Case SV208 SV210 SV212 & SV216 Vibratory Rollers Operator's Manual - PDF DOWNLOAD

SV208, SV210, SV212, and SV216 Vibratory Rollers Tier II Engine

Operator’s Manual Revision Date: 10/2004 Lep 6-39011NA

SV208, SV210, SV212 and SV216 Vibratory Rollers Tier II Engine

Operator’s Manual Lep 6-39011NA Replaces Cre 6-39010NA

THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO THE POSSIBILITY OF DEATH OR SERIOUS INJURY 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.

WARNING IMPROPER OPERATION OF THIS MACHINE CAN CAUSE DEATH OR SERIOUS INJURY. BEFORE USING THIS MACHINE, MAKE CERTAIN THAT EVERY OPERATOR:

• Is instructed in safe and proper use of the machine.

• Reads and understands the Manual(s) pertaining to the machine.

• Reads and understands ALL Safety Decals on the machine.

• Clears the area of other persons.

• Learns and practises safe use of machine controls in a safe, clear area before operating this machine on a job site.

It is your responsibility to observe pertinent laws and regulations and follow Case, LLC instructions on machine operation and maintenance.

Copyright  2004 CNH America LLC All rights reserved

Lep 6-39011NA Issued September 2003 (Revision October 2004) CASE is a registered trademark of CNH America LLC

OPERATOR’S MANUAL SV208 SV210 SV212 SV216

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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/Lubrication/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 SV208, SV210, SV212 and SV216 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 ............................................................................. 1-5 Safety rules .............................................................................................................................................. 1-6 Personal safety ........................................................................................................................................ 1-7 Before using the machine ........................................................................................................................ 1-8 Operating the machine ............................................................................................................................. 1-9 Parking the machine .............................................................................................................................. 1-10 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 .......................................................................................................................................... 1-24 SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES .................................................................... 2-1 Cab door .................................................................................................................................................. 2-1 Steps and access handles ....................................................................................................................... 2-1 Location of controls, instruments and accessories .................................................................................. 2-2 Front console control functions (SV208, SV210) ..................................................................................... 2-6 Front console control functions (SV212, SV216) ................................................................................... 2-12 Front upper control functions ................................................................................................................. 2-19 Right-hand arm control functions ........................................................................................................... 2-20 Operator’s seat ....................................................................................................................................... 2-24 Accessory functions ............................................................................................................................... 2-29 SECTION 3 - OPERATING INSTRUCTIONS ............................................................................................. 3-1 Before operating the machine .................................................................................................................. 3-1 Operating the machine ............................................................................................................................. 3-1 Run in period ............................................................................................................................................ 3-2 Starting the engine (SV208, SV210) ........................................................................................................ 3-3 Starting the engine (SV212, SV216) ........................................................................................................ 3-5 Shutting down the engine ......................................................................................................................... 3-7 Engine emergency shut down .................................................................................................................. 3-8 Machine travel and direction of travel (SV208, SV210) ........................................................................... 3-9 Machine travel and direction of travel (SV212, SV216) ......................................................................... 3-11 Troubleshooting according to flashing codes (SV212, SV216) .............................................................. 3-13 ASC function .......................................................................................................................................... 3-14 Parking the machine .............................................................................................................................. 3-15

TABLE OF CONTENTS

Operating instructions (continued) Tilting the operator’s compartment and hood .........................................................................................3-16 Tilting the operator’s compartment and hood using the electric hydraulic system .................................3-19 Driving the machine on rough ground ....................................................................................................3-22 ROPS frame removal and installation ....................................................................................................3-23 Cab removal and installation ..................................................................................................................3-24 Adapting the smooth drum for tamping compaction ...............................................................................3-25 Machine articulation locking ...................................................................................................................3-29 Transporting the machine .......................................................................................................................3-31 Handling the machine .............................................................................................................................3-33 Towing the machine ...............................................................................................................................3-34 Filling the tires with liquid ballast ............................................................................................................3-38 Operating the machine in special conditions ..........................................................................................3-41 Dozer blade ............................................................................................................................................3-43 SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS .............................................................. 4-1 Servicing intructions .................................................................................................................................4-1 Hourmeter .................................................................................................................................................4-1 Servicing interval table .............................................................................................................................4-2 Fluids and lubricants .................................................................................................................................4-4 Fluid and lubricant specifications ..............................................................................................................4-6 Fluid and lubricant capacities ...................................................................................................................4-6 Environment .............................................................................................................................................4-6 Grease points ...........................................................................................................................................4-7 Levels .....................................................................................................................................................4-11 Engine ....................................................................................................................................................4-15 Cooling system .......................................................................................................................................4-17 Fuel system ............................................................................................................................................4-20 Air filter ...................................................................................................................................................4-26 Hydraulic system ....................................................................................................................................4-32 Drum .......................................................................................................................................................4-40 Transmission ..........................................................................................................................................4-42 Planetary reduction gears .......................................................................................................................4-44 SECTION 5 - MAINTENANCE/ADJUSTMENTS ........................................................................................ 5-1 Warning and control devices ....................................................................................................................5-1 Engine fan ................................................................................................................................................5-3 Crankcase breather tube (SV208, SV210) ...............................................................................................5-3 Engine alternator and fan belt ..................................................................................................................5-4 Tires and wheels ......................................................................................................................................5-6 Engine air intake system ..........................................................................................................................5-8

TABLE OF CONTENTS

Maintenance/Adjustments (continued) Radiator and oil cooler ............................................................................................................................. 5-8 Shock absorbers/Mounting blocks ........................................................................................................... 5-9 Engine valve clearance (SV208, SV210) ............................................................................................... 5-11 Engine valve clearance (SV212, SV216) ............................................................................................... 5-14 Operator’s compartment and engine hood tilting system strainer .......................................................... 5-17 Drum vibration frequency ....................................................................................................................... 5-18 Vibration shock absorber ....................................................................................................................... 5-19 Cleaning the machine ............................................................................................................................ 5-19 Operator’s compartment intake air dust filter ......................................................................................... 5-20 Air-conditioning ...................................................................................................................................... 5-21 Scrapers ................................................................................................................................................. 5-23 Hardware torque specifications .............................................................................................................. 5-24 Engine troubleshooting .......................................................................................................................... 5-25 SECTION 6 - ELECTRICAL SYSTEM ........................................................................................................ 6-1 Fuses ....................................................................................................................................................... 6-1 Batteries ................................................................................................................................................... 6-3 Booster batteries ...................................................................................................................................... 6-5 SECTION 7 - STORAGE ............................................................................................................................. 7-1 Storing the machine ................................................................................................................................. 7-1 SECTION 8 - SPECIFICATIONS ................................................................................................................ 8-1 SV208 - SV210 specifications .................................................................................................................. 8-1 SV212 - SV216 specifications .................................................................................................................. 8-7 SECTION 9 - ALPHABETICAL INDEX ...................................................................................................... 9-1

TABLE OF CONTENTS

NOTES

SECTION 1

26

TO THE OWNER/SAFETY SV208, SV210, SV212 AND SV216 VIBRATORY ROLLERS

CS00M515

1

Model shown: SV216 (Smooth drum)

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 from 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 Dealer 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 CS00M511A

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 (A) Type..........................................................................

(B) Serial number...........................................................

(C) Year of manufacturer ...............................................

A

C B

CS01A520B

3 ENGINE Make and type ...............................................................

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

CD00M009

4 ROPS FRAME

CD00M010

5

1-4

SECTION 1 - TO THE OWNER/SAFETY

IDENTIFICATION OF THE MAIN COMPONENTS OF THE MACHINE Model SV208, SV210, SV212 and SV216 vibratory rollers come in different versions: - Smooth drum version - Pad food drum version - Pad foot drum version dozer blade The smooth drum version can be equipped with an optional pad foot compaction attachment. See "Adapting the smooth drum for pad foot compaction" in the "Operating Instructions" Section.

25 11

17

9

10 21 13

1

22

2

20

15 12 14

8

23

3

3

19 18

4 5

6

7

24

CS00M503A

6 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

Drum chassis Vibratory drum Scrapers Machine articulation Machine chassis Planetary reduction gears Fuel tank Batteries ROPS frame Hydraulic reservoir Cab Engine hood

13.

14.

15.

17.

18.

19.

20.

21.

22.

23.

24.

25.

Engine Radiator Oil cooler Operator’s compartment Travel pump Vibration pump Exhaust system Air filter Dozer blade (if equipped) Pad foot (if equipped) Hydraulic oil filter Air-conditioning (if equipped)

1-5

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.

CT04G010

7

1-6

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

as

and

1-7

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.

3.

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

4.

Operating the machine requires the full attention, and caution on the part of the operator to 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 as a guide for all work where visibility is not perfect.

5.

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

6.

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.

7.

Remove any obstructions which hinder visibility, clean the windshield, windows and rear view mirrors.

8.

Check that the windshield wipers are operating correctly.

9.

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.

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

1-8

11. Before undertaking any travel, make sure that the cab doors, the engine hood and the side compartment are correctly locked or fastened.

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

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

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

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

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

17. 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.

18. 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.

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

20. Be ready to meet emergencies. Always carry a first aid kit.

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

SECTION 1 - TO THE OWNER/SAFETY

22. 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.

7.

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

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.

24. 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.

25. 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.

26. Get to know the means of evacuating the machine (emergency exit via the left-hand door) if the machine should turn over or if access by the right-hand door is impossible. Make sure that the left-hand door is not locked.

27. Regularly check the condition and pressure of tires.

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 articulation 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.

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

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. Make sure that no one is in the operating area of the dozer blade before moving it (if equipped).

17. If the use of the dozer blade is not required, make sure that it is locked mechanically (if equipped).

18. To enter or leave the operator’s position, it is essential that the right-hand control arm is in the raised position. Never try to by-pass this safety system.

19. Dust, smoke or mist can reduce visibility and cause an accident. Stop or slow down the machine until visibility is restored to normal.

1-9

SECTION 1 - TO THE OWNER/SAFETY

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

PARKING THE MACHINE When parking your machine, proceed in the following manner:

21. 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.

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

22. Never work with the engine hood open.

2. Place the vibratory drum in line with the machine.

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

3. Place the direction of travel lever in the neutral position.

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

25. Before tilting the operator’s compartment, make sure that the doors are correctly closed and that there is no obstacle to prevent it tilting completely.

26. Before lowering the operator’s compartment, make sure that there is nobody in the vicinity.

27. 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.

28. When parking on a slope, use wheel chocks to immobilize the machine.

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

30. Wear acoustic protection when working with the cabin windows open.

31. During travel over long distances, stop the machine every three hours and allow it to cool down for an hour. Non-compliance with this basic requirement may result in damage to the machine and invalidate the manufacturer’s warranty.

1-10

4. Lower the dozer blade (if equipped).

5. Stop the engine and remove the starter switch key.

6. It is essential to raise the right-hand control arm before leaving the operator's compartment.

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

8. Make sure that the engine hood is correctly locked and lock the cab doors and the side compartment.

9. 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.

SECTION 1 - TO THE OWNER/SAFETY

MAINTENANCE AND ADJUSTMENTS 1.

8 Do not carry out any maintenance work until you have first read and understood 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.

5.

6.

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

Before you service the machine, put a "Do not operate" tag on the right lever.

B9502062

2.

7.

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

Before carrying out any servicing operations on this machine, proceed as follows: 1. Place the machine on flat, level ground.

2. Lower the dozer blade until it is resting on the ground or raise the dozer blade and lock it mechanically (if equipped).

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

4. Block the wheels to prevent any machine movement.

5. Place the "Do not operate" sign on the handle of the left-hand cab door.

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.

13. Periodically inspect the fastening of the main components, as part of a programmed maintenance system. If any problem is found, consult your Dealer.

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

15. When carrying out welding operations on the machine, as authorized by the manufacturer and in accordance with its specifications, disconnect the alternator, 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.

16. A burst tire can cause serious bodily injury. Regularly check the condition of tires and always maintain the recommended inflation pressures.

1-11

SECTION 1 - TO THE OWNER/SAFETY

17. When checking pressure or inflating a tire, never stay in front of the tire but instead face the tread.

Always use an inflation cage when the wheels have been removed from the machine. Keep all other people in the area away from the tire.

PREVENTION OF BURNS 1.

The electrolyte in batteries can cause serious burns. Batteries contain sulphuric acid. Avoid contact with skin, eyes and clothing.

Antidote: EXTERNAL: rinse thoroughly with water and remove soiled clothes.

INTERNAL: do not induce vomiting. Rinse the mouth out with water. Seek medical advice.

EYES: rinse thoroughly with water for 15 minutes and seek medical advice.

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 batteries charged at all times.

3.

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

4.

Boiling coolant fluid can escape if the coolant reservoir cap is removed while the system is still hot.

Before removing the cap, let the system cool down and then turn the cap to the first notch, waiting until all pressure is released. Then remove the cap.

18. Never weld close to a tire. It is mandatory for the tire to be removed before any welding operation.

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 the 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.

4.

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

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.

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 diplay 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

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

BC00G075

10

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, fuel, etc.

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

8

21 3

9

11

1

10

2

22 20

15

14

23 12 17

5

18

4

19

6

7

24

13

18

16

CS00M503B

11 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 READ OPERATOR’S MANUAL Left front of steering column.

1

Part number: 382622A1

CS00N524B

12 ROLL OVER/USE SEAT BELT

1

Front left of steering column.

Part number: 321-7030

CS00N524B

13 MUST USE SEAT BELT

2

Part number: ND081871

CS03G013

14

1-15

SECTION 1 - TO THE OWNER/SAFETY

EMERGENCY EXIT Left front top corner of right door.

3

Part number: 329051A1

329051A1

15 GENERAL HAZARDOUS AREA

4

Left/right rear sides drum structure.

Part number: 283606A1

DECAL1

16 CRUSH-BLADE LOCK (if equipped)

5

Left/right front sides drum structure.

Part number: ND106587

CV003

17

1-16

SECTION 1 - TO THE OWNER/SAFETY

BASIC CRUSH HAZARD Move to chassis above articulation joint both sides of machine.

6

Part number: 323694A1

323694A1

18 CRUSH HAZARD STEERING LOCK LINK

7

Left/right sides chassis.

