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DYNAPAC Vibratory roller CC4000 VI, CC4200 VI (Engine Cummins QSF 3.8 (Stage IV/T4F) / Cummins F 3.8 (Stage V)). Instruction manual - page 4

Maintenance - Lubricants and symbols

Maintenance - Lubricants and symbols

Always use high-quality lubricants and the

amounts recommended. Too much grease or

oil can cause overheating, resulting in rapid

wear.

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.

ENGINE OIL

Air temperature -15°C - +50°C

Dynapac engine oil 200

P/N 4812161855 (5 liters),

(5°F-122°F)

P/N 4812161856 (20 liters)

HYDRAULIC FLUID Air temperature -15°C - +50°C

Dynapac Hydraulic 300

P/N 4812161868 (20 litres),

(5°F-122°F)

P/N 4812161869 (209 litres)

Ambient air temperature above Shell Tellus S2 V100

+40°C (104°F)

BIOLOGICAL

Air temperature -10°C - +35°C

PANOLIN HLP Synth 46

HYDRAULIC

(14°F-95°F)

(www.panolin.com)

FLUID, 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

Dynapac Drum Oil 1000

P/N 4812161887 (5 liters),

(5°F-104°F)

P/N 4812161888 (20 liters)

GREASE

Dynapac Roller Grease P/N 4812030096

(0.4kg)

FUEL

See engine manual.

-

-

COOLANT

Anti-freeze protection down to

Dynapac coolant 100

P/N 4812161854 (20 liters)

about -37°C (-34.6°F)

(mixed 50/50 with water)

UREA (DEF)

DEF/AdBlue® as per

ISO 2224-1

109

Maintenance - Lubricants and symbols

Fluid volumes

Drum

- Drum CC4000 VI

13 liters

14 qts

- Drum CC4200 VI

14 liters

15 qts

- Drum CC5200 VI

15 liters

16 qts

- Drum CC6200 VI

17 liters

18 qts

Hydraulic reservoir

78 liters

82.5 qts

Diesel engine

- oil, incl. filter replacement

12 liters

13 qts

- coolant, no cab

24 liters

25.5 qts

- coolant, with cab

26,2 liters

28 qts

Maintenance symbols

Engine, oil level

Air filter

Engine, oil filter

Battery

Hydraulic reservoir, level

Sprinkler

Hydraulic fluid, filter

Sprinkler water

Drum, oil level

Recycling

Lubricating oil

Fuel filter

Coolant level

Pump gear, oil level

Air pressure

Sprinkler, tires

Urea (DEF)

110

Maintenance - Maintenance schedule

Maintenance - Maintenance schedule

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.

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.

Specific maintenance and checks on diesel

engines must be carried out by the engine

supplier’s certified personnel.

Applying authorized oil and correct

maintenance interval are essential factors of

component to its operation safety and service

life!

Every 10 hours of operation (Daily)

Refer to the contents to find the page number of the

sections referred to !

Pos. in

Action

Comment

fig

Before starting up for the first time on that

day

1

Check the engine oil level

Refer to the engine manual

9

Check the engine coolant level

5

Check the hydraulic reservoir level

11

Refuel

13

Fill the water tanks

14

Check the sprinkler system

12

Check the scraper setting

Fill the urea tank

111

Maintenance - Maintenance schedule

Every 1000 hours of operation

Refer to the contents to find the page number of the

sections referred to !

Pos. in

Action

Comment

fig

8

Clean the hydraulic fluid cooler/water cooler

10

Check the filter element in the air cleaner

Replace when necessary

20

Check the condition of the batteries

1,2

Change the diesel engine oil and oil filter *

See the engine's instruction manual

*) 500 h or once every 6 months

Check the engine belt drive system

Refer to the engine manual

3

Replace fuel filter

Refer to the engine manual

3

Replace fuel prefilter

Refer to the engine manual

16

Change the oil in the drums

19

Check the rubber elements and bolted joints

4

Change the hydraulic fluid filter

7

Check bleeder filter on hydraulic reservoir

18

Grease the chair bearing

17

Steering hitch - Tightening

21

Lubricate the pivot bearing

Machines with Offset

22

Replace the air cleaner filter in the cab

Optional

114

Maintenance - Maintenance schedule

Every 2000 hours of operation

Refer to the contents to find the page number of the

sections referred to !

