DYNAPAC Vibratory roller CA2500/2800/3500/4000 (Engine Cummins 4BT 3.9 102C). Operation & Maintenance (2013)
Instruction manual
Operating & Maintenance
Vibratory roller
CA2500/2800/3500/4000
Engine
Cummins 4BT 3.9 102C
Serial number
10000127x0E001375 -
(Carraro bakaxel)
Translation of original instruction
Reservation for changes
Printed in India
Table of Contents
Introduction
1
The machine
1
Intended use
1
Warning symbols
1
Safety information
1
General
2
Safety - General instructions
3
Safety - when operating
5
Slopes
5
Driving near edges
6
Special instructions
7
Standard lubricants and other recommended oils and fluids
7
Higher ambient temperatures, above +40°C (104°F)
7
Temperatures
7
High pressure cleaning
7
Fire fighting
7
Roll Over Protective Structure (ROPS), ROPS approved cab
8
Battery handling
8
Jump starting
9
Technical specifications
11
Vibrations - Operator station
11
Noise level
11
Dimensions, side view
12
Dimensions, top view
13
Weights and volumes
13
Working capacity
14
General
14
Hydraulic system
15
ROPS - bolts
15
Tightening torque
16
Machine description
17
Identification
17
Product identification number on the frame
17
Machine plate
17
Explanation of 17PIN serial number
18
Engine plates
18
Decals
19
Location - decals
19
Safety decals
20
Info decals
22
Instrument/Controls
23
Locations - Instruments and controls
23
Locations - Control panel and controls
24
Function description
25
Controls in the cab
27
Function description of instruments and controls in the cab
28
Electrical system
29
Main fuses
29
Relays
30
Fuses
31
Fuses, battery disconnector/fuse box (Cab)
31
Fuses and relay in cab heater box (Optional)
32
Fuses in heater box
32
Relay in heater box
32
Operation
33
Before starting
33
Master switch - Switching on
33
Driver seat (Std.) - Adjustment
33
Driver seat (Option)- Adjustment
34
Instruments and lamps - Checking
34
Operator position
35
View
35
Interlock
36
Starting
36
Start of diesel motor
36
Operating
38
Operating the roller
38
Vibration
39
Vibration On/Off
39
Vibration - Activation
39
Braking
40
Normal braking
40
Emergency braking
40
Switching off
41
Parking
41
Master switch
41
Chocking the drums
42
Long-term parking
43
Engine
43
Battery
43
Air cleaner, exhaust pipe
43
Fuel tank
43
Hydraulic reservoir
43
Steering cylinder, hinges, etc
44
Hoods, tarpaulin
44
Tires (All-weather)
44
Miscellaneous
45
Lifting
45
Locking the articulation
45
Lifting the roller
45
Unlocking the articulation
46
Towing/Recovering
46
Alternative 1
46
Short distance towing with the engine running
46
Alternative 2
47
Towing short distances when the engine is inoperative
47
Rear axle brake
47
Releasing the parking brake in the drum
48
Towing the roller
49
Re-activating the rear axle brake
50
Roller prepared for transport
50
Operating instructions - Summary
51
Preventive maintenance
53
Acceptance and delivery inspection
53
Warranty
53
Maintenance - Lubricants and symbols
55
Maintenance symbols
56
Maintenance - Maintenance schedule
57
Service and maintenance points
57
General
57
Every 10 hours of operation (Daily)
58
After the FIRST 50 hours of operation
58
Every 50 hours of operation (Weekly)
59
Every 250 hours of operation (Monthly)
59
Every 500 hours of operation (Every three months)
60
Every 1000 hours of operation (Every six months)
60
Every 2000 hours of operation (Yearly)
60
Maintenance, 10h
61
Scrapers - Check, adjustment
61
Steel scrapers (Optional)
62
Scrapers, Pad-drum
62
Soften scrapers (Optional)
63
Air circulation - Check
63
Coolant level - Check
64
Diesel engine Check oil level
65
Fuel tank - Filling
65
Hydraulic reservoir - Check fluid level
66
Brakes - Check
66
Steering cylinder - Lubrication
67
Maintenance - 50h
69
Air cleaner
Checking - Change the main air filter
69
Backup filter - Change
70
Air cleaner
- Cleaning
70
Articulation - Lubrication
71
Steering joint - Lubrication
71
Tires - Air pressure - Wheel nuts - Tightening
72
Automatic Climate Control (Optional) - Inspection
72
Maintenance - 250h
75
Rear axle differential - Check oil level
75
Rear axle transmission box - Check oil level
76
Rear axle planetary gears - Check oil level
76
Drum - Checking the oil level
77
Radiator - Check/Cleaning
77
Bolted joints - Checking tightening torque
78
Rubber elements and fastening screws - Check
78
Diesel engine - Oil and Filter change
79
Battery - Check electrolyte level
79
Battery cell
80
Air conditioning (Optional)
- Inspection
80
Maintenance - 500h
81
Bleeder filter - Inspection/Cleaning
81
Fuel pre-filter - Replacement
82
Maintenance - 1000h
83
Hydraulic fluid filter - Replacement
83
Hydraulic fluid reservoir - Draining
84
Fuel tank - Drainage
85
Rear axle differential - Oil change
86
Rear axle transmission - Oil change
87
Rear axle's planetary gears - Draining the oil
87
Rear axle's planetary gears - Oil change - Oil filling
88
Air conditioning (Optional)
Fresh air filter - Change
88
Maintenance - 2000h
89
Hydraulic reservoir - Changing the fluid
89
Drum - Oil change
90
Steering hitch - Check
90
Controls - Lubrication
91
Automatic Climate Control (Optional)
- Overhaul
91
Drying filter - Check
92
Compressor - Check (Optional)
93
Introduction
Introduction
The machine
CA250 is one of Dynapac's medium-heavy soil
compaction rollers. It is available in STD and D
versions.
Intended use
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.
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
It is recommended to at least train operators in
handling and daily maintenance of the machine
in accordance with the instruction manual.
Passengers are not allowed on the machine, and
you must sit in the seat when operating the
machine.
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.
1
Introduction
Read the entire manual before starting the
machine and before carrying out any
maintenance.
Replace immediately the instruction manuals if
lost, damaged or unreadable.
Ensure good ventilation (extraction of air by fan)
where the engine is run indoors.
General
This manual contains instructions for machine
operation and maintenance.
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.
2
Safety - General instructions
Safety - General instructions
(Also read the safety manual)
1.
The operator must be familiar with the contents of the OPERATION section
before starting the roller.
2.
Ensure that all instructions in the MAINTENANCE section are followed.
3.
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.
4.
Never use the roller if it is in need of adjustment or repair.
5.
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.
6.
The ROPS (Roll Over Protective Structure) should always be used when the
machine is operated on unsafe ground.
7.
Drive slowly in sharp bends.
8.
Avoid driving across slopes. Drive straight up or straight down the slope.
9.
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/ROPS-cab.
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:
- Stop the engine
- Do not smoke.
- No naked flames in the vicinity of the roller.
- Earth the filling equipment nozzle to the tank opening to avoid sparks.
15.
Before repairs or service:
- Chock the drums/wheels and under the strike-off blade.
- Lock the articulation if necessary
3
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
4
Safety - when operating
Safety - when operating
Prevent persons from entering or remaining in
the danger area, i.e. a distance of at least 7 m
(23 ft) in all directions from operating machines.