Part number: ND106589

DECAL4

19 BATTERY MASTER SWITCH

8

Switch the battery master switch into “0” position in the case of failure and after end of work. Inside left access door.

Part number: ND081677

CS03G014

20

1-17

SECTION 1 - TO THE OWNER/SAFETY

DO NOT WELD ON MACHINE Inside left access door.

9

Part number: ND106593

CS00N519A

21 HOT SURFACE HAZARD

10

Inside left access door.

Part number: 283608A1

CS00N519A

22 BASIC REMOVE KEY/READ SERVICE MANUAL

11

Inside left access door.

Part number: ND106592

CS00N519A

23

1-18

SECTION 1 - TO THE OWNER/SAFETY

ENTANGLEMENT HAZARD FAN Both sides of radiator support.

12

Part number: 332512A1

CS00N520A

24 ENTANGLEMENT HAZARD BELT

13

Both sides of radiator support.

Part number: 388112A1

DECAL2

25 HOT LIQUID HAZARD

14

Both sides of radiator support.

Part number: 384258A1

384258A1

26

1-19

SECTION 1 - TO THE OWNER/SAFETY

STARTER - START FROM SEAT Frame edge next to starter.

15

Part number: 321-7040

3217040

27 RUNOVER HAZARD

16

Rear, slightly left of hitch.

Part number: ND106580

DECAL5

28 BATTERY EXPLOSION/SERVICE

17

On battery mounting plate centered between batteries.

Part number: 412471A1

41247A1

29

1-20

SECTION 1 - TO THE OWNER/SAFETY

SLINGING POINTS Part number: ND081460

18

CS03G015

30 MACHINE MAXIMUM HEIGHT Part number: ND081518

19

CS03G016

31 EAR PROTECTION If there is no cab on the machine or if working with the windows open, be sure to wear ear protection.

20

Part number: ND081592

CS03G017

32

1-21

SECTION 1 - TO THE OWNER/SAFETY

FIRST AID KIT STORAGE Part number: ND081611

21

CS03G018

33 OPERATOR’S MANUAL Indication of a box containing the operator’s manual.

22

Part number: ND081612

CS03G019

34 PROTECT ELECTR. EQUIP. BEFORE WASHING Observe safety requirements as per decal (located on both sides of cooler).

23

Part number: ND081530

CS03G020

35

1-22

SECTION 1 - TO THE OWNER/SAFETY

HANDLING THE MACHINE (SV208, SV210) On the left access door.

24

Part number SV208: ND102911 Part number SV210: ND102912

CS01G518

36 HANDLING THE MACHINE (SV212, SV216)

24

On the left access door.

Part number SV212: ND081824 Part number SV216: ND081829 NOTE: For explanations, see "Handling the machine" in Section 3.

CS00N513

37

1-23

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 Move hands forward and rearward (palms in).

PDE0002A

SHUT DOWN THE ENGINE

38

PDE0003A

40 MOVE AWAY FROM ME Move hands forward and rearward (palms out).

PDE0002

39 PDE0003

41

1-24

SECTION 1 - TO THE OWNER/SAFETY

GO THIS FAR

EMERGENCY STOP Wave hands back and forth.

PDE0004A

42 ALL STOP AND HOLD

PDE0005

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

PDE0004

43 STOP Wave hands back and forth.

PDE0008A

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

PDE0005A

44 PDE0008

47

1-25

SECTION 1 - TO THE OWNER/SAFETY

NOTES

1-26

SECTION 2

38

CONTROLS/INSTRUMENTS/ACCESSORIES CAB DOOR The cab doors are opened by means of the handle (A) from the outside and by the handle (B) from the inside.

A

NOTE: To lock the doors, use the starter switch key.

!

WARNING

!

When closing the doors make sure you do not catch your hand, or clothing, etc. in the door.

Do not leave doors half open, fasten them in the closed position before undertaking any machine travel.

CI01C501

1

B

CI01C502

2

STEPS AND ACCESS HANDLES To get onto or off the machine, use the steps (D) and the access handles (E).

E

E

To gain access to the engine, use the folding steps (F) and access handles (G). Once you have got down from the machine, remember to fold the steps (F) back inwards.

!

WARNING

G F

!

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.

D F CS01G512

3

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.

1

3

2 4

CS00M504B

4 1. Front console control functions 2. Steering wheel 3. Right-hand arm control functions 4. Operator’s seat

2-2

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES

7

9

5

10

10

8

6

CS00M506A

5 5. Front upper control functions 6. Operator’s compartment lighting 7. Storage compartment 8. Sun visor 9. Air vents 10. Rear view mirrors

2-3

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES

20

11

27

15 14 29

12 19 28 16

17 18 13 24 21

13

11

25

22

26

23

CS00M505B

6

2-4

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES 11. Dozer blade control (if equipped) 12. Operator’s seat pivoting lever (SV212, SV216) 13. Air vents 14. Front windshield wiper 15. Rear windshield wiper 16. Windshield washer reservoir 17. Beverage holder 18. Storage net 19. Heater control 20. Operator's compartment air intake 21. Battery master switch 22. Operator's compartment tilting control (optional) 23. Engine hood opening/closing control (optional) 24. Pump lever 25. Manual pump 26. Tilting control fuse 50A (optional) 27. Rotating beacon (optional) 28. Rotating beacon socket (optional) 29. Storage box

2-5

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES FRONT CONSOLE CONTROL FUNCTIONS (SV208, SV210) 3

2

1

4

6

5

7

CT04G001

7

1. STARTER SWITCH This switch, when used with the starter switch key, has three positions "0" (Off), "1" (On) and "2" (Start the engine). See "Starting the engine" in Section 3.

4. ENGINE TACHOMETER The tachometer shows the engine speed in revolutions per minute. The figures on the gauge must be multiplied by 100. This tachometer is linked to the engine speed selector.

NOTE: Remove the key from the ignition box leaving the machine.

NOTE: This key is also used to lock/unlock the cab doors and the side compartment door. See "Side compartment".

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. FUEL LEVEL GAUGE The needle shows the level of fuel in the tank.

3. ENGINE COOLANT SOLUTION TEMPERATURE GAUGE The needle shows the temperature of the coolant solution. If the needle position exceeds 100°C (212°F), shut down the engine, remove the starter switch key and find the cause of the problem.

2-6

5. HYDRAULIC FLUID TEMPERATURE GAUGE The hydraulic fluid temperature when working should be between 50°C (122°F) and 60°C (140°F). If the temperature rises excessively during operation, shut down the engine, remove the starter switch key and find the cause of the problem.

6. HOURMETER The hourmeter shows the operating hours of the engine and enables servicing intervals to be determined. See the "Servicing interval table" in Section 4.

7. POWER SOCKET This socket can be used for connecting an inspection lamp or any other 24 volt electrical appliance.

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES

10

8

9

11

12

14

13

CT04G001

8

8. DIAGNOSTIC SOCKET (ASC) (if equipped) This socket is used for connecting a portable computer to carry out troubleshooting procedures. See your Dealer.

NOTE: A special harness adapter is required between this connection and the laptop. Contact your Dealer for that adapter. Connecting the laptop directly without it, might cause an incorrect reading or damage to the laptop if you DO NOT.

9. INDICATOR LAMP FOR TURN INDICATORS This indicator lamp comes on when the turn indicator control (27) is operated. It flashes at the same rate as the turn indicators.

10. AIR FILTER RESTRICTION WARNING LAMP This warning lamp comes on when the air filter primary element has to be cleaned or changed. See "Air filter" in Section 4.

11. HYDRAULIC OIL FILTER RESTRICTION WARNING LAMP This warning lamp comes on when the hydraulic fluid temperature is too low or when the hydraulic oil filter has to be changed. See "Changing the hydraulic oil filter" in Section 4.

12. DIRECTION OF TRAVEL NEUTRAL POSITION INDICATOR LAMP This indicator lamp comes on when the direction of travel lever is in the neutral position.

See "Right-hand arm control functions".

NOTE: This indicator lamp has to be on to allow the engine to be started.

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

See "Right-hand arm control functions".

14. MACHINE BRAKING WARNING LAMP This warning lamp comes on to indicate that the machine brakes are applied. It is coupled to the direction of travel lever. When the direction of travel lever is in the neutral position, this warning lamp comes on after 3 seconds and the machine brakes are automatically applied. When the direction of travel lever is operated, this warning lamp goes out and the machine brakes are released. See "Right-hand arm control functions".

NOTE: This warning lamp also comes on if the emergency stop control and the emergency brake control are operated. See "Right-hand arm control functions".

2-7

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES

16

18

15

17

CT04G001

9

15. HYDRAULIC FLUID LEVEL WARNING LAMP This warning lamp comes on to indicate that the hydraulic fluid level in the reservoir is below the permitted limits. In this case, the engine shuts down automatically. It is essential to add hydraulic fluid to the reservoir, see "Hydraulic system" in Section 4.

NOTE: To restart the engine, it is essential for the level of hydraulic fluid in the reservoir to be correct.

IMPORTANT: If this phenomenon occurs again quickly, check the hydraulic system to find the origin of the problem and consult your Dealer.

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

2-8

17. ENGINE OIL PRESSURE WARNING LAMP This warning lamp comes on when the starter key switch (1) 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 (1) and find the cause of the problem.

18. DRUM VIBRATION SELECTOR CONTROL This two-position control is used to select two types of drum vibration. When the switch is pushed forwards, low amplitude vibration with high percussion frequency is obtained. When the switch is pressed backwards high amplitude vibration with low percussion frequency is obtained. The vibration system is switched on by means of the push-button, see "Right-hand arm control functions".

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES

20

21

19

CT04G001

10

19. DRUM ANTI-SLIP CONTROL

OR

19. DRUM AND WHEEL ANTI-SLIP CONTROL (ASC) (optional) This two-position control is used to select the drum anti-slip function or the drum and wheel anti-slip function (optional). When the switch is pushed forwards, the drum anti-slip function or the drum and wheel anti-slip function (optional) is inoperative. When the switch is pushed backwards, the drum anti-slip function or the drum and wheel antislip function (optional) is obtained and the switch lights up.

IMPORTANT: This control should only be used when the machine is being loaded onto a trailer or the machine is driving on rough ground. See "Transporting the machine" and "Driving the machine on rough ground" in Section 3. Before engaging the anti-slip function, make sure the travel speed switch is in low speed position and never use the drum vibration control to engage drum vibration.

See "Right-hand arm control functions".

20. HEATER/BLOWER CONTROL This three-position control provides two heater/blower speeds. When the switch is pushed completely forwards, the blower is switched off. With the switch pushed backwards to the intermediate position: high blower speed. When the switch is pushed completely to the rear: low blower speed.

NOTE: The heater temperature depends on the position of the heater control. See "Accessory functions".

NOTE: The blower circulates the air inside the cab but does not change air. Ventilate the cab periodically.

21. 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 connected to the power socket. See "Rotating beacon socket".

2-9

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES

28

27 26

22

23

24

25

CT04G001

11

22. HAZARD WARNING SIGNAL CONTROL This two-position control is used, in an event of emergency, to operate the right and lefthand 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.

23. AUXILIARY LAMP CONTROL This two-position switch controls the auxiliary lamp. When the switch is pushed forward, the auxiliary lamp is off. When the switch is pushed completely backwards, the auxiliary lamp is selected and this switch also lights up.

24. INSTRUMENT LIGHTING, FRONT AND REAR LIGHT AND FRONT WORK LAMP CONTROL This three-position control selects the lighting for all the switches and indicators in the operator’s compartment and also switches on the front and rear lights. When the switch is pushed completely forward, all lights are off. When the switch is pushed backwards to the intermediate position, the lighting for switches and indicators and the front and rear position lights are selected. When the switch is pushed completely backwards, the front work lamps are selected.

2-10

25. REAR WORK LAMP CONTROL This two-position switch controls the rear work lamps. When the switch is pushed forward, the rear work lamps are off. When the switch is pushed completely backwards, the rear work lamps are selected and this switch also lights up.

26. HORN CONTROL When this switch is pressed and held, the horn sounds. Release the switch to stop the horn.

27. TURN INDICATOR CONTROL 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 operated, either to the right or the left, the indicator lamp (9) flashes at the same rate as the turn indicators.

28. ASC DIFFERENTIAL LOCK - WARNING LAMP Flashing lamp indicates an ASC defect, see “ASC function” in Section 3.

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES

29

30 CT04G001

12 29. FUSE COMPARTMENT See "Fuses" in Section 6.

30. 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. The needle of the tachometer (4) shows the engine speed.

NOTE: The lever is equipped with a connector which is used to enable drum vibration to be used if the speed is 1800 rpm or more. Below that speed it is not possible to engage the roller vibration.

2-11

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES FRONT CONSOLE CONTROL FUNCTIONS (SV212, SV216) 5

2

4

3

6

1 CS00M512A

13

1. STARTER SWITCH This switch, when used with the starter switch key, has three positions "0" (Off), "1" (On) and "2" (Start the engine). See "Starting the engine" in Section 3.

4.ENGINE DIAGNOSTICS Use the connector to connect ECM (Electronic Control Module) and diagnostics trouble.

NOTE: Remove the key from the ignition box leaving the machine.

NOTE: ECM processes engine function data and controls the engine. Sensors pick up information on engine function and malfunctions and transfer it to ECM. The control module analyses input and returns commands for the engine to function properly.

Malfunctions and other data is identified and stored in ECM memory. this data will be transferred after connecting a service device (notebook) to connector.

NOTE: This key is also used to lock/unlock the cab doors and the side compartment door. See "Side compartment".

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. FUEL LEVEL GAUGE The needle shows the level of fuel in the tank.

3. ENGINE TACHOMETER The tachometer shows the engine speed in revolutions per minute. The figures on the gauge must be multiplied by 100. This tachometer is linked to the engine speed selector.

2-12

5. HYDRAULIC FLUID TEMPERATURE GAUGE The hydraulic fluid temperature when working should be between 50°C (122°F) and 60°C (140°F). If the temperature rises excessively during operation, shut down the engine, remove the starter switch key and find the cause of the problem.

6. HOURMETER The hourmeter shows the operating hours of the engine and enables servicing intervals to be determined. See the "Servicing interval table" in Section 4.

