DYNAPAC Vibratory rollers CC125 Engine Mahindra – MDI 1895. Operation & Maintenance (2016)

Manual Revisions

Table 1: Revision History

REV. NO.

DATE

REVISION

May 2015

New release

May 2016

Updated electrical system

information.

Customer Acknowledgment

• Atlas Copco reserves the right to make any changes or modifications without prior

notice and without incurring any liability to retrofit machines previously shipped from

the factory.

• Atlas Copco will not be held responsible for any damages caused by unauthorized

modification of the machine and its associated equipment.

• The manufacturer is not liable for damages caused by inappropriate use.

• Damage that occurs as a result of substandard repairs, as well as injury to personnel

or damage to equipment that is attributable to older un-repaired damage, is not

covered by the customer warranty policy. Always refer to your customer warranty

policy.

• Always refer to equipment documentation for correct operation and repair

procedures.

CC 125

Instruction Manual

Table of Contents

Section 1: Introduction

1.1 General Information

Instruction Manual Location

Receiving the Roller

Identification Data

Roller Identification

Engine Identification

1.2 Roller Description

Identification of Major Components

Diesel Engine

Electrical System

Main and Light Fuses

Propulsion System/Transmission

Brake system

Secondary/Parking Brake

Steering System

FOPS and ROPS

Roller Applications

Designated Applications

Non-Designated Applications

Section 2: Safety First

2.1 General Information

Warnings and Cautions

Personnel Protective Equipment

Tools and Equipment

Operating Safety

Before Starting the Engine

Starting the Equipment

Parking the Roller

Driving Near Edges

Slopes

Gas Spring

Hydraulic Maintenance Safety

Cylinder Repairs or Replacement

Handling Fluids and Oil

Transporting

2.2 Equipment Safety Decals

CC 125

Instruction Manual

Table of Contents

Section 3: Special Instructions

3.1 Operational Limitations

Standard Lubricants and Other Recommended Oils and Fluids

Higher Ambient Temperatures

Lower Ambient Temperature - Freeze Risk

Temperatures

High Pressure Cleaning

Ambient Temperature Range

Operating Conditions For Stability

Grade Limitations

Fire Fighting

Roll Over Protective Structure (ROPS)

Battery Handling

Jump Starting

Section 4: Specifications

4.1 Weight and Dimensions

Diesel Engine

Fluid Volume

Working Capacity

Hydraulic System

Section 5: Operation Controls

5.1 Instruments and Controls

Starter Switch

Throttle Lever

Vibration On/Off Switch

Emergency Stop

Forward/Neutral (FNR) Lever

Sprinkler Switch

Seat Buzzer

Horn Button

Vibration Man/Auto Switch

Vibration Selector Switch

Fuse Box

Driving Lights Switch

Working Lights Switch(Optional)

CC 125

Instruction Manual

iii

Table of Contents

Hazard Warning Lights Switch

Rotating Beacon Switch(Optional)

Direction Indicator Switch

Parking Brake On/Off Switch

Control Panel

Control Panel Warnings Symbols

Control Panel Notification Symbols

Section 6: Inspections and Operations

6.1 General Information

General Checks

Operator Areas

Check Engine Oil Level

Check Engine Coolant Level

Check the Fuel Level

Check Batteries

Verify the Controls

6.2 Before Starting the Engine

Seat(Standard) Adjustment

Check the Instruments and Lamps

Interlock

6.3 Operating the Roller

Operation

Vibration on One Drum

Braking

Normal Braking

Emergency Braking

Switching Off

6.4 Lifting and Handling

Locking the Articulation

Lifting the Roller

6.5 Towing the Roller

Towing Information

Towing

6.6 Transporting the Roller

Transportation Procedures

Safety Precautions

Operator Checklist

Start Up

CC 125

Instruction Manual

Table of Contents

Before Driving

Securing for Loading

6.7 Special Conditions

Cold Weather Conditions

Hot Weather Conditions

High Altitude Conditions

Long-term Parking

Section 7: Maintenance

7.1 General Information

7.2 Maintenance Schedule

Maintenance Schedule Information

7.3 Refill Capacities/Lubricants

General Information

Lubrication Chart

Refill Capacities

7.4 Standard Torque Values

Head Markings

Recommended Torques

7.5 Maintenance as Required

Service as Required

Clean the Roller

Loose Bolted Connections

Air Cleaners

Air Cleaner Indicators

Connections and Ducts

Air Cleaner Pre-Cleaner

Air Cleaner Main Filter

Hose and Clamps

Engine

Batteries

Check Electrolyte Level

Fuel Tank

Lowering of Engine Hood

Water Tank

Brakes

Sprinkler System

7.6 Lubrication and Filters

CC 125

Introduction

Instruction Manual

Section 1:Introduction

1.1 General Information

This manual contains basic safety information, basic operation instructions, and preventive

maintenance information of the Atlas Copco CC 125 roller.

The purpose of this manual is to provide the operator and site maintenance personnel the knowledge

of the fundamental rules and criteria to be followed for on-site use and maintenance of a CC 125 roller.

The operator and site maintenance personnel must read and fully understand this instruction manual

before operating or servicing the roller. This manual has been organized to present the safety

precautions, operation requirements, and appropriate information needed to:

•

Safely operate the CC 125 roller while achieving optimum production.

•

Understand the operating principal of each system associated with the CC 125 roller.

•

React effectively and safely to emergency and alarm conditions.

•

Perform the necessary pre-operational and post-operational checks on the roller.

If any part of this manual cannot be understood, contact the supervisor or local Atlas Copco distributor.

This is an essential condition for working safely with the CC 125 roller. The correct CC 125 operation,

use, and regular maintenance are also essential elements to provide the highest performance and

safety.

Note Always keep the Safety and Instruction manuals on the roller and available to the

operator and the helper. Always provide the model and serial number of the roller when

contacting the local Atlas Copco service or parts office.

CC 125

Introduction

Instruction Manual

Instruction Manual Location

Identification Data

The instruction manuals are located under

An exact description of the model type and the

operator seat within easy access.

serial number of the roller facilitates fast and

efficient response from our parts and service

support operations.

Figure 1-1: Instruction manual Location

Provide the model type and serial number while

contacting the local Atlas Copco service or parts

office.

Enter your roller data on the following lines to

maintain roller and engine information necessary

to facilitate fast and efficient response from our

parts and service support operations:

Model:______________________________

Roller Serial

Number:_____________________________

Chassis VIN

Number:_____________________________

A Manual location

Year of

Manufacture:_________________________

Receiving the Roller

Engine (Mfg. and Type of

Engine):_____________________________

The CC 125 roller has been tested, accurately

checked, and prepared for shipment. Every part of

Engine Serial

the roller is accurately checked before being

Number:_____________________________

shipped from the factory.

When receiving the CC 125 roller and before

unpacking the equipment, check if damage has

occurred during transport and if any parts are

missing.

Check the equipment by consulting the shipment

documents.

If the goods are damaged or if parts are missing,

inform the freight agent and raise a complaint

against it.

CC 125

Introduction

Instruction Manual

Roller Identification

The machine Product Identification Number (PIN) plate is located on left hand side of the rear frame.

The PIN number is a 17 digit number which provides information about manufacturer, family model,

check letter, no coding, production unit, and serial number.

Figure 1-2: Location PIN

A Manufacturer

B Family/Model

A Serial number

C Check lett

D No coding

E Production unit

F Serial number

Pin number is punched on top right side of front frame.

Figure 1-3: Location PIN

A Pin number

CC 125

Introduction

Instruction Manual

Engine Identification

Figure 1-4: Identification Plate

Engine identification plate

The engine identification plate located on flywheel housing near engine oil filter. The engine

identification plate provides model identification and other important data about the engine. Refer to the

engine operation and maintenance manual for further information on the identification information.

Have the following engine data available when communicating with an authorized repair location or

engine dealer. The data on the engine identification plate is mandatory when sourcing service parts:

•

Engine serial number

•

Model

CC 125

Introduction

Instruction Manual

1.2 Roller Description

CC 125 are two self-propelled vibratory tandem rollers in the three metric tonnes class featuring

1200 mm wide drums. The machines are equipped with drive, brakes, and vibration on both drums.

To permit optimum performance on a wide range of applications and site requirements, the roller is

equipped with:

Diesel engine

Electrical system

Propulsion system/transmission

Brake system

Secondary/parking brake

Steering system

FOPS and ROPS

Identification of Major Components

Figure 1-5: Major Components Right Side

A Seat

E Hood

Drum

B Forward and reverse lever

Engine

K Propulsion pump

C Mirror

G Water tank

Propulsion pump

D Steering console

H Lights

M Fuel tank

CC 125

Introduction

Instruction Manual

Figure 1-8: Fuses

Electrical System

The roller is equipped with 12-V electrical system

and 36-A AC alternator.

Figure 1-7: Electric System

100-A Power relay

30-A Mini relay for

starter

B and C

30-A Main fuses

F Timer relay

Battery disconnector

switch

Main and Light Fuses

Fuse Boxes in Switch Box

The main fuse and light fuse are placed near to

The flat pin, type C (medium) fuses and first

the battery disconnector switch.

cavity 20-A fuse are used for driving lights.

On the same bracket, timer relay and 100-A

power relay for stop solenoid are placed.