The operator may allow a person to remain in
the danger area, but should then observe
caution and operate the machine only when the
person is visible or has given clear indications
of where he or she is.
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
Fig. Operating on slopes
Structure) or a ROPS-approved cab is always used
when driving on slopes or unsafe ground. Always
wear a seat belt.
Where possible, avoid driving across slopes.
Drive instead straight up and down sloping
ground.
5
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
6
Special instructions
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 - 105°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 S2V100 or
similar.
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 water directly onto electrical components
or the instrument panels.
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 ABC-class powder
fire extinguisher.
A BE-class carbon dioxide fire extinguisher can also
be used.
7
Special instructions
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.
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.
8
Special instructions
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.
1
2
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
3
connect the jump start battery's negative terminal (3)
to, for example, a bolt (4) or the lifting eye on the
machine with the flat battery.
4
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
9
Special instructions
10
Technical specifications
Technical specifications
Vibrations - Operator station
(ISO 2631)
The vibration levels are measured in accordance with the operational cycle described in
EU directive 2006/14/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 2006/14/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
107 dB (A)
Sound pressure level at the operator's ear (platform), LpA
90 ±3 dB (A)
Sound pressure level at the operator's ear (cab), LpA
85 ±3 dB (A)
During operation the above values may differ because of the actual operational
conditions.
11
Technical specifications
Dimensions, side view
Dimensions
mm
in
A
Wheelbase, drum and wheel
2879
113,3
L
Length, standard equipped roller
5550
218,5
H1
Height, with ROPS (STD, D)
2952
116,2
H1
Height, with cab (STD, D)
2952
116,2
H2
Height, without ROPS/cab (STD, D)
2190
86,2
D
Diameter, drum
1523
60
S
Thickness, drum sweep, nominal
25
0,98
K1
Clearance, tractor frame
453
17,8
K2
Clearance, drum frame (STD, D)
400
15,7
12
Technical specifications
Dimensions, top view
Dimensions
mm
in
B
Width, standard equipped roller
2384
93,9
O 1
Overhang, left frame side
127
5,0
O 2
Overhang, right frame side
127
5,0
R 1
Turn radius, external
5400
212,6
R 2
Turn radius, internal
3100
122
W 1
Width, tractor section
2130
83,9
W 2
Width, drum
2130
83.9
α
Steering angle
± 38°
Weights and volumes
Weights
Service weight (STD)
9700 kg
21 390 lbs
Service weight (D)
9900 kg
21 830 lbs
Fluid volumes
Fuel tank
250 liters
66 gal
13
Technical specifications
Working capacity
Compaction data
Static linear load (STD)
25,3 kg/cm
141,7 pli
Static linear load (D)
26,3 kg/cm
147,3 pli
Amplitude, high (STD, D)
1,7 mm
0,066 in
Amplitude, low (STD, D)
0,8 mm
0,031 in
Vibration frequency, high amplitude (STD,
33 Hz
1980 vpm
D)
Vibration frequency, low amplitude (STD, D)
33 Hz
1980 vpm
Centrifugal force, high amplitude (STD, D)
246 kN
55,35 lb
Centrifugal force, low amplitude (STD, D)
119 kN
26,77 lb
General
Engine
Manufacturer/Model
Cummins 4BT 3.9C
Water cooled turbo diesel
Power (SAE J1995)
76 kW
103 hp
Engine speed
2300 rpm
Electrical system
Battery
12V 150Ah
Alternator
12V 55A
Fuses
See the Electrical system section - fuses
Tire
Tire dimensions
Tire pressure
Std-type
23.1 x 26.0 8 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 500 kg/tire) (1102 lbs/tire). When
servicing, bear this extra weight in mind.
14
Technical specifications
Hydraulic system
Opening pressure
MPa
Drive system
38,0
Supply system
2.0
Vibration system
32,5
Control systems
17,5
Brake release
1,4
ROPS - bolts
Bolt dimensions :
M24 (PN 4700904562)
Strength class :
10.9
Tightening torque :
800 Nm (Dacromet
treated)
ROPS-bolts which are to be torque tightened
must be dry.
15
Technical specifications
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
M6
8,4
9,4
12
13,4
14,6
16,3
M8
21
23
28
32
34
38
M10
40
45
56
62
68
76
M12
70
78
98
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
M6
12,0
15,0
14,6
18,3
M8
28
36
34
43
M10
56
70
68
86
M12
98
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
16
Machine description
Machine description
Identification
Product identification number on the frame
The machine PIN (product identification number) (1) is
punched on the right edge of the front frame or the
upper edge of the right frameside.
1
1
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 manufacturers name and
address, the type of machine, the PIN product
1
identification number (serial number), operating
weight, engine power and year of manufacture. (If the
machine is supplied to outside the EU, there are no
CE markings and in some cases no year of
Fig. Operator platform
manufacture.)
1. Machine plate
Fig. Machine plate
Please state the machine's PIN when ordering
spares.
17
Machine description
Explanation of 17PIN serial number
100
00123
V
0
A
123456
A= Manufacturer
A
B
C
D
E
F
B= Family/Model
C= Check letter
D= No coding
E= Production unit
F= Serial number
Engine plates
The engine plate (1) is affixed to the right side of the
engine.
The plate specifies the type of engine, its serial
number and the engine specification.
1
Fig. Type plate
Fig. Engine
1. Type plate
Please specify the engine serial number when
ordering spares. Refer also to the engine manual.
18
Machine description
Decals
Location - decals
14, 4
16
2
3
1
12
15
8
6
10
12
11
11
5
9
14
2
1
10
3
15
5
6
11
11
13
5
7
1.
Warning, Crush zone
7. Product sign
13. Handbook compartment
2.
Warning, Rotating engine
8. Diesel fuel
14. Tire pressure
components
3.
Warning, Hot surfaces
9. Hydraulic fluid/Biohydraulic fluid
15. Hoisting plate
4.
Warning, Ballasted tire.
10. Lifting point
16. Hydraulic
fluid/Biohydraulic
5.
Warning, Read instructions
11. Fixing point
manual
6.
Warning, locking
12. Master switch
19
Machine description
Safety decals
Always make sure that all safety decals are completely
legible, and remove dirt or order new decals if they
have become illegible. Use the part number specified
on each decal.
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.
4700903459
Warning - Instruction manual
The operator must read the safety, operation and
maintenance instructions before operating the
machine.
4700908229
Warning - Risk of crushing
The articulation must be locked when lifting.
Read the instruction manual.
4700904165
Warning - Toxic gas (option, ACC)
Read the instruction manual.
20
Machine description
4700903590
-Emergency exit
4700903985
Warning - Ballasted tire.
Read the instruction manual.
21
Machine description
Info decals
Coolant
Diesel fuel
Lifting point
Hoisting plate
Handbook compartment
Master switch
Hydraulic fluid
Tire pressure
Securing point
Hydraulic fluid level
Noise power level
22
Machine description
Instrument/Controls
Locations - Instruments and controls
16
14
22
15
32
17
18
21
31
20
19
Fig. Instruments and control panel
14.
Driving lights, Low beam
22.
Control panel
15.
Driving lights, High beam
31.
Parking brake On/Off
16.
Hazard flashers
32.
Transport mode/Traction control (Optionr)
17.
Hazard beacon
18.
Direction indicators
19.
Horn
20.
Vibration On/Off, Amplitude High/Low
21.
