Case DV201 DV202 DV204 Vibratory Rollers Operator's Manual 6-35950NA - PDF DOWNLOAD

DV201 DV202 DV204 Vibratory Rollers

Operator’s Manual 6-35950NA

OPERATOR’S MANUAL DV201 DV202 DV204

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QUICK REFERENCE SECTION GUIDE Shown are the Sections contained within this book.

1 - To the owner/Safety 2 - Controls/Instruments/Accessories 3 - Operating Instructions 4 - Servicing intervals/Lubrification/Fluids 5 - Maintenance/Adjustments 6 - Electrical system 7 - Storage 8 - Specifications 9 - Alphabetical index

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TABLE OF CONTENTS SECTION 1 - TO THE OWNER/SAFETY .................................................................................................... 1-1 DV201, DV202 and DV204 vibratory rollers ..............................................................................................1-1 Right, left, front and rear of the machine ...................................................................................................1-3 Type, serial number and year of manufacture ..........................................................................................1-4 Identification of the main components of the machine ..............................................................................1-6 Safety rules ...............................................................................................................................................1-7 Personal safety .........................................................................................................................................1-8 Before using the machine .........................................................................................................................1-9 Operating the machine ............................................................................................................................1-10 Parking the machine ...............................................................................................................................1-11 Maintenance and adjustments ................................................................................................................1-11 Prevention of fire or explosions ...............................................................................................................1-12 Prevention of burns .................................................................................................................................1-12 ROPS protective structure ......................................................................................................................1-13 Read operators manual ...........................................................................................................................1-13 Decals .....................................................................................................................................................1-14 Hand signals ...........................................................................................................................................1-20 SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES ..................................................................... 2-1 Steps and access handles ........................................................................................................................2-1 Location of controls, instruments and accessories ...................................................................................2-2 Front console control functions .................................................................................................................2-4 Right-hand arm control functions ..............................................................................................................2-9 Battery master switch ..............................................................................................................................2-12 Hourmeter ...............................................................................................................................................2-12 Hydraulic travel circuit shut off valve lever ..............................................................................................2-12 Operator’s seat ........................................................................................................................................2-13 Drum sprinkler reservoirs ........................................................................................................................2-15 Storage box .............................................................................................................................................2-16 Front console cover .................................................................................................................................2-16 SECTION 3 - OPERATING INSTRUCTIONS .............................................................................................. 3-1 Before operating the machine ...................................................................................................................3-1 Operating the machine ..............................................................................................................................3-2 Run-in period .............................................................................................................................................3-3 Starting the engine ....................................................................................................................................3-4 Shutting down the engine ..........................................................................................................................3-7 Engine emergency shut down ...................................................................................................................3-8 Machine travel and direction of travel .......................................................................................................3-9 Parking the machine ...............................................................................................................................3-13 Driving the machine on rough ground .....................................................................................................3-14 Engine hood ............................................................................................................................................ 3-15 ROPS frame removal and installation .....................................................................................................3-17 Machine articulation locking .................................................................................................................... 3-18

TABLE OF CONTENTS Operating instructions (continued) Transporting the machine ....................................................................................................................... 3-20 Handling the machine ............................................................................................................................. 3-22 Towing the machine ............................................................................................................................... 3-23 Releasing hydraulic travel motor brakes (DV201, DV202) .................................................................... 3-24 Releasing hydraulic travel motor brakes (DV204) ................................................................................. 3-28 Operating the machine in special conditions .......................................................................................... 3-32 SECTION 4 - SERVICING INTERVALS/LUBRIFICATION/FLUIDS ........................................................... 4-1 Servicing intructions ................................................................................................................................. 4-1 Hourmeter ................................................................................................................................................. 4-1 Servicing interval ...................................................................................................................................... 4-2 Fluids and lubricants ................................................................................................................................. 4-4 Fluid and lubricant capacities and specifications ...................................................................................... 4-7 Environment ............................................................................................................................................. 4-7 Grease points ........................................................................................................................................... 4-8 Levels ....................................................................................................................................................... 4-9 Engine .................................................................................................................................................... 4-11 Fuel system ............................................................................................................................................ 4-14 Air filter ................................................................................................................................................... 4-18 Hydraulic system .................................................................................................................................... 4-23 Drum ....................................................................................................................................................... 4-27 Drum sprinkling system .......................................................................................................................... 4-29 SECTION 5 - MAINTENANCE/ADJUSTMENTS ........................................................................................ 5-1 Lighting system and horn ......................................................................................................................... 5-1 Hydraulic oil cooler ................................................................................................................................... 5-2 Engine air intake system .......................................................................................................................... 5-3 Engine oil cooler ....................................................................................................................................... 5-3 Vibratory shock absorbers ........................................................................................................................ 5-4 Air intake system ...................................................................................................................................... 5-5 Engine alternator and fan belt .................................................................................................................. 5-6 Engine valve clearance ............................................................................................................................ 5-9 Fuel system hoses (DV201, DV202) ...................................................................................................... 5-13 Fuel system hoses (DV204) ................................................................................................................... 5-14 Exhaust system ...................................................................................................................................... 5-14 Engine belt .............................................................................................................................................. 5-15 Steering belt ........................................................................................................................................... 5-15 Drum scrapers ........................................................................................................................................ 5-16 Cleaning the machine ............................................................................................................................. 5-17 Hardware torque specifications .............................................................................................................. 5-17 Engine troubleshooting ........................................................................................................................... 5-18

TABLE OF CONTENTS SECTION 6 - ELECTRICAL SYSTEM ......................................................................................................... 6-1 Fuses ........................................................................................................................................................6-1 Battery .......................................................................................................................................................6-2 Connecting a booster battery ....................................................................................................................6-4 SECTION 7 - STORAGE .............................................................................................................................. 7-1 Storing the machine ..................................................................................................................................7-1 SECTION 8 - SPECIFICATIONS ................................................................................................................. 8-1 Engine .......................................................................................................................................................8-1 Steering .....................................................................................................................................................8-1 Capacities .................................................................................................................................................8-1 Electrical system .......................................................................................................................................8-1 Travel ........................................................................................................................................................8-2 Weights .....................................................................................................................................................8-2 Vibration ....................................................................................................................................................8-2 ROPS protective structure ........................................................................................................................8-2 Equipment .................................................................................................................................................8-3 Overall machine dimensions .....................................................................................................................8-4 SECTION 9 - ALPHABETICAL INDEX ....................................................................................................... 9-1 AFTER DELIVERY CHECK

TABLE OF CONTENTS

NOTES

SECTION 1

22

TO THE OWNER/SAFETY DV201, DV202 AND DV204 VIBRATORY ROLLERS

CS02F592

1 Dealer’s Stamp

1-1

SECTION 1 - TO THE OWNER/SAFETY This manual contains important information concerning safety in operation, adjustment and maintenance of your machine. Use the detailed alphabetical index at the end of the manual to find what you are looking for.

Use this manual as a guide; your machine is a working tool and you will always be able to count on it, as long as it is correctly maintained.

Do not use the machine and prevent anyone else using or servicing the machine before (you yourself or other people) being fully aware of the instructions given in this manual concerning safety, operation and maintenance. Use only operators who have proved their ability to operate and maintain this machine in a correct, safe manner.

This machine with its type approved attachments and accessories is intended to carry out compacting operations of a medium or large extent, such as the construction of highways, railways, airport areas, industrial areas, etc.

Do not use this machine for applications other than those shown in this manual. Consult your approved Dealer or our Company for any information concerning changes, additions or modifications which have to be carried out on this machine to ensure that these are in compliance with the regulations and safety rules of various countries. Any unauthorized modification could cause serious or fatal injury. Any person carrying out such modifications is entirely responsible for the consequences.

This operator's manual must be kept in the "manual" compartment provided for that purpose on this machine. Make sure that the manual is in good condition. To obtain additional manuals or to obtain other information concerning this machine, consult your Dealer. Your Dealer can provide you with genuine parts and has specially trained technicians who know the best methods for repair and maintenance of your machine.

1-2

SECTION 1 - TO THE OWNER/SAFETY RIGHT, LEFT, FRONT AND REAR OF THE MACHINE As used in this manual, the terms "right", "left", "front" and "rear" indicate the sides of the machine as seen from the operator's seat.

A. B. C. D.

A

FRONT REAR RIGHT-HAND SIDE LEFT-HAND SIDE

D

C

B CF02F552

2

1-3

SECTION 1 - TO THE OWNER/SAFETY TYPE, SERIAL NUMBER AND YEAR OF MANUFACTURE When ordering parts, requesting information or assistance, always give your Dealer the type, serial number and year of manufacture of your machine.

In the spaces below, write the type, serial number and year of manufacture of your machine as well as the type and the serial number of the engine.

MACHINE

CD02E003

3 (A) Model Number .........................................................

(B) Product Inditification Number ..................................

A

B

CS01A520C

4 ENGINE (DV201, DV202) Make and type ...............................................................

Serial number.................................................................

CD02E004A

5

1-4

SECTION 1 - TO THE OWNER/SAFETY ENGINE (DV204) Make and type ...............................................................

Serial number.................................................................

CD02E004

6 ROPS FRAME

CD02E005A

7

1-5

SECTION 1 - TO THE OWNER/SAFETY IDENTIFICATION OF THE MAIN COMPONENTS OF THE MACHINE

21

10

15

18 19 14

11

16

22

9

8

4 23

24

25

25

1 1 2

6 17

25

12

13 7 3 20

5

25

6 17

2

CS02E688

8 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

1-6

Drum chassis Vibratory drums (front and rear) Machine articulation Front machine chassis Rear machine chassis Travel motor Fuel tank Battery ROPS frame Hydraulic reservoir Engine hood Engine Travel pump

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

Air filter Exhaust system Front console controls Vibration motor Vibration and power steering hydraulic pump Hydraulic oil cooler Sprinkler pump Front water reservoir Rear water reservoir Front sprinkler bar Rear sprinkler bar Scrapers (front and rear)

SECTION 1 - TO THE OWNER/SAFETY SAFETY RULES Your safety and that of people around you depends on you. It is essential that you understand this manual for the correct operation, inspection and maintenance of this machine.

Read this manual carefully and check that : - You understand fully the symbols on the controls and the safety signs used in this manual and on the machine.

- You understand fully the speed, stability, braking and steering characteristics of the machine. If you are in any doubt, consult your Dealer.

The safety messages in this manual concern situations which may arise during normal machine operation and servicing. These safety messages also indicate the various ways of coping with these situations. Other safety messages are used throughout the manual to indicate specific dangers.

Whatever type of work is being done, the safety measures for private or public work sites are those which conform to the current regulations in the country concerned or the profession concerned.

Safety instructions given in this manual are a summary of the basic rules to be observed at all times and do not exempt you from insurance requirements or from abiding by the highway code.

Always keep this manual in the storage compartment provided for it. Make sure that it is always complete and in good condition. Consult your Dealer to obtain additional manuals or manuals in a language other than that of the country in which the machine is being used.

CD02E006

9

1-7

SECTION 1 - TO THE OWNER/SAFETY PERSONAL SAFETY Safety Decals on this machine use the words Danger, Warning or Caution, which are defined as follows:

• DANGER: Indicates an immediate hazardous situation which, if not avoided, will result in death or serious injury. The color associated with Danger is RED. • WARNING: Indicates a potentially hazardous situation which, if not avoided will result in serious injury.

The color associated with Warning is ORANGE. • CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. The color associated with Caution is YELLOW. ISO two panel pictorial symbol decals are defined as follows:

• The first panel indicates the nature of the hazard.

• The second panel indicates the appropriate avoidance of the hazard.

• Background color is YELLOW. • Prohibition symbols such if used are RED. STOP

1-8

as

and

SECTION 1 - TO THE OWNER/SAFETY BEFORE USING THE MACHINE 1.

2.

To ensure that you do not get caught up in the machine, avoid any loose clothes, uncovered long hair, jewelry or floating personal articles.

Different types of work require different protective equipment. Protective equipment such as a safety helmet, protective shoes, reinforced gloves, reflective jackets, breathing masks and ear protection may be necessary. Before starting the work, decide what type of protective equipment is necessary. Wear that equipment continuously.

14. Check all controls and safety devices in a safe, unobstructed area before starting work.

15. Keep away from dangerous areas such as ditches, overhangs, unstable ground, etc. Inspect the work site before starting work and look for any danger areas.

16. Before moving the machine to work in a new area, walk around it to determine all possible causes of accidents there. Holes, obstacles, piles of rubble and other potential sources of danger on the work site can cause serious injury.

3.

Do not operate the machine until you have first read and assimilated the instructions and warnings given in this manual.

17. Make sure that no building is within the working area, in order to prevent it being damaged due to the vibration from the machine.

4.

Operating the machine requires your full attention, and caution on the part of the operator can avoid accidents. Get to know the abilities and the limitations of the machine and also the space required for its operation. There are some areas of poor visibility within the working range of the machine.

Have someone guide you for all work where visibility is not perfect.

18. Check that the main components are correctly attached to the machine. If any problem is found, consult your Dealer.

5.

6.

7.

Grease, oil, mud or ice on the steps and access handles can cause accidents. Make sure they are kept clean at all times.

Every day, inspect the machine all round to detect any signs of oil or hydraulic fluid leakage. Tighten the connections or replace any defective components if necessary.

Make sure that you are perfectly familiar with the hand signals in daily use on the work site so as to be able to obtain help with tight maneuvers or when carrying out operations where visibility is poor.

8.

Before undertaking any travel or working operations during hours of darkness, make sure the lighting and signalling equipment is fully operative.

9.

Before undertaking any travel, make sure the engine hood is correctly fastened.

19. Make sure you understand the symbols used on the machine safety decals. Keep the decals clean so that they are perfectly legible at all times.

20. Keep yourself fully informed of legal regulations and safety equipment required for transporting this machine on a road or highway.

21. Make sure that the route that the machine is to take during transport is safe. If there are bridges, make sure that they can withstand the weight of the machine in complete safety.

22. Always fasten your seatbelt before starting the engine. The seatbelt will protect you effectively if you fasten it correctly and if you always wear it.

The seatbelt should not be too loose. It should not be twisted or caught in the seat.

23. Under normal operating conditions, the hydraulic travel circuit shut-off valve lever should be in vertical (ON) position and locked mechanically.

10. Check that no tools or other items have been left on the machine or in the operator's compartment.

11. The operator must be the only person on the machine. Make sure there is no one else near or on the machine.

12. When entering or leaving the operator's compartment, always face the machine and use the steps and access handles.

13. Be sure you know the position and function of each control. Incorrect operation of the controls could cause serious injury.

1-9

SECTION 1 - TO THE OWNER/SAFETY OPERATING THE MACHINE 1.

When working on a public highway, use the statutory traffic warning signs and take into account the working range of the machine. National or local regulations will define the number, type and location of reflector strips.

2.

Avoid running the engine in a confined space. If there is no alternative, proper ventilation must be provided at all times.

3.

Do not allow anyone else on the machine. A passenger could fall and cause an accident.

4.

Never operate any control or driving control unless you are correctly seated in the operator's seat (with the seat locked in driving position).

5.

Before starting the engine, indicate your presence by sounding the horn.

6.

Never start the engine in any other manner than that shown in this manual.

7.

If the machine comes in contact with a live electric line, it is absolutely essential to follow the following points.

1. Never get down from the operator's compartment.

2. Warn all those in the vicinity that they must not approach or touch the machine.

3. Move the machine quickly away from the danger area.

8.

Always make allowance for working conditions (sloping or rough ground), the road surface and weather conditions. Move the machine slowly.

9.

Do not allow anyone to stand in the machine working area. Accidental operation of a control by the operator could cause an accident. Stop all operations until the person has moved away.

10. Operate all the controls gradually to ensure smooth machine operation.

11. Before moving in reverse, make sure that there is no one behind the machine.

12. Never move the speed switch from high speed to low speed without having first stopped the machine.

13. Select high speed only for travel on made-up roads. Never use it when working.

14. Stop the engine and remove the starter switch key even for short stops.

15. Never get down from the operator's position when the engine is running.

16. Dust, smoke or mist can reduce visibility and 1-10

cause and accident. Stop or slow down the machine until visibility is restored to normal.

17. Never jump down from the machine. To leave the operator's position, always face the machine and use the steps and access handles.

18. Before traveling on a slope, always place the machine perpendicular to the slope. Keep the engine speed at maximum. It is essential to move the machine in slow speed.

19. Never work with the engine hood open.

20. Before opening the engine hood, make sure that there is no obstacle preventing it being opened completely.

21. Before opening or closing the engine hood, make sure that there is nobody in the vicinity.

22. In the event of an operating problem or damage, move the machine to a safe place, stop the engine and remove the starter switch key. Identify or report the defect and if necessary, take measures to prevent the machine being used.

23. When parking on a slope, use blocks to prevent the machine from moving.

24. When lifting the machine, everybody in the vicinity must be kept at a safe distance.

25. Always wear hearing protection.

SECTION 1 - TO THE OWNER/SAFETY PARKING THE MACHINE

5.

Maintenance or adjustments which are incorrectly performed can cause serious injury. If you do not understand the servicing or adjustment procedure, call your Dealer.

6.

Before carrying out any servicing operations on this machine, proceed as follows:

When parking your machine, proceed in the following manner : 1.

Place the machine on flat, level ground, away from soft areas, excavations or badly shored cavities.

2.

Place the front chassis in alignment with the rear chassis.

3.

4.

2. Shut down the engine and remove the starter switch key.

Place the direction of travel lever in the neutral position.

Stop the engine and remove the starter switch key.

5.

Switch off the electrical circuit by means of the battery master switch.

6.

Make sure the engine hood is correctly fastened.

7.

Make sure that no component of the machine is protruding onto the public highway. If this cannot be avoided, set up approved traffic signs. Use flags, barriers, lighting and regulation signals. Provide signs at a reasonable distance on the road, to warn vehicles approaching from the rear.

MAINTENANCE AND ADJUSTMENTS 1.