Table 1: Placement of Fuses

Main fuse

30 A

Fuse-starter relay

30 A

CC 125

Introduction

Instruction Manual

Figure 1-9: Fuses- BoX

Brake system

The brake system consists of a service brake,

secondary brake and parking brake. The service

brake is hydrostatic and is activated by moving the

control lever to neutral.

Secondary/Parking Brake

The secondary and parking brake system

consists of spring multiple disc brakes in the

motors. The brakes are released with hydraulic

pressure and are operated with a switch on the

instrument panel.

A Fuse box

C Fuse for driving lights

B Fuse

Steering System

Table 2: Fuse Function and Amperage

The steering system is a hydrostatic system.The

control valve on the steering column distributes

Sl.No

Function

Amperage

the flow to the control cylinder, which actuates the

articulation.

Main fuse

20 A

(Ignition/Emergency/

The steering angle is proportional to the deflection

ECU/Vibration)

of the steering wheel.

Horn/Sprinkler Fuse

10 A

Empty

FOPS and ROPS

Flash input fuse

10 A

FOPS is the abbreviation for Falling Object

Rotating Beacon fuse

10 A

Protective Structure (roof protection) and ROPS is

Hazard

10 A

the abbreviation for Roll Over Protective

Structure. If any part of the FOPS/ROPS

Working Light switch

10 A

structure'sprotective construction displays plastic

illumination Fuse

deformation or cracks, the FOPS/ROPS structure

Working Light Load

10 A

mustbe replaced immediately. Never perform

unauthorized modifications on the FOPS/

ROPSstructure.

Propulsion System/

Transmission

The propulsion system is a hydrostatic system

with a hydraulic pump supplying two motors

connected in parallel. The motors drive the front

and rear drums.

The speed of the machine is proportional to the

deflection/angle of the control lever from neutral.

CC 125

Introduction

Instruction Manual

Roller Applications

The CC 125 roller is built in accordance with

international standards and recognized safety

rules. Nevertheless, misuse may constitute a risk

to the life and limb of the user or third parties, and

may cause damage to the roller or other material

property.

The CC 125 roller must be used in accordance

with its designated use as described in this

manual. The roller must only be operated by

trained, safety-conscious persons who are fully

aware of risks involved in operating the roller. Any

functional disorders, especially those affecting the

safety of the roller, must be corrected

immediately.

Designated Applications

The CC 125 roller is designed primarily for

compaction of asphalt. It has excellent

compaction capacity for reinforcement layers and

bearing courses.The roller is mainly intended for

compacting asphalt on streets and minor roads in

towns. It has sufficient capacity to follow a small

asphalt paver.

Non-Designated Applications

The CC 125 roller is not designed to use as a

ladder, support, or a work surface. it is not used to

carry or transport passengers or equipment. The

manufacturer/supplier cannot be held liable for

any damage resulting from such use. The risk of

such use lies entirely with the user.

Operating the CC 125 roller within the limits of its

designated use also involves compliance with the

inspection and maintenance directives contained

in the operating manual.

CC 125

Safety First

Instruction Manual

Section 2:Safety First

2.1 General Information

This information is intended as a guide for trained and qualified personnel who are aware of the dangers

involved in handling potentially hazardous equipment. It is not intended to contain a complete list of all

safety precautions which should be observed by personnel using this equipment.

Before you operate, maintain, work around, or in any other way use this equipment:

Note Read and study the Safety Manual, and this Instruction Manual.

Note Ensure that all instructions in the maintenance section are followed. Failure to obey

instructions or warnings could result in injury or death.

•

Those who operate, maintain, and work on equipment must be competent.

•

The maintenance and service of this equipment involves risks both to personnel and equipment

and must be performed only by qualified personnel exercising caution.

•

Personnel engaged in the operation, maintenance, or servicing of this equipment are urged to

become familiar with First Aid theory and practices.

•

During operation of this equipment, local safety, and fire protection standards must be observed.

•

Do not use the roller in need of adjustment or repair. 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. Do not jump on or

off a moving machine.

•

It strictly advised to use the ROPS (Roll Over Protective Structure), when the machine is operated

on unsafe ground.

•

Drive slowly and carefully during the sharp bends or during the uneven ground.

•

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

•

The seat belt must be fastened while driving.

•

Replace all the lost and damaged safety labels.

•

Keep the roller in good working condition.

•

Safety measures during refueling:

• Make sure to stop the engine.

• Do not smoke.

• Do not use naked flames in the vicinity.

• Ground the nozzle of the filling device against the tank to prevent sparks.

This safety summary includes general safety precautions and instructions that must be understood and

applied during operation and maintenance to make sure personnel safety and protection of equipment.

Before performing any task, the WARNINGs, CAUTIONs, and NOTEs included in that task shall be

reviewed and understood.

CC 125

Safety First

Instruction Manual

Warnings and Cautions

Personnel Protective

Equipment

Throughout the manual, Warnings, Cautions, and

Notes symbols are used to designate instructions

Anyone working around the roller must wear

of particular importance. Look for these symbols

approved safety equipment (safety shoes or

which point out items of extreme importance to

protective footwear, safety glasses, hearing

you and your co-workers’ safety. Read and

protection, hard hat, gloves, respirator, and the

understand thoroughly. Heed the warning and

like) when operating or maintaining the machine.

follow the associated instructions. In this manual,

Wear close fitting clothing and confine long hair.

these terms have the following significance:

Operating requires full attention of the operator.

Do not wear radio or music headphones while

operating.

WARNING ! Marks a danger or a

hazardous procedure that can result in

life threatening or serious injury if the

Tools and Equipment

warning is ignored.

Tools, lifting gear, fastening devices,

jacks, and other working equipment must

CAUTION ! Marks a danger or hazardous

be in safe operational working

procedure that can result in damage to

conditions.

the machine or property if the warning is

ignored.

Equipment or components which are

being fitted or removed or where their

Note Note is used for supplementary

installation position is being changed,

information not directly effecting

must be secured against unintentional

safety or damage to equipment. Note

movement, slipping, or falling over. Use

can also refer to special information

suitable lifting gear or suspension/

on the efficient use of the roller.

support devices.

Systems and units (tensioning units)

Modifications

must be depressurized in an appropriate

manner before opening.

The equipment is designed for safe operation. Do

not do anything that may hamper the safety

features or structural integrity of the equipment

Damaged hydraulic or mechanical pre-

tensioned spring elements must be

Do not make any unauthorized modifications to

exchanged as a completed unit. Further

this equipment. Atlas Copco cannot be held

information can be found in the

responsible for any accidents, incidents, or

respective component descriptions and/

damage to persons or property that are related to

or fitting and removal instructions.

the use of modified equipment.

CC 125

Safety First

Instruction Manual

Operating Safety

Driving Near Edges

Know the working area. Familiarize with work site

While driving near an edge make sure to maintain

obstructions and any other potential hazards in

2/3 of the drum width on the solid ground.

the area.

Note

The machine's center of gravity moves

outwards when steering. For example,

Before Starting the Engine

the center of gravity moves to the right

•

Inspect the roller for potential hazards.

when you steer to the left.

•

Adjust the rear view mirrors for good visibility.

Note

Never operate machine on side

slopes. The machine may roll over,

•

Make sure that the controls are in the neutral

even on stable ground. Always

position and the parking brake is applied.

operate the machine parallel to the

•

Make sure that there is no one in the immedi-

slope; never perpendicular.

ate vicinity and there are no obstructions

around the machine.

Figure 2-1:Position of the Drum

Starting the Equipment

•

Do not start the engine or move any of the

controls if there is a warning tag attached to

the controls. Check with the person who

attached the tag before starting.

•

Read and follow all the instruction decals.

•

Before starting the engine, check that all the

gear controls are in neutral position.

•

Always inspect the motor before and after

starting.

•

Check all the safety devices. Report any

defects immediately.

•

Listen for unusual noises.

•

Engage hydraulic controls slowly in cold

weather to avoid shock loading.

Slopes

Parking the Roller

The slope angle is measured on a hard, flat

surface with the machine stationary. The steering

•

Select the level and hard ground. If necessary

angle was zero, the vibration was switched OFF

to park on the slope, block the front of the

and all tanks were full.

drums on the downside of the slope.

•

Apply break in an emergency conditions.

CC 125

Safety First

Instruction Manual

Always take into consideration that loose ground,

Hydraulic Maintenance

steering the machine, vibration on, machine

Safety

speed across the ground and raising the center of

gravity can cause the machine to topple at smaller

The normal operating temperature of hydraulic oil

slope angles than those specified here.

is hot enough to cause serious burns. Use

precautions when working on any hot fluid lines or

Note It is recommended that ROPS (Roll

changing filters.

Over Protective Structure) or a ROPS

approved cab, is always used when

driving on slopes or unsafe ground.

Hot oil or components can burn. Avoid

contact with hot oil or components. Do

not allow used oil to drain into the

Figure 2-2:Operating on the Slopes

ground. Dispose the used oil properly in

accordance with the local guidelines.

Cylinder Repairs or Replacement

•

When repairing cylinders, make sure to block

them up to prevent dropping or rolling off the

equipment.

Handling Fluids and Oil

•

When draining fluids, make sure that

adequate sealable containers are available

and that every care is taken to prevent

spillage.

•

Always make sure waste fluids are disposed

in an environmentally safe manner.

•

Always make sure that used filters are stored

Gas Spring

in secure containers and disposed of in an

environmentally safe manner.

•

Do not expose gas spring to excessive heat

or naked flames.