Anti spin forward/equal share/back
23
Machine description
Locations - Control panel and controls
26
24
25
27
9
8
12
23
Fig. Control panel
30
11
3
28
7
1
6
Fig. Operator's
station
4
33
5
Fig. Operator position
1
Starter switch
23
Low fuel level
3
Emergency stop
24
Oil pressure, diesel engine
4
Vibration ON/OFF
25
Parking brake
5
Handbook compartment
26
Fuel level
6
Forward/Back control
27
Water temperature, diesel engine
7
Seat switch
28
Battery/charging
8
Fuse box
30
Hourmeter
9
Instrument guard
33
Engine speed control
11
Hydraulic temperature
12
Air filter
24
Machine description
Function description
No
Designation
Symbol
Function
1.
Starter switch
Positions 1-2: Shut off position, key can be
removed.
Position 3a: All instruments and electric controls
are supplied with power.
Position 3c: Starter motor activation.
3.
Emergency stop
When pressed, the emergency stop is activated.
The brake is applied and the engine stops. Brace
yourself for a sudden stop.
4.
Vibration On/Off. Switch
When the circuit breaker is pressed in and
released the vibrations are connected up. Press
again and the vibrations are disconnected. High or
low amplitude must first be chosen on the
instrument panel.
5.
Handbook compartment
Pull up and open the top of the compartment for
access to handbooks.
6.
Forward/Reverse lever
The lever must be in neutral to start the diesel
engine. The engine cannot be started if the 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 etc.
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.
7.
Seat switch
Remain seated at all times when operating the
roller. If the operator stands up during operation, a
buzzer sounds. After 3 seconds the brakes are
activated and the engine stops.
8.
Fuse box (on control column)
Contains fuses for the electrical system. See under
the heading ‘Electrical system’ for a description of
fuse functions.
9.
Instrument cover
Lowered over the instrument plate to protect the
instruments from the weather and sabotage.
Lockable
11.
Temperature gauge,
Shows hydraulic fluid temperature.
hydraulic fluid.
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.
12.
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.
14.
Driving lights, low beam,
When depressed, the driving lights low beam are
switch (Optional)
on.
15.
Driving lights, high beam,
When depressed, the driving lights high beam are
switch (Optional)
on.
16.
Hazard warning lights,
Where depressed, the hazard warning lights are on
switch (Optional)
25
Machine description
No
Designation
Symbol
Function
17.
Hazard beacon, switch
Where depressed, the hazard beacon is on
(Optional)
18.
Direction indicators,
When depressed to the left, the left direction
switch (Optional)
indicators are on etc. In the middle position the
function is shut off.
19.
Horn, switch
Press to sound the horn.
20.
Amplitude High/Low,
Low Amplitude Activate the vibration together with
Vibration On
the circuit breaker on forward/back control.
Vibration switched off.
Amplitude, high Activate the vibration together with
the circuit breaker on forward/back control.
21.
Anti spin Forward/Equal
Roller spinning symbol = less distribution of power
share/Back (Optional)
to the roller.
Mid position = Equal distribution of power
forward/back.
Wheel spinning symbol =Less distribution of power
to the roller.
22.
Control panel
23.
Warning lamp, low fuel level
This lamp lights when the fuel level in the diesel
tank is too low.
24.
Warning lamp, oil pressure
This lamp lights if the lubricating pressure in the
engine is too low. Stop the engine immediately and
locate the fault.
25.
Warning lamp, parking brake
The lamp lights when the parking brake is
activated.
26.
Fuel level
Shows the fuel level in the diesel tank.
27.
Warning lamp, water
The light comes on if the water temperature is too
temperature
high.
28.
Warning lamp, battery
If the lamp lights while the engine is running the
charging
alternator is not charging. Stop the engine and
locate the fault.
30.
Hourmeter
Shows the number of hours the engine has run.
31.
Parking brake On/Off, switch
Push in to activate the parking brake, the machine
stops with the engine running. Always use the
parking brake when the machine is stationary
on a sloping surface.
32.
Transport mode/Traction
Transport mode.
control (Optional)
Traction control mode (TC): Activate this function
together with the power distribution selector switch.
33.
Engine speed control
Turn the lever backwards and release it into the
groove to set engine speed to operating speed.
To select idling speed, move the lever to forward
end position.
26
Machine description
Controls in the cab
2
3
4
1
Fig. Cab roof, front
Fig. Cab roof, rear
1. Front wiper
4. Hammer for emergency escape
2. Rear wiper (Optional)
3. Front and rear windshield washers
6
5
8
7
9
Fig. Cab right side. Heater (Option)
Fig. Cab, rear
5 .Control, temperature
9. Switch, cab lighting (Optional)
6. Control, cirkulation
7. Control, fan
8. Switch, AC (Option)
10
11
Fig. Cab, left side
Fig. Cabin driving compartment
10. Windscreen washer fluid container
11. Manual compartment
(Optional)
27
Machine description
Function description of instruments and
controls in the cab
No
Designation
Symbol
Function
1
Front wiper, switch
Press to operate the front screen wiper.
2
Rear wiper, switch (Optional)
Press to operate the rear screen wiper.
3
Front and rear window screen washers,
Press at the top to spray the windshield.
switch
Press at the bottom to spray the rear windshield.
4
Hammer for emergency exit
To escape from the cab in an emergency, release
the hammer and break the REAR window.
5
Control, temperature (Optional)
In the left position, the heating is OFF.In the right
position, maximum heating.
6
Control, circulation (Optional)
In the left position, the circulation is OFF. In the
right position, maximum circulation
7
Control, fan (Optional)
In the left position, the fan is OFF. In the right
position, maximum fan.
8
AC, switch (Optinal)
9
Cab lighting, switch (Optional)
Push in to turn on cab lighting
10
Windscreen wiper fluid container
Fill with screenwash as required.
(Optional)
11
Handbook compartment
Stowage space for safety manual and instruction
books.
28
Machine description
Electrical system
3
2
1
4
Main fuses
The main fuse (1) is placed by the battery
disconnector (4). The fuse is of the flat pin type. The
fuel solenoid relay (2) and the starter relay (3) are also
fitted here.
Main fuse
40A (Orange)
Fig. Engine house
1. Main fuse
2. Fuel solenoid relay
3. Starter relay
4. Master switch
Control unit (ECU:n) 1 is places behind the front hatch
under the driver seat.
This control unit runs the electrical driving system,
vibration, start-stop, among other things.
1
Fig. Driving compartment
1 Control unit (ECU)
29
Machine description
Relays
2
1.
k7
Direction indicators
1
2.
K6
Stop lights
3.
Working lights
3
4
Fig. Control column
1. Flasher relay
2. Stop light relay
3. Working lights relay
4. Fuse boxes
30
Machine description
Fuses
The figure shows the position of the fuses.
F2
The table below gives fuse amperage and function. All
fuses are flat pin fuses.
The machine is equipped with a 12V electrical system
and an AC alternator.
F1
Fig. Fuses boxes.
Fuses in boxes F1
1.
Emergency stop, ECU, reversing alarm,
15A
5.
High/Low speed
10A
neutral position, seat switch, vibration
2.
Horn, buzzer, control panel
10A
6.
Windshield wipers cabin
10A
3.
Reserve
7.
Compaction meter
10A
4.
Rotating hazard beacon
10A
8.
Indicators, warning indicators, cab interior
10A
lightning
Fuses in boxes F2
1.