1. Place the machine on flat, level ground.

Before servicing the machine or carrying out any adjustments, place the " Do not operate " sign on the front console.

3. Use blocks to prevent the machine from moving.

7.

Any unauthorized modifications made to this machine can cause serious injury. Do not undertake any modifications without first consulting your Dealer. Any modifications made must be in conformity with the technical specifications of the machine and must meet current safety regulations.

8.

Certain components of the machine are subject to type approval. When replacing such components, it is compulsory to ensure that they conform to the regulations. For safety's sake, use genuine parts.

9.

The protective structure (optional) is in conformity with "ROPS" standards. Any modifications (drilling, welding, etc.) may jeopardize that conformity.

10. Pressurized hydraulic fluid or grease which penetrates the skin can cause serious injury. Take the necessary safety precautions (safety clothing and protection for face and hands) to avoid such risks.

Also, before handling these products, read the manufacturer's instructions concerning their use.

If hydraulic fluid penetrates the skin, call a doctor immediately.

11. When using compressed air, take the necessary measures to protect your face.

12. Clean the machine at regular intervals. Accumulation of grease, dirt and debris can cause injury or damage the machine.

B9502062

2.

10 Do not carry out any maintenance work until you have first read and assimilated the instructions and warnings shown in this manual.

3.

When servicing the machine wear suitable clothing.

4.

Always wear eye protection when you are using a tool which can cause metal particles to be projected. Use a hammer with a soft face, such as copper, when installing pins.

1-11

SECTION 1 - TO THE OWNER/SAFETY 13. Periodically inspect the fastening of the main components, as part of programmed maintenance. If any problem is found, consult your Dealer.

4.

Sparks can fly from the electrical system or the engine exhaust. Before running the machine in an area where there may be inflammable gases, make sure that there is adequate ventilation.

14. Never carry out any welding operation on the machine without the prior authorization of your Dealer.

5.

Clean the machine regularly, removing all debris and inflammable material.

6.

Make sure there are no leaks and replace any damaged hoses, lines or connectors. After any repair work, clean the machine before operating it.

15. When carrying out welding operations on the machine, as authorized by the manufacturer and in accordance with its specifications, disconnect the alternator and connect the earth of the welding set to the component on which the welding is to be carried out. Never connect the welding earth to a component of the hydraulic system.

PREVENTION OF BURNS 1.

The electrolyte in battery can cause serious burns. Battery contains sulphuric acid. Avoid contact with skin, eyes and clothing.

Antidote: EXTERNAL: rinse with water.

INTERNAL: drink large amounts of water or milk.

Then drink milk of magnesia, a beaten egg or vegetable oil. Call a doctor immediately.

EYES: Rinse with water for 15 minutes and consult a doctor immediately.

2.

When battery electrolyte freezes it can explode, if you try to charge it or start up the engine with a booster battery. To prevent the electrolyte from freezing, keep the battery charged at all times.

3.

Battery produces explosive gases. Keep all flames, sparks and cigarettes away. Ventilate adequately when charging battery or using them in a confined space. Always protect your eyes when you are working near a battery.

PREVENTION OF FIRE OR EXPLOSIONS 1.

Engine fuel can cause an explosion or a fire.

1. Never refuel while the engine is running.

2. Never smoke while refueling.

3. Take all necessary safety measures when welding, grinding or when working near a naked light.

2.

Always use a non-inflammable solvent for cleaning parts.

3.

A spark or a naked light can cause hydrogen in a battery to explode. To avoid all risk of explosion, be sure to follow the instructions below : 1. Place the battery master switch in the OFF position (circuit switched off).

2. When disconnecting battery cables, always disconnect the negative cable (-) first.

3. When connecting battery cables, always connect the negative cable (-) last.

4. Never short-circuit the battery terminals with metal objects.

5. Do not weld, grind or smoke near a battery.

1-12

SECTION 1 - TO THE OWNER/SAFETY ROPS PROTECTIVE STRUCTURE 1.

Never try to weld or to straighten a ROPS protective structure.

2.

Do not modify the ROPS protective structure in any manner, since any modification, such as welding, drilling, cutting, addition of accessories or any damage undergone due to an impact or the machine turning over reduces the protection provided by the structure.

3.

Replace the ROPS protective structure if it has been subject to an impact or if the machine has turned over. Never try to repair it.

4.

If you use the machine without a ROPS protective structure and if the machine turns over, you are exposing yourself to serious or fatal bodily injury.

Only remove the ROPS protective structure for maintenance operations or when replacing it.

Never use the machine until the ROPS protective structure has been installed.

READ OPERATORS MANUAL Decals which display the "Read Operators Manual" symbol are intended to direct the operator to the Operators Manual for further information regarding safety, maintenance, adjustments and/or procedures for specific areas of machine. When a decal displays the following symbol refer to the Operators Manual.

237187A1

11 When a decal displays the symbol shown below, refer to the appropriate page of the Service Manual.

BC00G075

12

1-13

SECTION 1 - TO THE OWNER/SAFETY DECALS

!

WARNING

!

An illegible or missing decal can have serious consequences. Check them every day. Make sure that the decals are perfectly legible, clean them regularly and replace decals that are destroyed, lost, painted over or no longer legible with new ones. When parts bearing decals are replaced, make sure to put a new decal on each new part.

When cleaning decals, use a cloth, water and soap.

Never use solvents, petrol, etc.

POSITION OF DECALS When replacing a decal, make sure it is located as shown in the illustration below.

CS02H555

13 This chapter only covers decals relating to safety, machine operation and servicing. For information on all decals on the machine, consult the spare parts catalog.

1-14

You can obtain new decals from your Dealer; the part numbers are shown at the bottom of the decal.

SECTION 1 - TO THE OWNER/SAFETY BASIC CRUSH HAZARD Located on the right and left-hand sides of the front chassis.

1

Part number : ND106588

CS02H556

14 GENERAL HAZARDOUS AREA Located on the right and left-hand sides of the front chassis.

2

Part number : ND106586

CS02H557

15 ROLL OVER/USE SEAT BELT Located on the front console cover.

3

Part number : ND109913

CS02H558

16 BASIC REMOVE KEY/READ SERVICE MANUAL Located on the front console cover.

4

Part number : ND106592

CS02H559

17 1-15

SECTION 1 - TO THE OWNER/SAFETY HOT SURFACE HAZARD Located under the engine hood, on both sides of the chassis.

5

Part number : ND106591

CS02H560

18 ENTANGLEMENT HAZARD FAN Located on the engine fan cover.

6

Part number : ND109916

CS02H561

19 RUNOVER HAZARD Located behind the operator's seat.

7

Part number : ND109912

CS02H562

20 BASIC READ OPERATOR’S MANUAL Located on the front console cover.

8

Part number : ND106584

CS02H563

21 1-16

SECTION 1 - TO THE OWNER/SAFETY BATTERY EXPLOSION/SERVICE Located on the left-hand side of the hydraulic reservoir.

9

Part number : ND106581

CS02H564

22 SLING POINTS Located on the drum hangers.

10

Part number : ND081460

CS02H565

23 STARTER - START FROM SEAT Located on the right-hand side, in front of the engine.

11

Part number : ND106579

CS02H566

24 OPERATOR'S MANUAL Located in the compartment behind the operator's seat.

12

Part number : ND081612

CS02H567

25 1-17

SECTION 1 - TO THE OWNER/SAFETY DO NOT WELD ON MACHINE Located on the left-hand side of the front console.

13

Part number : ND106593

CS02H568

26 BATTERY MASTER SWITCH Located in front of the hydraulic reservoir

14

Part number : ND081678

CS02H569

27 VERTICAL ARTICULATION CRUSH HAZARD Located at the bottom of the front chassis, on the lefthand side.

15

Part number : ND109915

CS02H570

28 HORIZONTAL ARTICULATION CRUSH HAZARD Located on the left-hand side of the front chassis.

16

Part number : ND109914

CS02H571

29 1-18

SECTION 1 - TO THE OWNER/SAFETY REFUELING Located on the left-hand side of the front chassis.

17

Part number : ND081458

CS02H572

30 HANDLING THE MACHINE Located on the left-hand side of the rear chassis.

18

Part number : ND109995 NOTE : For more information, see " Handling the machine " in the " Operating Instructions " Section.

CS02H574

31 HYDRAULIC FLUID REFILL Located on the hydraulic reservoir cover.

19

Part number : ND081465

CS02H575

32 OVERALL MACHINE HEIGHT Located on the left-hand side of the rear chassis.

20

Part number : ND081777

CS02H576

33 1-19

SECTION 1 - TO THE OWNER/SAFETY HAND SIGNALS When operating the machine, never attempt to carry out tasks calling for fine control or working in areas where visibility is poor or impaired without seeking the assistance of a signalman. Make perfectly sure that you and the signalman understand the signals to be used.

START THE ENGINE

COME TO ME Wave hands back and forth (palms inwards).

PDE0002A

34

PDE0003A

SHUT DOWN THE ENGINE

36 MOVE AWAY FROM ME Wave hands back and forth (palms outwards).

PDE0002

35 PDE0003

37

1-20

SECTION 1 - TO THE OWNER/SAFETY GO THIS FAR

EMERGENCY STOP Wave hands back and forth.

PDE0004A

38

PDE0005

ALL STOP AND HOLD

41 TURN THE MACHINE TO THE LEFT To stop movement, stop moving hand and clench fist.

PDE0004

39 STOP PDE0008A

Wave hands back and forth.

42 TURN MACHINE RIGHT To stop movement, stop moving hand and clench fist.

PDE0005A

40 PDE0008

43

1-21

SECTION 1 - TO THE OWNER/SAFETY

NOTES

1-22

SECTION 2

16

CONTROLS/INSTRUMENTS/ACCESSORIES STEPS AND ACCESS HANDLES To get onto or off the machine, use the steps and the access handles.

!

WARNING

!

Never jump down from the machine. Always face the machine when getting down from it and use the steps and access handles. Keep the steps and access handles clean and remove all traces of grease, oil, mud and ice.

CS02F593

1

2-1

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES LOCATION OF CONTROLS, INSTRUMENTS AND ACCESSORIES

!

WARNING

!

Before starting the engine, make sure that you are fully aware of the location and function of each control.

Incorrect operation of the controls could cause serious bodily injury.

8

9

10

11

12

7

17 18

19 6 13

14

15

16 2

5

21

20 4

3 22

23

1 24

27

25

26 CS02H577

2

2-2

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES 1. Steering wheel

15. Drum vibration indicator lamp

2. Starter switch

16. Indicator lamp for turn indicators (optional)

3. Engine throttle control

17. Hazard warning signal control (optional)

4. Fuse compartment

18. Rotating beacon control (optional)

5. Drum vibration control (MANU/AUTO)

19. Sprinkling cycle control

6. Drum vibration configuration control

20. Direction of travel and travel speed lever

7. Front work light control (optional)

21. Drum vibration control (ON/OFF)

8. Rear work light control (optional)

22. Emergency stop control

9. Battery charge warning lamp

23. Horn control

10. Engine overheating warning lamp

24. Parking brake control

11. Machine braking warning lamp

25. Turn indicator control (optional)

12. Drum sprinkler indicator lamp

26. Power socket

13. Engine oil pressure warning lamp

27. Operator's seat

14. Hydraulic fluid overheating warning lamp

28 50 AMP electrical circuit protection fuse 29 Battery master switch 30 Hourmeter

28

29 30 CD02E007A

3

2-3

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES FRONT CONSOLE CONTROL FUNCTIONS

2 1 3 4

CS02H578

4 1. STEERING WHEEL The steering wheel (1) is used to steer the machine either to left or right, using the central articulation.

Avoid using the steering wheel when the machine is stationary, since there is a risk of damaging the drums.

IMPORTANT : Before carrying out any travel, with the machine, make sure the central articulation is not locked. See "Machine articulation locking " in the "Operating Instructions" Section.

2. STARTER SWITCH This switch is operated with the starter switch key and has five positions : "P" (Not used), "O" ( Off), "I" (Contact), "II" (Preheat) and "III" (Start). See "Starting the engine" in the "Operating Instructions" Section.

IMPORTANT: Before starting the engine, make sure that the direction of travel lever is in the neutral position, otherwise it is not possible to start the engine.

See "Right-hand arm control functions".

2-4

3. ENGINE THROTTLE CONTROL This lever is used to increase or decrease the engine speed. Tilt the lever upwards for the "idle speed" position. Tilt the lever downwards for the "maximum speed" position.

IMPORTANT : When using drum vibration, this lever must be placed in one of two preset positions. See "Slow travel with vibration" in the "Operating Instructions" Section.

4. FUSE COMPARTMENT See "Fuses" in the "Electrical System" Section.

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES

7 6 5

CS02H578

5

5. DRUM VIBRATION CONTROL (MANU/AUTO) When the selector is in left position, manual mode vibration is obtained in accordance with the operating parameters. In this mode the drums will vibrate without interruption.

When the selector is in right position, automatic mode vibration is obtained. In this mode drum vibration will automatically cease whenever the machine comes to a halt.

NOTE : The type of vibration depends on the engine throttle control. See "Slow travel with vibration" in the "Operating Instructions" Section.

IMPORTANT : To obtain drum vibration, operate the drum vibration control. See "Right-hand arm control functions".

6. DRUM VIBRATION CONFIGURATION SELECTOR When the selector is in left position, vibration may only be obtained with the front drum.

When the selector is in right position, vibration may be obtained with both drums.

7. FRONT WORK LIGHT CONTROL (optional) This two-position control is used to operate the front work lights. When the switch is pushed forward, the lights are off. When the switch is pushed backward, the lights are on and the switch also lights up.

IMPORTANT : In order to obtain drum vibration in automatic mode, the travel direction control lever must be engaged. It is not possible to obtain drum vibration if the travel direction control lever is in zero position.

See "Right-hand arm control functions".

!

WARNING

!

When in manual mode, never vibrate on the spot for more than thirty seconds.

2-5

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES

8

9

10

11

12

CS02H578

6

8. REAR WORK LIGHT CONTROL (optional) This two-position switch controls the rear work lights. When the switch is pushed forward, the rear work lights are off. When the switch is pushed completely backwards, the rear work lights are selected and this switch also lights up.

9. BATTERY CHARGE WARNING LAMP This warning lamp comes on when the starter key switch is in the "On" position and it goes out in the "Starting" position. If the warning lamp comes on when the engine is running this means that the alternator/fan belt is broken or that the alternator is not charging the battery. Move the machine to a safe place, shut down the engine, remove the starter switch key and find the cause of the problem.

10. ENGINE OVERHEATING WARNING LAMP This lamp comes on and the audible alarm device sounds when the engine temperature is too high. Move the machine to a safe place, shut down the engine, remove the starter switch key and find the cause of the problem.

2-6

11. MACHINE BRAKING WARNING LAMP This lamp comes on to remind the operator the machine brakes are applied. It works in conjunction with the direction control lever. When the direction control lever is in "0" (Neutral) position, this lamp comes on after 2 seconds and the machine brakes are automatically applied. The lamp goes out as soon as the brakes are released.

See "Right-hand arm control functions".

NOTE : This lamp also comes on if the emergency shut down control is operated or the parking brake is applied. See "Right-hand arm control functions".

12. DRUM SPRINKLER INDICATOR LAMP This lamp comes on when the drum sprinkler system is operating.

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES

17

13

14

15

16

CS02H578

7

13. ENGINE OIL PRESSURE WARNING LAMP This warning lamp comes on when the starter key switch is in the "On" position and it goes out in the "Starting" position. If the warning lamp comes on when the engine is running, this indicates that the engine oil pressure is too low. Move the machine to a safe place, shut down the engine, remove the starter switch key and find the cause of the problem.

14. HYDRAULIC FLUID OVERHEATING WARNING LAMP This lamp comes on and the audible alarm device sounds when the hydraulic fluid temperature is too high.

Move the machine to a safe place, shut down the engine, remove the starter switch key and find the cause of the problem.

15. DRUM VIBRATION INDICATOR LAMP This indicator lamp comes on when the vibration control push button is operated.

See "Right-hand arm control functions".

16. INDICATOR LAMP FOR TURN INDICATORS (optional) This indicator lamp comes on when the turn indicator control (25) is operated. It flashes at the same rate as the turn indicators. See "Right-hand arm control functions".

17. HAZARD WARNING SIGNAL CONTROL (optional) This two-position control is used, in an event of emergency, to operate the right and left-hand turn indicators simultaneously. When the switch is pushed forward: off. When the switch is pushed backwards: on. In the on position, this switch flashes at the same rate as the turn indicators.

2-7

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES

18 19

CS02H578

8

18. ROTATING BEACON CONTROL (optional) This two-position control is used to switch the rotating beacon on and off. When the switch is pushed forwards, the rotating beacon is off. When the switch is pushed backwards, the rotating beacon comes on and this switch also lights up.

NOTE : The rotating beacon should be placed on the ROPS frame and connected to the power socket. See “Power socket”.

19. SPRINKLING CYCLE CONTROL Sprinkling cycle adjustment may be made using this five-position switch.

In "0" position the sprinkler is inoperative .

Positions "I", "II", "III" and "IV" regulate the drum sprinkling intervals.

IMPORTANT : Do not operate the sprinkling control when both reservoirs are empty. This could damage the electric pump.

NOTE : Sprinkling stops automatically when the travel direction control lever is returned to "0" position. When the machine is at a complete halt, sprinkling will continue only if the travel direction control lever is in "D" position. See "Right-hand arm control functions".

2-8

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES RIGHT-HAND ARM CONTROL FUNCTIONS 20. RIGHT-HAND ARM CONTROL This lever allows the operator to select the machine travel direction and speed.

With the engine started and running, tilt the lever (20) to the left (Position D).

Then tilt the lever to one of the four other possible positions (F1, B1, F2, B2).

Position F1: machine moves forward at slow speed.

Position B1: machine moves backward at slow speed.

Position F2: machine moves forward at high speed.

Position B2: machine moves backward at slow speed.

