the fault.

Voltmeter (Optional).

Shows electrical system voltage.

Normal range is 12-15 volts.

Temperature gauge, hydraulic

Shows hydraulic fluid temperature.

fluid (Optional).

Normal temperature range is 65°-80°C (149°-176°F).

Stop the engine if the gauge shows a temperature of

more than 85°C (185°F). Locate the fault.

Temperature gauge, water

Shows the water temperature.

(Optional).

Normal temperature is around 90°C (194°F).

Stop the engine if the gauge shows a temperature of

more than 103°C (217°F). Locate the fault.

Engine revs/Frequency meter

The inner scale indicates the current engine speed.

(Optional).

The outer scale shows the vibration frequency.

Compaction meter (Optional)

See separate instructions

Fuel gauge

Shows level in the fuel tank.

Preheating lamp

Lights up when the diesel engine is being preheated

and the switch is in position I.

Reserve

Fault indicating lamp, "Minor

Indicates fault and shows error code together with knob

fault"

19. See error codes under tab X in machine folder.

Diagnostics "ON"

Check error code together with lamp 18 and 20.

Browse in error codes

Turning to right (+): Stepping forward.

Turning to left (-): Stepping backwards.

Speedometer (Optional).

The outer scale shows speed in km/h.

The inner scale shows speed in mph.

Fault indicating lamp, "Serious

Stop the engine.

fault"

Machine description - Instruments/Controls

Designation

Symbol

Function

Engine speed control for Diesel

900 = Idling speed

engine

1,500 = Speed for loading/unloading

2,200 = Working and transport speed

Amplitude selector.

Left mode gives low amplitude.

In the 0 position, the vibration system is switched off.

Right mode gives high amplitude.

CMV selector (Optional).

Mode 150 gives reading on outer scale.

Mode 50 gives reading on inner scale.

Hourmeter

Engine running time is shown in hours.

Brake warning lamp

The lamp come on when the parking or emergency

brake knob is depressed and the brakes are applied.

Warning lamp, oil pressure

The lamp comes on if the engine oil pressure is too low.

Stop the engine immediately and locate the fault.

Warning lamp, hydraulic filter

If the lamp comes on while the engine is running at full

speed, the hydraulic filter must be changed.

Warning lamp, air filter

If the lamp comes on while the engine is running at full

speed, the air filter must be cleaned or replaced.

Warning lamp, battery charging

If the lamp comes on while the engine is running, the

alternator is not charging.

Stop the engine and locate the fault.

Warning lamp, hydraulic fluid

If the lamp comes on, the hydraulic fluid is too hot.

temperature

Do not drive the roller. Cool the fluid by allowing the

engine to idle and locate the fault.

Warning light, coolant

If the lamp comes on, the engine is too hot. Stop the

temperature

engine immediately and locate the fault.

Refer also to the engine manual.

Warning lamp, low fuel level

When the lamp comes on, there is only a small amount

of fuel left.

Refuel as soon as possible.

Speed selector, drum/wheels

Position 1: Working mode

(Optional)

Position 2: Used if the drum spins.

Position 3: Used if the rear tires spin.

Position 4: Transport mode

Speed selector, wheels

Transport speed (Low)

Transport speed (High)

Machine description - Instruments/Controls

Designation

Symbol

Function

Emergency brake / Parking

Press to activate the emergency brakes. When the

brake

machine is stationary, the parking brake is activated.

Both brakes are released when pulled out.

Vibration On/Off, switch

Press once and release to switch the vibration on,

press again to switch the vibration off.

The above only applies when the amplitude selector 17

is in the High or Low position.

Forward/Reverse lever

The lever must be in neutral to start the engine. The

engine cannot be started if the forward/reverse lever is

in any other position.

The forward/reverse lever controls both the roller's

driving direction and speed. When the lever is moved

forward, the roller moves forward.

The roller's speed is proportional to the distance the

lever is from the neutral position. The further the lever

is from the neutral position, the higher the speed.

Horn, switch

Press to sound the horn.

Antispin function (Optional)

Optimized antispin function forwards is obtained with

the knob in the left position.

Optimized antispin function backwards is obtained with

the knob in the middle position.

Set the knob in the right position during transport.

Machine description - Instruments/Controls

Function description of instruments and

controls in the cab

Designation

Symbol

Function

Front working lights, switch

Press to switch on the front working lights.

Rear working lights, switch

Press to switch on the rear working lights.

Front wiper, switch

Press to operate the front screen wiper.

Rear wiper, switch

Press to operate the rear screen wiper.

Front and rear window screen

Press the upper edge to activate the front screen

washers, switch

washers.

Press the lower edge to activate the rear screen

washers.

Fuse box (cab)

Contains fuses for the electrical system. See the

"Electrical system" section in the operation

manual for functional descriptions of the fuses.

Heater control

Right mode, maximum heating. In the left

position, the heating is off.

Ventilation fan, switch

In the left position, the fan is OFF. To the right,

the fan has three levels.

Cab air recirculation, switch

In the left position, the maximum volume of air is

recirculated.

In the right position, the volume recirculated is

minimal.

Temperature sensor

Registers the temperature in the cab. Do not

cover.

Air conditioning, switch

Starts and stops the air conditioning.

Handbook compartment

Stowage space for safety manual and instruction

manuals.

Hammer for emergency exit

To escape from the cab in an emergency,

release the hammer and break the REAR

window.

Machine description - Electrical system

Electrical system

Fuses

The electrical regulating and control system is

protected against overload by 27 fuses and 12 relays.

The quantity depends on how much extra equipment

the machine has.

The four fuse boxes (1) and relays (3) are located

behind the lower instrument plate, which is opened by

turning the four quick-fit screws (2) a 1/4 turn

counter-clockwise.

The machine is equipped with a 12V electrical system

and an AC alternator.

Fig. Instrument panel

1. Fuse boxes (4)

2. Quick-screws

3. Relays

Machine description - Electrical system

Fuses

The figure shows the position of the fuses.

The table below gives fuse amperage and function. All

fuses are flat pin fuses.

The tachograph and memory for the radio are

protected at the battery master disconnect switch by a

0.5 A and 3 A fuse, respectively.

Fig. Fuse box,

left and right side.

Fuse boxes, left side

Fuse boxes, right side

Brake valve, starter relay, hourmeter

7.5A

* Left working lights

20A

VBS relay

7.5A

* Working lights, right, instrument

20A

illumination

Indicator panel

7.5A

* Headlight, left

7.5A

Horn

7.5A

* Headlight, right, instrument illumination

7.5A

* Low/High speed/Strike-off blade

7.5A

Reserve

* Reverse warning

Reserve

Instrumentation

7.5A

* Hazard beacon

10A

* Compaction meter

* Direction indicators, main fuse

10A

* Hazard beacon

7.5A

* Position light, left, front and rear

7.5A

10. * Anti-spin

7.5A

10. * Position light, right, front and rear

11. * Air conditioning

20A

11. * Direction indicator, left, front, rear and side

12. * Air conditioning

20A

12. * Direction indicator, right, front, rear and

side

* Optional

** When driving lights are fitted

Machine description - Electrical system

Fuses in cab

The electrical system in the cab has a separate fuse

box located on the front right side of the cab roof.

The figure shows fuse amperage and function.

Fig. Cab roof fuse box

All fuses are flat pin fuses.

1. Rear cab headlight

20A

2. Front cab headlight, Radio

10A

3. Cab interior lighting

4. Air-Conditioning fan

25A

5. Rear screen wiper/washer

10A

6. Front screen wiper/washers

10A

Main fuses

There are four main fuses (2). They are located behind

the battery master disconnect switch. The three

screws need to be unscrewed to remove the plastic

cover.

The fuses are of flat pin type.