Working lights
20A
2.
Traffic lights: headlight, navigation light,
20A
braking lights, number plate illumination
Fuses, battery disconnector/fuse box (Cab)
9
To access the fuse (9), remove the front of the battery
disconnector/fuse box by unscrewing the screws. Pull
off the top of the fuse holder to see the fuse.
9
50 A Main fuse for cab
Fig. Battery disconnector/fuse box in
cooler compartment.
9. Fuse
31
Machine description
Fuses and relay in cab heater box (Optional)
3
2
To access the fuses (x2) in the heater box, release the
plug (1)
The relay in the heater box is accessed by releasing
1
the screws (2) and (3) on the top of the cover, and the
4
screws (3) on the front of the cover, after which the
cover (4) can be lifted off the heater box.
3
3
Fig. Heater box in cab.
1. Plug
2. Screws (x5)
3. Screws (x9)
4. Cover
Fuses in heater box
5
To access the fuses (x2) in the heater box, release the
plug (1). Unscrew the cover (7) on the fuse box.
5.
20 A Fan
6.
20 A AC (Optional)
1
6
7
Fig. Heater box in cab.
1. Plug
5. Fuse (x1)
6. Fuse (x1)
7. Cover for fuse box
Relay in heater box
8.
To access the relay (8) (x1) in the heater box:
Unscrew the screws (2) and (3) on the top of the
cover, and the screws (3) on the front of the cover.
The cover (4) can now be lifted off the heater box.
Fig. Heater box in cab.
8. Relay 12V
32
Operation
Operation
Before starting
Master switch - Switching on
Remember to carry out daily maintenance. Refer to
the maintenance instructions.
1
The master switch is located in the engine
compartment. Open the engine cover and set 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 house
1. Battery disconnection switch
Driver seat (Std.) - Adjustment
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 lengthways (1).
1
Fig. Operator's seat
1. Length adjustment
33
Operation
Driver seat (Option)- Adjustment
Adjust the operator’s seat so that the position is
comfortable and so that the controls are within easy
reach.
2
1
The seat can be adjusted as follows.
4
- Length adjustment (1)
3
- Weight adjustment (2)
Fig. Driver seat
- Back support angle (3)
1. Lock lever - Length adjustment
2. Weight adjustment
3. Back support angle
4. Seat belt
Always make sure that the seat is secure before
beginning operation.
Do not forget to use the seat belt (4).
Instruments and lamps - Checking
Make sure that the emergency stop (2) is pulled
22
out. When the roller is in neutral or there is no load
on the operator seat, the automatic brake function
is engaged.
2
1
Pull out the emergency stop (2).
Fig. Instrument panel
Turn the switch (1) to position 3a.
1. Starter switch
2. Emergency stop
22. Warning panel
Check that the warning lamps in the warning panel
(22) come on.
34
Operation
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.
2
Replace the seat belt (1) if it shows signs of
wear or has been subjected to high levels of
1
force.
4
Check that rubber elements (3) on the platform
are intact. Worn elements will impair comfort.
3
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.
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
35
Operation
Interlock
The roller is equipped with Interlock.
The engine switches off 4 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.
Sit down for all operations!
Starting
Start of diesel motor
Make sure that the emergency stop (3) is pulled out.
Make sure that the parking brake switch (31) is
activated.
31
Set the forward/reverse lever (6) in neutral. The
engine can only be started when the lever is in neutral.
20
3
Turn the vibration switch (20) to the Off position
(position O).
1
At normal/high environmental temperature, set engine
speed control (33) at the position for idle running
(forward end position).
Turn switching starter(1) to position 3c. As soon as the
6
motor has started, let the starting switch go.
Do not run the starter motor for too long. If the
33
engine does not start, wait a minute or so before
trying again.
Fig. Control panel
1. Ignition starter switch
3. Emergency shut down
6. Forward/Back regulator
20. Vibration switch
31. Parking brake switch
Idle the engine for a few minutes until it is warm,
33. Engine speed control
longer if the ambient temperature is below +10 °C (50
°F)
At temperatures below 0°C (32°F) the diesel engine
and hydraulic system should be warmed up for at least
15 minutes.
36
Operation
Check while warming the engine that the warning
lamps for the oil pressure (24) and charging (28) go
out.
The warning lamp (25) should remain on.
When starting and driving a machine that is cold,
20
remember that the hydraulic fluid is also cold and
that braking distances can be longer than normal
Fig. Instrument panel
until the machine reaches the working temperature.
20. Vibration switch
Ensure that there is good ventilation (air
extraction) if the engine is run indoors. Risk of
25
carbon monoxide poisoning.
24
28
Fig. Control panel
28. Charging lamp
24. Oil pressure lamp
25. Brake lamp
37
Operation
Operating
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.
Pull back the engine speed control (33) until it locks in
the operational position.
Check that the steering is working correctly by turning
the steering wheel once to the right and once to the
left while the roller is stationary.
Make sure that the area in front of and behind the
roller is clear.
3
1
6
Carefully move the forward/reverse lever (6) forwards
or backwards, depending on which direction of travel
33
is required.
The speed increases as the lever is moved away from
Fig. Control panel
the neutral position.
1. Ignition starter switch
3. Emergency shut down
The speed should always be controlled by using
6. Forward/Back regulator
the forward/reverse lever, and never by changing
33. Engine speed control
the engine speed.
Test the emergency stop by pressing the
emergency stop button (3) while the roller is
moving slowly forward. Brace yourself for a
sudden stop. The engine will be switched off and
the brakes activated.
Check while driving that the warning lamps have not
gone on.
If the engine is overheated or if the oil pressure is
to low then the buzzer sounds for 10 seconds and
the engine shuts off. Brace your self for a sudden
stop.
38
Operation
Vibration
Vibration On/Off
Activation/deactivation of the vibration is selected with
the switch (20).
The operator must activate the vibration via the switch
(4) on the underside of the forward/reverse handle.
See illustration below.
20
Fig. Instrument panel
20. Vibration switch.
Vibration - Activation
Never activate vibration when the roller is
stationary. This can damage both the surface and
the machine.
Engage and disengage vibration using the switch (4)
on the underside of the forward/reverse lever.
4
Vibration can only be engaged at low and high speed.
Always switch off vibration before the roller comes to a
standstill.
Fig. Forward/Reverse lever
4. Switch, vibration On/Off
39
Operation
Braking
Normal braking
Press the switch (4) to switch off the vibration.
Move the forward/reverse lever (6) to the neutral
position to stop the roller.
Turn the engine speed control (33) forward to idling
31
position.
Set the parkering brake switch (31) in the On position.
3
Always use the parking brake (31) when the
1
machine is stationary on a sloping surface.
6
4
When starting and driving a machine that is cold,
remember that the hydraulic fluid is also cold and
33
that braking distances can be longer than normal
until the machine reaches the working temperature.
Fig. Control panel
1. Key
3. Emergency shut down
4. Vibration On/Off.
6. Forward/Back regulator
31. Parking brake starting switch
33. Engine speed control
Emergency braking
Braking is normally activated using the
forward/reverse lever. The hydrostatic transmission
brakes the roller when the lever is moved towards the
neutral position.
There is also a brake in the drum motor and rear axle
3
that acts as an emergency brake during operation.