Machine travel speed depends on the angle to which the lever is tilted as well as the type of speed chosen (F1, B1, F2, F2). The further the lever is tilted, the faster the speed. The lever may be released at any given moment and it will stay in place at the chosen speed.

20

NOTE : When the machine is stationary (with the brakes applied), if the steering wheel is turned, the machine brakes will be released in order to protect the braking system.

NOTE : To start the engine, it is imperative for the lever (20) to be in the "0" (Neutral) position, otherwise starting is impossible. See "Starting the engine" in the "Operating Instructions" Section.

CS02E698

9 IMPORTANT : When the lever is left in "0" position (Neutral) for more than two seconds the brakes are automatically applied and the machine braking warning light comes on. As soon as the lever is operated, the machine braking warning light goes out and the brakes are released. See "Front console control functions". Quick transition of the lever through "0" position (less than two seconds) will not cause the brakes to be applied.

!

WARNING

!

High speed should only be used for travel on madeup roads. In the event of insufficient drive power, stop the machine travel and select low speed.

IMPORTANT : It is possible to change from low speed to high speed while the machine is traveling. On the other hand, never change from high speed to low speed directly, since this is likely to cause damage to the hydraulic system. Stop the machine travel and then select low speed.

2-9

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES 21. DRUM VIBRATION CONTROL (ON/OFF) This push button is used to obtain drum vibration with the front drum or with both drums (see "Drum vibration configuration selector"). Press the button to obtain vibration and the drum vibration indicator lamp will light up. Press the button again to stop vibration and the drum vibration indicator lamp will go out. See also "Drum vibration control (MANU/ AUTO)".

21

NOTE : The type of vibration depends on the engine throttle control.

IMPORTANT : This control may only be used when in low speed.

IMPORTANT : Engine speed must also be at least 1800 rpm. Below this speed, drum vibration can not be obtained.

22.EMERGENCY STOP CONTROL This control is used to shut down the engine in the event of an emergency, or when shutting down by means of the starter switch key is impossible or if there is an operating problem with the direction of travel lever. Press the button, the engine will stop, the brakes will be applied and the machine braking warning light will come on. See "Front console control functions". To restart the engine, turn the button in the direction of the arrow and operate the starter switch key, see "Engine emergency stop" in the "Operating Instructions" Section.

IMPORTANT : This control should only be used in the event of an emergency. Never use it during normal operation to shut down the engine.

NOTE : To start the engine, it is essential for the button to be in the raised position, otherwise it is impossible to start. See "Starting the engine" in the "Operating Instructions" Section.

23. HORN CONTROL Press and hold down the button (23) for the horn to sound. Release the button (23) to stop the horn.

2-10

22

23

CS02E698

10

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES 24.PARKING BRAKE CONTROL This control is used to park or stop the machine immediately in case of an emergency (or for coming to a complete halt on a slope, where the machine may briefly continue traveling forward or moving backwards). Place the direction control lever (20) in neutral and then press the switch. The machine brakes are immediately applied and the machine braking warning light comes on. See "Front console control functions".

Press the switch once more to release the machine brakes before engaging travel.

25. TURN INDICATOR CONTROL (optional) This three-position switch controls the turn indicators. When the switch is pushed to the left, the left-hand indicator functions. When the switch is pushed to the right, the right-hand indicator functions. When the switch is pushed, whether to the left or to the right, the turn indicator lamp flashes at the same speed as the turn indicators.

20

24

25

26 CS02E698

11 26. POWER SOCKET This socket is used to connect an inspection lamp, a rotating beacon or any other 12 volt electrical appliance.

26

CD02F006

12

2-11

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES BATTERY MASTER SWITCH The battery master switch (29) is located near the battery. When it is tilted upwards in "0" position, the battery is completely disconnected from the electrical circuit and the system is switched off. In position "I" the system is switched on.

!

WARNING

0

!

The battery master switch must be in the "0" position (system switched off) after each working day, during maintenance operations and during any service work on the electrical circuit and the battery.

I 29 CD02E007A

13

HOURMETER The hourmeter (30) shows the number of engine operating hours and enables servicing intervals to be scheduled. See the "Servicing Intervals/Lubrication/ Fluids" Section.

30 CD02E007A

14

HYDRAULIC TRAVEL CIRCUIT SHUT OFF VALVE LEVER This lever is located under the engine hood and is used to open (ON) or close (OFF) the hydraulic travel circuit. It must be used to release the hydraulic motor brakes if the machine has to be towed. See "Releasing hydraulic travel motor brakes" in the "Operating Instructions" Section.

ON

IMPORTANT : During normal operating conditions this lever must always be in the vertical (ON) position and locked mechanically.

OFF

CD02G010

15

2-12

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES OPERATOR’S SEAT For correct operation of the machine with maximum efficiency and comfort, adjust the seat properly, to suit the weight and height of the operator.

!

WARNING

!

Before operating the controls, make sure that the seat is correctly adjusted.

SEAT SUSPENSION ADJUSTMENT Use the handle to obtain, in 10 kg (22 lb) increments, the rigidity corresponding to an operator weighing between 50 and 130 kg (110 to 266 lb).

CD02F003

16 BACKREST ANGLE ADJUSTMENT To tilt the seat back, push the lever, move the backrest to the required position and then release the lever.

CD02F002

17 FORWARD/REARWARD POSITION ADJUSTMENT Raise the lever to adjust the seat forward or rearward.

CD02F004

18

2-13

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES OFFSET LEVER (DV204 only) In order to make it easier to get in or out of the driver's compartment, the operator's seat may be moved from right to left. Press the lever and slide the seat sideways. Follow the same procedure to return the seat to operating position.

CD02F005

19 INERTIA TYPE SEAT BELT Sit comfortably in the operator's seat, pull a sufficient length of belt and fasten it. Allow the reel to take up the slack.

To unbuckle the seat belt, press the unlocking plate.

IMPORTANT : Inspect the seat belt, make sure it is not damaged and that the retaining screws are correctly tightened and change any defective parts.

The seat belt must be clean. To clean it, use only soap and water, never use bleach or dye solution.

CD02F001A

!

WARNING

!

Always fasten your seat belt before starting the engine. The seat belt will protect you efficiently if you fasten it correctly and if you always wear it. The seat belt should not be too loose. It must not be twisted or caught in the seat.

2-14

20

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES DRUM SPRINKLER RESERVOIRS The machine has two reservoirs for sprinkling the drums with water. The two reservoirs are connected to a common circuit.

One reservoir is under the engine hood.

CD02F007

21 The other is under the operator's seat.

The sprinkling system is controlled using the switch on the front console. See "Front console control functions".

IMPORTANT : Do not operate the sprinkling control when both reservoirs are empty. This could damage the electric pump.

NOTE : During cold water add antifreeze to the water in the reservoirs.

CD02F008

22

2-15

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES STORAGE BOX Located at the rear of the operator’s seat, this box is to be used for storing the operator’s manual.

CD02E006

23

FRONT CONSOLE COVER Tilt the cover downwards to protect the console. It is possible to lock the cover with a padlock.

CD02F010

24

2-16

SECTION 3

32

OPERATING INSTRUCTIONS BEFORE OPERATING THE MACHINE 9.

!

WARNING

!

Make sure that no-one is under or on the machine. The operator must be alone on the machine.

Do not operate this machine until you have first read and assimilated the instructions and warnings shown in this manual.

Observe the operating instructions shown in this chapter, since any other use without the prior agreement of the manufacturer is considered to be forbidden.

10. Make yourself aware of work-site safety measures.

Before operating the machine, observe the following instructions:

12. Before starting the engine, warn of your presence by sounding the horn.

1.

Check the levels (engine oil and hydraulic fluid) and make sure that the various fluids correspond to the conditions of use. See "Fluids and lubricants" in the "Servicing Intervals/Lubrication/ Fluids" Section.

13. Never start the engine in any other manner than that shown in this manual.

2.

Carry out the daily maintenance operations. See the "Servicing Intervals/Lubrication/Fluids" Section.

3.

Check all round the machine, identify any leaks and inspect the hoses. Tighten or replace where necessary. See the "Maintenance/Adjustments" Section.

4.

Before carrying out any work in the hours of darkness, check that the lighting and signalling systems are operating correctly.

5.

Clean the steps and access handles. The presence of grease, oil, mud or (in winter) ice can cause accidents. Make sure they are always clean.

6.

Clean or change safety decals which are no longer legible. See "Decals" in the "To the owner/ Safety" Section.

7.

Make sure that the engine hood is closed and locked correctly.

8.

Make sure that no objects or tools are on the machine or in the operator's compartment.

11. Holes, obstacles, debris and other dangers on the work site can cause serious bodily injury. Inspect and identify all possible risks before driving the machine into a new working area.

3-1

SECTION 3 - OPERATING INSTRUCTIONS OPERATING THE MACHINE

!

WARNING

!

Check the correct operation of all the controls and all the safety devices in a safe, unobstructed area before starting work.

When operating the machine observe the following instructions: 1.

Start the engine, taking into account the weather conditions. See "Starting the engine".

2.

Regularly consult the hourmeter to observe the servicing intervals. See the "Servicing Intervals/ Lubrication/Fluids" Section.

3.

If the machine is used under particularly severe conditions (dusty or corrosive environment, etc.) reduce the length of the servicing intervals.

11. Use all the controls gradually so that the machine operates smoothly.

12. Before moving in reverse, make sure that there is no one behind the machine.

13. Never tilt the speed switch from high speed to low speed without having first stopped the machine.

14. Select high speed only for travel on made-up roads. Never use it for work.

15. Before traveling on a slope, place the machine perpendicular to the slope. Set the engine speed to maximum and travel only in low speed.

16. Never work with the engine hood open.

17. When moving the machine onto a low loader, see "Transporting the machine".

18. When handling the machine see "Handling the machine".

4.

If this machine is new or if the engine has been reconditioned, see "Run in period".

19. When towing the machine, see "Towing the machine".

5.

When operating on a work site on the public road, use the regulation traffic signs, taking into account the operating range of the machine. Local regulations define the number, type and location of reflective strips.

20. Avoid running the engine in a confined space. If this cannot be avoided, provide good ventilation in all circumstances.

6.

Be vigilant, make yourself aware of places where other people are working close to your working area. Keep all other persons away from the machine. Non-observance of these instructions can cause serious bodily injury.

7.

Make sure the operator's seat is correctly adjusted in operating position.

8.

Never operate a control or driving component without being correctly seated in the operator's seat with the seat belt fastened.

9.

Always make allowance for working conditions (sloping or rough ground), the conditions of the ground and weather conditions.

10. Never allow any other person within the working range of the machine. Stop all movement until the person has moved away.

3-2

21. Dust, smoke or mist can reduce visibility and cause and accident. Stop or slow down the machine until normal visibility is regained.

22. In the event of an operating problem or damage, move the machine to a safe place, shut down the engine and remove the starter switch key. Identify or report the defect and, if necessary, take measures to prevent the machine being operated.

23. When parking the machine, see "Parking the machine".

SECTION 3 - OPERATING INSTRUCTIONS RUN-IN PERIOD Longer engine life, improved characteristics and more economic operation can be obtained by taking great care with the engine during the first 60 operating hours.

During this period: Warm the engine up before using it under load.

Do not run the engine for long periods at idle speed.

Check the warning and indicator lamps and indicators and gauges frequently.

Check the oil levels frequently.

Use the lowest vibration frequency possible (53Hz).

During the first 50 and 150 hours of operation Change oil engine. See "Engine" in the "Servicing Intervals/Lubrication/Fluids" Section.

Replace engine oil filter. See "Engine" in the "Servicing Intervals/Lubrication/Fluids" Section.

Clean the sprinkler pump filter. See "Drum sprinkler system" in the "Servicing Intervals/Lubrication/Fluids" Section.

Change the fuel filter. See "Fuel system" in the "Servicing Intervals/Lubrication/Fluids" Section.

Check the engine alternator/fan belt . See "Engine alternator and fan belt" in the "Maintenance/Adjustments " Section.

Check and tighten nuts, vibration shock absorbers.

See "Vibratory shock absorbers" in the "Servicing Intervals/Lubrication/Fluids" Section.

!

WARNING

!

Check there are no leaks from the engine, such as oil or fuel leaks. Check the engine to chassis mountings.

After the first 500 hours of operation Check the engine valve clearance.

3-3

SECTION 3 - OPERATING INSTRUCTIONS STARTING THE ENGINE NOTE : After shutting down the machine for a prolonged period, see "Starting up after storage" in the "Storage" Section.

NOTE : All levels must be checked every day, before starting the engine.

NOTE : If you have to start the engine by means of booster battery, see "Connecting a booster battery" in the "Electrical System" Section.

1.

Place the battery master switch in the (I) position (system switched on).

0

I

CD02E007A

1 2.

Sit correctly in the operator's seat, check that it is correctly locked in the driving position and fasten your seat belt. See "Operator's seat" in the "Controls/Instruments/Accessories" Section.

CD02F001A

2 3.

Make sure that the direction of travel lever (20) is in the neutral position and the emergency stop button (22) in the raised position.

IMPORTANT : If the lever (20) is not in the neutral position or if the button (22) is lowered, it is impossible to start the engine.

20

22

CS02F501

3

3-4

SECTION 3 - OPERATING INSTRUCTIONS 4.

Turn the starter switch key (2) to "Contact" position (Position "I") and make sure the battery charge warning lamp (9), engine oil pressure warning lamp (13) and machine braking warning lamp (11) are on.

9

11

13

2 CS02F502

4 5.

Move the engine throttle lever (3) one quarter of its stroke.

3 CS02F502

5 6.

Make sure that no-one is in the vicinity of the machine, and sound the horn (23) as a safety measure.

23

CS02F501

6 7.

Turn the starter switch key (2) to "Preheat" position (Position "II") for about a minute.

NOTE : It is not necessary to do this if the engine is still warm or ambient temperature is high.

2 CS02F502

7 3-5

SECTION 3 - OPERATING INSTRUCTIONS 8.

Turn the key (2) to the starting position (position "III"). Release the key as soon as the engine fires.

If the engine stops, wait about 30 seconds and then start the operation again.

IMPORTANT : Do not operate the starter motor for more than 15 seconds at a time. Do not operate the starter motor when the engine is running.

9.

9 13

Make sure that the battery charge (9) and engine oil pressure (13) warning lamps go out.

2 CS02F502

8 10. Adjust the engine throttle lever (3) so the engine is running at half speed.

11. Allow the engine to run until it reaches normal operating temperature. (3 to 5 minutes).

IMPORTANT : When the engine is running, regularly check the indicators, gauges and warning lights.

3 CS02F502

9

3-6

SECTION 3 - OPERATING INSTRUCTIONS SHUTTING DOWN THE ENGINE 1.

2.

If drum vibration is being used, press the push button (21) to stop it and check that the drum vibration indicator lamp on the front console is out.

21

Place the direction of travel lever (20) in the "0" position (neutral).

20

NOTE : In this position the machine's brakes are automatically applied.

3.

Turn off drum sprinklers and other electrical items such as beacons and work lights (if equipped).

CS02F501

10 4.

Place the engine throttle lever (3) in the idle speed position.

5.

Run the engine at idle for about 1 minute.

IMPORTANT : In cold weather, allow the engine to run at idle for 3-5 minutes in order to reduce the engine temperature before completely shutting down.

6.

Turn the starter switch key (2) to the "Off" position.

2 3 CS02F502

11 7.

If you have to leave the operator's compartment, remove the starter switch key (2).

IMPORTANT: For any prolonged shut down of the engine, see "Parking the machine".

2

CD02F010

12

3-7

SECTION 3 - OPERATING INSTRUCTIONS ENGINE EMERGENCY SHUT DOWN In the event of emergency, or if it is impossible to shut down the engine by means of the starter switch key (1), or if an operating problem with the direction of travel lever (20) occurs, immediately press the button (22). The engine will stop, the machine's brakes are automatically applied and the machine braking warning lamp on the front console comes on.

IMPORTANT: This control should only be used in the event of emergency. Never use it during normal operation to shut down the engine.

Before restarting the engine, turn the button (22) in the direction of the arrow, make sure that the direction of travel lever (20) is in the neutral position and restart the engine if the cause for the shut down is not due to an operational problem. If there is a problem, determine its cause or consult your Dealer.

NOTE: To start the engine, it is imperative for the button (22) to be in the raised position, otherwise it is impossible to start.

3-8

20

22

CS02F501

13

SECTION 3 - OPERATING INSTRUCTIONS MACHINE TRAVEL AND DIRECTION OF TRAVEL Before any travel, make sure that no obstacle or person is in front of or behind the machine and make sure also that hood is correctly closed, then start the engine. See "Starting the engine".

In the event of poor visibility, use the controls on the front console to turn on the work lights (7) and (8) (optional).

FAST TRAVEL

!

7 WARNING

8

!

High speed is only to be used for travel on made-up roads. If there is insufficient driving force, stop the travel and then select low speed.

IMPORTANT : Never change from high speed to low speed directly, since this is likely to cause damage to the hydraulic system. Stop the machine travel and then select low speed 1.

CS02H579

14

Make sure, by means of the control (21) that drum vibrations are switched off (the indicator lamp (15) on the console should be out).

21

IMPORTANT: Never operate the control (21) when in high speed. Since this is likely to cause damage to the hydraulic system.

CS02E698

15 2.

Use the lever (3) to increase engine speed.

15 3 CS02F502

16

3-9

SECTION 3 - OPERATING INSTRUCTIONS 3.

Move the machine forwards (F2) or in reverse (B2) by means of the direction of travel lever (20).

See "Right-hand arm control functions" in the "Controls/Instruments/Accessories" Section.

NOTE: Travel speed depends on the angle to which the lever (20) is tilted. It can be released at any time and will remain in position at the chosen speed.

4.

20

Steer the machine by means of the steering wheel.

IMPORTANT: Do not use the engine throttle control lever to increase travel speed.

CS02E698

5.

To stop travel, place the lever (20) in the neutral position. After 2 seconds, the machine's brakes are automatically applied and the machine braking warning lamp also comes on. If necessary, shut down the engine, see "Shutting down the engine".