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES

10

7

12

26 8

9

11 13

CS00M512

14

7. POWER SOCKET This socket can be used for connecting an inspection lamp or any other 24 volt electrical appliance.

8. DIAGNOSTIC SOCKET (if equipped) This socket is used for connecting a portable computer to carry out troubleshooting procedures. See your Dealer.

NOTE: A special harness adapter is required between this connection and the laptop. Contact your Dealer for that adapter. Connecting the laptop directly without it, might cause an incorrect reading or damage to the laptop if you DO NOT.

9. INDICATOR LAMP FOR TURN INDICATORS This indicator lamp comes on when the turn indicator control (26) is operated. It flashes at the same rate as the turn indicators.

11. HYDRAULIC OIL FILTER RESTRICTION WARNING LAMP This warning lamp comes on when the hydraulic fluid temperature is too low or when the hydraulic oil filter has to be changed. See "Changing the hydraulic oil filter" in Section 4.

12. DIRECTION OF TRAVEL NEUTRAL POSITION INDICATOR LAMP This indicator lamp comes on when the direction of travel lever is in the neutral position.

See "Right-hand arm control functions".

NOTE: This indicator lamp has to be on to allow the engine to be started.

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

See "Right-hand arm control functions".

10. AIR FILTER RESTRICTION WARNING LAMP This warning lamp comes on when the air filter primary element has to be cleaned or changed. See "Air filter" in Section 4.

2-13

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES

14

18

16

15

17

CS00M512

15

14. MACHINE BRAKING WARNING LAMP This warning lamp comes on to indicate that the machine brakes are applied. It is coupled to the direction of travel lever. When the direction of travel lever is in the neutral position, this warning lamp comes on after 3 seconds and the machine brakes are automatically applied. When the direction of travel lever is operated, this warning lamp goes out and the machine brakes are released. See "Right-hand arm control functions".

NOTE: This warning lamp also comes on if the emergency stop control and the emergency brake control are operated. See "Right-hand arm control functions".

15. HYDRAULIC FLUID LEVEL WARNING LAMP This warning lamp comes on to indicate that the hydraulic fluid level in the reservoir is below the permitted limits. In this case, the engine shuts down automatically. It is essential to add hydraulic fluid to the reservoir, see "Hydraulic system" in Section 4.

NOTE: To restart the engine, it is essential for the level of hydraulic fluid in the reservoir to be correct.

IMPORTANT: If this phenomenon occurs again quickly, check the hydraulic system to find the origin of the problem and consult your Dealer.

2-14

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

17. AUXILIARY LAMP CONTROL This two-position switch controls the auxiliary lamp. When the switch is pushed forward, the auxiliary lamp is off. When the switch is pushed completely backwards, the auxiliary lamp is selected and this switch also lights up.

18. DRUM VIBRATION SELECTOR CONTROL This two-position control is used to select two types of drum vibration. When the switch is pushed forwards, low amplitude vibration with high percussion frequency is obtained. When the switch is pressed backwards high amplitude vibration with low percussion frequency is obtained. The vibration system is switched on by means of the push-button, see "Right-hand arm control functions".

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES

20

19

21

CS00M512

16

19. DRUM ANTI-SLIP CONTROL

OR

19. DRUM AND WHEEL ANTI-SLIP CONTROL (ASC) (optional) This two-position control is used to select the drum anti-slip function or the drum and wheel anti-slip function (optional). When the switch is pushed forwards, the drum anti-slip function or the drum and wheel anti-slip function (optional) is inoperative. When the switch is pushed backwards, the drum anti-slip function or the drum and wheel antislip function (optional) is obtained and the switch lights up.

IMPORTANT: This control should only be used when the machine is being loaded onto a trailer or the machine is driving on rough ground. See "Transporting the machine" and "Driving the machine on rough ground" in Section 3. Before engaging the anti-slip function, make sure the travel speed switch is in low speed position and never use the drum vibration control to engage drum vibration.

See "Right-hand arm control functions".

20. HEATER/BLOWER CONTROL This three-position control provides two heater/blower speeds. When the switch is pushed completely forwards, the blower is switched off. With the switch pushed backwards to the intermediate position: high blower speed. When the switch is pushed completely to the rear: low blower speed.

NOTE: The heater temperature depends on the position of the heater control. See "Accessory functions".

NOTE: The blower circulates the air inside the cab but does not change air. Ventilate the cab periodically.

21. 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 connected to the power socket. See "Rotating beacon socket".

2-15

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES

27

26

22

23

24

25

CS00M512

17

22. HAZARD WARNING SIGNAL CONTROL This two-position control is used, in an event of emergency, to operate the right and lefthand 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.

23. INSTRUMENT LIGHTING, FRONT AND REAR LIGHT AND FRONT WORK LAMP CONTROL This three-position control selects the lighting for all the switches and indicators in the operator’s compartment and also switches on the front and rear lights. When the switch is pushed completely forward, all lights are off. When the switch is pushed backwards to the intermediate position, the lighting for switches and indicators and the front and rear position lights are selected. When the switch is pushed completely backwards, the front work lamps are selected.

24. REAR WORK LAMP CONTROL This two-position switch controls the rear work lamps. When the switch is pushed forward, the rear work lamps are off. When the switch is pushed completely backwards, the rear work lamps are selected and this switch also lights up.

2-16

25. HORN CONTROL When this switch is pressed and held, the horn sounds. Release the switch to stop the horn.

26. TURN INDICATOR CONTROL 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 operated, either to the right or the left, the indicator lamp (9) flashes at the same rate as the turn indicators.

27. ENGINE SPEED CONTROL This knob is used to increase or decrease the engine speed. Turn the knob to the left for the "idle speed" position. Turn the knob to the right for the "maximum speed" position. The needle of the tachometer (3) shows the engine speed.

NOTE: The knob is equipped with a connector which is used to enable drum vibration to be used if the speed is 1800 rpm or more. Below that speed it is not possible to engage drum vibration.

NOTE: When the IDLE switch (29) is placed in On position, the indicator lamp lights up and the engine returns to idle, whatever the position of the engine speed control. If the switch is in the off position, it is possible to set the engine speed continuously from 1600 rpm to 2300 rpm maximum, depending on engine load.

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES

32 31

29

28

30

33

CS00M512

18 28. FUSE COMPARTMENT See "Fuses" in Section 6.

29. ENGINE IDLE SPEED CONTROL This two-position control makes it possible to select engine idle speed without having to turn control knob (27). Press the front of the switch to select HIGH idle speed. Press the rear of the switch to return to the original LOW IDLE engine speed.

NOTE: Repair the defect as soon as possible.

32. STOP ENGINE - WARNING LAMP Stop the engine as soon as possible if this RED lamp goes on.

NOTE: After turning on the DIAG switch (30), the red warning lamp (32) will start flashing in the code of the first defect.

!

30. ENGINE DIAGNOSTICS SWITCH In case of a malfunction of the engine, press the diagnostics switch to identify the defect on the basis of flashing code on signal lamp (32).

NOTE: Signal lamp (31) or (32) will go on in case of an engine malfunction, depending on severity of the defect. After activating switch (30) they will start flashing the code of the first defect see “Troubleshooting according to flashing codes” in Section 3.

NOTE: If both pilot lamps indicating defects (yellow 31 and red 32) go on after pressing the switch when the starter switch is “On” that means no defects have identified by engine ECM. 31. ENGINE DEFECT - WARNING LAMP This YELLOW lamp indicates a defect. The engine must be checked.

WARNING

!

If the warning lamp goes on, stop operation and engine while remembering safety at work.

Do not start the engine before the defect has been repaired.

33. TROUBLESHOOTING SWITCH Press the top of the switch to view the faults. Press the bottom of the switch to review the previous faults. Flash codes will illuminate on signal lamps (31) or (32).

IMPORTANT: Before using this switch, shut down the engine and turn the starter switch key to "I" position.

NOTE: Use the switch for troubleshooting only. See “Troubleshooting according to flashing codes” in Section 3.

NOTE: After turning on the DIAG switch (30), the red lamp (32) will start flashing in the code of the first defect.

2-17

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES

36

34

35

CS00M512

19

34. WATER IN FUEL - WARNING LAMP This lamp indicates water or other deposits detected in the fuel filter separator.

35. MAINTENANCE INDICATOR LAMP This lamp goes on to indicate engine maintenance is necessary.

NOTE: Perform maintenance according to the Operator’s Manual, on the basis of hours indicated on the hourmeter (6).

2-18

36. ASC DIFFERENTIAL LOCK - WARNING LAMP Flashing lamp indicates an ASC defect, see “ASC function” in Section 3.

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

1

1

2

4

2

5

3

3

CS00M507A/B

20

1. FRONT WINDSHIELD WIPER CONTROL This two-position control is used to operate the front windshield wiper. When the switch is pressed forwards, off. When the switch is pushed backwards, the windshield wiper operates.

IMPORTANT: Do not operate the windshield wiper if the windshield is dry, since this may damage the windshield wiper blade.

2. REAR WINDSHIELD WIPER CONTROL This two-position control is used to operate the rear windshield wiper. When the switch is pushed forwards, off. When the switch is pushed backwards, the windshield wiper operates.

IMPORTANT: Do not operate the windshield wiper if the rear windshield is dry, since this may damage the windshield wiper blade.

3. WINDSHIELD WASHER CONTROL This control is used to operate simultaneously the front and rear windshield washers. Press the switch and hold it completely backwards, release it to stop.

4. CAB BLOWER CONTROL (SV208, SV210) This is a four-position control used to operate the cab blower.

(0): Off. (1): Slow.

(2): Medium.

(3): Fast.

5. CAB BLOWER CONTROL (SV212, SV216) This is a two-position control used to operate the cab blower.

Off. On.

!

WARNING

!

The blower supplies fresh air from the outside.

Use the blower to ventilate the cab when the windows are closed.

IMPORTANT: Never operate the windshield washer control when the windshield washer reservoir is empty since this can damage the electric pumps.

2-19

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES RIGHT-HAND ARM CONTROL FUNCTIONS RIGHT-HAND ARM CONTROL This arm is equipped with a safety system which, when it is in the raised position, prevents the engine from being started and also provides space for the operator to pass by. To raise the arm, use the red lever (A) located at the front of the arm (SV212, SV216). Before starting the engine, lower the arm and make sure it is correctly locked. If the arm is raised when the machine is operating, the engine shuts down and the machine brakes are automatically applied.

SV208, SV210

CT04G003

21 SV212, SV216

!

WARNING

!

A

To enter or leave the operator’s compartment, it is mandatory for the arm to be in the raised position.

Never attempt to by-pass this safety system.

CS02B551A

22

2-20

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES 1. DIRECTION OF TRAVEL AND TRAVEL SPEED LEVER This lever is used to select the direction of travel as well as the machine’s travel speed.

When the lever is tilted forwards to "Position F", the machine moves forwards. When the lever is tilted rearwards to "Position R", the machine travels in reverse. When the lever is in neutral position, the machine stops traveling and in this position the indicator lamp (12) lights up, see "Front console control functions".

The travel speed of the machine depends on the angle to which the lever is tilted as well as the type of speed chosen by the controls (3) and (4). The more the lever is tilted, the higher is the speed. It is possible at any moment to release the lever and it will stay in the speed position which has been selected.

1

4

3 CS02B551

23

IMPORTANT: When the lever is in the neutral position for more than 2 seconds, the machine brakes are automatically applied and the indicator lamp (14) comes on. When the lever is operated, the indicator lamp (14) goes out and the machine brakes are released. See "Front console control functions". A quick movement of the lever (less than 2 seconds) does not cause the machine brakes to be applied.

!

WARNING

!

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 (wheels).

NOTE: To start the engine, it is imperative for the lever (1) to be in the neutral position, otherwise starting is impossible. See "Starting the engine" in Section 3.

2. DRUM VIBRATION CONTROL This push button is used to engage drum vibration.

Press the button to engage vibration, the indicator lamp (13) comes on. Press the button again to stop vibration, the indicator lamp (13) goes out. See "Front console control functions".

2

3

IMPORTANT: To engage vibration, the lever (1) has to be operated. It is not possible to engage vibration if the lever (1) is in the neutral position. The engine speed also must be at least 1800 rpm. Below that speed, it is not possible to engage the drum vibration.

See "Front console control functions".

4

NOTE: The type of vibration depends on the control (18). See "Front console control functions".

IMPORTANT: This control can only be used in slow speed.

CS02B551

24

2-21

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES 3. TRAVEL SPEED SWITCH This control is used to select two types of speed, both in forward or reverse drive.

Slow speed (machine working) or high speed (fast travel).

To select the high speed press the part of the switch with the "Hare" symbol. In this position this switch lights up.

To select low speed, press on the part of the switch with no symbol. In this position the switch light goes out. In low speed it is also possible to select three preset speed ranges by means of the selector (4), depending on the work which has to be carried out.

See "Travel speed" in Section 8 to find the maximum speed depending on the type selected.

Once the type of speed has been defined, use the lever (1) to move the machine. Note that the travel speed also depends on the angle to which the lever (1) is tilted.

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.

!

WARNING

!

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

4. WORK SPEED RANGE SELECTOR This selector is used to select from among three low speed ranges, preset to suit the work to be carried out, operating in the same manner both in forward travel and reverse. These can only be used if the control (3) is in the "Low speed" position.

See "Travel speed" in Section 8 to find the speeds possible in each of the three ranges. Place the selector in position 1, 2 or 3 (low, medium, high) speed and use the lever (1) to move the machine. Note that the travel speed also depends on the angle to which the lever (1) is tilted.

NOTE: It is possible to change from one position to another while the machine is traveling.

2-22

2 1

3

4

CS02B551

25

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES 5.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 (1). Press the button, the engine will shut down, the machine brakes will be applied and the indicator lamp (14) comes 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 shut down" in Section 3.

5

4 1 6

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 (5) to be in the raised position, otherwise it is impossible to start. See "Starting the engine" in Section 3.

3 CS02B551

26

6. EMERGENCY BRAKE CONTROL This control is used to 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 backwards). Place the direction control lever (1) in neutral and then press the switch. The machine’s brakes will be applied immediately and the warning lamp (14) will come on. See "Front console control functions". The brakes are released automaticaly as soon as the direction control lever (1) is operated or the steering is turned.