For emergency braking, press the emergency stop
(3), hold the steering wheel firmly and be prepared
for a sudden stop. The brakes are applied and the
Fig. Instrument panel
3. Emergency stop
engine stops.
After emergency braking, return the forward/reverse
lever to neutral position and pull out the emergency
stop (3). When the roller is fitted with an Interlock it is
necessary to sit down in the driver seat to restart the
engine.
40
Operation
Switching off
Check instruments and warning lamps to see if any
22
faults are indicated. Switch off all lights and other
electrical functions.
9
Turn the starter switch (1) to the left to switched off
position 1. At the end of the shift, lower the instrument
cover (22) and lock it.
1
Fig. Instrument panel
1. Starter switch
9. Instrument guard
22. Panel for warning lamps
Parking
Master switch
Before leaving the roller for the day, switch the master
switch (1) to the disconnected position and remove the
key.
1
This will prevent battery discharging and will also
make it difficult for unauthorized persons to start and
operate the machine. Also lock the engine hood.
Fig. Engine compartment
1. Master switch
41
Operation
Chocking the drums
Never disembark from the machine when the is
engine running, unless the reserve/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
1
if the roller is parked on sloping ground.
Fig. Arrangement
1. Chock
Keep in mind that there is a risk of freezing during
the winter. Fill the engine cooling system and the
screenwash bottle in the cab with suitable
anti-freeze mixtures. See also the maintenance
instructions.
42
Long-term parking
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.’)
43
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.
Tires (All-weather)
Check that tire pressure is 110 kPa (1.1 kp/cm 2 ), (16
psi).
44
Miscellaneous
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.
4
Pull out the lowermost locking pin (2), which has a a
3
2
1
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
1
1
that the lifting hooks are properly secured.
Fig. Roller prepared for lifting
1. Hoisting plate
45
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
4
the locking stud (3). The locking lug (4) is located on
3
1
2
the tractor frame.
Fig. Articulation in the open position
1. Locking arm
2. Locking pin
3. Locking stud
4. Locking lug
Towing/Recovering
The roller can be moved up to 300 meters (330 yards)
using the instructions below.
1
Alternative 1
2
1
Short distance towing with the engine running
2
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.
46
Miscellaneous
Alternative 2
Towing short distances when the engine is
inoperative
First release both towing valves as per alternative 1.
Chock the drums to prevent the roller from moving
when the brakes are mechanically disengaged.
Rear axle brake
On both sides remove the lock screws (1)
Screw in the brake release bolts (3), 1/2 turn at a time,
in sequence (A, B, C) until the torque drops off sharply
(4-5 turns).
Clear the area of any personnel before removing the
stop blocks on the drum and two wheels, and then tow
the machine to a safe location.
Fig. Rear axle
1. Lock screw
2. Loch nut
3. Brake release screw
47
Miscellaneous
Releasing the parking brake in the drum
Fig. Drum motor
1
Remove and dispose of the rubber plug from the
brake protector.
Loosen the metallic plug.
2
Use a screw fitted with a nut and washer.
Tighten to the bottom of the threading into the
piston without blocking the screw.
3
Then tighten the nut until the motor shaft turns
freely, while holding the screw.
The brake is now disengaged and the machine can be
towed.
Reset the drum motor brake after towing.
48
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 185 kN
(41590 lbf).
Fig.Towing
Restore the items for towing according to
alternative 1 or 2 on the preceding pages.
49
Miscellaneous
Re-activating the rear axle brake
Chock the drum and wheels to prevent the roller
from moving when the brakes are mechanically
disengaged.
Apply pressure (13 bar) into the parking brake ports
(4).
Remove the lock screws (1) and unscrew all the brake
release screws (3) on both sides until the end of stroke
has been reached.
NOTE!Do not move the lock nuts (2).
Release the pressure at the parking brake ports (4).
Apply sealant on the lock screws (1) and refit the lock
nuts (2).
Fig. Rear axle
1. Lock screw
Hold the lock nuts (2) and tighten the screws (1) with
2. Locknut
torque (140Nm). The same procedure on both sides of
3. Brake release bolt
4. Brake port (rear axle)
the rear axle
The parking brakes should now be re-activated and
the wheels are locked.
Clear the area of any personnel and that the parking
brakes work properly before removing the stop blocks
from drum and wheels.
Remove any warning tags from the ignition key and
from the steering wheel.
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.
3
1
2
1
3
Block up under the drum frame (2), to avoid overload
Fig. Transport
on the rubber suspension of the drum when lashing.
1. Chock
2. Block up
Clamp down the roller with lashing strap at all four
3. Lashing wire
corners; decals (3) indicate the fixing points.
Remember to return the articulation to its
unlocked position before starting the roller.
50
Operating instructions - Summary
Operating instructions - Summary
1.
Follow the SAFETY INSTRUCTIONS specified in the Safety Manual.
2.
Make sure that all instructions in the MAINTENANCE section are followed.
3.
Turn the master switch to the ON position.
4.
Move the forward/reverse lever to the NEUTRAL position.
5.
Set the switch for Manual/Automatic vibration to the 0 position.
6.
Set the engine speed control to idle.
7.
Start the engine and allow it to warm up.
8.
Set the engine speed control to the operating position.
9.
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.
51
Operating instructions - Summary
52
Preventive maintenance
Preventive maintenance
Complete maintenance is necessary for the machine
to function satisfactorily and at the lowest possible
cost.
The Maintenance section includes the periodic
maintenance that must be carried out on the machine.
The recommended maintenance intervals assume that
the machine is used in a normal environment and
working conditions.
Acceptance and delivery inspection
The machine is tested and adjusted before it leaves
the factory.
On arrival, before delivery to the customer, delivery
inspection must be conducted as per the check list in
the warranty document.
Any transport damage must be immediately reported
to the transport company.
Warranty
The warranty is only valid if the stiplulated delivery
inspection and the separate service inspection have
been completed as per the warranty document, and
when the machine has been registered for starting
under the warranty.
The warranty is not valid if damage has been caused
by inadequate service, incorrect use of the machine,
the use of lubricants and hydraulic fluids other than
those specified in the manual, or if any other
adjustments have been made without the requisite
authorisation.
53
Preventive maintenance
54
Maintenance - Lubricants and symbols
Maintenance - Lubricants and symbols
Fluid volumes
Rear axle (Carraro)
- Differential
14,5 ±0,5 liter
- Planet gear
1,3 ±0,1 liters/side
- Transmission box
0,5 ±0,1 liters
Drum
15 liter
Hydraulic reservoir
52 liters
Oil in hydraulic system
23 liters
Lubrication oil, diesel engine
11 liter
Coolant, diesel engine
24 liter
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
AtlasCopco Engine
P/N 5580020624 (5 liters),
(5°F-122°F)
100, API CH-4 or
P/N 5501522700 (20 liters)
equivalent.
HYDRAULIC FLUID
Air temperature -15°C - +50°C
AtlasCopco Hydraulic
P/N 9106230330 (20 liters),
(5°F-122°F)
300 or equivalent.
P/N 9106230331 (209
liters)
Air temperature over +40°C
Shell Tellus S2 V100 or
(104°F)
equivalent.
BIOLOGICAL
When it leaves the factory, the
BP BIOHYD SE-S 46
HYDRAULIC FLUID
machine may be filled with
biologically degradable fluid.
The same type of fluid must be
used when changing or topping
up.