•

Under any circumstances, gas springs must

not be exposed to damaging external influen-

ces or violent handling.

•

Do not try to use a gas spring that exhibits

tiny dents or bends on its cylinder.

CC 125

Safety First

Instruction Manual

Transporting

•

Use only appropriate means of transport and lifting gear of adequate capacity.

•

Fastening of loads and instructing the crane operators should be entrusted to the

experienced persons only. The person giving the instructions must be within sight or sound of the

operator.

•

Do not attempt to load the equipment on the transport vehicle without knowledge and experience

with the operation of the

equipment.

•

Use proper chock blocks in front and rear of the wheels of the transport vehicle when

loading the equipment.

•

Position the equipment on the transport vehicle centered from side to side and use proper chock

blocks in front and rear of the tracks.

•

Secure the equipment to the deck of the transport vehicle with adequate chains or cables and

blocks to meet local regulations.

•

When moving the equipment on public access roads, obey all traffic regulations and make sure

that proper clearance flags, lights, and warning signs are properly displayed. Never turn corners at

excessive speeds. Look in all directions before reversing the travel direction.

CC 125

Safety First

Instruction Manual

2.2 Equipment Safety Decals

Before you operate, maintain, work around, or in any other way use this roller, read and understand the

safety decals and safety labels located on the roller. Follow all directions on the labels. Do not remove

or deface the labels. Replace them if they become damaged or lost

Table 1: Decal List

Decal

Message

Location

Warning - Crush zone

Quantity 2: Located on side of

the hydraulic reservoir.

Warning - Rotating engine

Quantity1: Located on rear left

components

side of the hood.

Quantity1: Located on rear right

side of the hood.

Warning: Hot surfaces

Quantity 2: Located on cooler

housing.

Warning: Instruction manual

Quantity 2: Located on top of

receiver and on receiver end

plate.

Warning - Risk of crushing

Quantity2: Located on the front

left and right side fork.

Warning: Combustible Gas

Quantity 1: Located on the

carrier battery box.

CC125

Special Instructions

Instruction Manual

Section 3:Special Instructions

3.1 Operational Limitations

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 5°C to +45°C

(41°F to 113°F).

Higher Ambient Temperatures

For operation of the machine at higher ambient temperatures, however maximum +50°C (122°F).

The diesel engine can be run at this temperature using normal oil.

Hydraulic system - mineral oil Shell Tellus S2V68 or similar.

Lower Ambient Temperature - Freeze Risk

Make sure that the watering system is empty/drained of water (sprinkler, hoses, tank/s) or that

anti-freeze has been added, to prevent the system freezing.

Temperatures

The temperature limits apply to standard versions of rollers.

CC125

Special Instructions

Instruction Manual

Note Specifications represented are

High Pressure Cleaning

calculated values at 100% efficiency.

Do not spray water directly onto electrical

components or the instrument panels.

Operator life may be endangered if the

following is not complied with. Do not add

attachments to the roller that intrude into

Place a plastic bag over the fuel filler cap and

the operator protective area, reduce

secure with a rubber band. This is to avoid high

visibility, restrict emergency exits, or add

pressure water entering the vent hole in the filler

weight exceeding certification weight.

See the operation manual or contact the

cap. This could cause malfunctions, such as the

dealer for complete inspection

blocking of filters.

requirements and maintenance

instructions.

Do not spray with high-pressure cleaner directly

onto gaskets and bearing spacings in steering

Grade Limitations

hitch.

Exceeding the slope or grade limitations of the

roller and its configuration can cause the roller to

Do not spray water directly onto electrical

tip over. Prior to moving the roller into position,

components or the instrument panels.

always determine the safe operating grade of the

Place a plastic bag over the fuel filler cap

roller.

and secure with a rubber band. This is to

avoid high pressure water entering the

vent hole in the filler cap. This could

Fire Fighting

cause malfunctions, such as the blocking

of filters.

If the machine catches fire, use an ABC-class

powder fire extinguisher.

Ambient Temperature

A BE-class carbon dioxide fire extinguisher can

Range

also be used.

The ambient temperature working range between

limits of 5°C and 45°C (41°F and 113°F).

Operating Conditions For

Stability

Stability is affected by the orientation of the roller,

surface stability (bearing strength), and wind

conditions.

Travel at a safe speed relevant to

surrounding conditions.

Contact the local Atlas Copco distributor, dealer,

or service office for further information.

CC125

Special Instructions

Instruction Manual

Roll Over Protective

Jump Starting

Structure (ROPS)

Do not connect the negative cable to the

negative terminal on the dead battery. A

Operator life may be endangered if the

spark can ignite the oxy-hydrogen gas

following is not complied with. Do not add

formed around the battery.

attachments to the roller that intrude into

the operator protective area, reduce

visibility, restrict emergency exits, or add

Check that the battery used for jump

weight exceeding certification weight.

starting has the same voltage as the

See the operation manual or contact the

dead battery.

dealer for complete inspection

requirements and maintenance

instructions.

Turn the ignition and all power consuming

equipment off. Switch off the engine on the

Never attempt to repair a damaged ROPS

machine which is providing jump start power.

structure or cab. These must be replaced

with new ROPS structure or cabs.

First connect the jump start battery's positive

terminal (1) to the flat battery's positive terminal

Battery Handling

(2).Then connect the jump start battery's negative

terminal (3) to, for example, a bolt (4) or the lifting

When removing batteries, always

eye on the machine with the flat battery.

disconnect the negative cable first.

Start the engine on the power providing machine.

Let it run for a while. Now try to start the other

When fitting batteries, always connect the

machine. Disconnect the cables in the reverse

positive cable first.

order.

Dispose of old batteries in an

Figure 3-1:sJump Starting

environmentally friendly way. Batteries

contain toxic lead.

Do not use a quick-charger for charging

the battery. This may shorten battery life.

Battery's positive terminal one

Battery's positive terminal two

C Battery's negative terminal three

D Battery's negative terminal four

CC 125

Specifications

Instruction Manual

Fluid Volume

Table 4: Fluid Volumes

Fuel tank

50 L (13.2 gal)

Water tank

160 L (42.2 gal)

Hydraulic tank

45 L (11.9 gal)

Drum oil

5 L (1.3 gal)

Coolant

12 L ( 3.17 gal) Coolant + 8 L (2.1gal) Water

Working Capacity

Table 5: Working Capacity

Static linear load front

12.5 kg/cm

Static linear load rear

13.3 kg/cm

Amplitude

0.5 mm (0.01 in)

Vibration frequency

58 Hz

Centrifugal force

27 kN

Hydraulic System

Table 6: Hydraulic System

Opening pressure (Absolute pressure)

MPa

Drive system

35.0

Vibration system

21.0

Steering system

17.5

Charge pressure

2.0

Brake release

2.0

CC 125

Operation Controls

Instruction Manual

Section 5: Operation Controls

5.1 Instruments and Controls

The instruments and controls section of this manual provides basic information about the operating

controls, instruments, and indicators located on the consoles and around the roller.

All the operation control from the operator console located in front of operator seat under steering

wheel. The slim profile and quick opening side panels provide easy access for maintenance and

service.

Figure 5-1: CC 125 Console

Working light

H Rotating beacon

Direction indicators

Horn

C High beam

K Manual/automatic sprinkler

D Driving lights

Vibration selector front/rear drum

Hazard warning lights

M Vibration manual/automatic

Control panel

N Parking brake On/Off

G Sprinkler timer

CC 125

Operation Controls

Instruction Manual

Starter Switch

Throttle Lever

The starter switch starts and stops the engine.

The throttle control regulates the speed of the

There are three positions in the starter switch,

engine. In forward position, the engine idles and in

they are:

the backward position, the engine runs with a full

speed.

•

OFF position: In this position all the electric

systems and the engine are switched off, and

the key can be removed.

Figure 5-3:Throttle Control

•

ON position: In this position, Engine is on run

mode. Charging circuit and lamp circuit are

energized.

•

Start position: In this position, the engine

cranks. Make sure to allow the switch to on

position until the engine is started.

A Throttle lever

Figure 5-2:Starter Switch

Vibration On/Off Switch

Vibration On/Off switch is a push button used for

vibration. Press and release to switch on the

vibration and press again to switch it off.

Figure 5-4: Vibration On/Off Switch

Off position

Start position to supply power

to the instruments and controls

On position

Hold position

50 a Starter motor activation.

A Vibration On/Off switch

CC 125

Operation Controls

Instruction Manual

Emergency Stop

Sprinkler Switch

The emergency button is used to stop the engine

Sprinkler switch controls the flow of water to the

in an emergency situation which it cannot be shut

drum. Push up to flow the water and down to stop

off in an usual manner. It switches off the engine

the flow of water.

and activates the brakes. The emergency stop

aborts the entire control operation in a quicker

Figure 5-7: Sprinkler Switch

way for the safety of the personnel.

Figure 5-5: Emergency Stop

Seat Buzzer

A Emergency stop button

Seat buzzer beeps if the operator is not seated

during the operation of the roller and it continues

Forward/Neutral (FNR)

to beep until the operator is seated. If the buzzer

Lever

beeps for long the brakes are activated and

engine is forced to stop.

Direction of travel and speed of the roller is

regulated with the forward/reverse lever. The

machine speed increases or decreases in

Horn Button

proportion to the position of the lever.

The horn button is located on the switch

assembly.

Figure 5-6: FNR Lever

Press the button to activate the horn.