2-23

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 and that the seat pivoting system is locked in the driving position SEAT SUSPENSION ADJUSTMENT By turning the crank handle the firmness may be adjusted to suit the driver’s weight within 50 to 130 kg (110 to 286 lb) in steps of 10 kg (22 lb).

CI01C503

27 SEAT ELEVATION ADJUSTMENT By grasping the seat from below, the height of the seat may be adjusted up to higher positions, in which it engages and a click-sound is heard. After it has reached its highest position it drops all the way down.

CI01C504

28

2-24

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES BACKREST ANGLE ADJUSTMENT

SV208, SV210

By lifting the lever the backrest tilts continually to the position required.

CT04G005

29 SV212, SV216

CI01C505

30 LUMBAR SUPPORT ADJUSTMENT (SV212, SV216) By turning the wing nut the firmness and shape of the backrest may be adjusted as required.

CI01C506

31

2-25

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES ADJUSTMENT OF ARM REST

SV208, SV210

By turning the nut the arm rest is raised.

CT04G006

32 SV212, SV216

CI01C507

33 CUSHION FORE AND AFT ADJUSTMENT By lifting the lever the seat may be moved back and forth.

CD01G293

34

2-26

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES SEAT FORE AND AFT ADJUSTMENT By lifting the lever the seat may be moved back and forback.

CD01G292

35 SEAT BELT Seat yourself comfortably on the seat, pull out a considerable length of seat strap and click it into the buckling system.

NOTE: If the length of strap pulled out at the first attempt is not sufficient, allow it to rewind and then pull it again.

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.

!

WARNING

CI01C508

36

!

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.

2-27

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES PIVOTING LEVER

SV208, SV210

To facilitate getting into and out of from the operator’s compartment, the seat can pivot to the right up to 50°.

Pull the lever and then pivot the seat to the right until the lever engages. Carry out the same procedure to return it to the driving position.

CT04G007

37 SV212, SV216

CI01C509

38

2-28

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES ACCESSORY FUNCTIONS STEERING WHEEL The steering wheel 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 tires and the roller.

IMPORTANT: Before moving the machine make sure that the central articulation is not locked.

CT04G008

39 OPERATOR’S COMPARTMENT LIGHTING (CAB VERSION) Located at the upper front right-hand side of the operator’s compartment, the lighting is controlled by a switch incorporated in the lamp base.

CD01G280

40 STORAGE COMPARTMENT (CAB VERSION) Located at the upper front left-hand side of the operator’s compartment, this storage compartment is used for the first-aid kit and is to be used among other things for storing the technical documentation and the conformity declarations of the machine.

IMPORTANT: Make sure the first-aid kit is always complete and regularly check the expiry date.

CD01G271

41

2-29

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES SUN VISOR Attached to the windshield, the sun visor can easily be positioned as required.

CD01G288

42 REAR VIEW MIRRORS The rear view mirrors can be turned 90 degrees inwards to facilitate work in confined spaces or when transporting the machine.

IMPORTANT: Before carrying out any movement, make sure that the rear view mirrors are correctly adjusted and cleaned.

CD00M001

43

2-30

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES AIR VENTS Located at the front and rear of the operator’s compartment and under the operator’s seat, the air vents are for the circulation and orientation of the airflow.

The vents are opened and closed manually.

IMPORTANT: When using air-conditioning (if equipped), the vents must be in the open position.

CD01G280

44

CS00505A

45

CS00505B

46

2-31

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES FRONT WINDSHIELD WIPER The front windshield wiper is controlled by the switch (1). See "Front upper control functions".

IMPORTANT: Do not operate the windshield wiper if the windshield is dry, since this can cause damage to the windshield wiper blade.

CS00M505

47 REAR WINDSHIELD WIPER The rear windshield wiper is controlled by the switch (2). See "Front upper control functions".

IMPORTANT: Do not operate the windshield wiper if the rear windshield is dry, since this can cause damage to the windshield wiper blade.

CS00M505

48 WINDSHIELD WASHER RESERVOIR Located at the rear of the operator’s compartment, this reservoir has two electric pumps controlled by the switch (4). See "Front upper control functions".

IMPORTANT: Never operate the windshield washer control when the reservoir is empty, since this can cause damage to the electric pumps.

Remove the filling cap to add windshield washer fluid.

NOTE: In cold weather, add a suitable additive to the windshield washer water.

CD01G273

49

2-32

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES BEVERAGE HOLDER Located at the rear of the operator’s compartment, the beverage holder, when opened, can be used for holding cups, bottles, etc.

CD00M002A

50 HEATER CONTROL Located on the left of the operator’s seat, and to the rear, the control is used to adjust the heater in the operator’s compartment. In the completely lowered position (minimum), the heater is not operating. In the completely raised position (maximum), the heater is on maximum.

To adjust, raise the control to the position corresponding to the desired temperature. The heater blower is controlled by the switch (20). See "Front console control functions".

CD00M003

!

WARNING

!

51

It is forbidden to attempt to adjust the heater control while the machine is traveling. Make any necessary adjustments before undertaking any travel.

OPERATOR’S COMPARTMENT AIR INTAKE The air intake is used to bring air into the operator’s compartment and is equipped with an anti-dust filter which must be regularly inspected. See "Operator’s compartment intake air dust filter" in Section 5.

CD01G286

52

2-33

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES SIDE COMPARTMENT Located on the left-hand side of the machine, the compartment gives access to the battery master switch and to the tilting controls for the operator’s compartment and for the engine hood.

NOTE: The compartment can be locked using the starter switch key.

!

WARNING

!

Make sure that the door of the compartment is properly locked before undertaking any travel.

CS00M505C

53 BATTERY MASTER SWITCH Located in the side compartment, the battery master switch, when tilted in horizontal position, completely disconnects the batteries from the electrical system (system switched off). In vertical position, the system is switched on.

!

WARNING

!

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

CD00M004

54

OPERATOR’S COMPARTMENT ELECTRICAL TILTING CONTROL (optional) Located in the side compartment, this three-position control is used to tilt the operator’s compartment to gain access to certain components of the machine.

Press and hold the top of the switch to tilt the operator’s compartment forwards. To stop the movement, release the switch (central position). Press and hold the bottom of the switch to return the operator’s compartment to the normal position.

NOTE: To carry out this operation, see "Tilting the operator’s compartment and hood using the electric hydraulic system" in Section 3.

!

WARNING

!

Before tilting the operator’s compartment, make sure that the doors are correctly closed, that no obstacle will interfere with complete tilting and that there is nobody in the vicinity during lowering.

NOTE: If a defect occurs in the operation of this control, it is nevertheless possible to carry out tilting manually by means of the lever and the pump. See "Tilting the operator’s compartment and hood" in Section 3.

2-34

CD00M004

55

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES ELECTRICAL CONTROL FOR OPENING AND CLOSING THE ENGINE HOOD (optional) Located in the side compartment, the control has three positions. Press and hold the top of the switch, the hood opens. To stop the movement, release the switch (central position). Press and hold the bottom of the switch, the hood closes.

To carry out this operation, see "Tilting the operator’s compartment and hood using the electric hydraulic system" in Section 3.

!

WARNING

!

CD00M004

56

Before opening the hood, make sure that no obstacle is going to interfere with its complete opening.

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

Never travel or work with the hood open.

NOTE: If a defect in the operation of this control should occur, it is nevertheless possible to open or close the hood manually by means of the lever (1) and the pump (2). See "Tilting the operator’s compartment and hood" in Section 3.

MANUAL PUMP AND LEVER Located in the side compartment, the lever (1) and the manual pump (2) are to be used to tilt either the operator’s compartment or the hood or if equipped to replace the electrical controls in the event of emergency. See "Tilting the operator’s compartment and hood" in Section 3.

1

CD01G289

57

2

CD01G290

58

2-35

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES TILTING CONTROL FUSE (optional) Located in the side compartment, the 50 amp fuse protects the tilting controls.

IMPORTANT: Before changing a fuse, place the battery master switch in horizontal position (system switched off).

IMPORTANT: Never replace this fuse by a fuse of a different amperage.

CD01G272

59 ROTATING BEACON SOCKET This socket may be used for connecting a rotating beacon (optional) or an inspection lamp.

NOTE: After connecting the rotating beacon, press switch (21) to activate this function. See "Front console control functions".

CD01A005

60 DOZER BLADE CONTROL (if equipped)

III

The lever or the pedal has four positions:

I

0 II

(0) Neutral position (dozer blade stops moving).

(I) Dozer blade lowers.

(II) Dozer blade rises.

(III) Dozer blade is in floating position.

The dozer blade will stop moving as soon as the lever is released. The lever or pedal automatically returns to neutral position (0) upon release, except when it is in position (III). See "Dozer blade" in Section 3.

III

I

0 II

CS00M505D

!

WARNING

!

Make sure that no one is in the operating area of the dozer blade before moving it.

2-36

61

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES STORAGE NET The net is for operator’s personal items.

CS00M505

62 STORAGE BOX Located at the rear of the operator’s seat, this box is to be used for storing the operator’s manual.

CT04G010

63 ENGINE FUSE BOX Located in the right-hand compartment, see "Engine fuses" in Section 6.

CD03G001

64

2-37

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES AIR-CONDITIONING CONTROLS (if equipped) Two controls are used to operate the air-conditioning system.

Control (1) is used to regulate the temperature.

In "0" position the temperature will be low. The more you turn this control to the left, the higher the temperature will be.

2 1

Control (2) is used to turn on the air-conditioning and regulate the air flow.

CD00N011A

65 The air-conditioning system will only work while the engine is running, with the heater control in lowered position. The air vent must be open and the cab doors must be closed. See "Air vents".

Turn control (2) to one and then select the required temperature by turning control (1). To switch the airconditioning system off, turn control (2) to "0" position.

NOTE: It is not necessary to alter the position of control (1) to switch off the air-conditioning.

NOTE: In order to ensure the air-conditioning system functions correctly and as effectively as possible, it should be turned on at least once a week, if only for a short period.

To service the various components of the air-conditioning system, see "Air-conditioning" in Section 5.

2-38

CD00M003

66

SECTION 3

46

OPERATING INSTRUCTIONS BEFORE OPERATING THE MACHINE

!

WARNING

!

Do not operate this machine until you have first read and understood 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.

Before operating the machine, observe the following instructions: 1.

Check the levels (engine oil, hydraulic fluid and cooling system) and make sure that the various fluids correspond to the conditions of use. See "Fluids and lubricants" in Section 4.

2.

Perform the daily maintenance operations. See Section 4.

3.

Check all round the machine, identify any leaks and inspect the hoses. Tighten or replace where necessary. See Section 5.

4.

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

5.

Check the correct operation of the windshield wipers.

6.

Check the condition and pressure of the tires.

See "Tires and wheels" in Section 5.

7.

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

11. Remove anything which can obstruct visibility.

Clean the window glasses and rear view mirrors.

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

13. Be aware of the possibilities for evacuating the machine (emergency exit via the left-hand door) in the event that access via the right-hand door is impossible.

14. Make sure that the left-hand door is not locked.

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

16. Be aware of work-site safety measures.

17. 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.

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

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

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:

8.

Clean or change safety decals which are no longer legible. See "Decals" in Section 1.

1.

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

9.

Make sure the engine hood is closed correctly.

2.

Regularly consult the hourmeter to observe the servicing intervals. See Section 4.

3.

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

4.

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

10. Make sure the cab doors and the side compartment are closed correctly.

3-1

SECTION 3 - OPERATING INSTRUCTIONS 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.

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.

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.

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

7.

8.

9.

Make sure that the operator’s seat is correctly adjusted and the seat pivoting system locked in the driving position.

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

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.

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 shift 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".

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

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

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

3-2

24. Make sure that no one is in the operating area of the dozer blade before moving it (if equipped).

25. Take care not hit the dozer blade against rocks (if equipped).

26. If the use of the dozer blade is not required, make sure that it is locked mechanically (if equipped).

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 thirty operating hours.

During this period: Warm-up the engine 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 and coolant solution levels frequently.

After the first 100 hours Change the oil in the transmission. See "Transmission" in Section 4.

Change the oil in the planetary reduction gears. See "Planetary reduction gears" in Section 4.

SECTION 3 - OPERATING INSTRUCTIONS STARTING THE ENGINE (SV208, SV210) NOTE: After shutting down the machine for a prolonged period, see "Starting up after storage" in Section 7.

NOTE: If you have to start the engine by means of booster batteries, see "Connecting booster batteries" in Section 6.

1.

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

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 Section 2.

3.

Place the right-hand arm in the lowered position.

IMPORTANT: If the arm is not in the lowered position, it is impossible to start the engine.

CD00M004

1 4.

Turn the starter switch key (1) to the "I" position and make sure that the machine braking (2), battery charge (3) and engine oil pressure (4) warning lights are on.

2

3

4 1

12

6 8

CT04G001

2 5.

Make sure that the direction of travel lever (5) is in the neutral position, with the indicator lamp (6) on the front console alight and the emergency stop button (7) in the raised position. Hydraulic fluid level lamp (12) must be off for engine to start.

5 2

3

IMPORTANT: If the lever (5) is not in the neutral position or if the button (7) is lowered, it is impossible to start the engine.

6.

Move the engine throttle lever (8) one quarter of its stroke.

7

1

4

CT04G002

3

3-3

SECTION 3 - OPERATING INSTRUCTIONS 7.

Make sure that no-one is in the vicinity of the machine, and sound the horn (9) as a safety measure.

8.

Turn the key to the “II” starting position. Release the key as soon as the engine fires. If the engine stops, wait about 30 seconds and then start the operation again.

3

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.

Make sure that the battery charge (3) and engine oil pressure (4) warning lamps go out after starting up the engine.

4

9

CT04G001

4

10. Move the engine throttle lever (8) so that the tachometer needle (10) is between 1300 and 1500 rpm.

11. Allow the engine to run until it reaches normal operating temperature. The needle on the temperature gauge (11) should show at least 60°C (140°F).

11

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

10

8 CT04G001

5

3-4

SECTION 3 - OPERATING INSTRUCTIONS STARTING THE ENGINE (SV212, SV216) NOTE: After shutting down the machine for a prolonged period, see "Starting up after storage" in Section 7.