BIOLOGICAL
Air temperature -10°C - +35°C
PANOLIN HLP Synth 46
HYDRAULIC FLUID,
(14°F-95°F)
PANOLIN
When it leaves the factory, the
machine may be filled with
biologically degradable fluid.
The same type of fluid must be
used when changing or topping
up.
DRUM OIL
Air temperature -15°C - +40°C
AtlasCopco Drum Oil
P/N 4812156456 (5 liters)
(5°F-104°F)
1000
GREASE
Shell Retinax LX2 or
Dynapac Grease (0.4kg),
equivalent.
P/N 4812030095
GREASE
SKF LGHB2
Dynapac Grease (0.4kg),
(NLGI-Klass 2) or
P/N 4812030096
eqvivalent for the
steering hitch.
55
Maintenance - Lubricants and symbols
FUEL
See engine manual.
-
-
TRANSMISSION OIL
AtlasCopco Engine
P/N 5501527800 (20 liters)
100, API GL-4 or
equivalent
COOLANT
Anti-freeze protection down to
GlycoShell/Carcoolant
about -37°C (-34.6°F)
774C or equivalent,
(mixed 50/50 with water)
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 symbols
Engine, oil level
Tyre pressure
Engine, oil filter
Air filter
Hydraulic reservoir, level
Battery
Hydraulic fluid, filter
Recycling
Transmission, oil level
Fuel filter
Drum, oil level
Coolant, level
Oil for lubrication
56
Maintenance - Maintenance schedule
Maintenance - Maintenance schedule
Service and maintenance points
6
7
8
9
33
10
5
1
35
2
34
4
11
12
3
32
31
30
28
27
19
18
21
20
29
26
24
25
23
22
17
16
14
13
15
Fig. Service and maintenance points
1. Cooler grille
13. Scrapers
25.
Draining, fuel tank
2. Fuel filter, fuel prefilter
14. Drum oil, level plug
26.
Diesel engine suspension, x4
3. Oil level, diesel engine
15. Shock absorbers and attachment
27.
Feed pump, fuel
screws
4. Air filter
16. Steering joint
28.
Diesel engine, filling
5. Hydraulic reservoir, sight
17. Steering cylinders, x2
29.
Battery
glass
6. Bleeder filter
18. Flywheel casing, hydraulic pumps
30.
Cooler
7. Hydraulic fluid filter, x1
19. Wheel-nuts
31.
Hydraulic fluid cooler
8. Draining, hydraulic fluid
20. Tires, air pressure
32.
Drive belts, cooling, alternator
reservoir
9. Hydraulic fluid, filling
21. Rear axle, differential
33.
Forward/Reverse lever
10. Fuse box
22. Rear axle, planetary gears, x2
34.
Engine hood, hinge
11. Drum oil, filling
23. Rear axle suspension, 2 sides
35.
Cooling liquid level, diesel motor
12. Drum gearbox
24. Oil filter, diesel engine
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.
57
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
13
Check the scraper setting
1
Check for free circulation of cooling air
35
Check coolant level
Refer to the engine manual
3
Check the engine oil level
Refer to the engine manual
28
Refuel
5
Check the hydraulic reservoir level
Test the brakes
17
Grease the steering cylinder bearings
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
2
Change the engine oil and oil filter
Refer to the engine manual
3
Change the fuel filter
Refer to the engine manual
8
Change the hydraulic fluid filter
21
Change oil in rear axle differential
22
Change oil in the rear axle planetary gearing
58
Maintenance - Maintenance schedule
Every 50 hours of operation (Weekly)
Refer to the contents to find the page number of the
sections referred to!
Pos. in fig
Action
Comment
Check that hoses and couplings are not leaking
4
Inspect/clean the filter element in the air cleaner
Replace as required
16
Lubricate the articulation
17
Check that the guiding cylinders are tight
19
Check the wheel-nuts are tightened
20
Check the tire pressure
Check the air conditioning
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
22
Check oil level in rear axle/planetary gearing
14
Check oil level in the drum
31
Clean the coolers
19
Check the bolted joints
The above applies to new
or reconditioned
components only
23
Check the bolted joints
The above applies to new
or reconditioned
components only
15
Check rubber elements and bolted joints
24
Change the engine oil and oil filter
Refer to the engine manual
29
Check battery
Check the AC
Optional
59
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
2
Replace the fuel filter
Refer to the engine manual
2
Clean the fuel pre-filter.
6
Check bleeder filter on hydraulic reservoir
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
4
Replace the air cleaner's main filter and backup
filter
7
Change the hydraulic fluid filter
8
Drain the condensate from hydraulic reservoir
25
Drain condensate from fuel tank
21
Change oil in rear axle differential
22
Change oil in the rear axle planetary gearing
Check engine valve clearances
Refer to the engine manual
32
Check belt tension for drive system
Refer to the engine manual
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
8, 9
Change the hydraulic fluid
11
Change the oil in the drum
33
Lubricate the Forward/Reverse lever
Overhaul air conditioning
Optional
60
Maintenance, 10h
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.
Ensure that there is good ventilation (air
extraction) if the engine is run indoors. Risk of
carbon monoxide poisoning.
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:
Undo the screws (2) on the scraper attachment.
Then adjust the scraper blade (1) to 20 mm from the
drum.
Tighten the screws (2).
1
2
Fig. Skrapers
1. Skraper blades
2. Screws (4)
61
Maintenance, 10h
Steel scrapers (Optional)
If necessary, adjust distance to the drum as follows:
Undo 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).
2
1
Fig. Scrapers
1. Scraper blades (x4)
2. Screws
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).
1
2
Fig. Scrapers
1. Screws
2. Scraper teeth (x18)
62
Maintenance, 10h
Soften scrapers (Optional)
Loosen the screws (2).
Then, adjust the scraper blade (1) so that it lightly
touches the drum.
Tighten the screws (2).
2
1
2
1
Fig. Scrapers
1. Scraper blade
2. Screws
Air circulation - Check
1
Ensure that the diesel engine has free circulation of
cooling air through the vents in the hood.
Observe extreme caution if the filler cap must be
opened when the engine is hot. NOTE, the engine
must be switched off. Wear protective gloves and
goggles.
Fig. Cooler grille
1. Filler cap, coolant
63
Maintenance, 10h
Coolant level - Check
Cooling liquid holder is placed up beside the hydraulic
oil tank and is seen easiest from the right side of the
roller.
The filler cap (2) is accessible from the top of the
engine hood.
2
1
Check the coolant level with the engine stopped and
cold.
Check that the coolant level is between the max/min
markings (1).
Make sure that cooling air flows freely through the
protective grille to the engine.
The coolant is hot and under pressure at
Fig. Coolant container
1. Level mark in coolant container
working temperature and the escaping steam
(min/max markings)
can cause serious scalding. Open the filler cap
2. Filler cap
carefully to release the pressure. Wear
protective goggles and protective gloves.
Fill with a mixture of 50% water and 50% antifreeze.
See instructions for lubricant and symbols.
64
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.
1
Fig. Engine compartment
1. Dipstick
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 diesel engine. Short-circuit (press) the
filler gun against a non-insulated part of the roller
before filling, and against the filler pipe (1) while
filling.
1
Never refuel while the engine is running. Do not
smoke and avoid spilling fuel.
Fig. Filling with fuel
1. Filler pipe
The tank holds 250 liters of fuel.
65
Maintenance, 10h
Hydraulic reservoir - Check fluid level
2
The sight glass is located on the right-hand side of the
roller behind the operator's seat.