Figure 5-8: Horn Switch

A FNR lever

CC 125

Operation Controls

Instruction Manual

Vibration Man/Auto Switch

Driving Lights Switch

In the upper position, the vibration is switched on/

Push up, to switch on the driving lights and

off with the switch on the forward/reverse lever.

depress to switch on the parking lights. In

The function is activated with the switch. In the

Intermediate position the lights are switched off.

intermediate position the vibration system is

completely switched off. In the lower position the

Figure 5-11: Driving Lights

vibration is switched on or off automatically

through the forward/reverse lever.

A Push up position

B Intermediate position

Figure 5-9: Vibration MAN/AUTO Switch

C Depressed position

Working Lights

Switch(Optional)

Depress the switch to switch on the working lights.

Vibration Selector Switch

In the upper position the vibration is switched off

Figure 5-12: Working Lights

on the front drum and in the lower position the

vibration is switched on in both the drums.

Figure 5-10:Vibration Selector Switch

Fuse Box

The fuse box is located on the control column

which contains the fuses for the electrical system.

Fuses protect the electrical components from

damage because of a short circuit. Refer to

electrical system for the description and functions

of the fuses.

CC 125

Operation Controls

Instruction Manual

Hazard Warning Lights

Direction Indicator Switch

Switch

The direction indicators are blinking lamps

Hazard warning lights are primarily used to warn

mounted near the left and right, front and rear

other vehicles that there is a problem either with

corners of the roller. Depress the switch either left

the roller, or there is a hazard in front of roller

or right, to on the left or right indicators. In the

causing the operator to reduce speed quickly.

middle position the function is shut off.

Depress the switch to switch on the hazard

Figure 5-15: Directional Indicator Lights

warning lights.

Figure 5-13: Hazard Warning Lights

Parking Brake On/Off

Switch

The parking brake On/Off switch is used to

activate the parking brake.

Note Parking brake must be activated while

Rotating Beacon

starting the engine. Always activate

Switch(Optional)

the parking brake when the machine is

stationary on a sloping surface.

Rotating beacon lighting is generally used to warn

the approaching machine of potential hazards,

such as machine that is stopped or moving slower

Figure 5-16: Parking brake On/Off Switch

than the rate of the traffic.

Depress the switch to switch on the rotating

beacon.

Figure 5-14: Rotating Beacon Switch

CC 125

Operation Controls

Instruction Manual

Control Panel

Figure 5-17: Control Panel

Battery/charging

Fuel level

Low fuel level

Parking brake lamp

Engine water temperature

G Glow plug

Oil pressure, engine

H Hourmeter

Control Panel Warnings Symbols

Warning lights comes on when the starter switch is turned to the on position and should goes off once

the engine has started. If the lights comes on when the engine is running indicates a faulty condition.

Table 1: Warning Lights

Designation

Function

Description

Battery charging

If light does not illuminate when ignition is

indicator lamp.

switched on, illuminates after engine is

started, the battery is not charging. Contact

maintenance personnel if the lamp comes

on during tramming.

Diesel engine lubricating

If the pressure is too low, the lamp comes

oil pressure indicator

on and the parking brake is applied. In this

lamp.

event, switch the engine off immediately

and rectify the cause. Contact maintenance

personnel.

Engine temperature

The lamp comes on when the temperature

signal lamp.

is too high. The engine must be switched

off immediately and contact the

maintenance personnel if the lamp comes

on during tramming.

Low fuel level indicator.

This lamp comes on if the oil level is low in

the fuel tank.

CC 125

Operation Controls

Instruction Manual

Control Panel Notification Symbols

Notifications are displayed when the starter switch is turned to the on position and notifies that

corresponding systems are operating.

Table 2: Notification Lights

Designation

Function

Description

Parking brake indicator lamp

The light illuminates when the parking brake is

activated.

The fuel level gauge

The fuel level gauge monitors the level of fuel in

the fuel tanks of the roller. The fuel gauge is

shown in increments of zero, 1/4, 1/2, 3/4, and

one. When the indicator needle shows 1/4, the

fuel tank should be filled.

Hour meter

It displays the number of hours the engine has

run.

CC 125

Inspections and Operations

Instruction Manual

Section 6:Inspections and Operations

6.1 General Information

Note If you are not experienced with the roller controls read and understand

section 5 - Operation Controls.

The following operational hints should be observed:

•

Do not speed the engine when it is cold.

•

Do not lubricate the roller while the engine is running.

•

Always perform safety checks prior to starting the roller.

•

Never stop the roller on a slope or surface that is liable to collapse.

•

Never stop the roller against a high wall that is liable to collapse or cause a crushing risk.

•

Before starting the engine, make sure all operator controls are either in off or neutral positions and

that the parking brake is applied.

•

Always sound the horn before moving the roller in either direction to alert personnel and to allow

sufficient time before putting the roller in motion.

•

Always judge when driving on unstable surfaces where there may be a risk of overturning or when

loading onto a transporter where there is a risk of overturning. Always use a spotter.

General Checks

General checks should be made for any wear and tear on the roller. Check for broken or cracked welds,

loose or missing bolts, broken or inoperative gauges, or any other irregularities which could lead to

more costly breakdowns.

Check all bolted assemblies for tightness. Inspect the entire roller for any loose, worn, or missing parts

and replace them as needed. Inspect fluid lines, hoses, filler openings, drain plugs, pressure caps, tires,

tower cables, hoist wire cables, muffler, engine, safety shrouds, and the area under the roller for signs

of leakage.

Note Frequently walk around the roller and inspect for leaks, loose or missing parts,

damaged parts or parts out of adjustment. Perform all recommended daily

maintenance.

Operator Areas

• Keep operator areas, mirrors, and all lights clean . Check for all lights function.

• Make sure the operator areas, steps, and grab rails are clean. Oil, grease, snow, ice, or mud in

these areas can be slippery. Clean the boots of excess mud before getting on the roller.

CC 125

Inspections and Operations

Instruction Manual

Check Engine Oil Level

Check Engine Coolant Level

•

Hot oil and hot components can cause

Check the coolant level through transparent

personal injury. Do not allow hot oil or

plastic of expansion tank. Fill the cooling system

hot components to contact the skin.

when coolant is empty. With the engine cold, top

•

Never operate the engine with the oil

off with premixed coolant of the desired freeze

level below the low (L) mark or above the

high (H) mark.

protection concentration. Add coolant through the

pressure cap neck of the surge tank.

Note Wait at least five minutes after

shutting off the engine to check the oil

Always shut off the engine and allow to

level. This allows time for the oil to

cool before removing the radiator cap.

drain into the oil pan.

Remove cap slowly to relieve pressure.

Avoid contact with steam or escaping

Level the roller. The roller must be level when

fluid.

checking the oil level to make sure the

measurement is correct.

Shut off the engine.

Removing the radiator cap on a hot

radiator can cause scalding coolant to

spray out and burn the body badly. If the

Check the engine oil level by viewing the

engine has been in operation within the

engine dipstick.

previous 30 minutes, be very careful in

removing the radiator cap. Protect face,

If the oil level is low, add oil through the fill cap

hands, and arms against escaping fluid

and steam by covering the cap with a

large, thick rag. If you see any steam or

Figure 6-1: Engine Oil Dipstick

coolant escaping, do not try to remove it

until the radiator cools down. If nothing is

escaping, remove the cap very slowly

and be careful. Be ready to step away if

any steam or coolant begins to escape.

Inhibitor contains alkali. Avoid contact

with skin and eyes.

Engine coolant must be properly

maintained to protect against engine

damage. Coolant must be tested at

regular intervals to make sure it can

provide adequate protection against

freezing, boiling, and corrosion. It is the

A Engine oil dipstick

owner’s responsibility to know the type of

coolant used and to maintain it properly.

If coolant must be added, use a reliable brand of

permanent antifreeze in a 60-40 mixture. It must

be used year round in all climates. Refer to

instructions in 7.5 Maintenance as Required for

the correct procedures.

CC 125

Inspections and Operations

Instruction Manual

Check the Fuel Level

Check Batteries

Fuel is flammable and may cause serious

Batteries contain an acid and can cause

injury or death. Shut off the engine,

injury. Battery fumes can ignite and

extinguish all open flames, and do not

explode. Do not smoke when observing

smoke while filling the tank. Always wipe

battery fluid level. Skin and eye contact

up any spilled fuel immediately

with battery fluid can cause injury. Avoid

skin and eye contact with battery fluid. If

contact occurs, flush area immediately

Check fuel level on the fuel level gauge on the

with water.

machine dashboard. Refill the tank when the

indicator needle moves to below 1/4 tank. Refer to

Check the battery posts and cables for corrosion.

the maintenance procedures in

Check and keep the electrolyte levels above the

section 7 - Maintenance. Select the proper

battery plates or to the bottom of the fill holes.

grade of fuel oil in accordance with the

Refer to section 7 - Maintenance for the correct

instructions given in the Lubrication Table in

procedures.

section 7 - Maintenance.

Verify the Controls

Maintain fuel tank(s) at a high level to minimize

water condensation inside the tank(s). This is best

Before starting the roller, check that the warning

accomplished by filling the fuel tanks at the end of

lights, backup alarm, horn and emergency stop

each shift or day. Check the fuel tank for possible

controls are functioning properly. This inspection

leaks. Because of the potential fire hazard, leaks

should be performed before each shift and at

must be corrected as soon as they are spotted.

every startup.