NOTE: If you have to start the engine by means of booster batteries, see "Connecting booster batteries" in Section 6.

1.

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

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 Section 2.

3.

Place the right-hand arm in the lowered position.

IMPORTANT: If the arm is not in the lowered position, it is impossible to start the engine.

CD00M004

1 4.

Turn the starter switch key (1) to the "I" position and make sure that the machine braking (2) and battery charge (3) warning lights are on.

5.

Engine diagnostics indicator lamps 4, 5, 6, and 7 will light up and go off after four seconds.

4

5

2

3 1

6

7

13

CS00M512B

2 6.

Make sure that the direction of travel lever (8) is in the neutral position, with the indicator lamp (9) on the front console alight and the emergency stop button (10) in the raised position. Hydraulic fluid level lamp (13) must be off for engine to start.

IMPORTANT: If the lever (8) is not in the neutral position or if the button (10) is lowered, it is impossible to start the engine.

7.

Press the engine idle speed control (11).

8.

Turn the key (1) to the “II” starting position.

Release the key as soon as the engine fires. If the engine stops, wait about 30 seconds and then start the operation again.

11

1

9 8

10

CS00M512C

3

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.

3-5

SECTION 3 - OPERATING INSTRUCTIONS 9.

Make sure that the battery charge warning lamp (3) goes out after starting up the engine.

10. Make sure that no-one is in the vicinity of the machine, and sound the horn (12) as a safety measure.

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

3

12

CS00M512D

4

3-6

SECTION 3 - OPERATING INSTRUCTIONS SHUTTING DOWN THE ENGINE 1.

2.

If drum vibration is being used, press the push button (1) to stop it and check that the indicator lamp (2) on the front console is out.

1

Place the direction of travel lever (3) in the neutral position and make sure that the indicator lamps (4) and (5) on the front console have come on.

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

3

CS02B551B

5 3.

(SV208, SV210) Place the engine throttle lever (6) in the idle speed position.

4

5

2

1

6 CT04G001

6 3.

4.

(SV212, SV216) Press engine idle speed control (6) to adjust idle speed.

4

5

6

Run the engine at idle for about 1 minute.

IMPORTANT: Allow the engine to run at idle for 3-5 minutes in order to reduce the engine temperature before completely shutting down.

5.

Turn the starter switch key (1) to the "Off" position.

7

2

CS00M512E

7

3-7

SECTION 3 - OPERATING INSTRUCTIONS 6.

If you have to leave the operator’s compartment, raise the arm and remove the starter switch key.

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

CD01C128

8

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, or if an operating problem with the direction of travel lever (1) occurs, immediately press the button (2). The engine will stop, the machine’s brakes are automatically applied and the indicator lamp (3) on the front console comes on.

3 2

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 (2) in the direction of the arrow, make sure that the direction of travel lever (1) 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 (2) to be in the raised position, otherwise it is impossible to start.

3-8

1

CS00M512C

9

SECTION 3 - OPERATING INSTRUCTIONS MACHINE TRAVEL AND DIRECTION OF TRAVEL (SV208, SV210) Before any travel, make sure that no obstacle or person is in front of or behind the machine and make sure also that all the doors and hood are correctly closed, then start the engine. See "Starting the engine".

If the use of the dozer blade is not required, make sure it is locked mechanically (if equipped).

In the event of poor visibility, use the controls (1) and (2) on the front console to turn on the work lamps.

FAST TRAVEL

!

WARNING

!

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

1.

Press on the part of the switch (3) showing the "Hare" symbol.

2.

Make sure, by means of the control (4) that drum vibration is switched off (the indicator lamp (5) on the console should be out).

IMPORTANT: Never operate the control (4) when in high speed.

3.

4.

8

1

9

4

5

Use the lever (6) to increase engine speed, to adjust oppropriate engine speed approximately 1800 rpm.

7

6

10

Move the machine forward or in reverse by means of the direction of travel lever (7). The indicator lamp (8) on the front console will go out.

NOTE: Travel speed depends on the angle to which the lever (7) is tilted. It can be released at any time and will remain in position at the chosen speed.

5.

2

3 CT04G011

11 10

Steer the machine by means of the steering wheel.

IMPORTANT: Do not use the engine speed control lever (6) to increase travel speed.

6.

To stop travel, place the lever (7) in the neutral position; the indicator lamp (8) on the front console will come on. After 2 seconds, the machine’s brakes are automatically applied and the indicator lamp (9) also comes on. If necessary, shut down the engine, see "Shutting down the engine".

NOTE: To stop on an incline, press button (11).

3-9

SECTION 3 - OPERATING INSTRUCTIONS IMPORTANT: During machine travel never tilt the switch (3) directly to the low speed position. There is a danger of damaging the hydraulic system. To change to low speed, stop traveling and then tilt the switch.

SLOW TRAVEL WITHOUT VIBRATION (WORK) 1.

Press on the part of the switch without a symbol (3).

2.

Choose one of the three speed ranges to suit the type of work to be carried out, using the selector (10).

3.

Carry out Steps 2 to 6 in "Fast travel".

NOTE: During travel, it is possible at any time, if conditions so permit, to change to high speed by means of the switch (3).

12 9

8

SLOW TRAVEL WITH VIBRATION (WORK) 1.

Carry out Steps 1 and 2 of "Slow travel without vibration".

2.

Select one of the two types of vibration using the control (12).

3.

Place the engine throttle lever (6) in the maximum speed position

4 5 7 6

IMPORTANT: Engine speed must be at least 1800 rpm, otherwise it is impossible to engage drum vibration.

4.

Set the machine in motion by means of the direction of travel lever (7); the indicator lamp (8) on the front console will go out. Then operate the push-button (4); the indicator lamp (5) on the front console will come on and the drum will begin to vibrate.

NOTE: The speed of travel depends on the angle to which the lever (7) is tilted. It can be released at any time and it will remain in position at the chosen speed.

5.

To stop drum vibration, press the push button (4) again. The indicator lamp (5) on the front console will go out.

6.

Carry out Steps 5 and 6 of "Fast travel".

3-10

10

3 CT04G012

11

SECTION 3 - OPERATING INSTRUCTIONS MACHINE TRAVEL AND DIRECTION OF TRAVEL (SV212, SV216) Before any travel, make sure that no obstacle or person is in front of or behind the machine and make sure also that all the doors and hood are correctly closed, then start the engine. See "Starting the engine".

If the use of the dozer blade is not required, make sure it is locked mechanically (if equipped).

In the event of poor visibility, use the controls (1) and (2) on the front console to turn on the work lamps.

FAST TRAVEL

!

7 9

WARNING

6

10

!

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

1.

Press on the part of the switch (3) showing the "Hare" symbol.

2.

Make sure, by means of the control (4) that drum vibration is switched off (the indicator lamp (5) on the console should be out).

1

5 4

8

IMPORTANT: Never operate the control (4) when in high speed.

3.

Press bottom of switch (6) to achieve engine low idle rpm of approximately 900 rpm.

4.

Press top of switch (6) and adjust knob (7) to adjust engine rpm from low idle to high idle maximum of 2340 rpm with no load on engine.

3 NOTE: 1600 to 2340 rpm can be set with knob (7).

Maximum engine rpm with no load is 2340 rpm and 2200 rpm with fully loaded engine.

5.

2

11

CS03G002

12

Move the machine forward or in reverse by means of the direction of travel lever (8). The indicator lamp (9) on the front console will go out.

NOTE: Travel speed depends on the angle to which the lever (8) is tilted. It can be released at any time and will remain in position at the chosen speed.

6.

Steer the machine by means of the steering wheel.

IMPORTANT: Do not use the engine speed control lever (7) to increase travel speed.

7.

To stop travel, place the lever (8) in the neutral position; the indicator lamp (9) on the front console will come on. After 2 seconds, the machine’s brakes are automatically applied and the indicator lamp (10) also comes on. If necessary, shut down the engine, see "Shutting down the engine".

3-11

SECTION 3 - OPERATING INSTRUCTIONS NOTE: To stop on an incline, press the park brake button (11).

IMPORTANT: During machine travel never tilt the switch (3) directly to the low speed position. There is a danger of damaging the hydraulic system. To change to low speed, stop traveling and then tilt the switch.

SLOW TRAVEL WITHOUT VIBRATION 1.

Press on the part of the switch without a symbol (3).

2.

Choose one of the three speed ranges to suit the type of work to be carried out, using the selector (12).

3.

Carry out Steps 2 to 6 in "Fast travel".

9

7

NOTE: During travel, it is possible at any time, if conditions so permit, to change to high speed by means of the switch (3).

SLOW TRAVEL WITH VIBRATION 1.

Carry out Steps 1 and 2 of "Slow travel without vibration".

2.

Select one of the two types of vibration using the control (13).

3.

Turn knob (7) to the maximum engine speed.

4.

Set the machine in motion by means of the direction of travel lever (8); the indicator lamp (9) on the front console will go out. Then operate the push-button (4); the indicator lamp (5) on the front console will come on and the drum will begin to vibrate.

NOTE: The speed of travel depends on the angle to which the lever (8) is tilted. It can be released at any time and it will remain in position at the chosen speed.

5.

To stop drum vibration, press the push button (4) again. The indicator lamp (5) on the front console will go out.

6.

Carry out Steps 5 and 6 of "Fast travel".

3-12

8 13

5 4

12 3

11

CS03G003

13

SECTION 3 - OPERATING INSTRUCTIONS TROUBLESHOOTING ACCORDING TO FLASHING CODES (SV212, SV216) 1.

In case of an engine fault, either the stop engine red warning lamp (1) or engine defect YELLOW warning lamp (2) will light up.

2.

Stop the engine and turn the starter switch key (3) to “I” position.

3.

Press the switch (4) to activate the fault code; the defect warning lamp will start flashing the code corresponding to the defect and repeat it in the same sequence.

4.

Press the front of the switch (5) to move to the next fault. You can search for fault codes stored in the ECM index using the arrows on the switch (5).

(Press the front of switch to go to the following faults or press the rear of switch to go to the previous faults).

1

4

5

2

3 CS03G004

14

Example of flashing fault code Flashing codes consists of three digits.

Example: code 123.

Yellow lamp (2) will flash, red lamp (1) will flash the code after 1-2 seconds.

Number 1: red will flash once, then pauses for 1-2 seconds.

Number 2: red will flash twice, then pauses for 1-2 seconds.

Number 3: red will flash three times, then pauses for 1-2 seconds.

When the number has finished flashing in red, a yellow lamp will appear again. The three digit code will repeat in the same sequence. Press the switch (5) to move to the next fault.

Example: code 234.

Yellow lamp (2) will flash, red lamp (1) will flash the code after 1-2 seconds.

Number 2: red will flash twice, then pauses for 1-2 seconds.

Number 3: red will flash three times, then pauses for 1-2 seconds.

Number 4: red will flash four times.

When the number has finished flashing in red, a yellow lamp will appear again. The three digit code will repeat in the same sequence. Press the switch (5) to move to the next fault.

!

WARNING

!

After the warning lamp (1) goes on, stop operation and engine, without endangering safety at work.

Do not start the engine before the defect has been repaired.

IMPORTANT: If warning lamp (2) lights up, repair the defect as soon as possible.

3-13

SECTION 3 - OPERATING INSTRUCTIONS ASC FUNCTION 1.

ASC (Anti Spin Control) prevents slipping of wheels and drum in case of exceeding adhesion limits when driving in heavy conditions or on slopes.

2.

Activate ASC by turning the starter switch key (1) to “I” position. It is then working in the whole range of working and transport gears.

3.

Flashing warning lamp (2) indicates an ASC defect consult your Dealer.

SV208, SV210

2

1

3

NOTE: In case of ASC failure, transport gear cannot be engaged or, if adhesion limit is exceeded, the drum or one of the wheels will start slipping.

CT04G001

15 4.

In case the drum or a wheel locks up (drum or wheel sensor failure or contact with wheel sensor device broken), the drum or wheel will be unlocked automatically (while driving) after 5 seconds and will start turning. The drum or wheel will lock up again for five seconds after stopping the machine and engine and subsequent starting and driving away. The machine may work in this condition.

SV212, SV216

2

3

Disabling ASC To avoid wheel or drum lock-up during repeated engine starts, disable ASC by removing fuse F4 10A (3) in the dashboard.

CS03G005

1 16

3-14

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.

Raise the dozer blade and locked it mechanically (if equipped).

3.

Switch off all the accessories (windshield wipers, heater, etc.) which were operating.

4.

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

5.

It is mandatory to raise the right-hand arm.

6.

Operate the lever to unlock the operator seat pivot and pivot the seat to the right until it engages. Leave 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.

CD01C128

17 7.

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

8.

Make sure the engine hood is correctly locked, then lock the doors of the cab and the side compartment.

IMPORTANT: Check that no part of the machine is encroaching on the highway. If this cannot be avoided, set up approved traffic signs and markers.

IMPORTANT: If the machine is being parked for a long time, see Section 7.

CD00M004

18

3-15

SECTION 3 - OPERATING INSTRUCTIONS TILTING THE OPERATOR’S COMPARTMENT AND HOOD To permit easier access to the hydraulic components, the operator’s compartment and the hood may be tilted.

SEQUENCE OF RAISING AND LOWERING OF THE OPERATOR’S COMPARTMENT

!

WARNING

!

Before tilting the operator's compartment, make sure the compartment is empty and the doors are correctly closed, that no obstacle will interfere with complete tilting and that nobody is in the vicinity of the machine.

NOTE: Make sure that no movable object is inside the operator’s compartment before tilting.

1.

Remove the nuts on the back of the operator’s seat that attach the panel to rubberized metal pieces.

CD00M006A

19 2.

Gain access to the levers that are located on the left-hand side of the machine, under the cab, near the left-hand side compartment.

CD02B101

20

3-16

SECTION 3 - OPERATING INSTRUCTIONS 3.

Slide the lever to position (A).

A

CD01G306A

21 4.

Open the left-hand side compartment and install the lever on the hand pump and operate the pump to raise the operator’s compartment.

CD01C170A

22 5.

To lower the cab, slide the lever to position (B) and operate the hand pump.

!

WARNING

!

After lowering, tighten the nuts on the operator’s compartment. Tighten the nuts on the operator’s compartment after it has lowered, since a fatal accident could occur should the machine turn over.