Place the roller on a flat surface and check the fluid
level in the sight glass (1). If the level is too low, top up
with the type of hydraulic fluid specified in the lubricant
1
specification.
Fig. Sight glass hydraulic reservoir
1. Sight glass
Brakes - Check
Check operation of the brakes as follows:
Checking the emergency stop
Drive the roller slowly forward. Hold the steering wheel
2
firmly and brace yourself for a sudden stop.
Press the emergency stop (1). The roller will stop
abruptly and the engine will be switched off.
After testing the brakes, set the forward/reverse lever
1
in neutral.
Fig. Instrument panel
Pull out the emergency stop (1). Start the engine.
1. Emergency stop
2. Parking brake lamp
The roller is now ready for operation.
Refer also to the section in the manual on operation.
66
Maintenance, 10h
Brakes - Check
Check operation of the brakes as follows:
Checking the parking brake
Drive the roller slowly forward. Hold the steering wheel
2
firmly and brace yourself for a sudden stop.
Push in the parking brake switch (1). The roller should
stop immediately with the engine running.
After testing the brakes, set the forward/reverse lever
1
in neutral.
Reset the parkering brake switch (1).
Fig. Instrument panel
1. Parkering brake switch
2. Parkering brake lamp
The roller is now ready for operation.
Refer also to the section in the manual on operation.
Steering cylinder - Lubrication
Wipe off any dirt and grease from the nipples.
Grease each nipple (1) with three strokes of a
hand-operated grease gun.
Leave a small amount of grease on the nipples
following lubrication to prevent dirt from penetrating in.
Use grease as per the lubricant specification.
1
Fig. Tractor frame/Steering hitch
1. Grease nipples
67
Maintenance, 10h
68
Maintenance - 50h
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.
Ensure that there is good ventilation (air
extraction) if the engine is run indoors. Risk of
carbon monoxide poisoning.
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.
2
3
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
1
4
5
6
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
69
Maintenance - 50h
Backup filter - Change
1
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.
70
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
1
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.
1
Fig. Articulation, right side
1. Lubricating nipples, articulation
(4 pcs)
71
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.
1
When changing the tires it is important that both
2
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
1
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.
The filter is located on the left side of the engine
compartment´s front edge
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.
Fig. Drying filter
The filter is located on the left side of the engine
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.
72
Maintenance - 50h
1
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
73
Maintenance - 50h
74
Maintenance - 250h
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.
Ensure that there is good ventilation (air
extraction) if the engine is run indoors. Risk of
carbon monoxide poisoning.
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 up with oil to the right level if the level is low.
Use transmission oil, see lubricant specification.
Fig. Check level - differential housing
Clean and refit the plug.
1. Level/Filler plug
75
Maintenance - 250h
Rear axle transmission box - 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 (5) and check
that the oil level reaches the lower edge of the plug
hole. Top up with oil to the right level if the level is low.
Use transmission oil, see lubricant specification.
Fig. Level check - transmission box
Clean and refit the plug.
5. Level/Filler plug
6. Drain plug
Rear axle planetary gears - Check oil level
Position the roller with the plug in the planetary gear
(4) in the "3 o'clock" position.
Wipe clean and remove the level plug (4) 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.
Check the fluid level in the same way on the rear
axle's other planetary gear.
Fig. Level check - planetary gear, std
4. Level/Filler plug
76
Maintenance - 250h
Drum - Checking the oil level
2
Place the roller on a level surface so that the filler plug
1
(1) and the drum's number plate (2) are visible on the
right side of the drum.
The oil level should now reach the sight glass (3).
If necessary, remove the filler plug (1) and fill to
halfway up the sight glass.
Clean any metal residue from the magnetic filler plug
3
(1) before reinstalling it.
See the lubrication specification for the correct oil
Fig. Roller, right-hand side
grade.
1. Filler plug
Do not overfill with oil - risk for overheating.
2. Number plate
3. Sight glass
Radiator - Check/Cleaning
Check that air can pass unobstructed through the
radiators (1) and (2).
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.
1
2
Wear protective goggles when working with
Fig. Engine compartment
1. Water cooler
compressed air or high-pressure water jets.
2. Hydraulic fluid cooler
77
Maintenance - 250h
1
Bolted joints - Checking tightening torque
Steering pump to diesel engine (1) 55 Nm, lightly oiled
Rear axle suspension (2) 330 Nm (243 lbf.ft), oiled.
Engine suspension (3). Check that all the M12 bolts
(x20) are tightened, 70 Nm, and lightly oiled.
3
4
2
Wheel nuts (4). Check that all nuts are tightened, 630
Nm oiled.
Fig. Right side of machine
1. Steering pump
2. Rear axle
(The above applies to new or replaced components
3. Engine suspension
only).
4. Wheel nuts
Rubber elements and fastening screws - Check
1
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.
2
Fig. Drum, vibration side
1. Rubber element
2. Fastening screws
78
Maintenance - 250h
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 15 liters
2
(4 gal) under the drain plug.
Replace the engine oil filter (2) at the same time. Refer
1
to the engine manual.
Deliver the drained oil and filter to
environmentally correct handling.
Fig. Left side of engine
1. Drain plug
2. Oil filter
Battery - Check electrolyte level
1
2
3
1
Never use a naked flame when checking the
battery as the electrolyte emits explosive gas while
the alternator is charging.
Open the engine cover and undo the quick-release
screws (1).
Raise the battery cover (2).
Fig. Battery shelf
Wipe the top of the battery.
1. Quick-screws
Wear safety goggles. The battery contains
2. Battery cover
corrosive acid. Rinse with water if electrolyte
3. Battery
comes into contact with the body.
79
Maintenance - 250h
Battery cell
1
Take off the cell caps (1) and make sure that
2
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.
3
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
2
sure that there are no signs of an oil film that can
indicate a refrigerant leakage.
1
Fig. Air conditioning
1. Refrigerant hoses
2. Condensor element
80
Maintenance - 500h
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.
Ensure that there is good ventilation (air
extraction) if the engine is run indoors. Risk of
carbon monoxide poisoning.
Bleeder filter - Inspection/Cleaning
3
If passage in either direction is blocked, clean the filter
with a little diesel oil and blow through with
2
compressed air until the block is removed, or replace
the cap with a new one.
Always wear protective goggles when working with
compressed air.
Fig. Hydraulic reservoir
2. Filler cap/Air filter
Check that the bleeder filter (2) is not clogged. Air
3. Sight glass
should be able to pass through the cap unobstructed
in both directions.
Start the engine and check that there is no leakage of
hydraulic fluid from the filter. Check level of fluid in the
sight glass (3) and top up as required.
81
Maintenance - 500h
Fuel pre-filter - Replacement
Ensure good ventilation (air extraction) if the
diesel engine is run indoors. Risk of carbon
monoxide poisoning.
Loosen the hose clamps (2) and remove the pre-filter
(1). Fit the new filter, taking care to fit in the direction
of flow.
1
2
Discard the pre-filter (1) in a safe manner, its of
Fig. Engine compartment
expendable type and can not be cleaned.
1. Fuel prefilter
2. Hose clamps (2 pcs.)
Start the engine and check that the pre-filter does not
leak.
82
Maintenance - 1000h
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.
Ensure that there is good ventilation (air
extraction) if the engine is run indoors. Risk of
carbon monoxide poisoning.