1. Check the fuel level by reading the fuel level

gauge.

If any controls, instruments or devices do

not function correctly, report the defects

2. Do not allow the fuel tank to completely empty,

to the proper personnel. Defects must be

otherwise the entire fuel system will require

corrected before starting and operating

bleeding.

the roller.

3. If the fuel level is low, add clean, filtered fuel.

4. Fill tank with the correct grade of fuel. Refer to

Lubrication Table for more fuel details.

CC 125

Inspections and Operations

Instruction Manual

6.2 Before Starting the

If any controls, instruments, or devices do

Engine

not function correctly report the defects

to the proper personnel. Defects must be

corrected before starting and operating

Remember to carry out daily maintenance before

the roller.

starting the engine.

Refer to section 7 - Maintenance.

Seat(Standard) Adjustment

Consider the following points before starting the

Adjust the operator’s seat to the comfortable

engine:

position so that the controls are within easy reach.

1. Before starting the engine, check inside,

The seat is adjusted in the following way:

outside, and underneath the roller for people

or obstructions.

• Length adjustment: Pull the lever and move

the seat forward or back.

2. Turn the battery disconnecter key to switched

on position which is located on the right side of

the operator compartment. This supplies the

Figure 6-3:Seat Adjustments

roller with the power.

Figure 6-2:Battery Disconnecter

A Battery disconnecter

3. Check for warnings on the controls.

4. Start the engine from the operator position

only.

A Length adjustment

5. Avoid leaving the controls with the engine

running. Never leave the operator platform

while the roller is running.

CC 125

Inspections and Operations

Instruction Manual

Check the Instruments and Lamps

Note Make sure that the emergency stop is pulled out and the parking brake is activated. If

the forward/reverse lever is in neutral, the automatic brake function is engaged.

1. Turn the switch to on position.

2. Check that the warning lamps in the warning panel come on.

3. Set the sprinkler switch to the operating position and check that the system is functioning.

Interlock

The roller is equipped with interlock. The diesel engine switches off after 10 seconds, if the operator

gets off the seat during tramming. If the operator is not seated during tramming a buzzer goes on

unless the parking brake is activated.

N o t e If the diesel engine is switched off, then wait for 15 seconds to restart it. Turning the

ignition key to on position will not restart the engine during this period.

CC 125

Inspections and Operations

Instruction Manual

6. Make sure the throttle control is turned to low

6.3 Operating the Roller

position.

Operation

Figure 6-5:Throttle control

1. Before the roller startup, a pre-operational

general inspection of the roller must be

performed in accordance with those

instructions previously mentioned and in the

instructions found in

section 7 - Maintenance.

2. Make sure all operator console controls are

either off or in the neutral position and all

control console gauges read zero.

Figure 6-4:Operator Consoles

7. Set the vibration switch for manual/automatic

vibration position. In the manual position, the

operator must activate the vibration using the

switch on the forward/reverse lever grip. In the

A Emergency stop

C Ignition switch

automatic position, vibration is activated when

B FNR lever

D Throtlle lever

the pre-set speed is reached. Vibration is

automatically deactivated when the FNR lever

is moved from neutral condition.

3. Make sure the emergency stop button is not

activated.

4. The FNR must be in neutral position.

Figure 6-6:Vibration Man/Auto Switches

5. Parking brake switch must be in engaged

condition.

A Vibration man/

B Vibration selector

auto switch

switch

CC 125

Inspections and Operations

Instruction Manual

Note As a general rule, do not operate the

Vibration on One Drum

starter motor more than 30 seconds at

a time without pausing to allow the

1. Activate the vibration selector switch to select

starter motor to cool for at least 2

vibration with the rear drum only, or with two

minutes. Overheating caused by

drums.

excessive cranking will seriously

damage the starter motor.

2. Vibration selector is activated through the

switch in the FNR Lever.

8. Turn the ignition switch on, check all the

warning lamps and then crank the engine.

3. In the lower position the vibration is activated

on both drums.

9. Allow the engine to warm up at idle speed for

few minutes. Warm up time should be

4. In the upper position the vibration on the front

extended when extremely low ambient

drum is switched off.

conditions (cold weather) occur or when

battery power is depleted during initial start up.

Braking

10.Check the engine air cleaner indicator gauge

Normal Braking

to determine if the elements require servicing.

1. Turn the vibration off by pressing the vibration

11.Make sure the parking brake is released and

control button on the forward/reverse lever.

the parking lights goes off.

2. Set the forward/reverse control to the neutral

position and apply brake to stop the roller.

Figure 6-7:Parking Brake

Note In cold climatic condition braking

distances can be longer than the

1/2

normal distance.

Note Never leave the operator platform

without activating the parking brake.

Emergency Braking

To hold the machine in a stopped position

(parked), there is a mechanical parking brake on

each drum drive motor. The mechanical parking

brakes are spring-activated and hydraulically

released type brakes.

Parking brake button

Parking brake indicator

1. In case of emergency, push in the emergency

stop knob, hold the steering wheel firmly and

be prepared for a sudden stop. The diesel

engine stops.

2. After emergency braking, reset the forward/

reverse lever to neutral position, pull out the

emergency stop and activate the parking

brake. Restart the engine.

CC 125

Inspections and Operations

Instruction Manual

Switching Off

1. Press the vibration control button to off

position.

2. Set the forward/reverse control to the neutral

position.

3. Turn the throttle control to forward position and

allow the engine to idle for a few minutes to

cool.

4. Press the parking brake button to activate the

parking brake. Always activate the parking

brake before leaving the machine.

Note If the machine must be parked on a

sloping surface, chock the drums with

wedges to prevent any movement.

5. Check instruments and warning lamps to see

if any faults are indicated. Switch off all lights

and other electrical functions.

6. Turn the starter switch to the off position to

stop the engine.

7. Switch off the battery disconnecter and

remove the key.

CC 125

Inspections and Operations

Instruction Manual

Lifting the Roller

6.4 Lifting and Handling

• Use a crane/forklift to lift the equipment.

Locking the Articulation

• Pay attention when lifting and balancing the

Note Lock the steering joint, before lifting

equipment.

the roller.

• Seek a person to guide the way when lifting

1. Turn the steering wheel to the straight ahead

and moving the equipment.

position.

• An experienced crane/forklift driver should

2. Switch off the machine and activate the

drive the crane/forklift.

parking brake.

• When lifting, add a pad at the joint of steel

3. Pull down the galvanized lock bar from its

cable of the crane and the hook hole and

holder, and place it from underneath in the

secure the hole.

hole on the lower steering joint bracket.

Note The weight of the machine is shown

4. Press the bar until the upper end is visible in

on the lifting plate.

the hole on the upper steering joint bracket.

Refer to section 4 - Specifications.

5. Secure the bar with the lock pin.

Figure 6-9:Lifting the roller

Note Remember to refit the lock bar in its

holder after operation.

Figure 6-8:Locking the articulation

A Lifting plate

A Lock bar

CC 125

Inspections and Operations

Instruction Manual

Towing

6.5 Towing the Roller

The roller can be moved up to 300 meters

Towing Information

(1,000 ft) using the instructions below.

Proper equipment must be used to prevent

Note Chock the drum to prevent the roller

damage to the vehicle and the roller during any

from moving when the brakes are

tow. Follow the state and local laws applying to

hydraulically disengaged.

vehicles.

Release the Brakes

If the vehicle is to be towed by a wrecker, use only

equipment designed for this purpose following the

The disc brake in each drive motor must be

instructions of the wrecker manufacturer. A safety

disengaged mechanically, according to the

chain system must be used.

following instructions, before the roller can be

towed.

Personal injury or death could result

1. Remove the center plug using a screwdriver.

when towing a disabled roller incorrectly.

2. Screw off the brake tool from its threaded

fixing hole. Then fix the brake tool in the center

Block the drums of the roller to prevent

hole by tightening the screw until it bottoms in

movement before releasing the

the hole.

emergency brake system or the disc brake

in each drive motor must be disengaged

3. Tighten the nut against the brake tool until it

mechanically, before the roller can be

stops, indicating that the brakes is now

towed. The roller can roll free if drum is

disengaged.

not blocked.

Follow the recommendations below to

Figure 6-10: Left Side of Drum

properly perform the towing procedure.

Make sure to block the drums of the roller

and reapply the emergency brake system

before disconnecting from the towing

vehicle.

Note Maximum towing speed is 2 mph

(3 Kmph).

A Brake tool

C Disengagement nut

B Fastening screw

Note Make sure to secure the steering

wheel to maintain a straight-ahead

position.

CC 125

Inspections and Operations

Instruction Manual

4. Slightly tap the plunger inside using a mallet.

Engaging the Brakes

1. Screw out the nut again after towing.

Figure 6-11: Plunger

2. Screw off the brake tool and fit it back into its

fixing holes

3. When machine is started, propulsion pump

plunger will automatically come out.

4. Refit the center plug to counteract the

information of rust inside the threaded hole.

5. When towing/retrieving a machine, the towing

device must be connected to both lifting holes.

The pulling force shall act longitudinally on the

machine. Maximum total pulling force 130 kN

(29225 lbf).

Figure 6-12:Towing

A Pluger

CC 125

Inspections and Operations

Instruction Manual

Start Up

6.6 Transporting the

Roller

1. Before starting the engine, check inside,

outside, and underneath the roller for people

or obstructions.