17

SLOW TRAVEL WITHOUT VIBRATION 1.

Make sure, by means of the control (21) that drum vibrations are switched off (the indicator lamp (15) on the console should be out).

21

CS02E698

18 2.

Use the lever (3) to increase engine speed.

15 3 CS02F502

19

3-10

SECTION 3 - OPERATING INSTRUCTIONS 3.

Move the machine forwards (F1) or in reverse (B1) by means of the direction of travel lever (20).

See "Right-hand arm control functions" in the "Controls/Instruments/Accessories" Section.

NOTE: Travel speed depends on the angle to which the lever (20) is tilted. It can be released at any time and will remain in position at the chosen speed.

4.

20

Steer the machine by means of the steering wheel.

IMPORTANT: Do not use the engine throttle control lever to increase travel speed.

CS02E698

5.

To stop travel, place the lever (20) in the neutral position. After 2 seconds, the machine's brakes are automatically applied and the machine braking warning lamp also comes on. If necessary, shut down the engine, see "Shutting down the engine".

20

SLOW TRAVEL WITH VIBRATION IMPORTANT : All work with vibration should be carried out in low speed.

1.

Use the selector (6) to obtain the vibration configuration required (front drum only or front and rear simultaneously). See "Front console control functions" in the "Controls/Instruments/Accessories" Section.

2.

Use the selector (5) to obtain the functioning mode (MANU/AUTO) required. See "Front console control functions" in the "Controls/Instruments/Accessories" Section.

NOTE : In manual mode, vibration will be obtained both while the machine is traveling and while the machine is standing still. In automatic mode vibration stops when the machine is standing still.

3.

Use the engine throttle lever (3) to select the type of vibration. Place the engine throttle lever (3) in one of the preset positions.

Position I : Vibration frequency will be 53 Hz and engine speed 2400 rpm.

Position II : Vibration frequency will be 62 Hz and engine speed 2800 rpm.

6 5 CS02H579

21

3 I

IMPORTANT : Do not leave the lever (3) in intermediate position when vibration is to be used.

II CD02H002

22

3-11

SECTION 3 - OPERATING INSTRUCTIONS 4.

Use the travel direction control lever (20) to travel in F1 or B1 and then press the push-button (21) on the front console. Either one or both of the drums will start vibrating, depending on the configuration selected.

21 20

NOTE: Travel speed depends on the angle to which the lever (20) is tilted. It can be released at any time and will remain in position at the chosen speed.

5.

To stop vibration, press the push-button (21) once more.

CS02E698

23 6.

The drum vibration indicator lamp (15) will go out.

15

CS02F502

24

3-12

SECTION 3 - OPERATING INSTRUCTIONS PARKING THE MACHINE 1.

Place the machine on flat, level ground, away from any soft area, excavation or poorly shored cavity.

2.

Place the front chassis in alignment with the rear chassis.

3.

Turn off all accessories, such as drum sprinklers , lights, etc.

4.

Shut down the engine, see "Shutting down the engine" and remove the starter switch key (2).

2

CD02F010

25 5.

(DV204 only) Use the lever (31) to release the operator's seat (27) and then slide it outwards until it engages. Climb down from the operator's compartment.

!

WARNING

!

Never jump down from the machine. To get down from the operator's compartment, always face the machine and use the steps and access handles.

31 27 CD02F005

26 6.

Switch off the electrical system by means of the battery master switch (29).

7.

Make sure the engine hood is correctly locked.

IMPORTANT: Make sure that no component of the machine protrudes onto the public highway. If this cannot be avoided, install signalling in conformity with regulations. Use regulation flags, barriers, lighting and signals. Install signs at a reasonable distance on the road to warn vehicles coming from the rear.

29

IMPORTANT: If the machine is being parked for a long time, see the "Storage" Section.

CD02F009

27

3-13

SECTION 3 - OPERATING INSTRUCTIONS DRIVING THE MACHINE ON ROUGH GROUND

!

WARNING

!

On sloping ground, place the machine perpendicular to the slope, otherwise there is a risk of it turning over. Always maintain maximum engine speed and travel, mandatorily, only in low speed (F1 or B1).

IMPORTANT : If it is necessary to apply the machine’s brakes immediately (for example, on a slope), place the direction of travel lever (20) in neutral position and then press the parking brake switch (24).

20

24

CS02E698

28

3-14

SECTION 3 - OPERATING INSTRUCTIONS ENGINE HOOD Located on the front chassis, the engine hood gives access to the engine compartment , the sprinkler reservoir, the hydraulic reservoir , the battery, the battery master switch, the hourmeter, etc.

OPENING

!

WARNING

!

Before opening or closing the hood, make sure nothing is obstructing the hood and preventing it from being fully opened and closed. Before opening or closing the hood, make sure nobody is standing close by. Never travel and never work with the machine with the hood in open position.

1.

Unlatch the hood by raising the clasp (1), located to the right of the hood and then releasing the hook (2).

2

1 CD02F071

29 2.

Use the handle (3) to raise the hood.

3

CD02F074

30

3-15

SECTION 3 - OPERATING INSTRUCTIONS 3.

Raise the hood completely to gain access to the various machine components.

NOTE : As soon as the hood is raised, the handle may be released ; the hood will be held open by the gas strut (4).

4

CD02F072

31 CLOSING Use the strap (5) to pull down the hood slightly and then lower it completely using the handle (3).

3

5

CD02F073

32 LATCHING Engage the hook (2) on the hood and then lower the clasp (1) completely to latch the hood.

2

NOTE : If equipped with a lock, use the starter switch key to lock the hood.

1 CD02H001

33

3-16

SECTION 3 - OPERATING INSTRUCTIONS ROPS FRAME REMOVAL AND INSTALLATION

!

WARNING

!

Only remove the ROPS frame for maintenance work or replacement. Never use the machine without the ROPS frame in place. If the ROPS frame is damaged, replace it, never attempt to repair it or straighten it.

IMPORTANT: To handle the ROPS frame, use lifting equipment and slings which are in perfect condition and capable of withstanding the load. Never attach the slings to anything else other than the two lifting eyes provided for this purpose.

REMOVAL 1.

Park the machine on a hard, flat surface. Stop the engine and remove the starter switch key.

2.

Screw the lifting eyes into the top of the ROPS frame.

3.

Secure the slings to the lifting eyes.

4.

Remove the structure mounting screws and washers from the rear chassis.

5.

Make nobody is standing near the machine or in the operating area.

6.

Carefully raise and remove the ROPS frame and then lower it gently to the ground.

INSTALLATION 1.

Carry out Steps 1 to 3 for removal.

2.

Handle the structure carefully and make sure nobody is standing in the area of the structure before positioning it on the rear machine chassis.

3.

Fasten the structure with the screws and washers.

Tighten the screws to a torque of 314 Nm (231 ft lb).

4.

CS02J565

34

Remove the slings and lifting eyes.

3-17

SECTION 3 - OPERATING INSTRUCTIONS MACHINE ARTICULATION LOCKING LOCKING 1.

Lock the horizontal movement of the machine.

Remove the pin and retaining pin from position (1).

Transfer the locking bar (B) from position (1) to position (2) and reinstall the pin and retaining pin (A).

A B

2

1

CD02F011A

35 2.

Lock the vertical movement of the machine.

Remove the screw (1) and remove the locking system (2).

1 2

CD02F012

36 3.

Turn the locking system (2) over, place it in vertical position and reinstall the screw (1).

1

2

CD02F013

37

3-18

SECTION 3 - OPERATING INSTRUCTIONS UNLOCKING 1.

Release the vertical movement of the machine.

Remove the screw (1) and remove the locking system (2).

1

2

CD02F013

38 2.

Turn the locking system (2) over, place it in horizontal position and reinstall the screw (1).

1 2

CD02F012

39 3.

Release the horizontal movement of the machine.

Remove the pin and retaining pin (A).

Transfer the locking bar (B) from position (2) to position (1) and reinstall the pin and retaining pin (A).

A 1

B

2 CD02F011A

40

3-19

SECTION 3 - OPERATING INSTRUCTIONS TRANSPORTING THE MACHINE IMPORTANT: Under no circumstances must this machine be driven on the public highway. It must always be transported on a trailer or low loader.

BY RAIL Since transport by rail is subject to special regulations, consult an approved organization.

BY TRAILER

!

WARNING

!

This machine could slip and fall from a trailer or ramp and cause serious injury. Make sure the trailer or ramps are clean. the machine should be in line with the trailer before being loaded.

Nobody, except a signalman, should remain within proximity of the machine or the trailer. Only the operator must be on the machine.

LOADING 1.

Make sure the trailer brakes are applied.

2.

Place blocks behind the trailer wheels.

3.

Align the machine with the trailer, with the front drum facing the ramps.

4.

Make sure drum vibration is disengaged.

5.

Select slow speed and move the machine slowly forward onto the ramps.

6.

When the machine is completely on the trailer, make sure the front chassis is in alignment with the rear chassis and then place all controls in neutral.

7.

Shut down the engine and remove the starter switch key.

8.

Make sure the hood is properly locked.

9.

Lock the machine horizontal and vertical articulations see “Machine articulation locking”.

3-20

CT02C196

41

SECTION 3 - OPERATING INSTRUCTIONS 10. Use blocks and chains to fasten the machine to the trailer.

11. Measure the distance between the ground and the highest point of the machine. You must know the overall height. If the overall height exceeds the authorized limit, it will be necessary to remove the ROPS frame. See “ROPS frame removal and installation”.

IMPORTANT: After driving a certain distance, check to see that the machine has not moved and that the chains are still tight.

IMPORTANT: During transport it is strictly forbidden for anyone to remain in the cab, on the machine or on the trailer.

CS02F509

42

UNLOADING 1.

Remove the blocks and chains used to fasten the machine to the trailer.

2.

Unlock the machine vertical and horizontal articulations see “Machine articulation locking”.

3.

Make sure all controls are in neutral and start the engine.

4.

Make sure that the machine is in low speed, that vibration is not engaged and check nobody is standing behind the machine.

5.

Reverse slowly until the machine is standing completely on the ground.

3-21

SECTION 3 - OPERATING INSTRUCTIONS HANDLING THE MACHINE

!

WARNING

!

Handling of the machine must be carried out very slowly and horizontally. Do not allow anybody to remain within the handling area. Never swing the machine over the heads of bystanders.

The location of the sling points (A) is shown by decals.

See “Decals” in the “To the owner/Safety” Section.

IMPORTANT: Never sling the machine from any other points other than those designated by the decals.

IMPORTANT: Lock the machine horizontal and vertical articulations. See “Machine articulation locking”.

Use lifting equipment and slings which are capable of lifting the weight of machine. See “Weights” in the “Specifications” Section.

Take careful note of the information given in the illustration opposite.

A

A

NOTE : For information : Lmin = Minimum length of front and rear slings.

3000 mm = 9 ft 10 in

CS02H554A

43

A

A

CS02H554

44

3-22

SECTION 3 - OPERATING INSTRUCTIONS TOWING THE MACHINE In the event of a failure, the machine can be towed for a short distance, but first make sure it can be towed without causing further damage. Where possible, carry out any necessary repairs on the spot or consult your Dealer.

IMPORTANT : Before towing the machine, it is necessary to release the hydraulic motor brakes. See "Releasing hydraulic travel motor brakes".

!

WARNING

!

Towing is a delicate maneuver which is always carried out at the risk of the user. The manufacturer’s warranty does not apply to incidents or accidents which occur during towing. Where possible, carry out the repairs at the site. The machine must be towed very slowly, over a short distance and only if it is really unavoidable. When towing , make sure nobody is standing near the machine or within its working area. Do not use chains to tow the machine, use ropes in good condition or suitable towing bars with a capacity of at least one and a half times the machine's weight. See "Weights" in the "Specifications" Section.

TOWING POINTS The machine can be towed either by the front chassis or the rear chassis. There are two towing points at the front and two towing points at the rear, located on each side of the chassis.

To prevent the machine from skidding during the towing operation, all brakes must be released.

IMPORTANT : It is forbidden to use the towing points to haul other vehicles.

CD02G007

45

3-23

SECTION 3 - OPERATING INSTRUCTIONS RELEASING HYDRAULIC TRAVEL MOTOR BRAKES (DV201, DV202) IMPORTANT: Never release the brakes with the engine running.

IMPORTANT : Before releasing the machine brakes, prevent it from moving with blocks.

!

WARNING

!

During the towing operation, check that the brakes are not overheating because they are not sufficiently released. When the hydraulic motors have been released and the hydraulic circuit shortcircuited, the brakes may no longer be applied. The service brakes, emergency and parking brakes will not function. Never start the engine while towing the machine.

IMPORTANT : During towing operations the steering angle must not exceed 30°.

Before towing the machine, it is necessary to close the hydraulic circuit, using the lever (4).

4

CD02G010

46 1.

Remove the screw (5) and the lever (4).

4

5

CD03A001

47

3-24

SECTION 3 - OPERATING INSTRUCTIONS 2.

Turn the washer (6) and then install the lever (4) and tighten the screw (5).

5

4 6

CD03A002

48 3.

Shut off the hydraulic travel circuit by lowering the lever (4) to "OFF" position.

ON

4

OFF

CD02G010

49 4.

Remove the two plugs (1) from the front drum hydraulic motor.

1

1

CS02G512

50 5.

Simultaneously push the two screws (2) located inside the hydraulic motor so as to compress the spring (3) then tighten both screws (2) at the same time as far as they will go.

6.

Install the two plugs (1).

7.

Carry out the same operations for the rear drum hydraulic motor.

2

1

3 CS02G513

51 3-25

SECTION 3 - OPERATING INSTRUCTIONS 8.

Once the towing operation has been completed, install blocks to prevent the machine from moving.

Remove the plugs (1), loosen the screws (2) without removing them completely and install the plugs (1).

2

1

CS02J566

52 9.

Place the lever (4) back into its original position ("ON" position).

ON

4 OFF

CD02G010

53 10. Remove the screw (5) and the lever (4).

4

5

CD03A002

54

3-26

SECTION 3 - OPERATING INSTRUCTIONS 11. Turn the washer (6) and then install the lever (4) and tighten the screw (5).

4

5

6

CD03A001

55

!

WARNING

!

It is mandatory to put the lever back in "ON" position and to lock it with the washer.

!

WARNING

!

The braking circuit will remain inoperative as long as the lever is in "OFF" position.

3-27

SECTION 3 - OPERATING INSTRUCTIONS RELEASING HYDRAULIC TRAVEL MOTOR BRAKES (DV204) IMPORTANT: Never release the brakes with the engine running.

IMPORTANT : Before releasing the machine brakes, prevent it from moving with blocks.

!

WARNING

!

During the towing operation, check that the brakes are not overheating because they are not sufficiently released. When the hydraulic motors have been released and the hydraulic circuit shortcircuited, the brakes may no longer be applied. The service brakes, emergency and parking brakes will not function. Never start the engine while towing the machine.

IMPORTANT : During towing operations the steering angle must not exceed 30°.

Before towing the machine, it is necessary to close the hydraulic circuit, using the lever (4).

4

CD02G010

56 1.

Remove the screw (5) and the lever (4).

4

5

CD03A001

57

3-28

SECTION 3 - OPERATING INSTRUCTIONS 2.

Turn the washer (6) and then install the lever (4) and tighten the screw (5).

5

4 6

CD03A002

58 3.

Shut off the hydraulic travel circuit by lowering the lever (4) to "OFF" position.

ON

4

OFF

CD02G010

59 4.

Remove the two screws (1) from the front drum hydraulic motor.

1

CD02G009

60 5.

First method : Install two M10x100 screws (2) with their (18x11x3) washers (3) in the two holes in the brake piston. Tighten the screws completely, one after the other.

2

3

3 2 CS02G510

61 3-29

SECTION 3 - OPERATING INSTRUCTIONS Second method : Install two M10x110 screws (2) with their (24x11x4) washers (3) in the two holes in the brake piston. Tighten the screws completely, one after the other.

6.

2

Carry out the same operation for the rear drum motor.

3

3

2

CS02G511

62 7.

Once the towing operation has been completed, install blocks to prevent the machine from moving.

Remove the two screws (2) and install the original two screws (1).

1

CD02G009

63 8.

Place the lever (4) back into its original position ("ON" position).

ON

4 OFF

CD02G010

64

3-30

SECTION 3 - OPERATING INSTRUCTIONS 9.

Remove the screw (5) and the lever (4).

4

5

CD03A002

65 10. Turn the washer (6) and then install the lever (4) and tighten the screw (5).

4

5

6

CD03A001

66

!

WARNING

!

It is mandatory to put the lever back in "ON" position and to lock it with the washer.

!

WARNING

!

The braking circuit will remain inoperative as long as the lever is in "OFF" position.

3-31

SECTION 3 - OPERATING INSTRUCTIONS OPERATING THE MACHINE IN SPECIAL CONDITIONS TRAVEL OVER HARD OR COMPACTED GROUND When the machine is traveling over compacted ground or small rocks with the drum vibrating, there may occur a momentary loss of contact with the ground due to the phenomenon known as “vibro impact”.

This phenomenon causes vibrations in the machine chassis and in the operator’s compartment. To help overcome this problem, either increase your travel speed or modify the level of vibration by selecting a lower frequency.

The machine may be used only after the fluids have been heated up to working temperature.

Do not operate the machine until the engine has reached normal working temperature.

OPERATING THE MACHINE AT HIGH ALTITUDES The engine will also suffer power losses at high altitudes, this being due to the drop in the atmospheric pressure and the specific gravity of the air.

Increasing vibration in the operator’s compartment can also be encountered when traveling over ground which is becoming more and more compact as the machine advances.

!

WARNING

!

When working in conditions where personnel are exposed to excessive vibrations, it is the foreman’s responsibility to modify the working process to avoid all corporal risks for the operator.

OPERATING THE MACHINE AT LOW TEMPERATURES In winter, good compaction results will depend on the amount of water and fine particles of matter in the ground. The lower the temperature, the more difficult it will be to obtain satisfactory results.