Hydraulic fluid filter - Replacement
3
Undo the cover/bleeder filter (2) on top of the reservoir
so that over-pressure inside the reservoir can be
2
eliminated.
Check that the bleeder filter (2) is not clogged, air
must flow 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
Fig. Hydraulic reservoir
the cap with a new one.
2. Filler cap
3. Sight glass
Wear protective goggles when working with
compressed air.
Carefully clean round the hydraulic filter.
1
Remove the filter (1) and hand in to an
environment-friendly waste disposal station. This
is a disposable filter and cannot be cleaned.
Make sure that the old seal is not left on the filter
head. Leakage will otherwise occur between the
new and old seal.
Fig. Engine compartment
1. Hydraulic fluid filter (x1)
Thoroughly clean the sealing surfaces on the filter
head.
83
Maintenance - 1000h
Apply a thin coat of fresh hydraulic fluid to the seal on
the new filter. Screw tight 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 seal.
Start the engine and check that there is no leakage of
hydraulic fluid from the filter. Check level of fluid in the
sight glass (3) and top up as required.
Hydraulic fluid reservoir - Draining
Condensate in the hydraulic reservoir is drained via
the plug (2).
1
Drainage must be performed when the roller has been
stationary for an extended period, e.g. after being
stationary overnight.
2
Drain as
follows:
- Remove the plug (2).
- Place a container under the tap. - Open the tap (1).
Fig. Hydraulic reservoir, bottom
Drain off any condensate.
1. Drainage tap
2. Plug
- Close the drainage tap and refit the plug.
Save the condensate and hydraulic fluid and
hand it in to an environment-friendly waste
disposal station.
84
Maintenance - 1000h
Fuel tank - Drainage
Water and sediment in the fuel tank are removed via
the drainage plug (1) 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.
Drainage must be performed when the roller has been
stationary for an extended period, e.g. after being
stationary overnight. The fuel level should be as low
as possible.
1
The roller should preferably have been standing with
Fig. Fuel tank
this side slightly lower, so that water and sediment
1. Drainage plug
have gathered near the drainage plug (1).
Save the condensate and sediment and hand it in
to an environment-friendly waste disposal station.
Drain as
follows:
- Place a container under the plug (1).
- Remove the plug (1).
- Drain out the condensate and sediment until only
pure fuel emerges at the plug.
- Screw in the plug again.
85
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.
Before draining the oil, use the breather (3) to release
possible internal pressure.
Wipe clean and remove one of the two level/filler plugs
(1) and the drain plug (2) and drain the oil into a
suitable receptacle. The volume is approximately 15
liters (16 qts).
Save the oil and hand in to an
environment-friendly waste disposal station.
Fig. Differential - Draining
1. Level/Filler plug
2. Drain plugs
Clean and refit the drainage plug (2) and tighten with
3. Breather
torque (60Nm)
Fill with fresh oil in the level/filler hole until the oil level
reaches the lower edge of the plug hole. Use
transmission oil, see lubricant specification.
Note that it takes a while for the oil to be distributed in
the axle. Do not fill the entire volume at once.
Refit the level/filler plug (1) and tighten with torque
(25Nm).
Fig. Differential - filling
1. Level/Filler plugs
86
Maintenance - 1000h
Rear axle transmission - Oil change
Before draining the oil, use the breather (7) to release
possible internal pressure.
Wipe clean and remove one of the two level/filler plugs
(5) and the drain plug (6) and drain the oil into a
suitable receptacle. The volume is approximately 1
liter (1.1 qts).
Save the oil and hand in to an
environment-friendly waste disposal station.
Clean and refit the drainage plug (6) and tighten with
torque (60Nm).
Fill with fresh oil in the level/filler hole until the oil level
reaches the lower edge of the plug hole. Use
Fig. Rear axle - draining
transmission oil, see lubricant specification.
5. Level/Filler plug
6. Drain plug
Use transmission oil, see lubricant specification.
7. Breather
Refit the level/filler plug (5) and tighten with torque
(60Nm).
Rear axle's planetary gears - Draining the oil
Before draining the oil rotate the wheel so that the plug
(4) is at the highest positions (pos.A) and partially
unscrew the plug to release possible pressure.
Then rotate the wheel so that the plug (4) is at its
lowest position (pos.B).
Wipe clean and remove the plug (4) and drain the oil
into a receptacle. The volume is approx. 2 liters (2.1
qts).
Fig. Oil drain - planet gear
4. Level/Filler plug
Save the oil and hand in to an
environment-friendly waste disposal station.
87
Maintenance - 1000h
Rear axle's planetary gears - Oil change - Oil
filling
Set the roller so that the plug (4) in the planetary gear
is at "3 o' clock".
Wipe clean and remove the plug (4).
Fill with oil to the lower edge of the level hole. Use
transmission oil. See lubrication specification.
Clean and refit the plug (4).
Fill with oil in the same way as for the rear axle's
Fig. Oil filling - planet gear
second planetary gear.
4. Level/Filler plug
Air conditioning (Optional)
Fresh air filter - Change
2
1
2
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)
88
Maintenance - 2000h
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.
Ensure that there is good ventilation (air
extraction) if the engine is run indoors. Risk of
carbon monoxide poisoning.
Hydraulic reservoir - Changing the fluid
Observe care when draining the hydraulic fluid.
1
Wear protective gloves and goggles.
2
Place a receptacle that holds at least 60 liters (15.9
gal)) beside the roller.
Unscrew the drain plug (2).
Open the stock cock and allow the oil to run through a
hose to the drainage receptacle.
Fig. Hydraulic reservoir, bottom
1. Stop cock (3/4")
Refit the plug.
2. Plug
Deliver the drained fluid to environmentally
correct handling.
Fill with fresh hydraulic fluid. Refer to the lubricants
specification for grade information.
Change the hydraulic fluid filter as described under the
heading 'Every 1000 hours of operation'.
Start the engine and operate the hydraulic functions.
Check the level in the reservoir and top off as required.
89
Maintenance - 2000h
Drum - Oil change
3
Place the roller on a level surface so that the drain
plug (1) is straight down. Position a container that
holds 15 liters under the plug.
Save the oil and dispose of it in an approved
manner.
2
1
Clean and remove the drain plug (1). Allow all of the
Fig. Roller, right-hand side
oil to drain off. Fill with oil according to "Drum -
1. Drain/Filler plug
Checking the oil level."
2. Number plate
Take great care when draining warm fluids and
3. Sight glass
oils. Wear protective gloves and goggles.
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
90
Maintenance - 2000h
Controls - Lubrication
Grease Forward/Back- throttle mechanical
mechanism. Take away the outer hatch down below
the seat by loosening the screws (2). Grease the
workings with oil.
Refit the hatch.
2
Fig. F/B control
2. Screws
Automatic Climate Control (Optional)
- Overhaul
1
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.
91
Maintenance - 2000h
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)
1
2
Fig. Automatic climate control
1. Cooling element
2. Drain valve (x2).
Drying filter - Check
1
The drying filter is located on the left side of engine
compartment´s front edge.
2
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.
Fig. Drying filter in engine
compartment
1. Sight glass
Do not disconnect or undo the hose couplings.
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.
92
Maintenance - 2000h
Compressor - Check (Optional)
Inspect the attachment of the compressor (1).
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 V-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.
2
1
Fig. Engine compartment
1. Compressor
2. Drive belt
93