Transportation Procedures

2. Always horn before starting the roller to alert

Safety Precautions

everyone in the area.

Before moving the roller on public roads, check for

3. Check all the gauges (including fuel).

instructions and information with respect to traffic

regulations regarding construction machinery.

4. Check for excessive noise or vibration.

Before Driving

The roller must be driven and transported only in

accordance with the operating instructions.

Fasten the seat belts.

1. When driving the roller, observe the prescribed

Adjust each mirror so that the side of the

transport position, admissible speed, and

vehicle is visible in the side of the mirror

itinerary.

closest to the vehicle. This helps you

determine the relation to objects seen in the

2. Do not attempt to drive unless knowledgeable

mirror.

and experienced.

Release the parking brake.

3. Always know the overall height, weight, width,

and length of the roller. Make sure there is

sufficient clearance when crossing

underpasses, bridges, and tunnels or when

passing under overhead lines.

4. When moving the roller on public access

roads, obey all traffic regulations and make

sure that proper clearance flags, lights, and

warning signs, including the slow moving

vehicle emblem, are properly displayed. Know

your approximate stopping distance at any

given speed. Never turn corners at excessive

speeds. Look in all directions before reversing

the direction of travel.

Operator Checklist

•

Make sure to know the vehicle and its equip-

ment and how to use it safely.

•

See that mirrors, and lights are clean and

unobstructed.

•

Check for fluid leaks.

•

Check lights and reflectors.

•

Check oil and coolant levels.

CC 125

Inspections and Operations

Instruction Manual

Securing for Loading

Figure 6-13:Securing for Loading

1,2

Double lashings, i.e. one lashing with two parts secured to two different lashing mounts.

3,4

symmetrically located on the right and left sides.

rubber

Table 1: Lashings' Permitted Distance

The lashings' permitted distance interval in meters

(1 - 4: Double lashings, LC at least 1.7 tonnes (1700 daN), STF 300 kg (300daN))

Double L₁ - L₂

Double L₃ - L₄

0,6 - 3,0

0,1 - 3,0

The distance L₁ above is between points D and E. D is the projected point directly at right angles

laterally in relation to the edge of the platform from the lashing mount C on the roller. E is the lashing

mount at the edge of the platform. L₂ - L₃have a corresponding relationship.

CC 125

Inspections and Operations

Instruction Manual

•

Lubricate the steering joint bearings and both

6.7 Special Conditions

bearings on the steering cylinder with

grease. Grease the steering cylinder piston

Cold Weather Conditions

with conservation grease. Grease the hinges

•

Refer to section 7 - 7.3 Refill Capacities/

on the doors to the engine compartment and

Lubricants in the maintenance section for

the cab. Grease both ends of the forward/

information regarding cold weather lubricants,

reverse control (bright parts).

hydraulic fluids, coolants, fuel, and the like.

•

Change all lubricants and fluids that may

•

Use winter grade diesel fuel for operation at

have deteriorated with use.

subzero temperatures.

•

Replace and secure all weatherproof covers.

•

Be extremely careful when using cold

weather starting aids. Starting aids are very

flammable and should only be used if

Figure 6-14:Long Term Parking

needed.

•

Remove batteries and store in a warm area to

about 68 °F (20 °C).

Hot Weather Conditions

•

Monitor temperature gauges.

•

Keep cooling fins on radiator and oil cooler

clean and free of accumulated dirt.

High Altitude Conditions

•

Be aware that engine power will be reduced.

•

Keep cooling fins on radiator and oil cooler

clean and free of accumulated dirt.

Long-term Parking

•

Observe the following when storing the roller

for short periods of time.

•

Remove the battery/batteries from the

machine, clean and charge once a month.

• Cover the air cleaner (Refer section 7 -

Maintenance) or its opening with plastic or

tape.

• Also cover the exhaust pipe opening. This is

to avoid moisture entering the engine.

• Fill the fuel tank completely full to prevent

condensation.

• Fill the hydraulic reservoir to the uppermost

level mark.

• Empty the water tank completely to avoid

fouling.

CC 125

Maintenance

Instruction Manual

Section 7:Maintenance

7.1 General Information

Safety should be the main concern for anyone working on or around the roller. Do not perform any

function that could put someone in danger.

Always wear proper safety gear while working on or around the roller. This includes an approved hard

hat, safety glasses, steel toe shoes, gloves, respirator, and ear protection. Do not wear loose fitting

clothing that can get caught in rotating components.

Note If not experienced with the roller controls and instruments, read and understand

Operation Controls.

The following operational hints are observed:

•

Do not speed the engine when it is cold.

•

Always chock the drum if there is a possibility of uncontrolled movement.

•

Do not lubricate the roller while the engine is running.

•

Always perform safety checks prior to starting and using the roller.

•

Always operate the roller at the full engine power.

•

Never propel or stop the roller on a slope or surface that could possibly collapse.

•

Never stop the roller against a high wall that could possibly collapse or cause a crushing risk.

•

Before starting the engine all the controls are in the off or neutral position on the operator control

panel.

•

Always sound the attention horn before moving the roller in either direction to alert personnel and

allow sufficient time before putting the roller in motion.

CC 125

Maintenance

Instruction Manual

7.2 Maintenance Schedule

Maintenance Schedule Information

The maintenance schedule shows those items requiring regular service and the interval at which they

are performed. A regular service program is geared to the items listed under each interval. These

intervals are based on average operating conditions. Before each consecutive interval is performed, all

of the maintenance requirements from the previous interval must also be performed.

N o t e In the event of extremely severe, dusty, or wet operating conditions, more frequent

maintenance than specified is necessary.

Table 7-1: Maintenance Daily/Every 8 Hours

Description

Action

Lubrication

Engine oil

Check

Outer air cleaner element

Check

Radiator coolant

Check

Hydraulic Oil

Check

Greasing

Grease

See lubrication chart

Table 7-2: Maintenance at First 50 Hours

Description

Action

Lubrication

Engine oil filter element

Change

See engine manual

Engine oil

Change

See engine manual

Fuel filter element

Change

See engine manual

Mud filter

Change

See engine manual

Hydraulic oil filter

Change

Table 7-3: Maintenance at 50 Hours or Weekly

Description

Action

Lubrication

Alternator belt

Check

Water separator

Drain

AVM Bolts

Check

CC 125

Maintenance

Instruction Manual

Table 7-4: Maintenance at 250 Hours/750 Hours/Three Months

Description

Action

Lubrication

Engine Oil filter element

Change

See engine manual

Engine oil

Change

See engine manual

Fuel filter element

Change

See engine manual

Mud filter

Change

See engine manual

ROC cleaning

Clean

Fuel pipe and clamps

Check

Intake air line

Check

Drum oil

Check

Battery

Check

Table 7-5: Maintenance at 500 Hours/Six Months

Description

Action

Lubrication

Engine oil filter element

Change

See engine manual

Engine Oil

Change

See engine manual

Fuel filter element

Change

See engine manual

Mud filter

Change

See engine manual

Outer air cleaner element

Change

Inner air cleaner element

Change

Alternator belt

Check

See engine manual

Fan belt

Check

See engine manual

ROC Cleaning

Clean

Fuel pipe and clamps

Check

Intake air line

Check

CC 125

Maintenance

Instruction Manual

Table 7-6: Maintenance at 1,000 Hours/One Year

Description

Action

Lubrication

Engine oil filter element

Change

See engine manual

Engine oil

Change

See engine manual

Fuel filter element

Change

See engine manual

Mud filter

Change

See engine manual

Alternator belt

Check

See engine manual

Fan belt

Check

See engine manual

Valve cover gasket

Change

See engine manual

Radiator coolant

Change

ROC cleaning

Clean

Fuel pipe and clamps

Check

See engine manual

Intake air line

Check

Valve clearance

Check

See engine manual

Hydraulic oil filter

Change

Drum oil

Change

Table 7-7: Maintenance at 2,000 Hours/Two Years

Description

Action

Lubrication

Engine oil filter element

Change

See engine manual

Engine oil

Change

See engine manual

Fuel filter element

Change

See engine manual

Mud filter

Change

Outer air cleaner element

Change

Inner Air cleaner element

Change

Alternator belt

Check

See engine manual

Fan belt

Check

See engine manual

Valve cover gasket

Change

See engine manual

Radiator coolant

Change

ROC cleaning

Clean

Fuel pipe and clamps

Check

See engine manual

Intake air line

Check

Valve clearance

Check

See engine manual

CC 125

Maintenance

Instruction Manual

7.3 Refill Capacities/Lubricants

General Information

Lubrication is an essential part of preventive maintenance, affecting to a great extent the useful life of

the unit. Periodic lubrication of the moving parts reduces to a minimum the possibility of the mechanical

failures.

The lubrication chart that follows in this section shows those items requiring regular service and the

interval at which they should be performed. Details concerning the oil and other lubricants follow the

lubrication chart. A regular service program should be geared to the items listed under each interval.

These intervals are based on the average operating conditions. In the event of extremely severe, dusty,

or wet operating conditions, more frequent lubrication than specified may be necessary.

•

Specific recommendations of the brand and grade of lubricants are not made here due to regional

availability, operating conditions, and also the continual development of the improved products.

For more information, refer to component manufacturer’s manual.

•

All the oil levels are to be checked with the roller parked on a level surface and while the oil is cold,

unless otherwise specified.

•

On plug type check points, the oil levels are to be at the bottom edge of the check port.