When temperatures are below 0°C (32°F), it is possible, where necessary, to work with the machine, on condition that the ground is not frozen through. Never try to compact materials which are frozen solid.

PREPARING THE MACHINE FOR USE AT LOW TEMPERATURES 1.

Use engine oil which is suitable for use in the prevailing temperature range.

2.

Use hydraulic oil of the correct viscosity.

IMPORTANT: Starting at temperatures below -23°C (-9.4°F) is not possible without an oil pre-heating system.

3.

Replace the drum oil by an oil which is suitable for use in the prevailing temperature range.

4.

Use winter-grade fuel.

5.

Check the battery charge level.

For the engine to start correctly at low temperatures, the battery must be properly charged. To gain 4°C (39.2°F) or 5°C (41°F) on the starting temperature limit, warm the battery beforehand by leaving it in a room where the temperature is 20°C (68°F).

3-32

Altitude

Power loss

500 m (1640 ft) 1000 m (3281 ft) 1500 m (4921 ft) 2000 m (6562 ft) 2500 m (8202 ft) 3000 m (9843 ft)

3% 6% 10% 15% 21% 28%

At altitudes above 1500 m (4921 ft), if the engine emits black smoke, consult your Dealer.

OPERATING THE MACHINE IN VERY DUSTY CONDITIONS Shorten the service intervals for the air filter, the oil cooler and the hydraulic circuit. See the “Servicing Intervals/Lubrication/Fluids” Section.

OPERATING THE MACHINE IN CLOSE PROXIMITY OF BUILDINGS, UNDERGROUND CONDUITS AND CABLES It is mandatory to assess the effect of vibrations produced by the machine before using it to determine whether any damage will be caused.

OPERATING THE MACHINE AT HIGH TEMPERATURES AND HIGH HUMIDITY LEVELS When the machine is used in hot climates, where the humidity is high, the engine will suffer some loss of power. As heat and humidity are two different factors, their effect on engine power can be resumed as follows: 1.

Every 10°C (50°F) increase in temperature, with no change in humidity level, will result in a power loss of about 4%.

2.

Every 10% increase in humidity, with no change in temperature level, will result in a power loss of about 2%.

SECTION 4

32

SERVICING INTERVALS/LUBRIFICATION/FLUIDS SERVICING INTRUCTIONS Respect the maintenance intervals by checking the hourmeter daily. Before carrying out any service work, park the machine on flat, firm ground, away from any obstacles. Unless otherwise specified, all service work should be carried out with the engine shut down and the starter switch key removed. It is preferable to wait for all circuits to cool down before beginning work.

Wear suitable clothing and use appropriate safety equipment.

Clean all grease points before greasing. Clean around plugs and orifices before adding fluid. No dirt or foreign matter must be allowed to enter components or circuits.

!

WARNING

!

Be sure all the service operations in this section are carried out punctually at the intervals given, in order to ensure optimum performance levels and maximum safety when using the machine.

There is a risk of serious injury if maintenance or repairs are not performed correctly. If you do not understand the maintenance procedures, consult your Dealer.

!

WARNING

!

Before carrying out any service work, proceed as follows: - Park the machine on hard, flat ground.

- Shut down the engine and remove the starter switch key.

- Put blocks under the drums to prevent the machine from moving.

- Block the machine articulation.

When performing maintenance work on the machine, place a “Do not operate” label on the front console.

Never leave the operator’s compartment while the engine is running.

Any modification to this machine without prior authorization could cause serious injury. Do not make any modifications without authorization. Consult your Dealer.

IMPORTANT: If you use your machine in particularly harsh conditions (dusty or corrosive atmosphere), the servicing intervals should be reduced accordingly.

Take particular care to replace all filters regularly.

Clean filters mean longer engine running life.

Do not pour used oil onto the ground or down a drain. Stock the oil in sealed containers for collection by a company which recycles or disposes of it.

HOURMETER Located under the engine hood, near the battery, the hourmeter enables servicing operations to be scheduled. It works in the same way as a clock when the engine is running.

Servicing intervals are carefully calculated to guarantee safe and efficient machine operation.

Be sure to carry out all the servicing operations properly, as defined in this manual.

CD02F007A

1

4-1

SECTION 4 - SERVICING INTERVALS/LUBRIFICATION/FLUIDS SERVICING INTERVAL

NOTE

DRAIN

GREASE

CHECK

REPLACE

CLEAN

SERVICE POINTS

BLEED

PAGE

INTERVALS IN HOURS

4-11

Engine oil level

20

Q

4-14

Fuel tank level

20

Q

4-18

Ail filter restriction indicator

20

Q

4-22

Air filter dust ejector

20

Q

4-23

Hydraulic oil level

20

Q

4-25

Hydraulic oil filter restriction indicator

20

Q

4-27

Drum oil level

20

Q

4-29

Water level (drum sprinkler system and screens)

20

Q

5-1

Lighting and warning devices

20

Q

5-2

Hydraulic oil cooler

20

Q

4-8

Machine articulations and operator's seat guide

4-32

Sprinkler system filter

5-3

Engine air intake system

5-3

Engine oil cooler

5-5

Air system intake

6-3

Electrolyte level check

4-11

Engine oil

4-11

Engine oil filter

5-6

Alternator/fan belt tension

4-15

Fuel pump screen

4-15

Fuel filter

4-28

Drums

5-4

Shock absorber and nut torque

5-9

Engine valve clearance

5-13

Fuel system hoses

250 250 (H)

B 250 (H)

250 (H)

250 (H) 250 (H) 250

P 500 (B)

500 (B)

A 500 (B)

D

A A

1000

C

1000 (B)

C 1000

(S)

5-14

Exhaust system

4-24

Hydraulic fluid

2000 (R)

4-25

Hydraulic oil filter

2000 (R)

4-26

Hydraulic reservoir suction strainer

2000 (R)

C

1000 (B)

C

1000

C, N

1000 (C) 1000 (C) F, G

5-8

Engine alternator and fan belt

3000

J

5-15

Engine/tension roller belt

4500

M

4-17

Fuel tank

4-18

Air filter element

4-31

Water reservoir

5-14

Engine belt tension

I

5-15

Steering drive belt tension

I

5-16

Drum scrapers

I

5-17

Cleaning the machine

5-17

Hardware torque specifications

4-2

D E D

K I, L

SECTION 4 - SERVICING INTERVALS/LUBRIFICATION/FLUIDS NOTE A : Replace/Check every 500 hours or every 6 months, whichever comes first.

NOTE B : Or after the first 50 and 150 hours during the run-in period.

NOTE C : Replace/Check every 1000 hours or every year, whichever comes first.

NOTE D : If necessary.

NOTE E : Clean or replace whenever the restriction indicator is red or systematically after one year or cleaning five times.

NOTE F : Clean or replace whenever the restriction indicator is red or systematically every 2000 hours.

NOTE G : To be carried out also whenever the hydraulic fluid is replaced.

NOTE H : Every 250 hours or every 3 months, whichever comes first.

NOTE I : Check regularly.

NOTE J : Replace every 3000 hours or every 5 years, whichever comes first.

NOTE K : Once a week minimum.

NOTE L : The self-locking nuts can be used 3 times only.

NOTE M : Replace every 4500 hours or every 5 years, whichever comes first.

NOTE N : Check the valve clearance after the first 500 hours during the run-in period.

NOTE P : Check every 250 hours or every 3 months, whichever comes first or whenever the battery charge warning light on the front console stays on after starting the engine.

NOTE Q : Or daily.

NOTE R : Or every 2 years.

NOTE S : Systematically every 2 years.

4-3

SECTION 4 - SERVICING INTERVALS/LUBRIFICATION/FLUIDS FLUIDS AND LUBRICANTS Lubricants must have the correct properties for each application.

!

WARNING

!

The conditions of use for individual fluids and lubricants must be respected.

ENGINE OIL IMPORTANT: Use high quality oil and respect the oil changing intervals so as to ensure maximum engine life.

Categories of oil to be used : CASE N°1 Multiperformance or Performance or API/CG/CF. The type of oil to use depends on ambient temperature: - SAE 15W40: All seasons - SAE 10W30: Winter - SAE 5W30: Arctic The following table gives the temperature ranges for different oils, depending on their viscosity.

A

CS02B553

B 2

(A) Fahrenheit Temperature (B) Celsius Temperature (*) Use of an engine oil heater is required NOTE: Do not put any Performance Additive or other additive in the sump. Oil change intervals shown in this manual are based on tests carried out on lubricants.

4-4

SECTION 4 - SERVICING INTERVALS/LUBRIFICATION/FLUIDS GREASE

HYDRAULIC FLUID

Use extreme pressure oil, type NLGI grade 2 or CASE Molydisulfide grease.

It is indispensable to use a high quality, Hytran Ultra oil type hydraulic fluid which is suitable for high pressure applications.

FUEL Use fuel which is to ASTM (American Society for Testing and Materials) D975 standard.

Use grade N°2 fuel. The use of other types of fuel can result in a loss of power and may cause high fuel consumption.

When the temperature is very cold, the use of a mixture of N°1 and N°2 fuel is permitted. See your fuel vendor for winter fuel requirements in your area.

If the temperature falls below the fuel cloud point (point at which wax begins to form) the wax crystals will cause power loss or will prevent the engine from starting.

IMPORTANT: In cold weather, fill the fuel tank at the end of the day’s work, in order to prevent the formation of condensation.

Long storage can lead to the accumulation of impurities and condensation in the fuel. Engine trouble can often be traced to the presence of water in the fuel.

The storage tank must be placed outside and the temperature of the fuel should be kept as low as possible.

Drain off water and impurities regularly.

ANTI-FREEZE/ANTI-CORROSION Use anti-freeze in all seasons to protect the sprinkling system from corrosion and any risk of freezing.

For areas where ambient temperature is over -36°C (-32.8°F), use a blend of 50% ethylene-glycol based anti-freeze.

For areas where the temperature is below -36°C (-32.8°F), it is advisable to use a blend of 40% water and 60% anti-freeze.

4-5

SECTION 4 - SERVICING INTERVALS/LUBRIFICATION/FLUIDS BIODEGRADABLE HYDRAULIC FLUID The hydraulic system may be filled with synthetic oil under the following conditions : PANOLIN-HLP Synth 15/22/32/68 is a fully synthetic, high performance oil classified according to VDMA directive 24/568. It complies with articles 2 and 3 of DIN 51524. In case of leakage oil is completely degradable by microorganisms present in water and in the soil.

During operation of the machine all contamination in all forms must be avoided (wear, dust, etc.).

The fluid used must be checked regularly by taking samples (see table below) and having them tested.

When taking the samples it is necessary to follow the procedure laid down by PANOLIN Company laboratories. The best solution is to have PANOLIN Company take the samples directly.

Sample taking interval

Use in normal conditions

Use in harsh conditions

First check

500 h

250 h

Second check

1000 h

500 h

Every 1000 hours or once a year

Every 500 hours or once a year

Subsequent checks

NOTE : When filling up with biodegradable oil, mixing of up to 2% with other types of oil is authorized.

Organic oil may be replaced by synthetic oil in compliance with VDMA directive 24/569.

IMPORTANT : Water content in the oil may not exceed 0.1%.

IMPORTANT : Mixing PANOLIN-HLP Synth oil with other biodegradable oils is strictly forbidden.

NOTE : Always contact the manufacturer or PANOLIN Company prior to deciding to mix or change oils.

4-6

SECTION 4 - SERVICING INTERVALS/LUBRIFICATION/FLUIDS FLUID AND LUBRICANT CAPACITIES AND SPECIFICATIONS Components

Fluids and lubricants

Capacity

Engine

CASE N°1 oil

6.5 liters (1.72 gal US)

Hydraulic system

Hytran Ultra oil

38 liters (10.04 gal US)

Fuel system (DV201, DV202)

Grade N°2 fuel

67 liters (17.7 gal US)

Fuel system (DV204)

Grade N°2 fuel

72 liters (19 gal US)

Machine articulation

CASE Molydisulfide grease

as needed

Drum vibration

SAE 15W40 - 10W30 - 5W30 oil

2 x 1.8 liters (2 x 0.48 gal US)

Battery

Distilled water

as needed

Water - Anti-freeze (DV201, DV202)

53 liters (14 gal US)

Water - Anti-freeze (DV204)

67 liters (17.7 gal US)

Water - Anti-freeze (DV201, DV202)

150 liters (39.6 gal US)

Water - Anti-freeze (DV204)

160 liters (42.3 gal US)

Front sprinkler reservoir

Rear sprinkler reservoir

ENVIRONMENT Before carrying out any maintenance operation on this machine and before disposing of used fluids or lubricants, always think of the environment. Never throw oil or fluid on the ground and never place it in leaking receptacles.

Contact your local ecological recycling center or your Dealer to obtain information on the correct method of disposing of these materials.

4-7

SECTION 4 - SERVICING INTERVALS/LUBRIFICATION/FLUIDS GREASE POINTS SERVICE SPECIFICATIONS Grease ........................................................................................................Every 250 hours or every 3 months Type of grease .................................................................................................................... CASE Molydisulfide Remove the caps from the grease fittings (if equipped), use the grease pump and stop as soon as the grease begins to escape. Remember to reinstall the caps.

STEERING CYLINDER 2 grease points.

CD02F014

3

CD02F015

4 OPERATOR'S SEAT GUIDE (DV204 only) 2 grease points.

CD02F016

5

4-8

SECTION 4 - SERVICING INTERVALS/LUBRIFICATION/FLUIDS LEVELS EVERY 20 HOURS OR DAILY ENGINE OIL See “Engine”.

H

MAX

L

MIN

CD02F017

6 FUEL See “Fuel system”.

CD02F018

7 HYDRAULIC FLUID See “Hydraulic system”.

CD02F019

8

4-9

SECTION 4 - SERVICING INTERVALS/LUBRIFICATION/FLUIDS WATER (SPRINKLING SYSTEM) See "Drum sprinkling system".

CD02F008

9 DRUM VIBRATION OIL See “Drum”.

CS02F507

10 EVERY 250 HOURS OR EVERY 3 MONTHS BATTERY ELECTROLYTE See “Batteries” in the “Electrical System” Section.

CD02F020

11

4-10

SECTION 4 - SERVICING INTERVALS/LUBRIFICATION/FLUIDS ENGINE SERVICE SPECIFICATIONS Engine oil level check .................................................................................................... Every 20 hours or daily Oil change .................................................................................................. Every 500 hours or every 6 months Or after the first 50 and 150 hours during the run-in period Oil filter replacement................................................................................... Every 500 hours or every 3 months Or after the first 50 and 150 hours during the run-in period Oil capacity ...................................................................................................................... 6.5 liters (1.72 gal US) Type of oil ................................................................................................................ See “Lubricants and fluids” LEVEL 1.

Park the machine on flat, level ground, stop the engine and remove the starter switch key.

2.

When the engine has been stopped for five minutes, remove the dipstick (A), wipe it with a clean cloth and replace it in the guide tube as far as it will go. Then take it out again.

3.

B A

If the oil level is below the mark (L) (minimum), remove the oil filler cap (B), add oil up to the mark (H) (maximum) on the dipstick (A) and then replace the oil filler cap (B).

NOTE: The level should not be higher than the mark (H) (maximum) on the dipstick (A).

4.

Wait for approximately one minute before using the dipstick (A) to check the level again.

H

MAX

L

MIN

CD02F017

12

ENGINE OIL CHANGE AND OIL FILTER REPLACEMENT NOTE: Change the oil while the engine is still warm.

The oil will flow more easily.

1.

Park the machine on flat, level ground, stop the engine and remove the starter switch key.

2.

Remove the oil filler cap (B).

B

CD02F021

13

4-11

SECTION 4 - SERVICING INTERVALS/LUBRIFICATION/FLUIDS 3.

Place a receptacle of a suitable capacity (10 liters/2.64 gal US) under the drain cap (C), remove the cap (C) from the crankcase and allow the oil to drain.

4.

Install a new seal on the cap (C) and put it back in place. Tighten the cap (C) to a torque of 50 Nm (37 ft lb).

C

CD02F022

14 5.

Clean the area around the filter (D) and then use a filter wrench to remove it.

6.

Lubricate the filter seal with a fine coat of oil.

7.

Install the new filter (D). Turn the filter until the seal comes into contact with the filter head and then tighten an extra half turn by hand.

D

IMPORTANT: Do not use the filter wrench to install the filter, as overtightening can damage the seal and the filter.

8.

9.

Fill the engine with new oil (6.5 liters/1.72 gal US).

Install the oil filler cap (B).

Run the engine for a few minutes and check that there are no leaks, then check the oil level again.

IMPORTANT: Always wait fifteen minutes to allow the oil to return to the crankcase before checking the oil level.

4-12

CD02F017

15

SECTION 4 - SERVICING INTERVALS/LUBRIFICATION/FLUIDS ENGINE TEMPERATURE SENSOR 1.

Open the engine hood and remove the engine cover.

CD02F045

16 2.

The engine temperature sensor is located next to the valves, near the alternator.

CD02F046

17 3.

Remove the sensor and clean the contact points.

4.

Check for continuity and check the sensor is functioning correctly.

5.

Replace the sensor if it is defective.

6.

Install the engine cover and close the engine hood.

!

WARNING

!

Before undertaking any travel, make sure the engine hood is correctly fastened.

CD02F070

18

4-13

SECTION 4 - SERVICING INTERVALS/LUBRIFICATION/FLUIDS FUEL SYSTEM SERVICE SPECIFICATIONS Check the fuel level........................................................................................................ Every 20 hours or daily Fill the fuel tank...............................................................................................................Every 20 hours or daily Replace the fuel pump screen ........................................................................ Every 1000 hours or once a year Replace the fuel filter ...................................................................................... Every 1000 hours or once a year Or after the first 50 and 150 hours during the run-in period Bleed the fuel filter ............................................................................................................................. As needed Clean the fuel tank ............................................................................................................................. As needed Clean the fuel tank screen ................................................................................................................. As needed Fuel tank capacity ................................................................................. (DV201, DV202) 67 liters (17.7 gal US) (DV204) 72 liters (19 gal US) Type of fuel .............................................................................................................. See “Fluids and lubricants” FUEL LEVEL Before starting the engine, check the fuel level on the gauge (1).