The starter relay (1) and preheating relays (3) for the

diesel engine are also fitted here.

Supply standard

30A

(Green)

Supply cab *

50A

(Red)

Fig. Engine compartment

1. Starter relay

Supply lighting *

40A

(Orange)

2. Main fuses

Supply, Air conditioning*

30A

(Green)

3. Preheating relays

* Optional equipment

Machine description - Electrical system

Fuses at battery master disconnect switch

Positioning of fuses at battery master disconnect

switch in the engine compartment.

QSB engine (ignition)

Diagnostics lamps, engine

ECM electronics

30A

Fig. Engine compartment

1. QSB engine (ignition)

2. Diagnostics lamps engine

3. ECM electronics

4. Reserve

Relays

VBS relay

Main relay

Horn relay

Fuel gauge relay

Reversing alarm relay

Light relay

Indicator relay

Fig. Instrument panel

K10

Brake relay

* Optional

Operation - Starting

Before starting

Master switch - Switching on

Remember to carry out daily maintenance. Refer to

the maintenance instructions.

The master switch is located in the engine

compartment. Turn the key (1) to the on position. The

entire roller is now supplied with power.

The engine hood must be unlocked when

operating, so that the battery can be quickly

disconnected if necessary.

Fig. Engine compartment

1. Master switch

Operator’s seat - Adjusting

Adjust the operator’s seat so that the position is

comfortable and so that the controls are within easy

reach.

The seat can be adjusted as follows.

- Length adjustment (1)

- Weight adjustment (2)

Release locking lever (3) to adjust the steering

column. Lock in the new position.

Always make sure that the seat is secure before

Fig. Operator's seat

beginning operation.

1. Locking lever - Length adjustment

2. Lever - Weight adjustment

3. Locking lever - Steering column

angle

Operation - Starting

Control unit - Setting

The control unit has two adjustment options, rotation

and steering column angle.

Pull the lever (1) upwards to allow rotation.

Release the locking lever (2) to adjust the steering

column to the desired slope and then lock the steering

column in its new position.

The seat can be adjusted as follows:

- Length adjustment (3)

- Back slope (4)

Fig. Operator's station

- Weight adjustment (5)

1. Locking lever - rotation (Optional)

2. Locking lever - steering column

Always make sure that the seat is secure before

angle

beginning operation.

3. Locking lever - length adjustment

4. Lever - backrest slope

5. Lever - weight adjustment

Operator’s seat in cab - Adjusting

The control unit has three adjustment options,

transverse travel, rotation and steering column angle.

Adjust the operator's seat so that the position is

comfortable and so that the controls are within easy

reach.

The seat can be adjusted as follows:

- Length adjustment (1)

- Height adjustment (2)

- Seat-cushion inclination (3)

- Backrest inclination (4)

- Armrest inclination (5)

Fig. Operator’s seat

- Lumbar support adjustment (6)

1. Lever - length adjustment

2. Wheel - height adjustment

3. Wheel - seat cushion inclination

4. Wheel - backrest inclination

Always ensure that the seat is locked in position

5. Wheel - armrest inclination

before operating the roller.

6. Wheel - lumbar support

adjustment

Operation - Starting

Instruments and lamps - Checking

Turn the switch (1) to the mid-position. All warning

lamps should light for about 5 seconds and the beeper

should sound.

During this time check that the warning lamps light up.

Check that the voltmeter (10) reads at least 12 volts,

and that the fuel gauge (15) shows a reading.

Check that the warning lamps for charging (31), oil

pressure (28), and the parking brake (27) come on.

The hourmeter (26) registers and shows the number of

hours the diesel engine has been running.

Fig. Instrument panel

1. Starter switch

The preheating lamp (16) must go on.

10. Voltmeter (Optional)

15. Fuel gauge

16. Preheating lamp

26. Hourmeter

27. Brake lampa

28. Oil pressure lamp

31. Charging lamp

Parking brake - Check

Make sure that the reserve/parking brake knob (37)

is actually in the pressed-in position. The roller

can start to roll when the engine is started on

sloping ground, if the reserve/parking brake is not

applied.

Fig. Control panel

37. Reserve/parking brake knob

Operation - Starting

Interlock (Optional)

The roller can be equipped with Interlock.

The engine switches off 7 seconds after the operator

rises from the seat.

The engine stops whether the forward/reverse lever is

in the neutral or the drive position.

The engine does not stop if the parking brake is

activated.

Operator position

If a ROPS (2) (Roll Over Protective Structure) or a cab

is fitted to the roller, always wear the seat belt (1)

provided and wear a protective helmet.

Replace the seat belt (1) if it shows signs of

wear or has been subjected to high levels of

force.

Check that rubber elements (3) on the platform

are intact. Worn elements will impair comfort.

Fig. Operator's station

1. Seat belt

Ensure that the anti-slip (4) on the platform is in

2. ROPS

good condition. Replace where anti-slip friction is

3. Rubber element

poor.

4. Anti-slip

If the machine is fitted with a cab, make sure that

the door is closed when in motion.

Operation - Starting

View

Before starting, make sure that the view forwards and

backwards is unobstructed.

All cab windows should be clean and the rear view

mirrors should be correctly adjusted.

Fig. view

Strike-off blade (Optional)

Always ensure that the strike-off blade is secured

by the locking pin (1) when driving with the blade

in its raised position. Always lower the blade to the

ground before leaving/parking the roller.

Fig. Strike-off blade

1. Cotter pin

Starting

Operation - Starting

Starting the engine

Set the forward/reverse lever (39) in neutral. The

diesel engine cannot be started in any other position

on the control.

Set the amplitude selector (24) for Low/High vibration

in position O.

Set the engine speed control (23) in the idling position.

Turn the starter switch (1) to the right to the first

position. The preheating lamp (16) now comes on.

When the lamp goes off, turn the control to the start

position and release as soon as the engine starts. This

Fig. Control panel

particularly important when starting a cold machine.

39. Forward/Reverse lever

Do not run the starter motor for too long. If the

engine does not start immediately, wait a minute

or so before trying again.

Let the engine idle for a few minutes to warm, longer if

the ambient temperature is below +10°C (50°F).

While the engine is warming up, check that the

warning lamps for oil pressure (28) and charging (31)

are not on, and also that the voltmeter (10) shows

13-14 volts. The warning lamp (27) for the parking

brake must still be on.

31 28

Ensue that there is good ventilation (air extraction)

if the engine is run indoors. Risk of carbon

Fig. Instrument panel

monoxide poisoning.

1. Starter switch

When starting up and driving a cold machine,

10. Voltmeter (Optional)

which implies cold hydraulic fluid, the braking

16. Preheating lamp

distance will be longer than normal until the

23. Engine speed control

24. Amplitude selector

machine reaches working temperature.

27. Brake lampa

28. Oil pressure lamp

31. Charging lamp

Operation - Driving

Operating the roller

Under no circumstances is the machine to be

operated from the ground. The operator must be

seated inside the machine during all operation.

Turn the engine speed control (23) to the position for

2,200 rpm.

Check that the steering is working correctly by turning

Fig. Instrument panel

the steering wheel once to the right and once to the

13. Tachometer (Optional)

left while the roller is stationary.

23. Engine speed control

Make sure that the area in front of and behind the

roller is clear.

Operation - Driving

Pull up the emergency/parking brake knob (37) and

check that the parking brake warning lamp is off.

Remember that the roller can start rolling, if it is on

a slope.

Set the High/Low speed selectors (35) and (36) to the

desired mode, see decal on the control panel.

Maximum speed

Fig. Control panel

Low drum/Low rear axle

5.0 km/h

35. Speed selector, drum/wheels

Low drum/High rear axle

9.0 km/h

(Optional)

* High drum/Low rear axle

6.5 km/h

36. Speed selector, wheels

37. Emergency/Parking brake knob

* High drum/High rear axle

16.0 km/h

39. Forward/Reverse lever

*Only with accessory

The High/High mode may only be used for

transport runs on an even surface.