Pos. in

Action

Comment

fig

8

Clean the hydraulic fluid cooler/water cooler

10

Check the filter element in the air cleaner

Replace when necessary

1,2

Change the diesel engine oil and oil filter *

See the engine's instruction manual

*) 500 h or once every 6 months

Check the engine belt drive system

Refer to the engine manual

3

Replace fuel filter

Refer to the engine manual

3

Replace fuel prefilter

Refer to the engine manual

11

Drain and clean the fuel tank

16

Change the oil in the drums

4

Change hydraulic fluid filter

6

Change the hydraulic fluid **

**) not for PANOLIN hydraulic fluid

7

Check bleeder filter on hydraulic reservoir

13

Drain and clean the water tanks

17

Check the condition of the articulation

17

Steering hitch - Tightening

21

Lubricate the pivot bearing

Machines with Offset

Replace the filter in the urea tank

Replace the filter in the urea pump

22

Replace the air cleaner filter in the cab

Optional

23

Overhaul the air conditioning

Optional

Every other year

Refer to the contents to find the page number of the

sections referred to !

Pos. in

Action

Comment

fig

31

Change the coolant (glycol)

10

Change the fluid in the hydraulic reservoir *)

*) not for PANOLIN hydraulic oil

4

Inspect the filter element in the air cleaner

Replace as required

16

Check rubber elements and bolted joints

19

Check belt tension in the drive belt system

Refer to the engine manual

115

Maintenance, 10h

Maintenance, 10h

Every 10 hours of operation (Daily)

Park the roller on a level surface.

The engine must be switched off and the

parking brake activated when checking or

adjusting the roller, unless otherwise specified.

Ensure that there is good ventilation (air

extraction) if the engine is run indoors. Risk of

carbon monoxide poisoning.

Diesel engine - Check oil level

The dipstick is accessible in the engine compartment

on the right side of the machine.

Take care not to touch any hot parts of the engine

or the radiator when removing the dipstick. Risk of

2

burns.

The dipstick is located down on the front of the engine.

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

between the upper and lower marks.

1

For further details, refer to the engine's instruction

manual.

Fig. Engine compartment

1. Dipstick

2. Oil filler cap

117

Maintenance, 10h

Coolant level - Check

Release the expansion tank hood locks, with the help

of the wire with key ring, accessed inside the

right-hand engine compartment door.

Check that the coolant level is between the max. and

min. marks (2).

Top up with coolant if the level is too low.

Key ring

Use the following protective equipment:

Eye protection

Protective gloves

Fig. Open the right-hand engine

compartment door.

For filling, loosen the filler cap (1) and make sure that

the coolant level is between the max/minmarking (2).

Now screw on the filler cap (1) again.

1

Do not open the radiator cap while the engine is

warm, as the radiator may contain fluid and/or

steam under pressure, which may cause skin and

eye damage.

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

2

See the lubrication specification in these instructions

and the engine manual.

Flush the system every other year and change

the coolant. Also check that the air has

unobstructed passage through the reservoir.

Fig. Expansion tank

1. Filler cap

2. Level marks

118

Maintenance, 10h

Hydraulic reservoir - Check fluid level

Place the roller on a level surface and check that the

1

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

min markings.

If necessary, fill with hydraulic fluid by unscrewing the

filler cap (2). See under the "Lubricants" heading for

the correct oil grade.

2

Figure. Hydraulic reservoir

1. Oil sight glass

2. Filler cap

Urea tank - Refilling

Top up the urea tank every day. Follow the engine

manufacturer's specifications for urea usage.

1

The urea solution may only be filled in the tank

designed for this. Unintentional filling with another

media (e.g. diesel fuel) will cause irreparable

damage to the metering system. If the tank is

unintentionally filled with water, the Onboard

diagnosis system (OBD) generates an error

message.

Never refuel while the engine is running. Do not

smoke and avoid spilling fuel.

Fig. Urea tank

1. Refilling

119

Maintenance, 10h

Fuel tank - Filling

Never refuel while the engine is running. Do not

smoke and avoid spilling fuel.