FILLING THE FUEL TANK 1.

Park the machine on flat, level ground, shut down the engine and remove the starter switch key.

!

WARNING

1

!

Fuel can cause a fire or an explosion.

Never fill the fuel tank while the engine is running.

Never smoke while filling the fuel tank.

CD02F018

19 2.

Remove the padlock, clean the cap (A) with a clean cloth and then remove the cap.

3.

Fill the tank with fuel up to the bottom edge of the filler neck maximum, install the cap (A) and lock it with the padlock supplied.

A

IMPORTANT: Use appropriate fuel.

NOTE: Use a clean cloth to wipe up any splashed fuel around the filler neck.

NOTE : The reservoir capacity is sufficient for a day's work.

CD02F023

20

4-14

SECTION 4 - SERVICING INTERVALS/LUBRIFICATION/FLUIDS FUEL PUMP SCREEN 1.

Park the machine on flat, level ground, shut down the engine and remove the starter switch key.

2.

Use a crosshead screwdriver to remove the cover (1) and the screen.

1

CD02F024

21 3.

Clean the screen (2) in clean diesel fuel. Replace the screen (2) if necessary.

4.

Clean the seals (3). Replace them if necessary.

5.

Install the cover (1) and the screen, using a crosshead screwdriver.

6.

Run the engine for a few minutes and check there are no leaks.

2

3 CD02F025

22 FUEL FILTER 1.

Park the machine on flat, level ground, shut down the engine and remove the starter switch key.

2.

Clean the area around the filter heads.

(DV201, DV202)

CD03A005

23

4-15

SECTION 4 - SERVICING INTERVALS/LUBRIFICATION/FLUIDS (DV204)

CD02F026

24 3.

Place a receptacle of a suitable capacity under the filter and then use a filter wrench to remove the filter.

4.

Replace the seal under the filter head.

5.

Apply a fine coat of oil or grease to the seal of the new filter.

NOTE : Fill the new filter with fuel before installing it.

6.

Install the new filter. Turn the filter until the seal comes into contact with the filter head, then tighten it another half turn by hand.

IMPORTANT: Do not use the filter wrench.

Overtightening can damage the filter and seal.

PH08325

25 BLEEDING THE FUEL FILTER If dirt has got into the fuel system then it will be necessary to bleed the sediment.

Place a receptacle of a suitable capacity under the filter, loosen the valve under the filter approximately four turns and allow the soiled fuel to drain. Tighten the valve as soon as clean fuel is seen.

CD02F027

26

4-16

SECTION 4 - SERVICING INTERVALS/LUBRIFICATION/FLUIDS CLEANING THE FUEL TANK 1.

Wait till the fuel is down to the lowest level before cleaning the fuel tank.

2.

Park the machine on flat, level ground, shut down the engine and remove the starter switch key.

3.

Put the battery master switch in “0” position (system switched off).

4.

Place a receptacle of a suitable capacity under the reservoir, remove the plug and allow the fuel to drain.

5.

When the fuel has finished flowing out, remove the filler cap from the reservoir and pour in some clean fuel to rinse it and remove any accumulated foreign matter.

6.

Install and tighten the plug (B), fill the tank with appropriate fuel and then install and lock the filler cap with the padlock provided.

If the fuel drained is very dirty, then it will be necessary to clean the inner walls of the reservoir.

1.

Remove the cover and the gauge.

2.

Clean the walls of the fuel tank.

3.

Replace the sealing between the cover and the reservoir.

4.

Install the cover.

5.

Make sure the plug (B) is properly installed and then fill the reservoir with the correct fuel.

B

CD02F028

27

CD02F030

28 CLEANING THE FUEL TANK SCREEN Check the condition of the screen and rinse it in clean fuel.

CD03A004

29

4-17

SECTION 4 - SERVICING INTERVALS/LUBRIFICATION/FLUIDS AIR FILTER INSPECTION Frequent inspection should be made of the air filter, the intake manifold, the seals, the tightness of the intake manifold screws, the hoses and hose clamps.

AIR FILTER ELEMENT The air filtration system of your machine uses a single, high capacity element , designed to ensure maximum protection for the engine.

AIR FILTER RESTRICTION INDICATOR Stop the engine and open the hood.

If the restriction indicator (1) is red, the element must be checked.

1

CD02F029

30 SERVICE SPECIFICATIONS Clean or replace the element whenever the restriction indicator is red or systematically once a year or after cleaning five times.

Dust ejector: check every 20 hours or daily.

Check the restriction indicator : Every 20 hours or every day.

!

WARNING

!

Be sure to service the air filter at the intervals given.

A clean air filter means longer engine life.

4-18

SECTION 4 - SERVICING INTERVALS/LUBRIFICATION/FLUIDS REMOVING THE ELEMENT 1.

Remove the dust ejector and clean it.

CD02F031

31 2.

Remove the cover mountings and remove the cover.

CD02F032

32 3.

Remove the element.

CD02F033

33

4-19

SECTION 4 - SERVICING INTERVALS/LUBRIFICATION/FLUIDS CLEANING THE ELEMENT IMPORTANT : Be sure to protect your face before using compressed air.

If the element is dry: Blow compressed air from the inside towards the outside at very low pressure. The compressed air nozzle should be held at least three centimetres (1.18 in) from the inside wall of the element. Cleaning is completed once no more dust comes out of the element.

IMPORTANT: Compressed air pressure should not exceed 2.76 bar (40 psi).

NOTE: Do not use compressed air if there is oil or soot in the element.

CD01G192

34 If the element is oily: Clean it in water with a suitable detergent (consult your Dealer). Instructions for using the detergent are printed on the packaging.

IMPORTANT: Allow the element to dry completely before installing. It is advisable to keep a spare, clean element for installation while the other element is drying.

PDE0088

35 INSPECTING THE ELEMENT Check the element for damage by placing a lamp inside.

IMPORTANT: Replace the element if light can be seen through a hole, however small.

PDE0378

36

4-20

SECTION 4 - SERVICING INTERVALS/LUBRIFICATION/FLUIDS INSTALLING THE ELEMENT 1.

Install the element.

CD02F033

37 2.

Install the cover and fasten the mountings.

CD02F032

38 3.

Install the dust ejector.

CD02F031

39

4-21

SECTION 4 - SERVICING INTERVALS/LUBRIFICATION/FLUIDS 4.

Press the restriction indicator button and make sure the red band goes out.

CD02F029

40 DUST EJECTOR The purpose of the dust ejector is to collect and eject any dust which has accumulated in the air filter automatically. It is important for the ejector to be kept in good condition. Check the condition of the ejector and replace it if necessary.

!

WARNING

!

Never use the machine if the dust ejector is damaged.

CD02F031

41

4-22

SECTION 4 - SERVICING INTERVALS/LUBRIFICATION/FLUIDS HYDRAULIC SYSTEM SERVICE SPECIFICATIONS Hydraulic reservoir fluid level check .............................................................................. Every 20 hours or daily Oil filter restriction indicator check.................................................................................. Every 20 hours or daily Hydraulic fluid replacement ......................................................................... Every 2000 hours or every 2 years Hydraulic filter cartridge replacement .......................................................... Every 2000 hours or every 2 years or whenever the oil filter restriction indicator is red Hydraulic reservoir suction strainer ............................................................. Every 2000 hours or every 2 years Hydraulic system capacity ................................................................................................... 38 liters (10 gal US) Type of oil ................................................................................................................ See “Fluids and lubricants” LEVEL IN HYDRAULIC RESERVOIR 1.

Park the machine on flat, level ground, shut down the engine and remove the starter switch key.

2.

The hydraulic fluid must come up to between the “MAX” and “MIN” marks on the sight gauges (A).

A

CD02F019

42

MAX

MIN

CD02F034

43

4-23

SECTION 4 - SERVICING INTERVALS/LUBRIFICATION/FLUIDS 3.

To add fluid, raise the engine hood and remove the filler cap (B).

4.

Fill the reservoir with appropriate fluid until it comes up to the strainer in the filler tube neck.

5.

Install the filler cap (B) and close the hood.

6.

Start and run the engine at idle speed, perform some movements with the machine and then shut down the engine and check the level once more in the sight glasses (A). Add hydraulic fluid if necessary.

B

CD02F035

44 HYDRAULIC FLUID REPLACEMENT NOTE: It is recommended to change the hydraulic fluid in spring time, preferably, or whenever the machine has been in storage for a fairly long time.

DRAINING NOTE: It is preferable to drain the hydraulic fluid while it is warm.

1.

Park the machine on flat, level ground, shut down the engine and remove the starter switch key.

2.

Use the battery master switch to disconnect the electrical system.

3.

Place a receptacle with a capacity of approximately 50 liters (13.2 gal US) under the reservoir.

4.

Remove the drain cap (1) and allow the fluid to flow out.

1

CD02F036

45

4-24

SECTION 4 - SERVICING INTERVALS/LUBRIFICATION/FLUIDS 5.

6.

Check the inside of the reservoir. Carefully clean the bottom and flush it with new oil if there are any impurities at the bottom. For easier cleaning it is possible to dismantle the filler (B).

B

Replace the hydraulic filter. See “Hydraulic oil filter”.

CD02F035

46 HYDRAULIC OIL FILTER Check the restriction indicator every 20 hours and change the hydraulic fluid filter every 2000 hours.

The filter must be replaced every time the hydraulic fluid or the system components (cylinders, pumps, etc) are changed, or whenever the hydraulic fluid filter restriction indicator is red.

CD02F037

47 1.

Change the filter cartridge (2) on the filtration block.

1

2

CD02F036

48

4-25

SECTION 4 - SERVICING INTERVALS/LUBRIFICATION/FLUIDS 2.

Dismantle the filter housing (B) with the filter cartridge (C) using a 36 mm wrench and take out the cartridge.

3.

Carefully clean the housing.

4.

Clean the contact surface of the filtration block on the lower side (A).

A

5.

Check the condition of sealing ring and lubricate it with clean oil.

C

6.

Insert a new cartridge into the filter housing, tighten to a torque between 40 and 50 Nm (30 and 37 lb ft).

B

7.

CD01G317

49

Install the drain cap (1).

HYDRAULIC RESERVOIR SUCTION STRAINER 1.

Remove the cover.

2.

Remove the suction strainer.

3.

Wash the suction strainer in gasoline and blow the strainer with compressed air from inside.

IMPORTANT : Be sure wear facial protective before using compressed air.

4.

Chech the condition of the suction strainer, replace the strainer in case of a damage filter part.

5.

Check the inside of the reservoir.

6.

Carefully clean the bottom and flush it with new oil if there are any impurities at the bottom.

7.

Mount the strainer on the suction pipe.

8.

Install the cover with the suction pipe.

9.

Lubricate o-ring with clean oil.

CCD03A006

50

10. If the entire upper cover has been removed, use a new Teflon sealing strip.

FILLING THE HYDRAULIC RESERVOIR 1.

Remove the cap (B) and add fluid (approx. 38 liters, 10 US gal), pouring it through the top of the reservoir.

2.

After filling the reservoir, install the filler cap (B).

3.

Start the engine, run it at idle speed and test the functioning of the machine.

B

CD02F035

51

4-26

SECTION 4 - SERVICING INTERVALS/LUBRIFICATION/FLUIDS 4.

Check the fluid level and add fluid if necessary.

Check that there are no leaks.

CD02F019

52

DRUM SERVICE SPECIFICATIONS Oil level check ............................................................................................................... Every 20 hours or daily Oil change ........................................................................................................ Every 1000 hours or every year Oil capacity ..................................................................................................................... 1.8 liters (0.48 gal US) Type of oil ................................................................................................................ See “Fluids and lubricants” OIL LEVEL NOTE: It is preferable to check the level while the oil is warm.

1.

Park the machine on flat, level ground.

2.

Move the machine so the filler plug (A) is in the upper position.

3.

Shut down the engine and remove the starter switch key.

4.

Clean and remove the filler plug (B) and check the level. The level should come up to the edge of the orifice.

5.

If it is necessary to add oil, remove the plug (A) and fill the drum via this orifice with suitable oil until the oil comes up to the edge of the orifice (B).

6.

Install the plugs (A) and (B).

NOTE : Carry out the same operations on the other drum.

A

B CS02F507

53

4-27

SECTION 4 - SERVICING INTERVALS/LUBRIFICATION/FLUIDS OIL CHANGE IMPORTANT: Change the oil while it is hot.

!

WARNING

!

Take the necessary measures to avoid being scalded.

1.

Park the machine on flat, level ground.

2.

Move the machine so the drain plug (A) is in the lowest position.

3.

Shut down the engine and remove the starter switch key.

4.

Place a receptacle of a suitable capacity under the drain plug (A).

5.

Clean and remove the plugs (A) and (B) and allow the oil to drain.

B

A CS02F506

54 6.

Move the machine so the filler plug (A) is in the upper position.

7.

Fill the drum with suitable oil via the orifice (A) until it comes up to the edge of the orifice (B).

8.

Install the plugs (A) and (B).

A

NOTE : Carry out the same operations on the other drum.

B CS02F507

55

4-28

SECTION 4 - SERVICING INTERVALS/LUBRIFICATION/FLUIDS DRUM SPRINKLING SYSTEM SERVICE SPECIFICATIONS Water level check ........................................................................................................... Every 20 hours or daily Fill the reservoirs and clean the screens ........................................................................ Every 20 hours or daily Clean the sprinkler system filter .................................................................. Every 250 hours or every 3 months or after the first 50 and 150 hours during the run-in period Clean the reservoirs ...........................................................................................................................As needed Reservoir water capacity (front and rear) ............................................(DV201, DV202) 203 liters (53.6 gal US) (DV204) 227 liters (60 gal US) Type of water ........................................................................................................... See “Fluids and lubricants” WATER LEVEL Check the water level before starting the engine.

1.

Park the machine on flat, level ground. Shut down the engine and remove the starter switch key.

2.

Check the water level. The level indicator is on the side of the reservoir located under the operator's seat.

CD02F008

56 FILLING 1.

Park the machine on flat, level ground. Shut down the engine and remove the starter switch key.

4-29

SECTION 4 - SERVICING INTERVALS/LUBRIFICATION/FLUIDS 2.

Release and remove the cap from each reservoir.

CD02F007

57

CD02F008

58 3.

Clean the screen in each reservoir and rinse with a hose to remove all impurities. Fill the reservoirs through the screens with clean water.

4.

Install and lock the cap on each reservoir.

CD02F039

59 5.

Before using the sprinkling system, check that valves (A) and (B) are open and valves (C) and (D) are shut.

A

NOTE : During cold water add antifreeze to the water in the reservoirs.

D C B CD02F040

60 4-30

SECTION 4 - SERVICING INTERVALS/LUBRIFICATION/FLUIDS RINSING 1.

Park the machine on flat, level ground. Shut down the engine and remove the starter switch key.

2.

Open all the valves, (A), (B), (C) and (D).

3.

Clean the sprinkling system. See "Sprinkling system filter".

A

D C B CD02F040

61 4.

Remove the cap from each reservoir and rinse the reservoirs with clean, running water.

5.

Close all the valves (A), (B), (C) and (D).

6.

If it is necessary to remove mud from the reservoirs, release and remove the reservoirs , rinse them in clean, running water and then install them.

7.

Fill the reservoirs and then open valves (A) and (B).

CD02F007

62

CD02F008

63

4-31

SECTION 4 - SERVICING INTERVALS/LUBRIFICATION/FLUIDS SPRINKLING SYSTEM FILTER 1.

Park the machine on flat, level ground. Shut down the engine and remove the starter switch key.

2.

Close valve (A).

A

CD02F040

64 3.

Unscrew the filter bowl (B) and remove the filter (C).

4.

Rinse the bowl (B) and the filter (C) in clean, running water and then clean them.

5.

Install the filter and its bowl.

B

C CD02F041

65 6.

Open valve (A).

A

CD02F040

66

4-32

SECTION 5

20

MAINTENANCE/ADJUSTMENTS LIGHTING SYSTEM AND HORN SERVICE SPECIFICATION Check ............................................................................................................................ Every 20 hours or daily

7

8

9

13

11

17

16

18

2

22 23

25

CS02H577

1 Check that the horn, the turn indicators, the position lights, the front and rear work lamps and the rotating beacon are working correctly. Install new bulbs if replacement is necessary.

1.

Operate switches (7), (8), (17), (18), (23) and (25) to be sure the road lights, working lights (if equipped) and horn are functioning correctly.

3.

Turn the starter switch key (2) in “Start” position (position "III"). Lamps (9) and (13) should go out.

2.

Turn the starter switch key (2) in “Contact” position (position "I") and make sure lamps (9), (11) and (13) light up.

4.

Speed up the engine slightly above idle.

5.

While driving the machine, the parking brake indicator lamp (11) goes out, press the emergency stop button (22). The engine should stop, the brakes should be applied and lamp (11) should light up.

5-1

SECTION 5 - MAINTENANCE/ADJUSTMENTS HYDRAULIC OIL COOLER SERVICE SPECIFICATION Visual check................................................................................................................... Every 20 hours or daily Clean the hydraulic oil cooler : 1.

Mud, remove with a hose.

2.

Dry dust, remove with compressed air.

IMPORTANT : Be sure wear facial protection before using compressed air.

3.

Greasy deposits, remove with perchlorethylene

IMPORTANT : The use of trichlorethylene is strictly forbidden.

CD02F043

2

CD02F044

3

5-2

SECTION 5 - MAINTENANCE/ADJUSTMENTS ENGINE AIR INTAKE SYSTEM SERVICE SPECIFICATION Check ......................................................................................................... Every 250 hours or every 3 months Check that the engine air intake system is completely airtight.

1.

Open the engine hood.

2.

Check that there are no damaged or missing components.

3.