Carefully move the forward/reverse lever (39) forwards

or backwards, depending on which direction of travel

is required. The speed increases as the lever is moved

away from the neutral position.

The speed should always be controlled using the

forward/reverse lever and never by changing the

engine speed.

Check the emegency brake by depressing the

emergency/parking brake knob (37) while the roller

is slowly moving forward.

Operation - Driving

Check while driving that the gauges show normal

readings. In the event of abnormal values or if the

buzzer sounds, immediately stop the roller and the

diesel engine. Check and remedy any fault; see also

the chapter on maintenance and the engine manual.

If the warning lamp for the air filter (30) comes on

during operation (when the diesel engine is

running at full speed), the main filter must be

cleaned or replaced. See the Maintenance

Manual.

Fig. Instrument panel

11. Hydraulic oil temperature (Optional)

12. Engine temperature (Optional)

30. Warning lamp, air filter

Operation of strike-off blade (Optional)

Before driving, make certain that the blade is in its

uppermost position (raised). Inspect the condition

of the ground before using the blade.

The lever (1) has three positions.

Backward - Raising the blade.

Forward - Lowering the blade.

Forward locked - Float mode, only its own weight

Fig. Controls

presses the blade down.

1. Lever

Lower the blade to the ground before leaving or

parking the roller.

Use the blade only when driving FORWARD.

When using the strike-off blade, the safety link (2)

must be secured with its locking pin in the parking

catch (3).

Fig. Strike-off blade

1. Locking pin

2. Safety link

3. Parking catch

Operation - Driving

Operation on difficult surfaces (Optional)

Drive, drum/wheels

If the machine should get stuck and it is equipped with

a 2-speed drum drive, set the drive knob as shown

below.

If the drum spins: Turn the knob (35) to Position 2

If the rear tires spin: Turn the knob (35) to Position 3.

When the machine has regained its grip set the knobs

in their original positions.

Fig. Control panel

35. Speed selector, drum/wheels

(Optional)

2. Position 2

3. Position 3

Operation - Vibration

Vibration

Amplitude/frequency - Changeover

There are two drum vibration settings. Use the switch

(24) to adjust.

Turn the knob to the left for low amplitude/high

frequency and to the right for high amplitude/low

frequency.

Setting the amplitude may not be performed

when vibration is in operation.

Switch the vibration off first and wait until

vibration stops before setting amplitude.

Fig. Instrument panel

24. Amplitude selector Low/0/High

Manual vibration - Switching on

Never activate vibration when the roller is

stationary. This can damage both the surface and

the machine.

Engage and disengage vibration using the switch (38)

on the front of the forward/reverse lever.

Always switch off vibration before the roller comes to a

standstill.

Fig. Control panel

38. Switch, vibration On/Off

The engine does not stop if the parking brake is

activated.

Operating - Stopping

Braking

Emergency brake

Braking is normally activated using the

forward/reverse lever. The hydrostatic transmission

retards and slows the roller when the lever is moved

towards the neutral position.

A disc brake in the drum motor and rear axle acts as

an emergency brake when in motion and as a parking

brake when stationary.

To brake, press the reserve/parking brake knob

(37), hold the steering wheel firmly and be

prepared for a sudden stop.

Fig. Control panel

37. Reserve/parking brake knob

39. Forward/Reverse lever

After braking, return the forward/reverse lever to the

neutral position and pull up the emergency/parking

brake knob.

Normal braking

Press the switch (38) to switch off the vibration.

Move the forward/reverse lever (39) to the neutral

position to stop the roller.

Turn the engine speed control back to idling. Allow the

engine to idle for a few minutes to cool down.

When starting and driving a machine that is cold,

remember that the hydraulic fluid is also cold and

that braking distances can be longer than normal

until the machine reaches the working temperature.

Fig. Control panel

37. Reserve/Parking brake knob

Always press the reserve/parking brake knob (37),

38. Switch, vibration On/Off.

39. Forward/Reverse lever

even for brief stops when on sloping ground.

Operating - Stopping

Switching off

Check instruments and warning lamps to see if any

faults are indicated. Switch off all lights and other

electrical functions.

Turn the starter switch (1) to the left to the shut off

position. On rollers without a cab, lower and lock the

instrument cover.

Fig. Instrument panel

1. Starter switch

2. Panel for warning lamps

Parking

Chocking the drums

Never disembark from the machine when the is

engine running, unless the emergency/parking

brake knob is depressed.

Make sure that the roller is parked in a safe place

with respect to other road users. Chock the drums

if the roller is parked on sloping ground.

Remember the risk of freezing during the winter.

Fig. Arrangement

1. Chock

Fill the engine cooling system and the

screenwash bottle in the cab with suitable

anti-freeze mixtures. See also the maintenance

instructions.

Master switch

Before leaving the roller for the day, switch the master

switch (1) to the disconnected position and remove the

handle.

This will prevent battery discharging and will also

make it difficult for unauthorized persons to start and

operate the machine. Lock the engine compartment

doors.

Fig. Tractor frame, rear left

1. Master switch

Long-term parking

The following instructions should be followed

when long term parking (more than one month).

These measures apply when parking for a period of up

to 6 months.

Before re-commissioning the roller, the points marked

with an asterisk * must be returned to the pre-storage

state.

Wash the machine and touch up the paint finish to

Fig. Roller weather protection

avoid rusting.

Treat exposed parts with anti-rust agent, lubricate the

machine thoroughly and apply grease to unpainted

surfaces.

Engine

* Refer to the manufacturer’s instructions in the engine

manual that is supplied with the roller.

Battery

* Remove the battery from the machine. Clean the

battery, check that the electrolyte level is correct (see

under the heading 'Every 50 hours of operation') and

trickle-charge the battery once a month.

Air cleaner, exhaust pipe

* Cover the air cleaner (see under the heading 'Every

50 hours of operation' or 'Every 1000 hours of

operation') or its opening with plastic or tape. Also

cover the exhaust pipe opening. This is to avoid

moisture entering the engine.

Fuel tank

Fill the fuel tank completely full to prevent

condensation.

Hydraulic reservoir

Fill the hydraulic reservoir to the uppermost level mark

(see under the heading ‘Every 10 hours of operation.’)

Tires (All-weather)

Check that tire pressure is 110 kPa (1.1 kp/cm 2 ), (16

psi).

Long-term parking

Steering cylinder, hinges, etc.

Lubricate the articulation bearing with grease (see

under the heading "Every 50 hours of operation").

Grease the steering cylinder piston with conservation

grease.

Grease the hinges on the doors to the engine

compartment and the cab. Grease both ends of the

forward/reverse control (bright parts) (see under the

heading 'Every 500 hours of operation').

Hoods, tarpaulin

* Lower the instrument cover over the instrument

panel.

* Cover the entire roller with a tarpaulin. A gap must

be left between the tarpaulin and the ground.

* If possible, store the roller indoors and ideally in a

building where the temperature is constant.

Miscellaneous

Lifting

Locking the articulation

Articulation must be locked to prevent inadvertent

turning before lifting the roller.

Turn the steering wheel to the straight ahead position.

Push in the emergency/parking brake knob.

Pull out the lowermost locking pin (2), which has a a

wire attached. Pull up the locking dowel (3) which also

has a wire attached.

Fig. Articulation in the locked position

1. Locking arm

2. Locking pin

Fold out the locking arm (1) and secure it to the upper

3. Locking stud

locking lug (4) on steering joint.

4. Locking lug

Fit the locking stub (3) in the holes through the locking

arm (1) and locking lug (4) and secure the stud in

position with the locking pin (2).