B

CD01G305A

23

3-17

SECTION 3 - OPERATING INSTRUCTIONS SEQUENCE OF RAISING AND LOWERING OF THE HOOD

!

WARNING

!

Before opening the hood, make sure that no obstacle can interfere with its complete opening.

Before opening or closing the hood, make sure that nobody is in the vicinity of the machine.

Never travel or work with the hood open.

1.

Slide the lever to position (A).

A

CD01G308A

24 2.

Install the lever in the hand pump and pump the hood up.

CD01C170A

25 3.

To lower the hood, slide the lever to the position (B) and operate the hand pump.

B CD01G307A

26

3-18

SECTION 3 - OPERATING INSTRUCTIONS TILTING THE OPERATOR’S COMPARTMENT AND HOOD USING THE ELECTRIC HYDRAULIC SYSTEM (optional) To permit easier access to the hydraulic components, the operator’s compartment and the hood may be tilted.

SEQUENCE OF RAISING AND LOWERING

!

WARNING

!

Before tilting the operator's compartment, make sure the doors are correctly closed, that no obstacle will interfere with complete tilting and that nobody is in the vicinity of the machine.

NOTE: Make sure that no movable object is inside the operator’s compartment before tilting

!

WARNING

!

Before opening the hood, make sure that no obstacle can interfere with its complete opening.

Before opening or closing the hood, make sure that nobody is in the vicinity of the machine.

Never travel or work with the hood open.

1.

Remove the nuts at the rear end of the operator’s compartment that attach brackets to rubberized metals.

CD00M006A

27 2.

Switch power on by turning the battery master switch on.

3.

Press and hold down push button switch (1) for raising the operator’s compartment or push button switch (2) for hood raising in position (A) until the end of process. For lowering, press the switch and hold it in position (B) until the end.

NOTE: Lifting and lowering may be interrupted anytime by releasing the switch.

NOTE: Make sure that the controlling valve locking device is inoperative, otherwise it will cause a malfunction. See "Manual raising and lowering".

1

A B

A B

2

CD00M004

28

3-19

SECTION 3 - OPERATING INSTRUCTIONS 4.

After lowering, tighten the nuts on the operator’s compartment.

NOTE: If an operating failure occurs, it is, nevertheless, possible to tilt the operator’s compartment and the hood manually. Proceed as follows: MANUAL RAISING AND LOWERING (in case of electrical failure) OPERATOR’S COMPARTMENT 1.

Slide the locking device (D) on the control valve (C) and lock it in this position (E).

C D

E CD01C171

29 2.

IInstall the lever in the hand pump and pump the operator’s compartment.

CD01C170A

30 3.

Before lowering remove the locking device (D) install it on the other side of the control valve (C), and secure (E). Pump to lower the operator’s compartment.

!

WARNING

E

C

!

After lowering, tighten the nuts on the operator’s compartment. Tighten the screws on the operator’s compartment after it has lowered, since a fatal accident could occur should the machine turn over.

D

CD01C172

31

3-20

SECTION 3 - OPERATING INSTRUCTIONS HOOD 1.

Slide the locking device (D) on the control valve (C) and lock in this position (E).

C

E

D CD01C173

32 2.

IInstall the lever in the hand pump and pump the hood up.

CD01C170A

33 3.

Before lowering, remove the locking device (D), install it on the other side of the control valve (C) and secure (E). Pump to lower the hood.

D

CD01C174

E

C 34

3-21

SECTION 3 - OPERATING INSTRUCTIONS DRIVING THE MACHINE ON ROUGH GROUND On rough ground or on a slope, there is a danger that the wheels or the roller will slip. To avoid this happening, use the drum anti-slip device or the drum and wheels anti-slip device (optional).

Press the rear of the switch this will activate the drum or drum and wheel anti-slip device and the switch will light up. To disengage the drum or drum and wheel anti-slip device, press the front of the switch, and the switch light will go out.

!

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.

CS03G006

35 IMPORTANT: If it is necessary to apply the machine’s brakes immediately (for example, on a slope), place the direction of travel lever (1) in neutral position and then press the emergency brake switch (2).

1 2 CS02B551

36

3-22

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 two lifting eyes into the top of the ROPS frame.

3.

Secure the slings to the lifting eyes.

4.

Remove the mounting screws and washers.

5.

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

CD01G295

37 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.

Make sure nobody is in the operating area and then carefully raise and install the ROPS frame around the cab.

3.

Install and tighten the mounting screws and washers to a torque of 549 Nm (405 ft lb).

4.

Remove the slings and lifting eyes.

CD01G294

38

3-23

SECTION 3 - OPERATING INSTRUCTIONS CAB REMOVAL AND INSTALLATION IMPORTANT: Use lifting equipment which is capable of supporting the weight of the cab.

REMOVAL 1.

Remove the cab mounting hardware.

CD01G296

39 2.

Disconnect the electrical connector between the steering column and the front windscreen.

CD01G297

40 3.

Disconnect the windshield washer electrical installation and hose.

4.

Make sure nobody is standing near the cab or in the operating area.

5.

Use the lifting points on top of the cab to raise it and lower it to the ground.

INSTALLATION 1.

Use the lifting equipment to lower the cab onto the machine.

2.

Reconnect all items previously disconnected.

3.

Install and tighten all the cab mounting hardware.

3-24

CD01G298

41

SECTION 3 - OPERATING INSTRUCTIONS ADAPTING THE SMOOTH DRUM FOR TAMPING COMPACTION (optional) This equipment consists of three drum surfacing segments. The feet on the segments make it possible for the machine to be used as a tamping compactor at the same time as a vibratory compactor.

INSTALLATION 1.

Park the machine on flat, level ground.

2.

Remove the scrapers.

CD01A009

42 3.

Clean the drum surface.

CD01G300

43 4.

Use lifting equipment with hooks and chains to remove blade from smooth drum.

CD01G299

44

3-25

SECTION 3 - OPERATING INSTRUCTIONS 5.

Insert the hooks (A) in the holes provided on each side of the first segment.

6.

Position the segment on top of the drum so the left and right edges of the segment are in alignment with the left and right edges of the drum.

A

CD00N002

45 7.

Mount four of the fixing clamps (B) supplied, placing two on the right and two on the left at about 20 cm (7.8 in) from the extremities of the segment and then tighten the clamps (B).

8.

Remove the hooks (A) from the first segment.

9.

Move the machine forward approximately 1.60 m (5.2 ft), making sure the fixing clamps (B) are not fouled by the drum chassis.

B

B CD00N003

46 10. Insert the hooks (A) in the holes provided on each side of the second segment.

A

CD00N002

47

3-26

SECTION 3 - OPERATING INSTRUCTIONS 11. Position the segment on the drum so the left and right edges of the segment are in alignment with the left and right edges of the drum, leaving a 26 mm (1.02 in) gap between each segment.

CD00N004

48 12. Mount the other four fixing clamps (B) supplied, placing two on the right and two on the left at about 20 cm (7.8 in) from the extremities of the segment and then tighten the four clamps (B).

B

CD00N004

49 13. Fasten the two segments together with the hardware provided. Install a washer (C) under the screw head, insert the screw (D) in the assembly hole, add another washer (C) and tighten the two nuts (E). Repeat this operation for every assembly hole.

C E

14. Remove the four clamps (B) from either side of the outside hardware installed between the first and second segment.

C

15. Remove the hooks (A) from the second segment.

16. Move the machine forward approximately 1.60 m (5.2 ft), making sure the fixing clamps (B) are not fouled by the drum chassis.

D CD01G301

50

17. Insert the hooks (A) in the holes provided on each side of the third segment.

18. Position the segment on the drum so the left and right edges of the segment are in alignment with the left and right edges of the drum, leaving a 26 mm (1.02 in) gap between each segment.

19. Mount the four fixing clamps (B) just removed, placing two on the right and two on the left at about 20 cm (7.8 in) from the extremities of the segment and then tighten the four clamps (B).

3-27

SECTION 3 - OPERATING INSTRUCTIONS 20. Install all the fastening hardware on the third segment, making sure there is a gap of 26 mm (1.02 in) between each segment.

21. Remove all the fixing clamps (B).

22. Tighten all hardware to a torque of 314 Nm (231.6 ft lb).

CD00N004

51 23. Use the fastening hardware from the scrapers already removed to install the special scrapers supplied with the segments. Tighten the hardware to a torque of 314 Nm (231.6 ft lb).

IMPORTANT: After one hour’s use, check the torque of all fastening hardware.

REMOVAL 1.

Remove the special scrapers.

2.

Move the machine until the segment to be removed is on top of the drum.

3.

Fasten the fixing clamps (B) to the extremities of the other two segments.

4.

Insert the hooks (A) in the holes provided on each side of the segment to be removed.

5.

Remove all the segment fastening hardware.

6.

Use lifting equipment to remove the segment.

7.

Carry out Steps 2 to 6 to remove the other segments.

8.

Use the fastening hardware from the special scrapers removed to install the original scrapers (3). Tighten the hardware to 314 Nm (231.6 ft lb).

3-28

CD01A008

52

SECTION 3 - OPERATING INSTRUCTIONS MACHINE ARTICULATION LOCKING LOCKING 1.

Lock the horizontal machine articulation. Remove the locking bar (B) retaining pin (A), place the bar in position (C) and install the retaining pin (A).

A

B E D CS00N511

53 2.

Lock the vertical machine articulation. Remove the retaining pin (D) from the locking system (E), bring it into position (F) and install the retaining pin (D).

C

F

A

D

CS00N512

54

3-29

SECTION 3 - OPERATING INSTRUCTIONS UNLOCKING 1.

Release the vertical machine articulation.

Remove the retaining pin (D) from the locking system (F), bring it into position (E) and install the retaining pin (D).

A

C

D

F

CS00N512

55 2.

Release the horizontal machine articulation.

Remove the locking bar (C) retaining pin (A), place the bar in position (B) and install the retaining pin (A).

A

B E D CS00N511

56

3-30

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.

Place the machine in line with the trailer, with the drum facing the access ramps.

4.

Engage the drum anti-slip function or the drum and wheel anti-slip function (if equipped) and make sure drum vibration is disengaged. See "Front console control functions" in Section 2.

5.

Raise the dozer blade and lock it mechanically (if equipped).

6.

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

7.

When the machine is completely on the trailer, make sure the drum is completely in line with the machine and then put all controls into neutral.

8.

Shut down the engine, remove the starter switch key and raise the right-hand control arm.

9.

Make sure the doors and hood are properly locked.

CD95M248

57

10. Fold the rear view mirrors inwards.

11. Lock the machine horizontal and vertical articulations, see "Machine articulation locking".

3-31

SECTION 3 - OPERATING INSTRUCTIONS 12. Use blocks and chains to fasten the machine to the trailer.

13. 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 and the cab. See "ROPS frame removal and installation" and "Cab 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.

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.

Adjust the rear view mirrors.

4.

Lower the right-hand control arm, make sure all controls are in neutral and start the engine.

5.

Make sure the drum anti-slip function or the drum and wheel anti-slip function (if equipped) is engaged. See "Front console control functions" in Section 2.

6.

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

7.

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

8.

Release the dozer blade if necessary (if equipped).

9.

Disengage the drum anti-slip function or the drum and wheel anti-slip function (if equipped). See "Front console control functions" in Section 2.

3-32

CS00N510

58

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 Section 1.

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".

1

2

A

A

Use lifting equipment and slings which are capable of lifting the weight of machine. See "Weights" in " Section 8.

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

NOTE: The values followed by an asterisk on these illustrations are for: - figure 56: with asterisk: SV216 (without asterisk: SV212) - figure 57: with asterisk: SV210 (without asterisk: SV208) For information: 1800 kg = 3968 lbs 2700 kg = 5952 lbs 3400 kg = 7496 lbs 6000 kg = 13 228 lbs 7400 kg = 16 314 lbs 9200 kg = 20 282 lbs 10 400 kg = 22 928 lbs 15 100 kg = 33 290 lbs 18 250 kg = 40 234 lbs

CS00N513

59

2

1 A

A

CS01G518

60

4 m = 13 ft 1 in 5 m = 16 ft 5 in Lmini = Minimum slings length (1) = 2 x mini = Front slings capable of lifting a minimum weight of : (2) = 2 x mini = Rear slings capable of lifting a minimum weight of :

3-33

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.

!

WARNING

!

Towing is a delicate maneuver which is always carried out at the risk of the user. 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. The operator must be the only person on the machine when towing.

Make sure that nobody else is on the machine or within its working range.

TOWING POINTS The machine has two towing points, one at the rear, on the fuel tank and the other in front, on the drum chassis. The rear towing point has a pin held in position by a safety clip. This pin can also be used for the front towing point.

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

IMPORTANT: The machine towing points must not be used for hauling trailers, tank, etc.

CD01G302

61

CD01G303

62

3-34

SECTION 3 - OPERATING INSTRUCTIONS RELEASING THE TRANSMISSION AND WHEEL HYDRAULIC MOTOR BRAKES IMPORTANT: Never release the brakes with the engine running.

1.

Use wooden blocks to immobilise the machine.

2.

Disconnect the hose (A) and release the quick coupler (B) held by the clamp (C).

(SV208, SV210)

B

C

A

CD01G121

63 (SV212, SV216)

A

C

B

CD00N007

64 3.

Disconnect the quick coupler (D) on the hose (E) running from the pressure filter to the hydraulic reservoir.

(SV208, SV210)

E D

CD01G121

65

3-35

SECTION 3 - OPERATING INSTRUCTIONS (SV212, SV216)

D E

CD00N008

66 4.

Connect the quick coupler (D) on hose (E) to the quick coupler (F) on the hose (A) running to the emergency hand pump.

(SV208, SV210)

E D F

A

CD01G122

67 Use the quick coupler (D) on hose (E) to connect the hose (A) to the emergency hand pump.

(SV212, SV216)

D E

A

CD00N009

68

3-36

SECTION 3 - OPERATING INSTRUCTIONS 5.

With the engine stopped, it is now necessary to short-circuit the travel circuit. The travel pump has two multi-purpose main relief valves. Use a 27 mm (1-1/16") hex. wrench to unscrew the center body of each valve (F) three complete turns counterclockwise, using a 32 mm (1-1/4" ) wrench to prevent the counter-nut from turning.