Check that the seal (A) between the hood and the air filter is airtight. If it is damaged, replace it.

A

IMPORTANT: Do not use the machine if the seal (A) is not in good condition.

CD02F042

4

ENGINE OIL COOLER SERVICE SPECIFICATIONS Clean .......................................................................................................... Every 250 hours or every 3 months Hose and hose clamp check ...................................................................... Every 250 hours or every 3 months 1.

Raise the engine hood.

2.

Remove the engine cover.

CD02F045

5 3.

Clean the oil cooler : 1. Mud, remove with a hose.

2. Dry dust, remove with compressed air.

IMPORTANT: Be sure wear facial protection before using compressed air.

3. Greasy deposits, remove with perchlorethylene.

IMPORTANT: The use of trichlorethylene is strictly forbidden.

4.

5.

Check the condition of the hoses and hose clamps. If necessary, tighten the clamps and replace the hoses.

CD02F046

6

Install the engine cover.

5-3

SECTION 5 - MAINTENANCE/ADJUSTMENTS VIBRATORY SHOCK ABSORBERS SERVICE SPECIFICATIONS Check and tighten nuts ...................................................................................Every 1000 hours or once a year or after the first 50 and 150 hours during the run-in period DRUMS 1.

Check condition of the shock absorbers (1).

Replace them if they are worn or defective.

2.

Check the nuts (2) are correctly tightened. The nuts should be tightened to a torque of 44 Nm (32 ft lb).

2

1

CD02F051

7 (DV201, DV202)

1

2 CD02F053

8 (DV204)

1

2

1 CD02F052

9

5-4

SECTION 5 - MAINTENANCE/ADJUSTMENTS AIR INTAKE SYSTEM SERVICE SPECIFICATION Check ......................................................................................................... Every 250 hours or every 3 months 1.

Check the hose (1) and the fixing clamps (2).

2

1

2 CD02F056

10 2.

Check the air filter assembly.

CD02F057

11

5-5

SECTION 5 - MAINTENANCE/ADJUSTMENTS ENGINE ALTERNATOR AND FAN BELT SERVICE SPECIFICATIONS Visual check.........................................................................................................................................Regularly Tension check .............................................................................................Every 500 hours or every 6 months or after the first 50 and 150 hours during the run-in period Belt replacement ...........................................................................................Every 3000 hours or every 5 years IMPORTANT : These checks should be made while the engine is cold.

VISUAL CHECK Check to see that the belt and the pulleys show no sign of wear. Check carefully to see that the belt is correctly positioned in the pulley grooves. If the belt is stretched, cracked or frayed, replace it.

CD00N051

12 TENSION CHECK 1.

Press the center of the belt with a finger, applying a pressure of 30 to 50 N (6.7 to 11.2 lb).

CD02F047

13 2.

The maximum deflection should be between 10 mm (0.4 in) to 15 mm (0.6 in).

PDE0090

14 5-6

SECTION 5 - MAINTENANCE/ADJUSTMENTS TENSION ADJUSTMENT IMPORTANT : These checks should be made while the engine is cold.

1.

Loosen the bolts (1) on the idler (2).

2

1 CD03A003

15 2.

Use a lever to move the idler (2) in the right direction to obtain correct belt tension.

2

CD02F050

16 3.

Tighten the bolts (1) and carry out the belt tension check.

IMPORTANT : Do not stretch the belt too tight as this will shorten the life of the alternator bearings.

1 CD03A003

17

5-7

SECTION 5 - MAINTENANCE/ADJUSTMENTS BELT REPLACEMENT IMPORTANT : The belt must be replaced with the engine shut down and cold.

1.

Loosen the bolts (1) on the idler (2).

2

1 CD03A003

18 2.

Use a lever to move the idler (2) and slacken the belt.

3.

Remove the belt and install a new one.

4.

Adjust the belt tension.

2

CD02F050

19 5.

Tighten the idler bolts (1) and carry out the belt tension check.

6.

Run the engine for 15 minutes and then check the belt tension once more.

1 CD03A003

20

5-8

SECTION 5 - MAINTENANCE/ADJUSTMENTS ENGINE VALVE CLEARANCE SERVICE SPECIFICATION Check ............................................................................................................. Every 1000 hours or once a year or after the first 500 hours during the run-in period IMPORTANT: The valve clearance should be measured while the engine is cold.

1.

Park the machine on flat, level ground. Shut down the engine and remove the starter switch key.

2.

Use the battery master switch to disconnect the electrical system.

3.

Remove the valve covers.

0

CD02F009

21 4.

Use a lever to rotate the engine to the point where cylinder 1 (A) exhaust valve is beginning to close and the intake valve is beginning to open.

CD02F068

22 5.

Check and adjust the valves (B).

(DV201, DV202)

A B

CS02F554

23

5-9

SECTION 5 - MAINTENANCE/ADJUSTMENTS (DV204)

A

B CS02F553

24 6.

Use a feeler gauge to measure the clearance (1) between the rocker arm (2) and the valve (3).

Valve clearance : Intake valves : 0.3 to 0.4 mm (0.012 to 0.015 in).

Exhaust valves : 0.5 to 0.6 mm (0.019 to 0.023 in).

7.

Check and adjust the other valves.

CS02F555

25 VALVE CLEARANCE ADJUSTMENT 1.

Loosen the lock nut (4) with a wrench.

CS02F555

26

5-10

SECTION 5 - MAINTENANCE/ADJUSTMENTS 2.

Turn the adjustment screw (5) with a screwdriver (7) until the clearance is correct. Check the clearance with a feeler gauge (6).

CS02F556

27 3.

Hold the adjusting screw (5) firmly with the screwdriver to prevent it from turning and tighten the lock nut (4) to a torque of 21 Nm (15.5 ft lb). After tightening check the clearance once more.

CS02F555

28 4.

Make a mark on the torsion vibration damper and turn the crankshaft by 360°.

CD01G323

29

5-11

SECTION 5 - MAINTENANCE/ADJUSTMENTS 5.

Check and adjust the clearances of the remaining valves (B).

(DV201, DV202)

B CD02F558

30 (DV204)

B

CD02F557

31 6.

Install the valve covers and replace the seal if necessary. Tighten the screws to a torque of 8.5 Nm (6.3 ft lb).

5-12

SECTION 5 - MAINTENANCE/ADJUSTMENTS FUEL SYSTEM HOSES (DV201, DV202) SERVICE SPECIFICATIONS Check ............................................................................................................... Every 1000 hours or every year Replace ......................................................................................................................................... Every 2 years 1.

Park the machine on flat, level ground. Shut down the engine and remove the starter switch key.

2.

Check the condition of the fuel system hoses.

3.

Replace any defective or damaged hoses. Place a container of a suitable capacity under the fuel tank.

4.

Remove the defective hose along with its connector.

5.

Install the new hose and tighten the connections.

6.

Start the engine and check there are no leaks from the connections.

IMPORTANT : It is essential to replace the hoses every two years.

CD02E004A

32

!

WARNING

!

Replace the hoses in a well ventilated area, away from any sources of heat.

Do not smoke.

CD03A005

33

5-13

SECTION 5 - MAINTENANCE/ADJUSTMENTS FUEL SYSTEM HOSES (DV204) SERVICE SPECIFICATIONS Check................................................................................................................Every 1000 hours or every year Replace..........................................................................................................................................Every 2 years 1.

Park the machine on flat, level ground. Shut down the engine and remove the starter switch key.

2.

Check the condition of the fuel system hoses.

3.

Replace any defective or damaged hoses. Place a container of a suitable capacity under the fuel tank.

4.

Remove the defective hose along with its connector.

5.

Install the new hose and tighten the connections.

6.

Start the engine and check there are no leaks from the connections.

IMPORTANT : It is essential to replace the hoses every two years.

CD02E004

34

!

WARNING

!

Replace the hoses in a well ventilated area, away from any sources of heat.

Do not smoke.

CD02F017

35

EXHAUST SYSTEM SERVICE SPECIFICATION Check................................................................................................................Every 1000 hours or every year IMPORTANT : These checks should be made while the engine is cold.

1.

Check the exhaust pipe connections.

2.

If there are any leaks, tighten the clamps to a torque of 21 Nm (15.5 ft lb).

CD02F055

36 5-14

SECTION 5 - MAINTENANCE/ADJUSTMENTS ENGINE BELT SERVICE SPECIFICATIONS Tension check.......................................................................................................................................Regularly Belt and idler pulley replacement ................................................................. Every 4500 hours or every 5 years IMPORTANT : These checks should be made while the engine is cold.

VISUAL CHECK Check to see that the belt and the pulleys show no sign of wear. Check carefully to see that the belt is correctly positioned in the pulley grooves. If the belt is stretched, cracked or frayed, replace it.

NOTE : It is essential to replace the belt (1) and idler pulley (2) after 4,500 hours or five years’ service.

1 2 CD02F047

37

STEERING BELT SERVICE SPECIFICATION Tension check.......................................................................................................................................Regularly IMPORTANT : This check should be made while the engine is cold.

VISUAL CHECK Check to see that the belt and the pulleys show no sign of wear. Check carefully to see that the belt is correctly positioned in the pulley grooves. If the belt is stretched, cracked or frayed, replace it.

CD02F048

38

5-15

SECTION 5 - MAINTENANCE/ADJUSTMENTS DRUM SCRAPERS SERVICE SPECIFICATION Check...................................................................................................................................................Regularly 1.

Park the machine on flat, level ground. Shut down the engine and remove the starter switch key.

2.

Use the battery master switch to disconnect the electrical system.

0

CD02F009

39 SCRAPER PRESSURE ADJUSTMENT 1.

Loosen the support (2) screws (1) on each side of the scraper.

2.

Push the scraper supports towards the drum until the desired pressure against the drum is established, then tighten the screws (1).

2

NOTE : If necessary, carry out the same operation on the other drum

1 CD02F054

40 SCRAPER REPLACEMENT 1.

Remove the screws (3) and then remove the scraper (4) and its bar (5).

2.

Install a new scraper (4) on the bar (5) and then install the screws (3).

3.

2 5

Adjust the scraper pressure.

4

NOTE : If necessary, carry out the same operation on the other drum.

3

1

CD02J009

41

5-16

SECTION 5 - MAINTENANCE/ADJUSTMENTS CLEANING THE MACHINE SERVICE SPECIFICATION Clean ..............................................................................................................................Once a week minimum Otherwise, every time oil or grease deposits accumulate on the machine, remove them by pressure cleaning (steam or water).

When working in tough conditions or compacting cohesive soils or soils stabilized with cement or lime, clean the machine at the end of each day.

Shut down the engine before cleaning the machine.

The battery master switch should be in the “0” position (system switched off).

Do not use harsh detergents or highly inflammable products.

It is possible to use pressure cleaning (steam or water) but in this case be sure to protect the electrical system and blank off all vents/openings that need protection.

HARDWARE TORQUE SPECIFICATIONS SERVICE SPECIFICATION Check ............................................................................................................... Regularly, with a torque wrench Check that all mounting screws and nuts are tightened correctly. Tighten them again if necessary, using the table below. Make sure no hardware is missing and replace it if necessary.

M4

M5

M6

M8

M10

M12

M14

M16

M18

M20

M22

M24

M27

5.8

2 (1)

4 (3)

7 (5)

16 (12)

31.5 (23)

53 (39)

79 (58)

113 (83)

172 (127)

226 (167)

284 (209)

392 (289)

520 (384)

8.8

3 (2)

6 (4)

10 (7)

22.5 (17)

44 (32)

75 (55)

118 (87)

165 (122)

245 (181)

314 (232)

392 (289)

549 (405)

716 (528)

10.9

4 (3)

8 (6)

14 (10)

32.5 (24)

62 (46)

105 (77)

165 (122)

226 (167)

343 (253)

441 (325)

559 (412)

755 (557)

1020 (752)

NOTE: These values are expressed in Nm (ft lb).

!

WARNING

!

The self-locking nuts can be used 3 times only.

5-17

SECTION 5 - MAINTENANCE/ADJUSTMENTS ENGINE TROUBLESHOOTING PROBLEM

Engine does not start.

POSSIBLE CAUSE

SOLUTION

Defective starter switch (starter does not run)

Check switch

Defective rotation of starter (starter rotates slowly)

Discharged battery, starter problems, contaminated or loose wiring connectors

Incorrect viscosity of engine oil

Inspect and replace as necessary

Engine too cold (cold weather)

Preheat the intake air

No fuel in fuel tank

Refill

Poor fuel quality

Inspect and replace as necessary

Fuel filter clogged

Clean or replace

Possible seizure in engine Low compression

See your Dealer

Defective fuel injection pump

Engine stops during operation.

No fuel in fuel tank

Refill

Fuel filter clogged

Clean or replace

Air in the fuel system

Retighten fuel in line connections

Low oil

Refill

Oil filter clogged

Replace oil filter

Low oil viscosity

Replace with oil of viscosity to match temperature

Oil leakage from connections

Tighten connections

Improper oil pressure.

Defective oil pressure switch Incorrect functioning of oil pump

Exhaust from engine is white or blue.

Excessive oil

Disassemble and repair, replace parts

Excessively low oil viscosity

Replace with correct oil viscosity

Incorrect fuel injection timing Low compression Improper fuel

Exhaust from engine is black or dark gray.

See your Dealer

See your Dealer Replace with correct fuel

Incorrect valve clearance

Adjust

Insufficient air intake (air cleaner clogged)

Service the air filter

Defective fuel injection pump Low compression

See your Dealer

Incorrect fuel

Replace with correct fuel

Insufficient air intake

Clean or replace element

Defective fuel injection pump Excessive fuel consumption

Incorrect spray from fuel injection nozzle Incorrect fuel injection timing

See your Dealer

Low compression

Excessive engine oil consumption.

Unusual noise (fuel or mechanical).

5-18

Excessive oil

Drain oil to proper level

Low oil viscosity

Replace with oil of viscosity to match temperature

Oil leakage

Retighten and replace parts if necessary

Worn cylinder piston ring

See your Dealer

Poor fuel quality

Replace

Damage inside muffler

Replace

SECTION 5 - MAINTENANCE/ADJUSTMENTS

PROBLEM Engine overheating

Defective battery charging.

POSSIBLE CAUSE

SOLUTION

Worn or damaged belt

Replace

Broken fan

See your Dealer

Incorrect belt tension

Adjust

Electrical wiring problems

Repair

Defective battery

Replace

Defective regulator Defective alternator

See your Dealer

5-19

SECTION 5 - MAINTENANCE/ADJUSTMENTS

NOTES

5-20

SECTION 6

4

ELECTRICAL SYSTEM FUSES The fuses are located in the compartment (4) in the front console.

IMPORTANT: Before changing a fuse, place the battery master switch in the “0” position (system switched off). Never replace a fuse with a fuse of different amperage.

CS02H580

4 1

F1 F2 F3 F4 F5

Front work lights 55 W ................................10 A Rear work lights 55 W ................................10 A Rotating beacon power socket ...................10 A Warning horn, turn indicators........................5 A Braking, engine shut down and audible warning device circuit .................................10 A F6 Drum sprinkling circuit ................................15 A F7 Indicator lamps ..........................................7.5 A F8 Spare

CS02H553

2 Electrical circuit protection..................................... 50 A

CD02E007A

3

6-1

SECTION 6 - ELECTRICAL SYSTEM BATTERY SERVICE SPECIFICATIONS Electrolyte level check ................................................................................Every 250 hours or every 3 months or whenever the battery charge warning lamp on the front console comes on NOTE: If the machine needs to be started with booster battery, see “Connecting a booster battery”.

!

WARNING

!

Before carrying out any service work on the components of the electrical system, the battery master switch must be placed in the “0” position (system switched off).

The electrolyte in battery can cause serious burns. Battery contains sulfuric acid. Avoid contact with skin, eyes and clothing.

Antidote: EXTERNAL:Rinse with water.

INTERNAL: Drink large quantities of water or milk. Follow with milk of magnesia, a beaten egg or vegetable oil. Call a doctor immediately.

EYES: Rinse with water for 15 minutes and get prompt medical attention.

A spark or flame can cause the hydrogen in a battery to explode. To prevent the risk of explosion, follow these instructions: - When disconnecting battery cables, always disconnect the negative (-) cable first.

- When reconnecting battery cables, always connect the negative (-) cable last.

- Never short-circuit the battery terminals with metal objects.

- Do not weld, grind or smoke near a battery.

- Battery gas is explosive. Keep flames, sparks and cigarettes away from the battery. Proper ventilation must be provided when charging a battery or using a battery in an enclosed area. Always wear eye protection when working near battery.

- Do not reverse battery terminals. Connect positive cable ends to positive (+) terminals and negative cable ends to negative (-) terminals.

- Recharge the battery in case of insufficient capacity. A discharged battery may freeze at temperatures of only a couple of degrees below zero.

- Recharge battery removed from the machine.

- Open the plugs before recharging.

- Connect the battery correctly after completed recharging.

- Do not disconnect the battery with the engine running.

- Disconnect wire of + terminal from the alternator before welding.

- Do not run the alternator with the wire disconnected from the + terminal.

- Refill battery with distilled water only, never with acid.

- Add distilled water immediately before operating the machine or before recharging the battery.

6-2

SECTION 6 - ELECTRICAL SYSTEM ELECTROLYTE LEVEL CHECK 1.

Park the machine on flat, level ground.

2.

Stop the engine and disconnect the electrical system with the battery master switch.

3.

Clean the surface of battery.

4.

Check the condition of terminals and clean them. Apply a light coat of grease to the terminals to ensure good contact.

CD02F020

4 5.

Check the level of electrolyte after opening the plugs (A) on the battery cells, the level of electrolyte in all cells should be 5 to 15 mm (0.2 to 0.6 in) above the plates, or to the lower edge of the gauge in the cells. Add distilled water to cells with an electrolyte level lower than 5 mm (0.2 in) above the plates. Check the level using a glass tube.

6.

Close the battery.

7.

Keep the battery dry and clean.