The fuel tank is located on the front drum frame and

the filling is on the right side of the machine. Step (2)

1

for easier access is mounted on the right front fork.

Top up the fuel tank every day.

Unscrew the lockable tank cap on the filling pipe (1) fill

with diesel up to the lower edge of the filler pipe.

Refit and lock the tank cap after refueling.

See the engine handbook for the grade of diesel fuel.

The tank holds 180 l (48 gallons) of fuel.

2

Fig. Fuel tank (STD)

1. Filler pipe

2. Step

Stage IV/Stage V engines require the use of Ultra

Low Sulphur Diesel (ULSD) fuel, which has a

1

sulphur content of 15 ppm (parts per million) or

less. Higher sulfur contents cause operating

problems and put the useful life of components at

risk, which can lead to engine trouble.

It is important to ground the filling device nozzle

when refuelling to avoid static electricity with the

2

risk of sparking and ignition.

Fig. Fuel tank (OFFSET)

1. Filler pipe

2. Step

Make sure that the step (2) for access to the fuel

tank is folded in and locked.

120

Maintenance, 10h

Water tank, Std - Filling

Filler caps are on the front right and left side of the

front frame.

When quick-filling on a machine with two filling pipes,

loosen the filler cap on the nonfilling side to ventilate

the water tank.

1

Unscrew the tank cap (1) and fill with clean

water. Do not remove the strainer (2).

Fill the central (standard) tank, it holds 540 - 850 liters

(143 - 224 gal) depending on machine model, see

Fig. Standard water tank

Technical specifications

1. Tank cap

Only additive: A small amount of

environment-friendly antifreeze.

Water tank, extra at rear - Filling

1

Filler capa (1) are located on both sides of the tank.

Unscrew the tank cap (1) and fill with clean

water.

1

Fill the rear tank, it holds 200 liters (53 gal) of water.

Only additive: A small amount of

environment-friendly antifreeze.

Fig. Rear water tank

1. Tank cap

121

Maintenance, 10h

Sprinkler system/Drum

Check

Start the sprinkler system and make sure that none of

the nozzles (1) are clogged. If necessary, clean

blocked nozzles and the coarse filter placed by the

water pump (2). See next section.

1

Figure. Front drum

1. Nozzle

Cleaning the coarse filter

The pumping system is available on the articulation

joint on the right side of the front frame.

To clean the coarse filter (1) open the drain cock (2)

on the filter and allow any dirt to run out.

If necessary, clean the filter and filter housing. Check

that the rubber gasket in the filter housing is intact.

After inspecting and cleaning, reset and start the

system to check that it works.

To drain the complete sprinkler system, see section for

Watering system - Draining, 2,000 h.

3

3

2

1

Fig. Pump system, front frame right

side

1. Coarse filter

2. Drain cock, filter

3. Water pump

122

Maintenance, 10h

Sprinkler system/Drum

Cleaning of sprinkler nozzle

Dismantle the blocked nozzle by hand.

Blow the nozzle (1) and fine filter (3) clean using

compressed air. Alternatively, fit replacement parts

and clean the blocked parts later on.

1

Nozzle

Colour

l/min (at 2.0

gal/min (at

2

bar)

40 psi)

Standard

yellow

0.63

0.20

3

Option

blue

0.98

0.30

Option

red

1.31

0.40

Figure. Nozzle

Option

brown

1.63

0.50

1. Nozzle

2. Gasket

3. Filter

After inspecting and carrying out any necessary

cleaning, start the system and check that it works.

When working with compressed air, use the

following protective equipment:

Eye protection

Protective gloves

Ear protectors

123

Maintenance, 10h

Scrapers, spring-action

Check

Make sure that the scrapers are undamaged.

1

Release with the arm (1).

Loosen the screws (3) to adjust the scraper blade up

2

or down.

3

Fig. Outer scrapers

1. Release arm

2. Scraper blade

3. Adjusting screw

Asphalt remnants can accumulate on the scraper and

affect the contact force. Clean when necessary.

The scrapers must be retracted from the drum

during transport driving.

1

2

Fig. Inner scrapers

1. Release arm

2. Lifting handle

124

Maintenance, 10h

Scrapers

Setting - Adjustment

2

Release the retaining unit (1) for the scraper bracket

and unscrew the adjusting screw (2) to release.