F

F

CD00N010

69 6.

Turn the starter switch key to the run position.

7.

Mount the emergency hand pump lever on the emergency hand pump and operate the pump until the brake warning lamp (1) on the front console goes out. The brakes are then released and the machine may be towed.

CD01C170A

70 NOTE: Because of possible leaks, pressure in the brake lines may drop while towing is in process. If the brake warning light (1) comes on, renew the pressure.

!

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.

8.

1

!

CS00M512

71

Once the towing operation is completed, return all hoses to their original position and put the lever back under the operator’s seat. Use a 27 mm (11/16") wrench to tighten the center body of each valve three complete turns clockwise and use a 32 mm (1-1/4") wrench to lock the counter-nut.

3-37

SECTION 3 - OPERATING INSTRUCTIONS FILLING THE TIRES WITH LIQUID BALLAST When the machine is being used in particularly harsh climatic conditions, it is possible to increase weight over the axle and lower the machine’s center of gravity by filling the tires with liquid ballast. The ballast may consist of a solution of water mixed with calcium hydroxide and unslaked calcium chloride (CaCl2). For any further information, please contact your Dealer.

The tables below show the quantities to be used for each machine.

Unslaked calcium chloride

Water

Freezing point

Added weight

Kg (lb)

Litres (gal US)

°C (°F)

Kg (lb)

42.3 (93.25)

160 (42.2)

-18 (0)

203 (447.5)

49.2 (108.46)

160 (42.2)

-25 (-13)

210 (463)

55 (121.25)

160 (42.2)

-30 (-22)

216 (476.2)

IMPORTANT: Do not use different proportions than those listed above.

!

WARNING

!

Before carrying out this procedure, be sure to take the necessary measures to protect your hands and eyes (gloves, goggles etc.).

PREPARING THE SOLUTION 1.

Choose a container with sufficient capacity.

2.

Put the water in the container first, then add the unslaked calcium chloride.

!

WARNING

!

SLOWLY add calcium chloride to water, stirring continuously. NEVER ADD WATER TO CALCIUM CHLORIDE. To do so will cause a violent reaction.

When correctly mixed, the solution will increase in temperature. Allow the solution to cool before adding to the tyre. See your authorized dealer for details.

NOTE: Clean up any splashed solution using clean water.

3.

Allow the solution to cool before adding the slaked lime.

IMPORTANT: Never allow this solution to come into contact with the electric circuit or parts made of metal.

!

WARNING

!

Do not use this solution to fill the engine radiator.

3-38

SECTION 3 - OPERATING INSTRUCTIONS FILLING 1.

Place blocks under each side of the drum.

2.

Use suitable lifting equipment to raise the rear of the machine.

3.

Release the wheel hydraulic motor brakes. See "Releasing the transmission and wheel hydraulic motor brakes".

4.

Deflate the tires and unscrew the valves (A) and remove the plugs (B).

5.

Spin the wheels manually so the valves (A) are at their highest possible point from the ground.

6.

Install a filler hose in place of the plug (B). Contact your Dealer to obtain a hose.

7.

Place the container or filler pump at a higher level and commence the filling operation.

8.

Remove the filler hose, install the plug (B) and tighten the valve (A).

9.

Repeat the filling operation for the other tire.

10. Remove the dust cap from the valve (A) and then inflate the tire to the recommended pressure. See "Tire pressures" in Section 5. Install the dust cap.

B A

CD00N020

72

11. Inflate the other tire.

12. Reinstate the wheel hydraulic motor braking system.

13. Lower the rear of the machine to the ground.

3-39

SECTION 3 - OPERATING INSTRUCTIONS DRAINING 1.

Carry out Steps 1 to 3 in "Filling".

2.

Spin the wheels manually to bring the valves (A) as high from the ground as possible.

3.

Unscrew the valves (A) and remove the plugs (B).

B A

IMPORTANT: Be careful when unscrewing the valves (A) as liquid ballast may spray out.

4.

Install a filler hose in place of the plug (B). Contact your Dealer to obtain a hose.

5.

Spin the wheel manually to bring the hose as close as possible to the ground.

6.

Connect the air supply to the valve (A) and inflate until no more liquid ballast runs out.

7.

Remove the filler hose, install the plug (B) and tighten the valve (A).

8.

Drain the other tire in the same manner.

9.

Carry out Steps 10 to 13 in "Filling".

3-40

CD00N020

73

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.

Increasing vibration in the operator’s cab 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 harm to the operators body.

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.

Check the density of the coolant.

2.

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

3.

Use hydraulic oil of the correct viscosity.

4.

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

5.

Check the battery charge level.

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

The minimum temperature for the engine coolant is 60°C (140°F).

Do not operate the machine until the engine has reached normal working temperature. Cover the radiator partially if necessary.

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.

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, contact your Dealer.

OPERATING THE MACHINE IN VERY DUSTY CONDITIONS Shorten the service intervals for the air filter, the oil cooler, the hydraulic circuit and the operator’s compartment anti-dust filter. See Section 4.

OPERATING THE MACHINE IN CLOSE PROXIMITY OF BUILDING, 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.

3-41

SECTION 3 - OPERATING INSTRUCTIONS OPERATING THE MACHINE AT HIGH TEMPERATURES AND HIGH HUMIDITY LEVELS In hot countries, where hydraulic oil temperature regularly reaches more than 90°C (194°F), thicker oil should be used (100 mm2/s).

At extremely high temperatures, where the hydraulic oil and engine coolant temperatures are at their very maximum, it is possible to obtain improved cooling by removing the lower panels from the machine, thereby ensuring more rapid dispersal of hot air from the engine compartment.

CD01G304

74

3-42

SECTION 3 - OPERATING INSTRUCTIONS DOZER BLADE (if equipped)

!

WARNING

!

Make sure that no one is in the operating area of the dozer blade before moving it.

1.

Unlock the dozer blade by removing the locking pins (A) from the holders in the front frame. The disconnected links (B) should be fastened to the holders (C) on the dozer blade using the locking pins (A).

2.

Be sure you have unlocked the dozer blade on both sides.

3.

Start up the engine.

B A

CD01C0157

75

C

A

CD01C0157A

76 4.

Use the speed control (1) to engage slow speed position and choose a suitable speed range using the speed range selector (2).

5.

Set engine speed to full (or near full) throttle using the engine speed control.

1

2

CS02B551

77

3-43

SECTION 3 - OPERATING INSTRUCTIONS 6.

Lower the dozer blade to ground by shifting the control lever (3) or pedal (4) from position "0" through position "I" to position "III" (fixed floating position). When shifting the lever into the position "III", increased resistance can be felt.

III

I

0

3

CS00M505

78 I

0

I III

4 CS03G007

79 7.

8.

Note the corresponding position between the fixed pointer (C) on the drum frame and the moving pointer (D) and remember this position. This is the "basic" position of the dozer blade.

D

C

Return the dozer blade control lever (3) or pedal (4) to the "0" position.

CD01C158

80

3-44

SECTION 3 - OPERATING INSTRUCTIONS 9.

Shift the travel control (5) - forward to move forward with the machine.

5

CS02B551

81 10. Lower the dozer blade to the required cutting depth by shifting the control lever (3) or pedal (4), to position "I". The actual cutting depth can be read from the pointers (every bar or space corresponds to 50 mm (1.96 in).

I

0 II

64

11. Control the volume of dozed material by shifting the control lever either forward "I" (to lower the dozer blade) or backward "II" (to lift the blade), depending on the tractive force of the machine.

CS00M505

82 I

0

I

II

4 CS03G007

83

3-45

SECTION 3 - OPERATING INSTRUCTIONS 12. When dozing material on a firm surface, it is possible to utilize the floating position of the dozer blade, place the control lever in fixed position "III".

In this position, the chambers above and below the piston in the cylinder are interconnected and the dozer blade is sliding on the removable skids (E). This position is also useful for spreading and leveling of material with the machine in reverse.

E

CD01C159

84 13. After finishing the work with the dozer blade, fasten the dozer blade to the frame by means of the links and locking pins, to avoid any lowering of the dozer blade.

CD01C157

85 14. Lifting and lowering speed of the dozer blade can be adjusted using the limiting valve (F) of the dozer blade control valve (G) under the driver’s compartment. Follow the symbols on the control valve.

G

NOTE: The cutting edges of the blade are removable.

When worn, use the other side of the edges (turn over 180°).

!

WARNING

!

Do not adjust the scrapers, do not carry out any maintenance on the dozer blade unless it is lowered to the ground and the engine stopped, or unless the dozer blade is securely fastened with both safety links. Do not work with the dozer blade when it is in fastened position. If only one link is fastened, the dozer blade can be damaged. When mounting the dozer blade, avoid any hand injuries.

3-46

F

CD01C160A

86

SECTION 4

46

SERVICING INTERVALS/LUBRICATION/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.

- Lower the dozer blade until it is resting on the ground or raise the dozer blade and lock it mechanically (if equipped).

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

- Put blocks under the drum and the wheels 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 handle of the cab left-hand door. 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 The hourmeter (6) 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.

CS03G008

1

4-1

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS SERVICING INTERVAL TABLE Servicing and inspection intervals are variable.

Depending on whichever occurs first, they should be carried out.

- Every 10 hours, or daily - Every 250 hours, or once every 3 months - Every 500 hours, or once every 6 months - Every 1000 hours, or once a year - Every 2000 hours, or once every two years

4-15

Engine oil

4-17

Coolant

4-20

Fuel tank

4-31

Air filter dust ejector

5-1

Warning and control devices

5-3

Engine fan

5-3

Crankcase breather tube

5-4

Engine alternator belt and fan

4-32

Hydraulic oil reservoir

5-6

Tire pressure

4-7

Articulations, dozer blade and pedal (if equipped)

4-15

Engine oil filter

4-31

Air filter restriction warning lamp

4-40

Drum

4-42

Transmission

C

4-44

Planetary reduction gears

C

5-8

Engine air intake system

5-8

Coolant radiator

6-3

Batteries (electrolyte/connections)

4-20

Fuel filter

5-6

Wheel nut tightening torque

5-9

Shock absorbers/Mounting blocks

5-11

Engine valve clearance

4-32

Hydraulic fluid

4-35

Hydraulic filter

5-17

Operator’s compartment and engine hood tilting strainer (if equipped)

5-18

Drum vibration frequency

5-19

Vibration shock absorbers

4-2

Note

2000

1000

500

250

Service points

100

see page

Intervals in hours 10

For servicing specifications

A

E/F

F

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS

Note

2000

1000

500

250

Service points

100

see page

Intervals in hours 10

For servicing specifications

4-20

Fuel system

D

4-26

Air filter primary element

G

4-26

Air filter secondary element

H

5-19

Cleaning the machine

I

5-20

Operator’s compartment intake air dust filter

B

5-21

Air conditioning (if equipped)

K

5-22

Air conditioning condenser (if equipped)

L

5-23

Scrapers

J

5-24

Hardware torque specifications

M

Bleed Clean Replace Check Grease Drain Check level NOTE A: Drain every 250 hours or 6 months, whichever comes first.

every

NOTE B: Clean at least once a month.

NOTE C: Drain after the first 100 hours during the run-in period.

NOTE D: Bleed if contamination is found in the fuel.

NOTE E: Replace when the hydraulic oil filter restriction warning lamp comes on on the console or imperatively every 2000 hours. See "Front console control functions" in Section 2.

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

NOTE H: Replace imperatively every 2 years or after cleaning the primary element five times and replace if the air filter restriction warning lamp remains alight on the front console after cleaning or replacing the primary element. See "Front console control functions" in Section 2.

NOTE I:

Once a week minimum.

NOTE J: Check regularly.

NOTE K: Check every 3 months.

NOTE L: Clean regularly.

NOTE M: The self-locking nuts must be changed systematically used 3 times only.

NOTE G: Clean or replace when the air filter restriction warning lamp lights up on the front console or imperatively after one year or cleaning five times. See "Front console control functions" in Section 2.

4-3

SECTION 4 - SERVICING INTERVALS/LUBRICATION/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 No. 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) Farenheit Temperature (B) Celsius Temperature (*) Use of an engine oil heater or/and engine coolant 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/LUBRICATION/FLUIDS HYDRAULIC FLUID

ANTI-FREEZE/ANTI-CORROSION

Use high quality hydraulic fluid which is suitable for use at high pressures.

Type of fluid: Hy-tran Ultra

Use anti-freeze in all seasons to protect the cooling system from corrosion and all risk of freezing.

TRANSMISSION OIL Use extreme pressure type oil of the API GL5 category.

SAE 80W/90: (-10°C to +30°C) (14°F to +86°F)

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.

GREASE Use extreme pressure grease of the CASE molydisulfide category.

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

Use grade No. 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 No. 1 and No. 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.

4-5

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

Fluids and lubricants

Engine

CASE No. 1 oil

Hydraulic system

Hy-tran Ultra

Transmission

API GL5 - SAE 80W90 oil

Planetary reduction gears API GL5 - SAE 80W90 oil Fuel system

Grade No. 2 fuel

Machine articulation

CASE Molydisulfide grease

Cooling system

Coolant - Water - Anti-freeze

Drum vibration

SAE 15W40 - 10W30 - 5W30 oil

Batteries

Distilled water

Windshield washers

Water - Anti-freeze

FLUID AND LUBRICANT CAPACITIES VIBRATORY ROLLERS CAPACITIES Components

SV208/SV210

SV212/SV216

11.2 litres (2.95 gal US)

16.3 litres (4.3 gal US)

Hydraulic system

73 litres (19.3 gal US)

90 litres (23.8 gal US)

Transmission

2.5 litres (0.66 gal US)

4.2 litres (1.1 gal US)

2x2.5 litres (2x0.66 gal US)

2x2.8 litres (2x0.74 gal US)

275 litres (72.7 gal US)

410 litres (108.3 gal US)

as needed

as needed

Cooling system

19 litres (5 gal US)

25 litres (6.6 gal US)

Drum vibration

6.7 litres (1.7 gal US)

8 litres (2.1 gal US)

as needed

as needed

2.75 litres (0.72 gal US)

2.75 litres (0.72 gal US)

Engine

Planetary reduction gears Fuel system Machine articulation

Batteries Windshield washers

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.