IMPORTANT : Batteries deteriorate, especially in winter. At low temperatures they have only part of their capacity available for starting the machine as compared to the capacity under normal conditions. Therefore, we recommend you test the condition of the battery electrolyte and recharge the battery, if necessary.

A

CD02F020

5

NOTA : Should the machine not be used during very cold periods for a couple of weeks, remove the battery and store it in a warm place, to prevent it being damaged by freezing.

6-3

SECTION 6 - ELECTRICAL SYSTEM CONNECTING A BOOSTER BATTERY

!

WARNING

!

Incorrect connection of starter cables or shortcircuiting battery poles can result in serious injury.

Connect starter cables following the instructions below.

Check that the voltage of booster battery is compatible with the machine’s electrical system (12 volts).

1.

Remove the terminal protection caps.

2.

Connect the positive (+) starter cable to the positive (+) pole of the machine battery.

3.

Connect the negative (-) starter cable to the negative (-) pole of the machine battery.

4.

Start the engine.

5.

Disconnect the booster battery negative (-) starter cable and then the booster battery positive (+) cable.

6.

Install the terminal protection caps.

6-4

SECTION 7

2

STORAGE STORING THE MACHINE PREPARATION FOR STORAGE

PERIODIC CHECKS

The following procedure applies when the machine is to be stored for one month or more. Store the machine on flat, level ground, with the front chassis in alignment with the rear chassis and inside a building, or where a building is not available, cover the machine with a tarpaulin. Before placing the machine in storage, carry out the following:

Every month, check the following:

1.

Clean and grease the machine completely.

2.

Drain the fuel tank and fill it with a solution of 90% diesel fuel and 10% anticorrosive oil. Run the engine at low idle for five minutes to allow the anticorrosive oil to reach the lines, the filters, the pump and the injectors.

3.

While the engine is still warm, drain the crankcase, fill it with anticorrosive oil and change the oil filter.

4.

When the engine is cold, clean the outer engine components with diesel fuel.

5.

Clean or change the air filter.

6.

Use the battery master switch to disconnect the electrical system.

7.

Remove the battery, clean the battery box and make sure there are no traces of acid. Store the battery in a cool dry area, where the temperature is always above 0°C (32°F).

8.

Paint any areas where the paintwork has been damaged.

9.

Remove the starter switch key, close and lock the front console cover and then place a " Do not operate " sign on the front console.

10. Lock the engine hood.

1.

The electrolyte level in the battery and the charge.

Recharge if necessary.

2.

The fuel level in the fuel tank and the anticorrosion oil level in the engine. Add more as necessary.

3.

The condition of the lines, clamps and connectors (rust). Grease if necessary.

4.

The condition of the paintwork. Apply a coat of primer if necessary.

STARTING UP AFTER STORAGE 1.

Drain the fuel tank and fill it with clean diesel fuel.

2.

Drain the engine crankcase, fill it with clean oil and check the level.

3.

Change the fuel filter.

4.

Install the battery.

5.

Grease the machine completely.

6.

Check the condition of the fan belt and change it if necessary.

7.

Check all levels and add as necessary.

8.

Remove the “Do not operate” label and then start up the engine, following the starting procedure.

9.

Keep a careful watch of all warning lamps and gauges.

!

WARNING

!

Check the machine for leaks and make sure that there are no broken, faulty or missing parts. Before starting the engine, make sure that all controls are in the neutral position. This will prevent any sudden machine movement or any electrically operated equipment from starting. Avoid running the engine in an enclosed area. Always make sure there is adequate ventilation.

7-1

SECTION 7 - STORAGE

NOTES

7-2

SECTION 8

6

SPECIFICATIONS ENGINE Make..................................................................................................................................................DEUTZ AG Type...............................................................................................................Diesel (DV201, DV202) F2L1011F (DV204) F3L1011F Number of cylinders................................................................................................................(DV201, DV202) 2 (DV204) 3 Bore/stroke ............................................................................................................ 91 x 105 mm (3.58 x 4.13 in) Displacement......................................................................................... (DV201, DV202) 1366 cm3 (83.3 cu.in) (DV204) 2049 cm3 (125 cu.in) Cooling ....................................................................................................................................................... by air Battery start ..................................................................................................................................... 12 V - 72 Ah Working conditions Speed ..........................................................................................................................................2400/2800 rpm Power: ISO 3046/1, DIN 6271 ........................................................................... (DV201, DV202) 20 kW (27 hp) (DV204) 27.5 kW (37.5 hp) Max. torque...................................................................................................... (DV201, DV202) 80 Nm (59 ft lb) (DV204) 113 Nm (83.4 ft lb) Fuel consumption at rated engine speed ................................................. (DV201, DV202) 3 L/H (0.8 gal US/h) (DV204) 3.5 L/H (0.9 gal US/h)

STEERING Oscillation angle ..........................................................................................................................................±10° Steering angle .............................................................................................................................................±33° Turning radius

DV201

DV202

DV204

Inner (edge)

2355 mm (92.7 in)

2255 mm (88.8 in)

2205 mm (86.8 in)

Outer (contour)

3415 mm (136.4 in)

3550 mm (139.8 in)

3600 mm (141.7 in)

CAPACITIES DV201, DV202

DV204

Fuel

67 L (17.7 gal US)

72 L (19 gal US)

Engine oil

6.5 L (1.7 gal US)

6.5 L (1.7 gal US)

Hydraulic system

38 L (10 gal US)

38 L (10 gal US)

2 x 1.8 L (2 x 0.48 gal US)

2 x 1.8 L (2 x 0.48 gal US)

Front sprinkler reservoir

53 L (14 gal US)

67 L (17.7 gal US)

Rear sprinkler reservoir

150 L (39.6 gal US)

160 L (42.3 gal US)

Drum vibrator

ELECTRICAL SYSTEM Battery ............................................................................................................................................. 12 V - 72 Ah Starter.............................................................................................................................. BOSCH 12 V - 2.3 kW

8-1

SECTION 8 - SPECIFICATIONS TRAVEL DV201, DV202

DV204

No. of travel speeds

4

4

Max. job site speed

7.5 km/h (4.7 mph)

5.3 km/h (3.3 mph)

Max. road speed

13.6 km/h (8.5 mph)

10 km/h (6.2 mph)

40 %

40 %

30°

30°

Hydrostatic

Hydrostatic

1.7 MPa (247 psi)

1.7 MPa (247 psi)

Theoretical gradeability (without vibration) Transversal stability - straight Service brake Brake release pressure

WEIGHTS DV201

DV202

DV204

Operating weight with ROPS

2645 kg (5831 lb)

2915 kg (6426 lb)

3480 kg (7672 lb)

Weight on front drum

1220 kg (2690 lb)

1355 kg (2987 lb)

1705 kg (3759 lb)

Weight on rear drum

1425 kg (3141 lb)

1560 kg (3439 lb)

1775 kg (3913 lb)

Front drum static linear load

12.2 kg/cm (68.6 lb/in)

11.3 kg/cm (63.2 lb/in)

13.1 kg/cm (73.3 lb/in)

Rear drum static linear load

14.2 kg/cm (79.7lb/in)

13.0 kg/cm (73.0 lb/in)

13.7 kg/cm (76.4 lb/in)

VIBRATION DV201 Frequency

DV204

53 or 62 Hz (3180 or 3720 VPM)

Nominal amplitude Centrifugal force per drum

DV202

0.47 mm (0.0185 in) 20.8 or 28.5 kN (4580 or 6277 lb)

0.45 mm (0.0177 in)

23.8 or 32.5 kN (5242 or 7159 lb)

29.4 or 40.3 kN (6476 or 8877 lb)

ROPS PROTECTIVE STRUCTURE

For maximum machine weight of Protective structure weight Installation on machine Tightening torque

8-2

DV201, DV202

DV204

2900 kg (6390 lb)

3800 kg (8370 lb)

65 kg (143 lb)

70 kg (154 lb)

M20x55 (8G) - qty 6 314 Nm (231 ft lb)

SECTION 8 - SPECIFICATIONS EQUIPMENT STANDARD Lockable vandal guard Hydrostatic drum drive Double mode vibration Articulated chassis Travel and vibration pre-selection Front or rear vibration selection OPTIONS ROPS protection Rotating beacon Back up alarm Rearview mirror Canopy

8-3

SECTION 8 - SPECIFICATIONS OVERALL MACHINE DIMENSIONS

CS02F569

1

8-4

A

B

C

D

E

F

G

DV201

1715 mm (67.5 in)

2453 mm (96.6 in)

2640 mm (104 in)

2660 mm (104.7 in)

310 mm (12.2 in)

738 mm (29 in)

12 mm (0.47 in)

DV202

1715 mm (67.5 in)

2453 mm (96.6 in)

2640 mm (104 in)

2660 mm (104.7 in)

310 mm (12.2 in)

738 mm (29 in)

12 mm (0.47 in)

DV204

1715 mm (67.5 in)

2461mm (96.89 in)

2640 mm (104 in)

2660 mm (104.7 in)

310 mm (12.2 in)

746 mm (29.4 in)

16 mm (0.63 in)

SECTION 8 - SPECIFICATIONS

CS02F570

2 H

I

J

K

L

DV201

1090 mm (42.9 in)

1000 mm (39.4 in)

45 mm (1.77 in)

1825 mm (71.8 in)

590 mm (23.2 in)

DV202

1290 mm (50.8 in)

1200 mm (47.2 in)

45 mm (1.77 in)

1825 mm (71.8 in)

590 mm (23.2 in)

DV204

1396 mm (55 in)

1300 mm (51.2 in)

48 mm (1.89 in)

1825 mm (71.8 in)

590 mm (23.2 in)

8-5

SECTION 8 - SPECIFICATIONS

NOTES

8-6

SECTION 9 ALPHABETICAL INDEX A

E

Air filter...............................................................4-18 Air filter restriction indicator ................................4-18 Air intake system..................................................5-5

Engine troubleshooting ...................................... 5-18 Engine valve clearance ........................................5-9 Environment.........................................................4-7 Equipment............................................................8-3 Exhaust system..................................................5-14

B Battery .................................................................6-2 Battery charge warning lamp................................2-6 Battery master switch .........................................2-12 Before operating the machine ..............................3-1 Bleeding the fuel filter.........................................4-16 C Capacities ............................................................8-1 Cleaning the fuel tank.........................................4-17 Cleaning the fuel tank screen .............................4-17 Cleaning the machine.........................................5-17 Connecting a booster battery ...............................6-4 D Decals................................................................1-14 Driving the machine on rough ground.................3-14 Drum ..................................................................4-27 Drum scrapers ...................................................5-16 Drum sprinkler indicator lamp...............................2-6 Drum sprinkler reservoirs ...................................2-15 Drum sprinkling system ......................................4-29 Drum vibration configuration selector ...................2-5 Drum vibration control .................................2-5, 2-10 Drum vibration indicator lamp...............................2-7 Dust ejector........................................................4-22 E Electrical system ..................................................8-1 Emergency stop control......................................2-10 Engine.........................................................4-11, 8-1 Engine air intake system ......................................5-3 Engine alternator and fan belt ..............................5-6 Engine belt .........................................................5-15 Engine emergency shut down ..............................3-8 Engine hood.......................................................3-15 Engine oil change and oil filter replacement .......4-11 Engine oil cooler...................................................5-3 Engine oil pressure warning lamp.........................2-7 Engine overheating warning lamp ........................2-6 Engine temperature sensor ................................4-13 Engine throttle control ..........................................2-4

F Fast travel ............................................................3-9 Filling the fuel tank ............................................. 4-14 Filling the hydraulic reservoir..............................4-26 Fluid and lubricant capacities and specifications ..4-7 Fluids and lubricants ............................................4-4 Front console control functions.............................2-4 Front console cover............................................2-16 Front work light control .........................................2-5 Fuel filter ............................................................4-15 Fuel level ...........................................................4-14 Fuel pump screen ..............................................4-15 Fuel system .......................................................4-14 Fuel system hoses ....................................5-13, 5-14 Fuse compartment ...............................................2-4 Fuses...................................................................6-1 G Grease points.......................................................4-8 H Hand signals ......................................................1-20 Handling the machine ........................................3-22 Hardware torque specifications ..........................5-17 Hazard warning signal control ..............................2-7 Horn control .......................................................2-10 Hourmeter...................................................2-12, 4-1 Hydraulic fluid overheating warning lamp .............2-7 Hydraulic fluid replacement ................................ 4-24 Hydraulic oil cooler...............................................5-2 Hydraulic oil filter................................................4-25 Hydraulic reservoir suction strainer ....................4-26 Hydraulic system................................................4-23 Hydraulic travel circuit shut off valve lever ..........2-12 I Identification of the main components of the machine .................................................1-6 Indicator lamp for turn indicators ..........................2-7 Inertia type seat belt...........................................2-14

9-1

SECTION 9 - ALPHABETICAL INDEX L

S

Level in hydraulic reservoir ................................ 4-23 Levels.................................................................. 4-9 Lighting system and horn..................................... 5-1 Location of controls, instruments and accessories ..................................................... 2-2

Safety rules ......................................................... 1-7 Scraper pressure adjustement........................... 5-16 Scraper replacement ......................................... 5-16 Servicing interval ................................................. 4-2 Servicing intructions ............................................ 4-1 Shutting down the engine .................................... 3-7 Slow travel with vibration ................................... 3-11 Slow travel without vibration .............................. 3-10 Sprinkling cycle control ........................................ 2-8 Starter switch....................................................... 2-4 Starting the engine .............................................. 3-4 Starting up after storage ...................................... 7-1 Steering............................................................... 8-1 Steering belt ...................................................... 5-15 Steering wheel..................................................... 2-4 Steps and access handles................................... 2-1 Storage box....................................................... 2-16 Storing the machine............................................. 7-1

M Machine articulation locking............................... 3-18 Machine braking warning lamp ............................ 2-6 Machine travel and direction of travel................... 3-9 O Operating the machine ........................................ 3-2 Operating the machine at high altitudes............. 3-32 Operating the machine at high temperatures and high humidity levels ................................ 3-32 Operating the machine at low temperatures ...... 3-32 Operating the machine in close proximity of buildings, underground conduits and cables.. 3-32 Operating the machine in special conditions ...... 3-32 Operating the machine in very dusty conditions. 3-32 Operator’s seat .................................................. 2-13 Overall machine dimensions................................ 8-4 P Parking brake control......................................... 2-11 Parking the machine.......................................... 3-13 Power socket..................................................... 2-11 Preparation for storage ........................................ 7-1 Preparing the machine for use at low temperatures................................................. 3-32

T Towing points .................................................... 3-23 Towing the machine .......................................... 3-23 Transporting the machine.................................. 3-20 Travel .................................................................. 8-2 Travel over hard or compacted ground .............. 3-32 Turn indicator control......................................... 2-11 Type, serial number and year of manufacture...... 1-4 V Valve clearance adjustement............................. 5-10 Vibration .............................................................. 8-2 Vibratory shock absorbers ................................... 5-4

R Read operators manual ..................................... 1-13 Rear work light control ......................................... 2-6 Releasing hydraulic travel motor brakes ... 3-24, 3-28 Right, left, front and rear of the machine .............. 1-3 Right-hand arm control functions ......................... 2-9 ROPS frame removal and installation ................ 3-17 ROPS protective structure ................................... 8-2 Rotating beacon control....................................... 2-8 Run-in period....................................................... 3-3

9-2

W Weights ............................................................... 8-2

AFTER DELIVERY CHECK AFTER FIRST 100 HOURS OF OPERATION OF NEW MACHINE Owners Name: Adress:

Dealers Name: Address: Machine Model Number:

Hourmeter Indication:

Machine Serial Number:

FUEL SYSTEM

HYDRAULIC SYSTEM

Check for leaks.

Check the oil level.

Drain water and sedimant from the fuel tank.

Replace the hydraulic oil filter.

Clean the hydraulic oil cooler fins.

ELECTRICAL SYSTEM

GENERAL

Check battery.

Look for oil leaks and loose parts.

Check operation of starter, alerrnator, and instruments.

Tighten all hose clamps.

Check operation of all intrument lamps and work lights.

Check brake operation.

Check the control lever for correct operation.

LUBRICATION Lubricate all pivot points.

ENGINE

Check sprinkler system operation and filters.

Check scrapers.

SAFETY

Check Condition of belts.

Inspect the ROPS.

Check engine oil level.

Check the safety decals and replace if necessary.

Check engine speed at idle and at full throttle.

Check the operator restraint system.

Service air cleaner.

Make sure the machine has the operators manual in the manual storage compartment.

Check the operation of the backup alarm.

DEALER: Make sure the owner and/or operator understands all the safety and information decals, the service information, and the service procedures in this manual.

Technician Signature Dealer Signature Owner Signature Dealer Copy

AFTER DELIVERY CHECK AFTER FIRST 100 HOURS OF OPERATION OF NEW MACHINE Owners Name: Adress:

Dealers Name: Address: Machine Model Number:

Hourmeter Indication:

Machine Serial Number:

FUEL SYSTEM

HYDRAULIC SYSTEM

Check for leaks.

Check the oil level.

Drain water and sedimant from the fuel tank.

Replace the hydraulic oil filter.

Clean the hydraulic oil cooler fins.

ELECTRICAL SYSTEM

GENERAL

Check battery.

Look for oil leaks and loose parts.

Check operation of starter, alerrnator, and instruments.

Tighten all hose clamps.

Check operation of all intrument lamps and work lights.

Check brake operation.

Check the control lever for correct operation.

LUBRICATION Lubricate all pivot points.

ENGINE

Check sprinkler system operation and filters.

Check scrapers.

SAFETY

Check Condition of belts.

Inspect the ROPS.

Check engine oil level.

Check the safety decals and replace if necessary.

Check engine speed at idle and at full throttle.

Check the operator restraint system.

Service air cleaner.

Make sure the machine has the operators manual in the manual storage compartment.

Check the operation of the backup alarm.

DEALER: Make sure the owner and/or operator understands all the safety and information decals, the service information, and the service procedures in this manual.

Technician Signature Dealer Signature Owner Signature Owner Copy