Push in the scraper bracket and tighten.

Adjust the screw (2) so that the scraper blade lies

approx. 2 mm (0.08 in) from the drum on the same

side as the screw.

1

Adjust the scraper bracket in or out on the other side

so that there is an equal gap between the scraper

blade and drum, and tighten the retaining unit (1).

1-2 mm

(0.04-0.08 in)

2

3

The adjusting screw (2) is adjusted until the scraper

blade has a gap of approx. 1 mm (0.04 in) to the roller,

or lies loosely on the roller, along its entire length.

Tighten the lock nut (3).

Figure. Scraper setting

1. Retaining unit

2. Adjusting screw

3. Lock nut

125

Maintenance - 50h

Maintenance - 50h

Every 50 hours of operation (Weekly)

Park the roller on a level surface.

The engine must be switched off and the

parking brake activated when checking or

adjusting the roller, unless otherwise specified.

Ensure that there is good ventilation (air

extraction) if the engine is run indoors. Risk of

carbon monoxide poisoning.

Air cleaner

- Check hoses and connections

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.

Replace if necessary, as damage to hoses/hose

clamps can seriously damage the engine

127

Maintenance - 50h

Pre-fuel filter - Draining

Unscrew the drain plug (1) at the bottom of the fuel

prefilter.

With the aid of the secondary hand-operated pump,

2

make certain that all sediment comes out.

Tighten the drain plug as soon as uncontaminated fuel

runs out.

1

Figure. Pre-fuel filter

1. Drain plug

2. Hand pump

128

Maintenance measures - 250 h

Maintenance measures - 250 h

Every 250/750/1250/1750

hours of operation (every

3 months)

Park the roller on a level surface.

The engine must be switched off and the

parking brake activated when checking or

adjusting the roller, unless otherwise specified.

Ensure that there is good ventilation (air

extraction) if the engine is run indoors. Risk of

carbon monoxide poisoning.

Cooler

Check - Clean

The water and hydraulic fluid coolers are accessible

when the cooler grill (4) is removed.

Make sure that the air flow through the coolers is

unobstructed. Clean a dirty cooler using compressed

air or wash with a high-pressure washer.

Blow or wash the coolers in the reverse order to the

cooling air.

Take care when using a high-pressure water jet.

Do not hold the nozzle too near the cooler.

3

4

2

1

Figure. Cooler

1. Charge air cooler

When working with compressed air or a

2. Water cooler

3. Hydraulic fluid cooler

high-pressure washer, use the following protective

4. Cooler grill

equipment:

Eye protection

Protective gloves

Ear protectors

129

Maintenance measures - 250 h

Battery

- Check condition

The batteries are sealed and maintenance-free.

Make sure there is no open flame in the vicinity

when checking the electrolyte level. Explosive gas

is formed when the alternator charges the battery.

Figure. Batteries

When disconnecting the battery, always

disconnect the negative cable first. When

connecting the battery, always connect the

positive cable first.

The cable shoes should be clean and tightened.

Corroded cable shoes should be cleaned and greased

with acid-proof Vaseline.

Wipe the top of the battery.

Automatic Climate Control (Optional) -

Inspection

Open the left-hand engine compartment door with the

1

unit in operation and check using the sight glass (1)

that bubbles are not visible on the drying filter.

The filter is located on the rear frame on the outer

edge of the engine compartment. If bubbles are visible

through the sight glass, this 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.

Fig. Drying filter

1. Sight glass

130

Maintenance measures - 250 h

Air conditioning (Optional) - Cleaning

1

If there is a significant loss of cooling capacity, clean

the condenser element (1).

Fig. Rear frame

1. Condenser element

Air conditioning (Optional)

- Inspection

Inspect refrigerant hoses and connections and make

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

indicate a refrigerant leakage.

The refrigerant contains tracing liquid, which makes it

possible to detect leaks with the aid of a UV lamp. If

the areas around the connections are strongly

coloured, this is an indication of a leak.

Edge cutter (Optional)

- Lubrication

Refer to the operation section for information on

2

how to operate the edge cutter.

1

Grease the two points as shown in the figure.

Grease should always be used for lubrication, see the

lubricant specifications.