Weight: refer to the hoisting plate on the

roller

Lifting the roller

The machine’s gross weight is specified on the

hoisting plate (1). Refer also to the Technical

specifications.

Lifting equipment such as chains, steel wires,

straps and lifting hooks must be dimensioned in

accordance with the relevant safety regulations

for the lifting equipment.

Stand well clear of the hoisted machine! Make sure

that the lifting hooks are properly secured.

Fig. Roller prepared for lifting

1. Hoisting plate

Miscellaneous

Unlocking the articulation

Remember to unlock the articulation before

operating.

Fold the locking arm (1) back and secure it in the

locking lug (4) with the locking stud (3). Insert the

lowermost locking pin (2) fitted with a wire, to secure

the locking stud (3). The locking lug (4) is located on

the tractor frame.

Fig. Articulation in the open position

1. Locking arm

2. Locking pin

3. Locking stud

4. Locking lug

Towing

The roller can be moved up to 300 meters (1,000 ft)

using the instructions below.

Alternative 1

Short distance towing with the engine running

Depress the emergency/parking brake knob and

temporarily shut off the engine. Chock the drums

to prevent the roller from moving

Turn both towing valves (1) (middle hexagonal nut)

three turns counter clockwise, while holding the

multifunction valve (2) (lowermost hexagonal nut) in

Fig. Propulsion pump

place. The valves are placed on the forward drive

1. Towing valve

2. Locknut

pump.

Start the engine and allow it to idle.

The roller can now be towed and can also be steered

if the steering system is otherwise functioning.

Miscellaneous

Alternative 2

Towing short distances where the engine is

inoperative

Chock the drums to prevent the roller from moving

when the brakes are mechanically disengaged.

34 mm

First release both towing valves as per alternative 1.

Fig. Rear axle

3. Locknut

4. Adjusting screw

Rear axle brake

Undo the lock nut (3) and screw the adjustment

screws (4) by hand until resistance increases, and

then one additional turn. The adjustment screws are

located on the rear axle, two screws on each side of

the differential housing.

Drum gearbox brake

The drum brake is disengaged by screwing out the 4

hexagonal socket screws (5) approx. 5 mm, and then

pulling out the engine adapter towards the screw

heads.

The brakes are now disengaged and the roller can be

towed.

After towing, remember to reset the towing valves

(1). Unscrew the adjusting screw (4) to its original

position 34 mm from the contact surface and

tighten the lock nuts (3). Tighten the four

hexagonal socket screws (5). See section "short

distance towing" alternative 1 and 2.

Fig. Drum brake

5. Screw

Miscellaneous

Drum gearbox brake (Option)

Disengage the drum brake by screwing in the two

screws (5) until they stop.

Screw in each screw equally, alternating between the

two. This is necessary to prevent jamming the brake

piston.

The brakes are now disengaged and the roller can be

towed.

After towing, don't forget to reset the towing

valves (1), Screw out the adjustment screw (4) to

its original position 34 mm from the stop surface,

and tighten the locking nuts (3). Loosen the drum

brake screws (5). See the section "Short distance

towing" options 1 and 2.

Fig. Drum brake

5. Screw

Miscellaneous

Towing the roller

When towing/recovering, the roller must be braked

by the towing vehicle. A towing bar must be used

as the roller has no brakes.

The roller must be towed slowly, max. 3 km/h (2

mph) and only towed short distances, max. 300 m

(330 yards).

When towing/retrieving a machine, the towing device

must be connected to both lifting holes. The pulling

force must act longitudinally on the machine as shown

in the figure. Maximum gross pulling force 200 kN

(44961 lbf).

Fig.Towing

Restore the items for towing according to

alternative 1 or 2 on the preceding pages.

Roller prepared for transport

Lock the articulation before lifting and

transporting. Follow the instructions under the

relevant heading.

Chock the drums (1) and secure the chocks to the

transport vehicle.

Block up under the drum frame (2), to avoid overload

on the rubber suspension of the drum when lashing.

Clamp down the roller with lashing strap at all four

corners; decals (3) indicate the fixing points.

Fig. Transport

1. Chock

Remember to return the articulation to its

2. Block up

unlocked position before starting the roller.

3. Lashing wire

Operating instructions - Summary

Follow the SAFETY INSTRUCTIONS specified in the Safety Manual.

Make sure that all instructions in the MAINTENANCE section are followed.

Turn the master switch to the ON position.

Move the forward/reverse lever to the NEUTRAL position.

Set the switch for Manual/Automatic vibration to the 0 position.

Set the engine speed control to idle (900 rpm).

Start the engine and allow it to warm up.

Set the engine speed control to the operating position (2,200 rpm).

Set the emergency/parking brake knob in the pulled-out position.

10. Drive the roller. Operate the forward/reverse lever with care.

11. Test the brakes. Remember that the braking distance will be longer if the

roller is cold.

12. Use vibration only when the roller is in motion.

13. IN AN EMERGENCY:

- Push in the EMERGENCY/PARKING BRAKE KNOB

- Hold the steering wheel firmly.

- Brace yourself for a sudden stop.

14. When parking:

- Push in the reserve/parking brake knob.

- Stop the engine and chock the drum and wheels.

15. When lifting: - Refer to the relevant section in the Instruction Manual.

16. When towing: - Refer to the relevant section in the Instruction Manual.

17. When transporting: - Refer to the relevant section in the Instruction Manual.

18. When recovering - Refer to the relevant section in the Instruction Manual.

Maintenance - Lubricants and symbols

Always use high-quality lubricants and the

amounts recommended. Too much grease or

oil can cause overheating, resulting in rapid

wear.

ENGINE OIL

Air temperature -15°C - +50°C (5°F-122°F)

Shell Rimula Super 15W/40, API CH-4 or equivalent.

HYDRAULIC FLUID

Air temperature -15°C-+40°C (5°F-104°F)

Shell Tellus TX68 or equivalent.

Air temperature above +40°C (104°F)

Shell Tellus T100 or equivalent.

BIOLOGICAL HYDRAULIC

BP Biohyd SE-S46

FLUID

When it leaves the factory, the machine may be

filled with biodegradable fluid. The same type of fluid

must be used when changing or topping up.

TRANSMISSION OIL

Air temperature -15°C - +40°C (5°F-104°F)

Shell Spirax AX 80W/90, API GL-5 or equivalent.

Air temperature 0°C (32°F) - above +40°C (104°F)

Shell Spirax AX 85W/140, API GL-5 or equivalent.

DRUM OIL

Mobil SHC 629

GREASE

SKF LGHB2 (NLGI-Klass 2) or equivalent for the

articulated joint.

Shell Retinax LX2 or equivalent for other grease

points.

FUEL

See engine manual.

COOLANT

GlycoShell or equivalent, (mixed 50/50 with water).

Anti-freeze protection down to about -37°C (-34.6°F).

Other fuel and lubricants are required when

operating in areas with extremely high or

extremely low ambient temperatures. See the

‘Special instructions’ chapter, or consult

Dynapac.

Maintenance - Maintenance schedule

Service and maintenance points

Fig. Service and maintenance points

Radiator grille

14. Scrapers

27. Engine suspension, 4 pcs.

Oil level, diesel engine

15. Drum oil, level plug, x2

28. Feed pump, fuel

Fuel filter, fuel pre-filter

16. Rubber elements and fastening

29. Diesel fuel, filler

screws

Air filter

17. Steering joint

30. Battery

Engine cover, hinges

18. Steering cylinders, x2

31. Radiator

Hydraulic reservoir, sight glass

19. Flywheel casing, hydraulic

32. Hydraulic fluid cooler

pumps

Bleeding filter

20. Wheel nuts

33. Drive belts, cooling, alternator

Hydraulic filter, 2 pcs.