•

All the grease fittings are SAE standard unless otherwise indicated. Grease the non-sealed fittings

until the grease is seen extruding from the fitting. One ounce (28 grams) of EP-MPG equals one

pump on a standard one pound (0.45 kg) grease gun.

•

Over lubrication on the non-sealed fittings will not harm the fittings or components, but under-lubri-

cation will definitely lead to a shorter lifetime.

•

Grease fittings that are worn and do not hold the grease gun or those that have a stuck check ball

must be replaced.

To prevent the minor irregularities from developing into serious conditions, several other services or

checks are recommended for the same intervals as the periodic lubrication:

•

Thoroughly wash all the fittings, caps, plugs, and the like with a non-flammable and non-toxic clea-

ning solution before servicing to prevent dirt from entering while performing the service. During the

regular lubrication service, visually check the entire unit with regard to capscrews, nuts, and bolts

being properly secured.

•

Spot check the several capscrews and the nuts for proper torque. If any are found loose, a more

thorough investigation must be made.

•

If a defect is detected, that requires special service, stop the roller operation until the defect has

been corrected. If necessary, contact the Atlas Copco representative for assistance.

CC 125

Maintenance

Instruction Manual

Lubrication Chart

Periodic lubrication requirements are listed in the following Lubrication Chart. These requirements

include lubricant checks and greasing designated areas of the roller.

Description

Part Number

Remarks

Quantity

Engine oil

5580020624

Atlas Copco engine 100

5 L (1.3 gallons)

Hydraulic oil

9106230330

Atlas Copco hydraulic 300

20 L (5.3 gallons)

Drum oil

4812030756

Dynapac Gear oil 300

5 L (1.3 gallons)

Coolant

2658326217

Coolant

20 L (5.2 gallons)

Refill Capacities

The following fluid capacities are provided for the servicing personnel who must perform roller

maintenance in the remote locations where complete shop facilities and resources are not available.

These capacities will give the servicing personnel an approximation of the fluid capacities of the

components to be serviced. Always use the specified method to check for accurate fluid levels.

Component

Approx. Quantity

Systems

Hydraulic Tank

45 L (11.9 gallons)

Engine

Engine Coolant

12L (13.17 gal) Coolant + 8L (2.1 gal) Water

Engine Oil Capacity

10 L (2.6 gallons)

Fuel Tank

50 L (13.2 gallons)

Drum

5 L (1.3 gallons)

CC 125

Maintenance

Instruction Manual

7.4 Standard Torque Values

Use only the proper tools (inches) on hardware. Other tools may not fit properly and may slip

and cause injury.

Head Markings

Fasteners should be replaced with the same grade or a higher grade. If higher grade fasteners are

used, these should only be tightened to the strength of the original grade fastener.

Do not use these values if a different torque value or the tightening procedure is listed for a specific

application. Torque values listed are for general use only. All values are suggested maximum with dry

plated hardware.

Make sure fastener threads are clean and you properly start thread engagement. This will prevent them

from falling when tightening.

The following pages list the recommended tightening torques for the various size bolts used for the

machine. Proper torque specifications should be used at all times.

Recommended Torques

This page lists the recommended tightening torques, in foot/pounds (ft·lb), for the various size bolts and

nuts that are used. Proper torque specifications should be used at all times. Dry means clean dry

threads and lube means a light film of oil. Excess oil in a threaded dead end hole can create a hydraulic

lock giving false torque readings. Suggested assembly torque values are per engineering

specifications.

Metric coarse screw thread, bright galvanized (fzb):

M-thread

Size

12.9,

8.8 Oiled

8.8 Dry

10.9 Oiled

10.9, Dry

12.9, Dry

Oiled

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

CC 125

Maintenance

Instruction Manual

Metric coarse screw thread, bright galvanized (fzb):

M-thread

Size

12.9,

8.8 Oiled

8.8 Dry

10.9 Oiled

10.9, Dry

12.9, Dry

Oiled

M24

570

640

800

900

960

1080

M30

1130

1260

1580

1770

1900

2100

Metric coarse thread, zinc-treated

(Dacromet/GEOMET)

M-thread Size

10.9 Oiled

10.9 Dry

12.9 Oiled

12.9 Dry

120

150

146

183

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

Bolt dimensions

M16 (PN 902889)

Strength class

10.9

Tightening torque

192 Nm, torque class 2

(Dacromet treated)

CC 125

Maintenance

Instruction Manual

Loose Bolted Connections

7.5 Maintenance as

Required

If any loose nuts or bolts are found during the

frequent walk-around and the daily inspections,

make sure they are properly torqued. Refer to 7.4

Service as Required

Standard Torque Values for the required torque

The preventive maintenance and service in this

for all bolt sizes and grades. Always replace self-

section requires attention on the need basis,

locking nuts if they have been loosened.

before, during, and after the operation shift. This

is in addition to the 8 to 10 hour daily routine

Air Cleaners

maintenance procedures. Performance of this

inspection can result in longer life and maximum

The following are detailed instructions for

productivity from the roller. Refer to the

performing routine maintenance procedures on

manufacturer’s service manuals for maintenance

the air cleaner.

and service on the carrier.

Raw, unfiltered air can damage the

Clean the Roller

roller. Never service the air cleaner

while the roller is running.

The complete roller must be given a weekly

cleaning. Daily cleaning will be required if material

is adhering to the machine working parts.

Airborne dust may be hazardous. Wear

proper personal protective equipment

•

Make sure the operator areas, steps, and

while handling air cleaners and

grab rails are clean. Oil, grease, snow, ice, or

elements.

mud in these areas can cause to slip and fall.

Clean the boots of excess mud before getting

in the roller.

Air Cleaner Indicators

•

Thoroughly wash all fittings, caps, plugs, and

Check the air cleaner visual restriction indicator

the like with a nonflammable, nontoxic clea-

before and after every shift.

ning

solution before servicing to prevent dirt from

entering while performing the service.

If the indicator on the air cleaner turns red, replace

•

After cleaning, check for defects in the air cle-

the main filter on the air cleaner. The dust pouch

aner ducts.

is emptied by pressing the rubber bellows with

your fingers. Check also that the air hoses are in

a. Check intake for accumulation of

good condition. Clean the air cleaner when

debris that could restrict air flow.

operated in extremely dusty environments.

b. Check the air cleaner mounting

hardware for security.

c. Check all hoses for cracks, chafing, or

deterioration and replace at the first

sign of probable failure.

CC 125

Maintenance

Instruction Manual

Connections and Ducts

Air Cleaner Main Filter

Check air cleaner and ducts for leaks before every

The air cleaner is the dry type with two elements;

shift, during every shift, and after every shift. Make

a main filter that is replaceable and can be

sure all connections between the air cleaner and

cleaned, and a backup filter that should only be

air compressor are tight and sealed.

replaced and never cleaned.

Note Dust that gets by the air cleaner

system can often be detected by

Figure 7-2: Air Cleaner Elements

looking for dust streaks on the air

transfer tubing or just inside the intake

manifold inlet.

Air Cleaner Pre-Cleaner

Wipe clean the inside of the cover and the filter

housing. Wipe also both surfaces for the outlet

pipe.

A Clips

D Backup filter

B Cover

Filter housing

Note Check that the hose clamps between

C Main filter

Dust valve

the filter housing and the suction hose

are tight and that the hoses are intact.

Inspect the entire hose system, all the

When the visual restriction indicator is red, clean

way to the engine.

and replace the air cleaner elements. The

following maintenance procedure must be

followed.

Figure 7-1: Pre-Cleaner

1. Unclip the clamps holding the main filter.

2. Remove the washer. Carefully withdraw the

main filter.

3. Inspect the main filter indicator (safety

signal). If the indicator is red, replace the

main filter.

Note Make sure new elements arrive

enclosed in plastic or in a protective

Never clean Donoclone tubes with

membrane. Do not install elements

compressed air unless both the safety

that are unprotected. This is a dust

and primary elements are installed in the

hazard.

air cleaner. Do not steam clean the tubes

N o t e Never attempt to clean a backup filter.

in the pre-cleaner.

Change the backup filter whenever

main filter replaced.

4. Examine the new or newly cleaned main filter

for torn or damaged pleats, bent end covers,

liners, and gaskets.

CC 125

Maintenance

Instruction Manual

5. Make sure the main filter washer are not

Air Circulation

cracked or damaged. Replace if necessary.

Check that the engine has free circulation of

6. The backup filter should be replaced if the air

cooling air through the grille in the engine

cleaner visual restriction indicator is red after

compartment.

servicing the main filter.

7. Clean the inside of the air cleaner housing

before removing backup filter.

Figure

7-4: Air Circulation

8. To replace the backup filter, remove the old

filter from the holder. Dispose of the used

element properly.

9. Install new backup filter into the holder.

10. Carefully install the cleaned or new main

filter.

Figure 7-3: Air Filter

Cooling air grille

Hose and Clamps

1. Periodic clamping bolts re-tightening is

necessary due to cold-flow present in all

rubber hoses. Tighten the boss clamps.

2. Examine and change out worn hoses and

weakened Boss clamps. If hoses are to be

Backup filter

changed out, change the Boss clamps also.

Boss clamps hold the hose connections

under a large amount of pressure. Boss

11. Re-install the back cover, make sure the dust

clamps (including nuts and bolts) are for

valve is positioned downwards.

single use only. Do not reuse. Once

removed, discard them.