Grease all bearing points with five strokes of a

Figure. Two grease points for

hand-operated grease gun.

lubricating the edge cutter

131

Maintenance measures - 500 h

Maintenance measures - 500 h

Every 500/1500

hours of operation (every six

months)

Park the roller on a level surface.

The engine must be switched off and the

parking brake activated when checking or

adjusting the roller, unless otherwise specified.

Ensure that there is good ventilation (air

extraction) if the engine is run indoors. Risk of

carbon monoxide poisoning.

Cooler

Check - Clean

The water and hydraulic fluid coolers are accessible

when the cooler grill (4) is removed.

Make sure that the air flow through the coolers is

unobstructed. Clean a dirty cooler using compressed

air or wash with a high-pressure washer.

Blow or wash the coolers in the reverse order to the

cooling air.

Take care when using a high-pressure water jet.

Do not hold the nozzle too near the cooler.

3

4

2

1

Figure. Cooler

1. Charge air cooler

When working with compressed air or a

2. Water cooler

3. Hydraulic fluid cooler

high-pressure washer, use the following protective

4. Cooler grill

equipment:

Eye protection

Protective gloves

Ear protectors

133

Maintenance measures - 500 h

Air cleaner

Checking - Change the main air filter

Change the air cleaner's main filter when the

warning lamp on the display lights when the

diesel engine is operating at full 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

Backup filter - Change

1

Change the backup filter with a new filter after every

second 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

134

Maintenance measures - 500 h

Air cleaner

- Cleaning

Wipe clean on both sides of the outlet

pipe.

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

housing (5). See the previous illustration.

Wipe also both surfaces for the outlet pipe; see

adjacent figure.

Inner edge of

Outer edge of outlet

outlet pipe.

pipe.

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.

135

Maintenance measures - 500 h

Diesel engine

Oil change

The engine's oil drain plug is located under the rear

frame on the machine on the right side.The drain plug

is accessed by first removing the rubber plug on the

underside of the frame.

Observe care when draining hot engine oil. Use

the following protective equipment:

Protective gloves

Eye protection

1

Figure. Underside of rear frame

Drain the oil when the engine is warm. Place a

1. Oil draining of diesel engine

receptacle that holds at least 14 liters (15 qts) under

the drain plugs.

Unscrew the drain plug (1). Allow all the oil to drain out

and refit the plug.

Deliver the drain oil for environmentally correct

handling.

Fill with fresh engine oil, see Lubricant specification or

the engine manual for the correct grade of oil.

Fill with the requisite volume of engine oil. See

technical specifications before starting the machine.

Allow the engine to idle for a few minutes, and then

switch off the engine.

Check the dipstick to ensure that the engine oil level is

correct. Refer to the engine manual for details. Top up

with oil if necessary to the max mark on the dipstick.

136

Maintenance measures - 500 h

Engine

Replacing oil filter

The oil filter (1) is located at the front of the engine and

is accessible in the engine compartment inside the

right engine door.

See the engine manual for information about replacing

the filter.

1

Figure. Engine compartment, right side

1. Oil filter

The engine fuel filter - replacement/cleaning

The fuel prefilter is placed on the right side of the

engine compartment.

Unscrew the bottom and drain off any water, and then

1

replace the filter unit.

Figure. Engine compartment, right side

1. Fuel prefilter

Replace the fuel filter, located on the right side of the

engine compartment.

Start the engine and check that the filter is well sealed.

1

Figure. Engine compartment, right

side.

1. Fuel filter

137

Maintenance measures - 500 h

Drum - oil level

Inspection - filling

Position the roller with the filler plug (1), the large plug,

at the highest point in its rotation.

Wipe clean around the level plug (2), the small plug,

1

and remove the plug.

Make sure that the oil level is up to the lower edge of

the hole. Top off with fresh oil if the level is low. Use oil

as specified in the lubricants specification.

2

When removing the filler plug, wipe any metal

accumulated on the plug magnet off. Make sure that

plug seals are intact and replace with new seals if not.

Refit the plugs and check that they are tight by driving

Fig. Drum, vibration side

the roller and then rechecking.