21. Tires, pressure

34. Steering chain

Drainage, hydraulic fluid

22. Rear axle, differential

35. Seat bearing

reservoir

10. Hydraulic fluid, filling

23. Rear axle, planetary gears, 2

36. Steering chain

pcs.

11. Fuse box

24. Rear axle suspension, 2 sides

37. Forward/reverse lever

12. Drum cartridge, filling, 2 fillers

25. Oil filter, diesel engine

38. Fresh air filter *

13. Drum gearbox

26. Drainage, fuel tank

39. Air conditioning *

* Optional equipment

General

Periodic maintenance should be carried out after the

number of hours specified. Use the daily, weekly etc.

periods where number of hours cannot be used.

Maintenance - Maintenance schedule

Remove all dirt before filling, when checking

oils and fuel and when lubricating using oil or

grease.

The manufacturer’s instructions found in the

engine manual also apply.

Every 10 hours of operation (Daily)

Refer to the contents to find the page number of the

sections referred to !

Pos. in fig

Action

Comment

Before starting up for the first time on that day

Check the scraper setting

Check for free circulation of cooling air

Check coolant level

Refer to the engine manual

Check the engine oil level

Refer to the engine manual

Refuel

Check fluid level in hydraulic reservoir

Test the brakes

After the FIRST 50 hours of operation

Refer to the contents to find the page number of the

sections referred to !

Pos. in fig

Action

Comment

Change the engine oil and oil filter

Refer to the engine manual

Change the fuel filter

Refer to the engine manual

Change the hydraulic fluid filter

Change the drum oil

Maintenance - Maintenance schedule

Every 50 hours of operation (Weekly)

Refer to the contents to find the page number of the

sections referred to!

Pos.

Action

Comment

in fig

Check that hoses and couplings are not leaking

Inspect/clean the filter element in the air cleaner

Replace as required

Lubricate the articulation

Check the wheel-nuts are tightened

Check the tire pressure

Check the air conditioning

Optional

Lubricate the strike-off blade bearings.

Optional

Every 250 hours of operation (Monthly)

Refer to the contents to find the page number of the

sections referred to !

Pos. in fig

Action

Comment

Check oil level in rear axle/planetary gearing

Check oil level in drum gearbox

Check oil level in the drum cartridge

Clean the coolers

Check the bolted joints

The above applies to new

or reconditioned

components only

Check the bolted joints

The above applies to new

or reconditioned

components only

Check rubber elements and bolted joints

Check battery

Check the AC

Optional

Maintenance - Maintenance schedule

Every 500 hours of operation (Every three

months)

Refer to the contents to find the page number of the

sections referred to !

Pos. in fig

Action

Comment

Replace the fuel filter

Refer to the engine manual

Lubricate controls and joints

Clean the fuel pre-filter.

Change the engine oil and oil filter

Refer to the engine manual

Grease the steering chain

Optional

Grease the chair bearing

Optional

Every 1000 hours of operation (Every six

months)

Refer to the contents to find the page number of the

sections referred to !

Pos. in fig

Action

Comment

Check bleeder filter on hydraulic reservoir

Change the hydraulic fluid filter

Drain the condensate from hydraulic reservoir

Drain condensate from fuel tank

Replace the main filter in the air cleaner

Change oil in rear axle differential

Change oil in the rear axle planetary gearing

Replace the fresh air filter in the cab

Optional

Check engine valve clearances

Refer to the engine manual

Check belt tension in the drive belt system

Refer to the engine manual

Maintenance - Maintenance schedule

Every 2000 hours of operation (Yearly)

Refer to the contents to find the page number of the

sections referred to !

Pos. in fig

Action

Comment

Change the hydraulic fluid

Change the oil in the drum cartridge

Change the oil in the drum gearbox

Lubricate the Forward/Reverse lever

Checking the steering hitch

Overhaul air conditioning

Optional

Maintenance - 10h

Park the roller on a level surface.

When checking and making adjustments, the

engine should be switched off and the

emergency/parking brake should be applied, if

not otherwise specified.

Scrapers - Check, adjustment

It is important to consider movement of the drum

when the machine turns, i.e., the scrapers can be

damaged or wear of the drum may increase if

adjustment is made closer than the values stated.

If necessary, adjust distance to the drum as follows:

Loosen the screws (2) on the scraper attachment.

Then adjust the scraper blade (1) to 20 mm from the

drum.

Tighten the screws (2).

Repeat the procedure for the other scraper blades (x4).

Fig. Scrapers

1. Scraper blades (x4)

2. Screws

Maintenance - 10h

Scrapers, Pad-drum

Undo the screws (1), then adjust each scraper tooth

(2) to 25 mm (1.0 in) between scraper tooth and drum.

Center each scraper tooth (2) between the pads.

Tighten the screws (1).

Fig. Scrapers

1. Screws

2. Scraper teeth (x18)

Soften scrapers (Optional)

Loosen the screws (2).

Then, adjust the scraper blade (1) so that it lightly

touches the drum.

Tighten the screws (2).

Fig. Scrapers

1. Scraper blade

2. Screws

Maintenance - 10h

Air circulation - Check

Ensure that the engine has free circulation of cooling

air through the protective grille in the hood.

To open the engine hood, turn the locking arm (1)

upward. Raise the hood to its fully open position,

checking that the red safety catch on the left gas

spring is latched.

If the engine's gas-springs are out of action and

the hood is put at its upper position - block the

hood so that it cannot fall.

Fig. Engine hood

1. Hood lock

2. Protective grille

Coolant level - Check

Check that level of the coolant is between the max.

and min. marks.

Take great caution if the radiator cap must be

opened while the engine is hot. Wear protective

gloves and goggles.

Fill with a mixture of 50% water and 50% anti freeze.

See the lubrication specifications in these instructions

and in the engine manual.

Flush the system every other year and change

Fig. Water tank

1. Max. level

the coolant. Make sure also that the air flow

2. Min. level

through the cooler is unobstructed.

3. Filler cap

Maintenance - 10h

Diesel engine Check oil level

Take care not to touch any hot parts of the engine

or the radiator when removing the dipstick. Risk

for burns.

The dipstick is located on the engine's right side.

Pull up the dipstick (1) and check that the oil level is

between the upper and lower marks. For further

details, refer to the engine's instruction manual.

Fig. Engine compartment

1. Dipstick

Hydraulic reservoir - Check fluid level

Place the roller on a level surface and check that the

oil level in the sight glass (1) is between the max and

min markings. Top up with the type of hydraulic fluid

specified in the lubricant specification, if the level is too

low.

Fig. Hydraulic reservoir

1. Sight glass

2. Filler pipe

Maintenance - 10h

Fuel tank - Filling

Refuel daily with diesel fuel up to the lower edge of the

filler pipe (1). Follow the engine manufacturer's

specification with regard to the quality of diesel fuel.

Stop the engine. Short-circuit (press) the filler gun

against a non-insulated part of the roller before

refuelling, and against the filler pipe (1) while

refuelling.

Never refuel while the engine is running. Do not

smoke and avoid spilling fuel.

Fig. Fuel tank

1. Filler pipe

The tank holds 320 liters (84.5 gal) of fuel.

Brakes - Check

Check the brakes by carrying out the following :

Drive the roller slowly forwards.

Depress the emergency/parking brake knob (1). The

warning lamp on the instrument panel should come on

and the roller should stop.

After testing the brakes, set the forward/reverse lever

Fig. Control panel

1. Emergency/parking brake knob

(2) in neutral.

2. Forward/reverse lever

Pull up the emergency/parking brake knob.

The roller is now ready for operation.

Maintenance - 50h

Park the roller on a level surface.

When checking and making adjustments, the

engine should be switched off and the

emergency/parking brake should be applied, if

not otherwise specified.