12. Inspect all air intake piping and joints

between the air cleaner and inspect the air

inlet to make sure that no dusty air can enter.

After servicing the elements, reset the restriction

indicator to green when the element is replaced in

the air cleaner housing.

Note Never leave the air cleaner open

longer than necessary.

Note The two most common servicing

problems are over servicing and

improper servicing.

CC 125

Maintenance

Instruction Manual

Engine

Batteries

Refer to the engine service and maintenance

The following battery maintenance must be

manuals for specific information on the engine

carried out as part of the 250 hour routine

maintenance.

maintenance schedule.

Note Switch off the engine before filling the

oil.

Batteries contain an acid and can cause

injury. Skin and eye contact with battery

Note Care must be taken while draining the

fluid can cause injury. Avoid skin and eye

oil. Wear protective gloves and eye

contact with battery fluid. If contact

glasses.

occurs, flush area immediately with

water.

Change the engine oil after 250 hours of

operation.

Battery fumes can ignite and explode. Do

not smoke when observing battery fluid

Remove the oil filler cap and oil drain plug.

level.

Drain the oil into a suitable container.

N o t e When disconnecting the battery,

Reinstall the drain plug and tighten.

always disconnect the negative cable

first. When connecting the battery,

Remove and replace the oil filter.

always connect the positive cable first.

Note Always wear protective glasses when

working with batteries. Wash hands

Figure 7-5: Fuel Filters

after touching batteries and

connectors. Use of gloves

recommended.

Batteries, Clamps, and Cables

The standard batteries supplied are heavy duty

lead acid type, requiring the following

maintenance.

1. Keep the top of the batteries clean.

2. Clean the terminals.

Mud filter

3. Keep battery connections tight.

Fuel filter

4. Apply a small amount of grease to the

terminal connections to prevent corrosion.

Remove the oil filler cap and fill the engine

crank case with recommended oil.

5. Inspect the cables, clamps, and hold down

brackets. Replace if necessary.

Start the engine and allow it to idle for a few

minutes. During this time, check around the

oil filter and drain plug for leaks.

Install the oil filler cap.

CC 125

Maintenance

Instruction Manual

Check Electrolyte Level

Fuel Tank

Shut off the engine.

Refuel every day before starting to work.

Lockout/tagout the roller as per the site

specific procedure.

1. Screw off the lockable tank cap.

Check the electrolyte level and keep the

2. Fill diesel fuel to the lower edge of the fil-

electrolyte level above the plates. Fluid level

ler pipe.

is low when below ring or ring is visible and

too high when slots are not visible.

Check fuel tanks and fuel lines for possible leaks.

Because of the potential fire hazard, leaks must

Refill with distilled water, if necessary.

be corrected as soon as they are spotted.

Over filling can cause poor performance

or early failure.

Fuel is flammable. May cause serious

injury or death. Shut off the engine,

extinguish all open flames, and do not

smoke while filling the fuel tanks. Always

wipe up any spilled fuel immediately.

Remove lockout / tagout.

Check the fuel level by reading the fuel level

Figure 7-6: Battery Location

gauge.

Never allow fuel tanks to completely empty.

Fill tank with the correct grade of fuel.

The fuel tank holds 50 liters.

Figure 7-7: Fuel Tank

Battery location

Fuel tank

CC 125

Maintenance

Instruction Manual

Coolant System

Lowering of Engine Hood

1. Stand on the left side of the engine hood.

Check that all hoses/hose connectors are intact

and tight. Fill with coolant as specified in the

2. Press in the black rod and carefully lower the

lubricants specification.

engine hood until the gas spring goes into

the slot.

Change the coolant every year. Failure to cool the

3. Release the black rod and then lower down

engine properly can result in engine failure or

the engine hood completely.

severely reduce engine life.

Figure 7-9: Lowering the Hood

Figure 7-8: Coolant Level Guage

A Coolant level guage

Personal injury can occur when removing

the radiator cap. Steam or fluid escaping

from the radiator can burn. Inhibitor

contains alkali. Avoid contact with skin

and eyes. Wear protective gloves and

A Engine hood

B Gas spring

eye glases.

Always shut off the engine and allow it to

cool down before removing the radiator

cap. Remove the radiator cap slowly to

relieve pressure. Avoid contact with

steam or escaping fluid.

CC 125

Maintenance

Instruction Manual

Water Tank

4. Tighten all the screws after adjustment.

Unscrew the tank cap and fill with clean water. Do

Figure 7-11: Drum

not remove the strainer. See technical

specifications for the tank volume.

Note A small amount of environment-

friendly antifreeze is added.

Figure 7-10: Water Tank

A Scraper blade

B Drum

The scrapers must be lifted from the drum during

transport.

Brakes

Tank cap

Run the roller very slowly forward. Hold the

steering wheel firmly and brace yourself for a

Fixed Scrapers

sudden stop. Press in the emergency stop. The

roller will stop abruptly and the engine will switch

Make sure that the scrapers are undamaged.

off. After testing the brakes, set the forward/

Adjust the scrapers so that they are 1-2 mm from

reverse lever in neutral. Pull out the emergency

the drum. For special asphalt compounds, it may

stop. Start the engine. The roller is now ready for

be better if the scraper blades lie lightly against

operation.

the drums.

Asphalt remnants can accumulate on the scraper

and affect the contact force. Clean as required.

1. Loosen the screws to adjust the contact

pressure of the scraper blade against the

drum.

2. Lock this setting by tightening the lock nut

against the mounting plate.

3. Adjust the contact surface on both scraper

attachments.

CC 125

Maintenance

Instruction Manual

Sprinkler System

Start the sprinkler system and make sure that

nonozzles are clogged. If necessary, clean

clogged nozzles and the coarse filter located by

the water pump.

The sprinkler system should be drained if

there is a risk of freezing.

Wear protective eye glases when working

with compressed air.

Dismantle the blocked nozzle by hand. Blow the

nozzle and fine filter clean with compressed air, or

install replacement parts and clean the clogged

parts later.

Figure 7-12: Sprinkler Pump

A Sprinkler pump

CC 125

Maintenance

Instruction Manual

2. Check the reservoir oil level by viewing the

7.6 Lubrication and

sight gauge. Verify that fluid level is near the

Filters

maximum level indicated on the sight glass.

Figure 7-13: Hydraulic Reservoir

Hydraulic Reservoir

The hydraulic reservoir oil level must be checked

daily as part of the 8 to 10 hour routine

maintenance procedure.

Excessive hydraulic oil can rupture

hydraulic tank and cause injury or

property damage.

N o t e Take extra care when working around

or on the hydraulic system to make

Sight glass

sure its complete cleanliness. When

operating, the oil level must be

Open the engine hood and unscrew the filler

between the maximum and minimum

cap, top up with hydraulic fluid (as per

levels. Top up with hydraulic fluid as

lubricant specification) if the level is too low.

per lubricant specifications if level is

too low.

Note Dirt in the hydraulic system will lead to

Figure 7-14: Hydraulic fluid Refilling

premature component failure. A clean,

contaminant free system is extremely

important for the roller to function

properly.

Checking Hydraulic Oil Level

If the hydraulic oil level is low, add hydraulic oil.

1. Level the roller.

A Hydraulic fluid refilling

CC 125

Maintenance

Instruction Manual

Steering Cylinder and Steering

Drum - Oil Level

Joint

1. Run the roller slowly until the oil plug is

opposite one of the inspection holes.

The steering cylinder is located under the

operator’s platform. There is a grease fitting near

2. Unscrew the plug and check that the oil level

the base and rod ends of the cylinder.

reaches up to the bottom of the hole. Top up

with new oil if necessary. Use oil as per the

lubricant specification.

1. Turn the steering wheel fully to the left. All

four grease nipples can now be accessed

3. Clean the magnetic oil plug from any metallic

from the right side of the machine.

residue, and refit the plug.

2. Wipe the grease nipples.

3. Grease each nipple with five strokes of the

Figure 7-16: Drum Oil Filling

hand-operated grease gun. Make sure that

grease penetrates into the bearing. If grease

does not penetrate the bearings, it may be

necessary to relieve the articulation joint with

a jack while repeating the greasing process.

Figure 7-15: Greasing

Filling

Level check

C Drain

A Grease nipple

Controls

If the lever gets stiff after a prolonged period of

use, remove the cover and lever and lubricate.

Lubricate the forward/reverse lever in the engine

compartment with a few drops of oil.

CC 125

Maintenance

Instruction Manual

Housekeeping

The complete roller must be given a weekly

cleaning. Daily cleaning will be required if material

is adhering to the roller working parts.

1. Make sure the operator areas, steps, and

grab rails are clean. Oil, grease, snow, ice, or

mud in these areas can be slippery. Clean

the boots of excess mud before getting in the

cab or on the roller operator platform.

2. Check the tower feed installation for debris

buildup around the sheaves.

3. Thoroughly wash all fittings, caps, plugs, and

the like with a nonflammable, nontoxic

cleaning solution before servicing to prevent

dirt from entering while performing the

service.

Note Protect all electrical components and

control panels against entry of water

or steam when using high pressure

cleaning methods. Cover the fuel and

hydraulic fill cap breathers located on

each tank.

4. After cleaning, check for defects in the air

cleaner ducts.

a. Check intake for accumulation of

debris that could restrict air flow.

b. Check air cleaner mounting hardware

for security.

c. Check all hoses for cracks, chafing, or

deterioration and replace at the first

sign of probable failure.