1. Filler plug

2. Level plug

Rubber elements and attachment screws

Check

Check all rubber elements (1). Replace all elements if

25% or more than 25% of the number on one side of

1

the drum have cracks deeper than 10-15 mm (0.4-0.6

in).

Check using a knife blade or pointed object.

2

Check also that the attachment screws (2) are

tightened.

Fig. Drum, vibration side

1. Rubber element

2. Attachment screws

138

Maintenance measures - 500 h

Pivot bearing (OFFSET) - Lubrication

1

Grease each nipple (1) with five strokes of a

hand-operated grease gun.

Use grease as specified in the lubricant specification.

Fig. Front drum, left side

1. Grease nipples, 4 off

Seat bearing - Lubrication

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

5

steering mechanism.

6

Remove the covers (5) to access the lubrication nipple

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

strokes of a hand-operated grease gun.

2

3

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

the steering column.

Also grease the seat slide rails (6).

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

screws (4) and move the steering column forward.

4

Tighten the screws and check chain tension.

1

7

No not tension the chain too tightly. It should be

possible to move the chain about 10 mm (0.4 in) to the

Figure. Seat bearing

side with a forefinger/thumb at the marking (7) in seat

1. Grease nipple

2. Gearwheel

frame. Fit the chain lock at the bottom.

3. Steering chain

If the seat starts to be stiff when adjusting, it

4. Adjusting screw

should be lubricated more often than specified

5. Covers

6. Slide rails

here.

7. Marking

139

Maintenance measures - 500 h

Edge cutter (Optional)

- Lubrication

Refer to the operation section for information on

2

how to operate the edge cutter.

1

Grease the two points as shown in the figure.

Grease should always be used for lubrication, see the

lubricant specifications.

Grease all bearing points with five strokes of a

Figure. Two grease points for

hand-operated grease gun.

lubricating the edge cutter

140

Maintenance - 1000h

Maintenance - 1000h

Performed after 1000 operating hours (each year)

Park the roller on a level surface.

The engine must be switched off and the

parking brake activated when checking or

adjusting the roller, unless otherwise specified.

Ensure that there is good ventilation (air

extraction) if the engine is run indoors. Risk of

carbon monoxide poisoning.

Cooler

Check - Clean

The water and hydraulic fluid coolers are accessible

when the cooler grill (4) is removed.

Make sure that the air flow through the coolers is

unobstructed. Clean a dirty cooler using compressed

air or wash with a high-pressure washer.

Blow or wash the coolers in the reverse order to the

cooling air.

Take care when using a high-pressure water jet.

Do not hold the nozzle too near the cooler.

3

4

2

1

Figure. Cooler

1. Charge air cooler

When working with compressed air or a

2. Water cooler

3. Hydraulic fluid cooler

high-pressure washer, use the following protective

4. Cooler grill

equipment:

Eye protection

Protective gloves

Ear protectors

141

Maintenance - 1000h

Air cleaner

Checking - Change the main air filter

Change the air cleaner's main filter when the

warning lamp on the display lights when the

diesel engine is operating at full 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

Backup filter - Change

1

Change the backup filter with a new filter after every

second 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

142

Maintenance - 1000h

Air cleaner

- Cleaning

Wipe clean on both sides of the outlet

pipe.

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

housing (5). See the previous illustration.

Wipe also both surfaces for the outlet pipe; see

adjacent figure.

Inner edge of

Outer edge of outlet

outlet pipe.

pipe.

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.

143

Maintenance - 1000h

Diesel engine

Oil change

The engine's oil drain plug is located under the rear

frame on the machine on the right side.The drain plug

is accessed by first removing the rubber plug on the

underside of the frame.

Observe care when draining hot engine oil. Use

the following protective equipment:

Protective gloves

Eye protection

1

Figure. Underside of rear frame

Drain the oil when the engine is warm. Place a

1. Oil draining of diesel engine

receptacle that holds at least 14 liters (15 qts) under

the drain plugs.

Unscrew the drain plug (1). Allow all the oil to drain out

and refit the plug.

Deliver the drain oil for environmentally correct

handling.

Fill with fresh engine oil, see Lubricant specification or

the engine manual for the correct grade of oil.

Fill with the requisite volume of engine oil. See

technical specifications before starting the machine.

Allow the engine to idle for a few minutes, and then

switch off the engine.