Air cleaner

Checking - Change the main air filter

Change the air cleaner main filter when the

warning lamp on the control panel comes on

when the engine is running at maximum speed.

Release the clips (1), pull off the cover (2), and pull out

the main filter (3).

Do not remove the backup filter (4).

Clean the air cleaner if necessary, see section Air

cleaner - Cleaning.

When replacing the main filter (3), insert a new filter

and refit the air cleaner in the reverse order.

Fig. Air cleaner

Check the condition of the dust valve (6); replace if

1. Clips

necessary.

2. Cover

3. Main filter

4. Backup filter

When refitting the cover, make sure that the dust valve

5. Filter housing

is positioned downwards.

6. Dust valve

Maintenance - 50h

Backup filter - Change

Change the backup filter with a new filter after every

third replacement of the main filter.

To change the backup filter (1), pull the old filter out of

its holder, insert a new filter and reassemble the air

cleaner in the reverse order.

Clean the air cleaner if necessary, see section Air

cleaner - Cleaning.

Fig. Air filter

1. Backup filter

Air cleaner

- Cleaning

Wipe clean the inside of the cover (2) and the filter

housing (5). See the previous illustration.

Wipe clean on both sides of the outlet

pipe.

Wipe also both surfaces for the outlet pipe; see

adjacent figure.

Check that the hose clamps between the filter

housing and the suction hose are tight and that

the hoses are intact. Inspect the entire hose

system, all the way to the engine.

Inner edge of

Outer edge of outlet

outlet pipe.

pipe.

Maintenance - 50h

Articulation - Lubrication

Do not allow anyone to remain in the vicinity of the

steering joint when the engine is running. Risk of

being crushed when the steering is operated.

Press the emergency/parking brake knob before

lubricating.

Turn the steering wheel fully to the left to gain access

to all the steering system's lubricating nipples (4) on

the right-hand side of the machine.

Fig. Steering hitch right side

Use grease as per the lubricant specification

Steering joint - Lubrication

Wipe off any dirt and grease from the nipples.

Grease each nipple (1) with five strokes of a

hand-operated grease gun. Make sure that grease

penetrates into the bearings.

If grease does not penetrate the bearings, it may

be necessary to relieve the articulation joint with a

jack while repeating the greasing process.

Fig. Articulation, right side

1. Lubricating nipples, articulation

(4 pcs)

Maintenance - 50h

Tires - Air pressure - Wheel nuts - Tightening

Check the tire pressures using a pressure gauge.

If the tires are filled with fluid, the air valve (1) must be

in the "12 o'clock" position during pumping.

Recommended pressure: See Technical

Specifications.

Check the tire pressure.

When changing the tires it is important that both

of them have the same rolling radius. This is

necessary to ensure proper functioning of the

Fig. Wheels

anti-slip in the rear axle.

1. Air valve

2. Wheel nut

Check the tightening torque of the wheel nuts (2) at

630 Nm (465 lbf.ft).

Check both wheels and all nuts. (This only applies to a

new machine or newly fitted wheels).

Check the safety manual that accompanies the

roller before filling the tires with air.

Automatic Climate Control (Optional) -

Inspection

The system described in this manual is type ACC

(Automatic Climate Control).

Never work under the roller when the engine is

running. Park the roller on a level surface, chock

the wheels and depress the parking brake control.

With the unit in operation, open the engine hood and

check using the sight glass (1) that bubbles are not

visible on the drying filter.

The filter is located on the left side of the engine

Fig. Drying filter

1. Sight glass

compartment's front edge. If bubbles are visible

through the sight glass, it is a sign that the refrigerant

level is too low. If so, stop the unit. The unit may be

damaged if it is run with insufficient refrigerant.

Maintenance - 50h

Where cooling capacity is markedly reduced, clean the

condensor element (1) located on the rear edge of the

cab. Also clean the cooling unit in the cab. See under

the heading 2000 hours, automatic climate control -

overhaul.

Fig. Cab

1. Condensor element

Strike-off blade (Optional)

- Lubrication

Always lower the blade to the ground before

leaving or parking the roller.

Make sure that nobody is in the way when

operating the blade.

Wipe the nipples clean from grease and dirt, three on

Fig. Strike-off blade

each side of the machine.

1. Lubrication nipples

Grease each nipple (1) with four strokes of the grease

gun. Ensure that grease penetrates the bearings.

Maintenance - 250h

Park the roller on a level surface.

When checking and making adjustments, the

engine should be switched off and the

emergency/parking brake should be applied, if

not otherwise specified.

Rear axle differential - Check oil level

Never work under the roller when the engine is

running. Park on a level surface. Block the wheels

securely.

Wipe clean and remove the level plug (1) and check

that the oil level reaches the lower edge of the plug

hole. Top off with oil to the right level if the level is low.

Use transmission oil according to the lubricant

specification.

Clean and refit the plug.

Fig. Level check - differential housing

1. Level/Filler plug

Maintenance - 250h

Rear axle planetary gears - Check oil level

Position the roller with the plug in the planetary gear

(1) in the "9 o'clock" position.

Wipe clean and remove the level plug (1) and check

that the oil level reaches the lower edge of the plug

hole. Top off with oil to the right level if the level is low.

Use transmission oil. See lubrication specification.

Clean and refit the plug.

Fig. Level check - planetary gear, std

Check the fluid level in the same way on the rear

1. Level/Filler plug

axle's other planetary gear.

Fig. Level check - planetary gear,

optional

1. Level/Filler plug

Drum gearbox - Checking the oil level

Position the drum so that the filler plug (2) is straight

up.

Wipe clean the area around the level plug (1) and then

undo the plug.

Ensure that the oil level reaches up to the lower edge

of the plug hole.

Top off with oil to the right level if the level is low. Use

Fig. Oil level check - drum gearbox

transmission oil according to the lubricant specification.

1. Level plug

2. Filler plug

Clean and refit the plugs.

3. Drain plug

Maintenance - 250h

Drum cartridge - Checking the oil level

Position the machine level so that the indicator pin (1)

on the inside of the drum is aligned with the top of the

drum frame.

Fig. Left drum side

1. Indicator pin

Wipe clean the filler plug (1) and level plug (3).

Unscrew the filler plug (1).

Fig. Right drum side

1. Filler plug

2. Drain plug

3. Level plug

Then loosen the level plug (3) on the underside of the

cartridge and unscrew it until the hole in the middle of

the plug becomes visible.

Top off with oil through the filler plug (1), until oil

begins to run out from the level plug's (3) hole. The

level is correct when it stops running.

Ensure that only MOBIL SHC 629 is used in the

cartridges..

Fig. Drum cartridge

2. Drain plug

Do not overfill with oil - risk for overheating.

3. Level plug

Clean and refit the plugs. Now repeat the procedure

on the opposite side.

Maintenance - 250h

Drum cartridge - Cleaning the ventilation screw

Clean the drum's ventilation hole and ventilation screw

(1). The hole is required to eliminate excess pressure

inside the drum.

Fig. Drum

1. Ventilation screw

Radiator - Check/Cleaning

Check that air can pass unobstructed through the

radiators (1), (2) and (3).

Clean a dirty radiator using compressed air or a

high-pressure water jet.

Blow air or direct water through the cooler in the

opposite direction to that of the cooling air.

Be careful when using a high-pressure washer -

do not place the nozzle too close to the radiator.

Wear protective goggles when working with

Fig. Engine compartment

1. Water cooler

compressed air or high-pressure water jets.

2. Charge air cooler

3. Hydraulic fluid cooler

Bolted joints - Checking tightening torque

Steering pump against engine (1) 38 Nm (28 lbf.ft).

Rear axle suspension (2) 330 Nm (243 lbf.ft), oiled.

Engine mounting (3). Check that all M12 bolts (x20)

are tightened, 78 Nm (57 lbf.ft).

Wheel nuts (4). Check that all nuts are tightened, 630

Nm oiled.

(The above applies to new or replaced components

only).

Fig. Right side of machine

1. Steering pump

2. Rear axle

3. Engine suspension

4. Wheel nuts

Maintenance - 250h

Rubber elements and fastening screws - Check

Check all rubber elements (1), replace all of the

elements if more than 25% of them on one side of the

drum are cracked deeper than 10-15 mm (0.4-0.6 in).

Check using a knife blade or pointed object.

Check also that the screw fasteners (2) are tightened.

Fig. Drum, vibration side

1. Rubber element

2. Fastening screws

Battery - Check electrolyte level

Never use a naked flame when checking the

battery as the electrolyte emits explosive gas while

the alternator is charging.

Lift up the engine compartment cover and undo the

quick-release screws (1).

Raise the battery cover (2).

Wipe the top of the battery.

Fig. Battery shelf

Wear safety goggles. The battery contains

1. Quick-screws

corrosive acid. Rinse with water if electrolyte

2. Battery cover

comes into contact with the body.

3. Battery

Maintenance - 250h

Battery cell

Take off the cell caps (1) and make sure that

electrolyte (2) is about 10 mm (0.4 in) above the plates

(3). Check the level of all cells. Top off with distilled

water to the right level if the level is low.

10 mm

If the ambient temperature is below freezing, run the

engine for a while before topping off with distilled

(0.4 in)

water. Otherwise the electrolyte might freeze.

Make sure that ventilation holes in the cell cover are

not clogged, then put the cover back on.

The cable shoes should be clean and well tightened.

Fig. Electrolyte level in battery

1. Cell cap

Clean corroded cable shoes and grease them with

2. Electrolyte level

acid-free Vaseline.

3. Plate

Always disconnect the negative cable first when

disconnecting the battery. When connecting the

battery, always connect the positive cable first.

Discard used batteries wisely. Batteries contain

lead, which is harmful to the environment.

Before doing any electric welding on the machine,

disconnect the battery ground cable and then all

electrical connections to the alternator.

Air conditioning (Optional)

- Inspection

Inspect refrigerant hoses and connections and make

sure that there are no signs of an oil film that can

indicate a refrigerant leakage.

Fig. Air conditioning

1. Refrigerant hoses

2. Condensor element

Maintenance - 500h

Park the roller on a level surface.

When checking and making adjustments, the

engine should be switched off and the

emergency/parking brake should be applied, if

not otherwise specified.

Ensue that there is good ventilation (air

extraction) if the engine is run indoors. Risk of

carbon monoxide poisoning.

Controls and moving joints - Lubrication

Lubricate engine hood hinges (1) and the slide rails of

the operator's seat with grease, other joints and

controls with oil. Lubricate the cab hinges with grease.

See the lubrication specification.

Fig. Engine hood

1. Hinge

Maintenance - 500h

Fuel pre-filter - Cleaning

Ensure good ventilation (air extraction) if the

diesel engine is run indoors. Risk of carbon

monoxide poisoning.

See instruction manual for the engine when cleaning

the filter, the chapter on the fuel system.

Fig. Engine compartment

1. Fuel prefilter

Diesel engine - Oil and Filter change

Take great care when draining warm fluid and oil.

Wear protective gloves and goggles.

The oil drain plug (1) is most easily accessible from

the bottom of the engine and is located attached to a

hose on the rear axle.. Drain the oil when the engine is

warm. Place a receptacle that holds at least 19 liters

(5 gal) under the drain plug.

Fig. Left side of engine

Replace the engine oil filter (2) at the same time. Refer

1. Drain plug

to the engine manual.

2. Oil filter

Deliver the drained oil and filter to

environmentally correct handling.

Maintenance - 500h

Steering chain and seat bearing - Lubrication

Optional on rollers without cab

Keep in mind that the chain is a vital part of the

steering mechanism.

Clean and lubricate the chain (1) between the seat

bearing and steering valve with grease. The chain can

be accessed from underneath the operator's position.

It is not necessary to remove the chain.

Adjust the chain as follows if it has slackened so that

size "a" is less than 30 mm (1.2 in): Loosen the nuts

Fig. Underneath operator's position

(4) and adjust the mount (5) backwards with the

1. Steering chain

adjusting nut (3) until size "a" is 50 mm (2 in).

2. Chain-tightening device

3. Adjusting nut

4. Nuts

5. Control valve mount

Maintenance - 500h

Seat bearing - Lubrication

Optional on rollers without cab

Keep in mind that the chain is a vital part of the

steering mechanism.

Remove the cover (5) to access the lubrication nipple

(1). Lubricate the operator seat slew bearing with three

strokes of a hand-operated grease gun.

Lubricate the seat locking latch (7) (accessible from

below).

Also grease the seat slide rails (6).

Fig. Seat bearing

If the seat starts to be stiff when adjusting, it

1. Grease nipple

should be lubricated more often than specified

2. Cogwheel

here.

3. Steering chain

4. Adjusting screw

5. Cover

6. Slide rails

7. Slew interlock

Clean and grease the chain (3) between the seat and

the steering column.

If the chain is slack on the sprocket (2), loosen the

screws (4) and move the steering column forward.

Tighten the screws and check chain tension.

Maintenance - 1000h

Park the roller on a level surface.

When checking and making adjustments, the

engine should be switched off and the

emergency/parking brake should be applied, if

not otherwise specified.

Ensue that there is good ventilation (air

extraction) if the engine is run indoors. Risk of

carbon monoxide poisoning.

Hydraulic filter - Replacement

Undo the filler cap/bleeder filter (2) on top of the

reservoir so that over-pressure inside the reservoir can

be eliminated.

Make sure that the bleeding filter (2) is not clogged, air

must have unobstructed passage through the cap in

both directions.

If passage in either direction is blocked, clean the filter

with a little diesel oil and blow through with

compressed air until the block is removed, or replace

the cap with a new one.

Wear protective goggles when working with

Fig. Hydraulic reservoir

compressed air.

2. Filler cap/Bleeding filter

3. Sight glass

Maintenance - 1000h

Clean thoroughly around the oil filters.

Remove the oil filters (1) and dispose of them in

an approved manner. They are single-use filters

and cannot be cleaned.

Make sure that the old sealing rings are not left

on the filter holders, as this could cause leakage

between the new and old gaskets.

Fig. Engine compartment

Thoroughly clean the sealing surfaces of the filter

2. Hydraulic fluid filter (x2).

holders.

Apply a thin coat of fresh hydraulic fluid to the rubber

gaskets on the new filters. Screw on the filter by hand.

First tighten the filter until its seal is in contact

with the filter attachment. Then turn an additional

half revolution. Do not tighten the filter too hard

as this could damage the gasket.

Start the engine and ensure that there is no leakage of

hydraulic fluid from the filters. Check level of fluid in

the sight glass (3) and top up as required.

Ensue that there is good ventilation (air extraction)

if the engine is run indoors. Risk of carbon

monoxide poisoning.

Hydraulic reservoir - Draining

The condensate from the hydraulic reservoir is drained

through the drainage tap (1).

Drain the roller after it has been stationary for a long

time, e.g. after standing overnight. Drain as follows:

Remove the plug (2).

Place a container under the tap.

Open the tap (1) and let any trapped condensate run

out.

Shut the drainage tap.

Fig. Underside of hydraulic reservoir

1. Drainage tap

Refit the plug.

2. Plug

100

Maintenance - 1000h

Fuel tank - Drainage

Water and sediment in the fuel tank are removed via

the drainage plug in the bottom of the fuel tank.

Be very careful during draining. Do not drop the

plug or else all the fuel will flow out.