Check the dipstick to ensure that the engine oil level is

correct. Refer to the engine manual for details. Top up

with oil if necessary to the max mark on the dipstick.

144

Maintenance - 1000h

Engine

Replacing oil filter

The oil filter (1) is located at the front of the engine and

is accessible in the engine compartment inside the

right engine door.

See the engine manual for information about replacing

the filter.

1

Figure. Engine compartment, right side

1. Oil filter

The engine fuel filter - replacement/cleaning

The fuel prefilter is placed on the right side of the

engine compartment.

Unscrew the bottom and drain off any water, and then

1

replace the filter unit.

Figure. Engine compartment, right side

1. Fuel prefilter

Replace the fuel filter, located on the right side of the

engine compartment.

Start the engine and check that the filter is well sealed.

1

Figure. Engine compartment, right

side.

1. Fuel filter

145

Maintenance - 1000h

Drum - oil level

Inspection - filling

Position the roller with the filler plug (1), the large plug,

at the highest point in its rotation.

Wipe clean around the level plug (2), the small plug,

1

and remove the plug.

Make sure that the oil level is up to the lower edge of

the hole. Top off with fresh oil if the level is low. Use oil

as specified in the lubricants specification.

2

When removing the filler plug, wipe any metal

accumulated on the plug magnet off. Make sure that

plug seals are intact and replace with new seals if not.

Refit the plugs and check that they are tight by driving

Fig. Drum, vibration side

the roller and then rechecking.

1. Filler plug

2. Level plug

Rubber elements and attachment screws

Check

Check all rubber elements (1). Replace all elements if

25% or more than 25% of the number on one side of

1

the drum have cracks deeper than 10-15 mm (0.4-0.6

in).

Check using a knife blade or pointed object.

2

Check also that the attachment screws (2) are

tightened.

Fig. Drum, vibration side

1. Rubber element

2. Attachment screws

146

Maintenance - 1000h

Hydraulic filter

Change

Filter is accessible from the left side of the machine, in

the engine compartment.

(1) Hydraulic fluid filter (Main filter)

Remove the hydraulic oil filter (1) and deliver to

environmentally correct handling. The filter is of

4

disposable type and cannot be cleaned.

2

Make sure that the old sealing ring is not left on

the filter holder. Otherwise, this could cause

leakage between the new and old seals.

3

1

Thoroughly clean the filter holder sealing surface.

Apply a thin coat of fresh hydraulic fluid to the rubber

gasket on the new filter.

Screw the filter on by hand, firstly until the filter gasket

Fig. Engine compartment left

1. Hydraulic oil filter (Main filter)

makes contact with the filter base. Then rotate a

2. Hydraulic reservoir cap

further 1/₅ turn.

3. Sight glass

4. High pressure filter - electronic

steering (Optional)

(4) High pressure filter - electronic steering

(Optional)

Unscrew the filter bowl and empty any liquid into a

container.

Remove the filter element and deliver to

environmentally correct handling.

Clean the filter bowl and filter head, also check the

o-rings and replace them if necessary.

Apply a thin layer of pure hydraulic oil to sealing

surfaces and threads.

Place a new filter element carefully on the filter head

guide pin.

Screw in the filter bowl completely, then unscrew with

1/₄ turn.

Check the hydraulic fluid level in the sight glass (3)

and top off as required. See under the heading 'Every

10 hours of operation' for more information.

Start the engine and check that the filter does not leak.

147

Maintenance - 1000h

Hydraulic reservoir cap - Check

The cap is accessible from the left side of the

machine, in the engine compartment.

Unscrew and make sure that the reservoir cap is not

clogged. Air must have unobstructed passage through

the cap in both directions.

1

If passage in either direction is blocked, clean the filter

with a little diesel oil and blow through with

compressed air until the block is removed, or replace

the cap with a new one.

When working with compressed air, use the

Fig. Engine compartment, left side

following protective equipment:

1. Tank cap

Eye protection

Protective gloves

Ear protectors

Pivot bearing (OFFSET) - Lubrication

1

Grease each nipple (1) with five strokes of a

hand-operated grease gun.

Use grease as specified in the lubricant specification.

Fig. Front drum, left side

1. Grease nipples, 4 off

148

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