Drain the roller after it has been stationary for a long

time, e.g. after standing overnight. The fuel level

should be as low as possible.

Fig. Fuel tank

The roller should preferably have been standing with

1. Drain plug

this side somewhat lower, so that water and sediment

will gather near the drainage plug (1). Drain as follows:

Place a container under the plug (1).

Remove the plug and drain the water and sediment

until only pure fuel runs from the plug. Refit the plug.

Air filter - Changing

Replace the air cleaner main filter (1) even if it has not

been cleaned five times See under the heading 'Every

50 hours of operation' for information on changing the

filter.

If a blocked filter is not replaced, the exhaust

Fig. Air cleaner

fumes will be black and the engine will loose

1. Main filter

power. There is also a risk of severe damage to

the engine.

101

Maintenance - 1000h

Rear axle differential - Oil change

Never work under the roller when the engine is

running. Park on a level surface. Block the wheels

securely.

Wipe clean and remove the level/filler plug (1) and all

three drain plugs (2), and then drain the oil into a

suitable receptacle. The volume is approx. 12 liters

(12.7 qts).

Save the oil and dispose of it in an

approved manner.

Fig. Rear axle

1. Level/Filler plug

2. Drain plugs

Refit the drainage plugs and top up with fresh oil until

the correct level is reached. Refit the level/filler plug.

Use transmission oil, see Lubricant Specification.

Rear axle's planetary gears - Draining the oil

Position the roller with the plug (1) at its lowest

position.

Wipe clean and remove the plug (1) and drain the oil

into a receptacle. The volume is approx. 2 liters (2.1

qts).

Save the oil and hand in to an

environment-friendly waste disposal station.

Fig. Draining the oil - planetary gear,

std

1. Level/Filler plug

Fig. Draining the oil - planetary gear,

optional

1. Level/Filler plug

102

Maintenance - 1000h

Rear axle's planetary gears - Oil change - Oil

filling

Set the roller so that the plug (1) in the planetary gear

is at "9 o' clock".

Wipe clean and remove the plug (1).

Fill with oil to the lower edge of the level hole. Use

transmission oil. See lubrication specification.

Clean and refit the plug (1).

Fig. Oil filling - planetary gear, std

Fill with oil in the same way as for the rear axle's

1. Level/Filler plug

second planetary gear.

Fig. Oil filling - planetart gear, optional

1. Level/Filler plug

Air conditioning (Optional)

Fresh air filter - Change

Use a step ladder to reach the filter (1). The filter

can also be accessed via the right cab window.

Loosen the two screws (2) on the cab's right side.

Take down the whole holder and remove the filter

insert.

Replace with a new filter.

It may be necessary to change the filter more often if

Fig. Cab

the machine is working in a dusty environment.

1. Fresh air filter

2. Screw (x2)

103

Maintenance - 2000h

Park the roller on a level surface.

When checking and making adjustments, the

engine should be switched off and the

emergency/parking brake should be applied, if

not otherwise specified.

Ensue that there is good ventilation (air

extraction) if the engine is run indoors. Risk of

carbon monoxide poisoning.

Hydraulic reservoir - Oil change

Obtain a container for collecting the used fluid. The

container should be able to hold at least 60 liters (16

gal).

Observe care when draining hot hydraulic fluid.

Wear protective gloves and goggles.

A suitable container may be an empty oil drum or

similar item which is placed beside the roller. The fluid

Fig. Underside of hydraulic reservoir

then runs in a hose from the drainage plug (1) to the

1. Drainage tap

oil drum, after the plug (2) has been removed and the

2. Plug

tap opened.

Save the oil and dispose of it in an approved

manner.

Fill up with fresh hydraulic fluid as per the instructions

under the heading "Hydraulic reservoir - Check fluid

level". Replace the hydraulic fluid filters at the same

time.

Start the diesel engine and operate the various

hydraulic functions.

Check the fluid level and top up if necessary.

105

Maintenance - 2000h

Drum cartridge - Oil change

Position the machine level so that the indicator pin (1)

on the inside of the drum is aligned with the top of the

drum frame.

Fig. Left drum side

1. Indicator pin

Place a receptacle for about 5 liters (1.32 gal)

underneath the drain plug (2).

Save the oil and hand in to an

environment-friendly waste disposal station.

Clean and unscrew the filler plug (1) and the drain

plug (2).

Allow all the oil to run out. Fit the drain plug and fill

with new synthetic oil in accordance with the

Fig. Right drum side

instructions under "Drum cartridge - checking the oil

1. Filler plug

level".

2. Drain plug

3. Level plug

Repeat the procedure on the opposite side.

Ensure that only MOBIL SHC 629 is used in the

cartridges..

106

Maintenance - 2000h

Drum gearbox - Oil change

Place the roller on a level surface with the plugs (1)

and (2) as illustrated.

Wipe clean, unscrew the plugs (1, 2 and 3) and drain

the oil into a suitable receptacle, capacity about 3.5

liters (1 gal.).

Refit the plug (1) and fill with oil up to the level plug

(3), according to "Drum gearbox - Checking the oil

level".

Use transmission oil according to the lubricant

specification.

Fig. Drum gearbox

Clean and refit the level plug (3) and filler plug (2).

1. Drain plug

2. Filler plug

3. Level plug

Forward/Reverse lever

- Lubrication

Remove the screws (1) and take off the plate (2).

Grease the contact surface on the cam disc (3).

Refit the plate (2) with the screws (1).

Fig. Forward/Reverse lever

1. Screw

2. Plate

3. Cam disc

107

Maintenance - 2000h

Steering hitch - Check

Inspect the steering hitch to detect any damage or

cracks.

Check and tighten any loose bolts.

Check also for any stiffness and play.

Fig. Steering hitch

Automatic Climate Control (Optional)

- Overhaul

Regular inspection and maintenance are necessary to

ensure satisfactory long-term operation.

Clean all dust from the condenser element (1) using

compressed air. Blow from above downwards.

The air jet can damage the element flanges if it is

too powerful.

Fig. Cab

Wear protective goggles when working with

1. Condensor element

compressed air.

Inspect the condenser element attachment.

Clean all dust from the cooling unit and the cooling

element (1) using compressed air.

Check the system hoses for chafing. Make sure that

drainage from the cooling unit is unobstructed so that

no condensation accumulates inside the unit.

Drain by pinching the valves (2)

Fig. Automatic climate control

1. Cooling element

2. Drain valve (x2).

108

Maintenance - 2000h

Compressor - Check (Optional)

Inspect the attachment of the compressor (1).

The compressor is located over the alternator in the

engine compartment.

The unit should, if possible, be run at least five

minutes every week to ensure the lubrication of the

gaskets and compressor in the system.

Check the drive belt (2) for any physical damage or

cracks.

The air conditioning unit should not be run when

the outdoor temperature is below 0 C, other than

for the above.

Fig. Engine compartment

1. Compressor

2. Drive belt

Drying filter - Check

With the unit in operation, open the engine hood and

check using the sight glass (1) that bubbles are not

visible on the drying filter. If bubbles are visible

through the sight glass, it is a sign that the refrigerant

level is too low. If so, stop the unit. The unit may be

damaged if it is run with insufficient refrigerant.

Check the moisture indicator (2). It should be blue. If it

is beige, the dryer cartridge should be changed by an

authorized service company.

The compressor will be damaged if the unit is run

with too little refrigerant.

Do not disconnect or undo the hose couplings.

Fig. Drying filter in engine

compartment

1. Sight glass

2. Moisture indicator

The cooling system is pressurized. Incorrect

handling can result in serious personal injury.

The system contains pressurized refrigerant. It is

forbidden to release refrigerants into the

atmosphere. Work on the refrigerant circuit is only

to be carriedd out by authorized companies.

109