4-6

SECTION 4 - SERVICING INTERVALS/LUBRICATION/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) and stop as soon as the grease begins to escape.

Remember to reinstall the caps.

MACHINE ARTICULATION 6 grease points.

CD01J005

3

CI01C513

4 STEERING CYLINDERS 4 grease points.

CD01J006

5

4-7

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS OPERATOR’S COMPARTMENT TILTING CYLINDER 2 grease point.

CD01G155

6 ENGINE HOOD OPENING CYLINDERS 4 grease points.

CI01C516

7 CAB DOOR HINGES 6 grease points.

CI01C517

8

4-8

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS ENGINE HOOD HINGES 2 grease points.

CI01C518

9 OPERATOR’S COMPARTMENT TILTING HINGES 2 grease points.

CI01C519

10 LEFT, RIGHT SIDE COVER HINGES 4 grease points.

CI01C520

11 .

4-9

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS DOZER BLADE (if equipped) 6 grease points.

CD01C155

12

CD01C156

13 DOZER BLADE PEDAL (if equipped) 2 grease points.

CS03G007

14

4-10

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS LEVELS EVERY 10 HOURS OR DAILY ENGINE OIL

SV208, SV210

See "Engine".

CD01G276

15 SV212, SV216

CD00N022

16 COOLANT See "Cooling system".

CD00N025

17

4-11

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS EVERY 10 HOURS OR DAILY FUEL See "Fuel system".

CD00N026

18 HYDRAULIC FLUID See "Hydraulic system".

CD00N027

19 EVERY 250 HOURS OR EVERY 3 MONTHS DRUM VIBRATION OIL See "Drum".

CD00N028

20

4-12

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS EVERY 250 HOURS OR EVERY 3 MONTHS TRANSMISSION OIL

SV208, SV210

See "Transmission".

CD01G160

21 SV212, SV216

CD00N029

22 BATTERY ELECTROLYTE See "Batteries" in Section 6.

CD00N030

23

4-13

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS EVERY 250 HOURS OR EVERY 3 MONTHS PLANETARY REDUCTION GEARS OIL See "Planetary reduction gears".

CD01A006

24

4-14

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS ENGINE SERVICE SPECIFICATIONS Engine oil level check .................................................................................................... Every 10 hours or daily Oil change .................................................................................................. Every 250 hours or every 6 months Oil filter replacement................................................................................... Every 250 hours or every 3 months Type of oil ................................................................................................................ See "Lubricants and fluids" Oil capacity (SV208, SV210) .........................................................................................11.2 litres (2.95 gal US) Oil capacity (SV212, SV216) .......................................................................................... 16.3 litres (4.3 gal US) 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.

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).

SV208, SV210

A

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.

CD01G276

25 SV212, SV216

A

B

CD01J010

26

4-15

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS 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

CD01J011

27 3.

Place a receptacle of a suitable capacity under the drain plug (C), remove the plug (C) from the crankcase and allow the oil to drain.

4.

Install a new seal on the plug (C) and put it back in place. Tighten the plug (C) to a torque of 60 Nm (44 ft lb).

C

CD01J012

28 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.

Fill the engine with new oil. Install the oil filler cap (B).

9.

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.

4-16

CD01J013A

29

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS COOLING SYSTEM SERVICE SPECIFICATIONS Coolant reservoir level check ........................................................................................ Every 10 hours or daily Coolant concentration check ...................................................................... Every 500 hours or every 6 months Drain ............................................................................................................ Every 2000 hours or every 2 years Cooling system capacity (SV208, SV210)............................................................................ 19 litres (5 gal US) Cooling system capacity (SV212, SV216)......................................................................... 25 litres (6.6 gal US)

!

WARNING

!

Boiling coolant fluid can escape if the coolant reservoir cap is removed while the system is still hot.

Before removing the cap, let the system cool down and then turn the cap to the first notch, waiting until all pressure is released. Then remove the cap. Check and service the cooling system according to the instructions given in this manual.

COOLANT SOLUTION Only put ethylene-glycol coolant solution in the cooling system. Use good quality ethylene-glycol that has a high boiling point, with no additives to prevent leakage. Do not employ non-approved anti-rust additives.

Anti-rust additives and ethylene-glycol can mix and work against each other, thereby reducing anti-corrosion protection, forming deposits in the cooling system and causing damage to the cooling system and radiator.

Consult your Dealer for suitable coolant solution.

LEVEL IMPORTANT: The level of the coolant should be checked when the engine is cold.

1.

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

Allow the engine to cool.

2.

The level in the coolant reservoir must come up to the top of the sight glass (A). If it does not, see "Filling".

IMPORTANT: The level should never be lower than the "Min" mark on the sight glass (A).

A

CD00N025

30

4-17

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS COOLANT CONCENTRATION CHECK Check the concentration level at an ambient temperature of 20°C (68°F), using a densimeter.

IMPORTANT: Always carry out this check before winter.

The minimum proportion of anti-freeze (ethylene-glycol or propylene-glycol) in the coolant solution is 50%. This will afford circuit protection down to -37.2°C (-35°F).

The solution not only protects the engine against frost but also raises the boiling point. The inhibitors contained in the coolant also protect engine components and give them a longer service life.

DRAINING NOTE: Carry out the operation after the machine has been working or after warming the coolant to a minimum temperature of 85°C (185°F).

1.

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

Allow the engine to cool.

2.

Remove the coolant reservoir cap (D).

D

CD00N025

31 3.

Place a receptacle of a suitable capacity under the radiator and open the drain tap. Allow the coolant to flow out and when the radiator is drained, close the tap and commence the filling operation.

CD01G176

32

4-18

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS FILLING 1.

Fill the system with coolant until it comes up to the edge of the filler.

IMPORTANT: Use a suitable coolant solution.

D

A CD00N025

33 2.

Install the cap (D).

3.

Start and run the engine until it reaches a temperature of 80°C (176°F).

4.

Stop the engine and remove the starter switch key.

5.

Use the sight glass (A) to check the level of coolant in the coolant reservoir. Add coolant if necessary.

D

A CD00N025

34

4-19

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS FUEL SYSTEM SERVICE SPECIFICATIONS Check the fuel level........................................................................................................ Every 10 hours or daily Fill the fuel tank...............................................................................................................Every 10 hours or daily Bleeding the sediment filter.............................................................................................Every 10 hours or daily Clean the fuel tank filter .....................................................................................................................Every week Replace the fuel filter ..................................................................................Every 500 hours or every 6 months Clean the fuel tank ..........................................................................................Every 1000 hours or once a year Fuel tank capacity (SV208, SV210) ............................................................................... 275 litres (72.7 gal US) Fuel tank capacity (SV212, SV216) ............................................................................. 410 litres (108.3 gal US) Type of fuel .............................................................................................................. See "Fluids and lubricants" FUEL LEVEL Use the fuel level gauge to check the fuel level.

IMPORTANT: Do not wait until there is no more fuel before refilling the fuel tank, because if the fuel tank is emptied it will be necessary to bleed the fuel system.

FILLING THE FUEL TANK 1.

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

!

WARNING

!

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.

2.

Clean around the cap (A) and the filler neck (B) with a clean cloth.

3.

Use the starter switch key to remove the cap (A).

4.

Fill the tank through the filler neck strainer, up to the bottom edge of the filler neck (B) and install the cap (A).

CT04G009

35

A B

IMPORTANT: Use appropriate fuel.

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

CD00N026

36

4-20

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS FUEL TANK FILTER Remove the filter and clean it in diesel fuel.

CD00N026A

37 FUEL FILTER 1.

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

2.

Disconnect water separator sensor connector, remove water separator sensor.

CD01J015A

38 3.

Clean the area around the filter head.

4.

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

5.

Replace the seal under the filter head.

CD01J015B

39

4-21

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS 6.

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

NOTE: Do not fill the new filter with fuel before installing them.

7.

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

IMPORTANT: Do not use the filter wrench.

Overtightening can damage the filter and seal.

PH08325

40 8.

Install the water separator sensor and reconnect it.

NOTE: If the engine does not regain full power after the filter have been replaced, bleed the system.

BLEEDING THE FUEL SYSTEM It will be necessary to bleed the fuel system whenever: 1. The fuel tank has been completely emptied.

2. Fuel system components have been removed for servicing or repair.

3. The machine has been in storage for a fairly long time.

1.

CD01J015A

41

Loosen the screw (G) on the fuel filter.

G

CD01J015B

42

4-22

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS 2.

Operate the priming pump (F) by hand until clean bubble-free fuel flows out and then tighten the screw (G) to a torque of 9 Nm (6.6 ft lb).

F

CD00N038

43 3.

Loosen the screw (H) on the injection pump.

4.

Turn the starter switch key to the "ON" position.

5.

Turn the starter switch key to "START" position and then back to "ON" position. The charge pump will begin to rotate.

6.

Operate the priming pump (F) until clean, bubblefree fuel flows out and then tighten the screw (H).

H

NOTE: If there is no fuel when you operate the hand primer pump, rotate the engine 1/2 turn and operate the hand primer pump.

CD00N040A

44 7.

Loosen the injectors connections, run the starter motor until clean, bubble-free fuel flows out and then tighten the connections to 30 Nm (22 ft lb).

NOTE: Never operate the starter motor for more than 15 seconds at a time. Wait 2 minutes before trying again.

The engine should run smoothly. If not, repeat the procedure.

If the problem persists, air is getting into the system.

Check that all connections are airtight.

CD00N041

45

4-23

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS BLEEDING THE SEDIMENT FILTER If dirt or water has got into the fuel system then it will be necessary to bleed the sediment filter.

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.

CLEANING THE FUEL TANK

CD00N039A

46 1.

Run the machine without refilling the tank until the fuel level is at its lowest point (use the fuel gauge to check).

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 horizontal position (system switched off).

CT04G009

47 4.

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

5.

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

6.

Install and tighten the plug (J), fill the tank with appropriate fuel and install the filler cap (A).

J

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

CD01G278

48

4-24

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS 1.

Remove the batteries (L).

2.

Remove the cover (K) and clean the inner walls.

3.

Replace the sealing between the cover (K) and the reservoir and then install the cover (K).

4.

Install the batteries (L).

5.

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

L

IMPORTANT: If air gets into the system then it will be necessary to bleed the system.

L

K CD01G313

49

4-25

SECTION 4 - SERVICING INTERVALS/LUBRICATION/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 ELEMENTS Your machine is fitted with a two-stage air filtration system, consisting of a high capacity primary element, designed to ensure maximum engine protection and a secondary element, for extra engine protection. Only the primary element may be cleaned, the secondary element has to be changed.

RESTRICTION WARNING LAMP

SV208, SV210

If the air filter restriction warning lamp comes on while the engine is running, it is necessary to check the air filter elements.

CT04G001

50 SV212, SV216

CS03G009

51

4-26

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS SERVICE SPECIFICATIONS Primary element: clean or replace when the restriction warning lamp comes on or imperatively once a year or after five cleanings.

Secondary element: replace imperatively every two years or after five primary element cleanings and replace if the warning lamp stays on after replacing or cleaning the primary element.

Dust ejector: check every 10 hours or daily.

Restriction warning lamp check: Every 250 hours or every 3 months.

!

WARNING

!

Be sure to service the air filter at the intervals given. A clean air filter means longer engine life.

REMOVING THE ELEMENTS 1.

Unscrew the wing nut and remove the cover and primary filter element.

CI01C522

52 If the secondary element needs replacement: 2.

Unscrew the nut and remove the secondary element.

!

WARNING

!

The secondary element must never be cleaned but always replaced.

CI01C523

53

4-27

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

If the primary 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 5 bar (72 psi).

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

CD01G192

54 If the primary 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 primary element for installation while the other primary element is drying.

PDE0088

55

4-28

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS INSPECTING THE PRIMARY ELEMENT Check the primary element for damage by placing a lamp inside.

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

PDE0378A

56 INSTALLING THE ELEMENTS 1.

If the secondary element has been removed, install the secondary element and tighten the nut.

CI01C523

57 2.

Install the primary element with the cover and tighten the wing nut.

CI01C524

58

4-29

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS 3.

Make sure the dust ejector functions correctly.

CD00N035

59 Start and run the engine at low speed and check that the restriction warning lamp is not alight.

SV208, SV210

CT04G001

60 SV212, SV216

CS03G009

61

4-30

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS 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.

CI01C525

62 RESTRICTION WARNING LAMP Check that the restriction warning lamp functions correctly.

1.

Start the engine.

2.

Remove the cap.

3.

Obstruct air filter intake by covering the tub with paper or rags.

4.

The restriction warning lamp must come on.

CD00N035

63 5.

If it does not, look for the cause (defective bulb, bad contact, wire hardness) and restart the operation.

CD01G193

64

4-31

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS HYDRAULIC SYSTEM SERVICE SPECIFICATIONS Hydraulic reservoir fluid level check............................................................................................Every 10 hours and whenever the hydraulic fluid level warning lamp on the front console comes on Hydraulic fluid replacement..........................................................................Every 2000 hours or every 2 years Hydraulic filter cartridge replacement ..........................................................Every 2000 hours or every 2 years and whenever the hydraulic oil filter restriction warning lamp on the front console comes on Hydraulic system capacity (SV208, SV210) .................................................................... 73 litres (19.3 gal US) Hydraulic system capacity (SV212, SV216) .................................................................... 90 litres (23.8 gal US) Type of oil................................................................................................................. See "Fluids and lubricants" LEVEL IN 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 gauge (A).

IMPORTANT: the level must not be allowed to drop below the "MIN" mark. Should this situation arise, for example as a result of a failure in the hydraulic system, the engine will stop immediately and cannot be restarted until fluid is added to the hydraulic reservoir.

A CD00N027B

65 3.

To add hydraulic fluid, remove the protection plate and 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 the protection plate.

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 glass (A). Add hydraulic fluid if necessary.

7.

Make sure the hydraulic fluid level warning lamp on the front console is not alight.

4-32

B

CD00N044

66

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS 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 (SV208, SV210) 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.

Remove the drain fitting.

CD01G274

67 4.

Screw it on the drain valve at the bottom of the reservoir and attach a hose.

5.

Place a receptacle of a suitable capacity under the reservoir and drain the oil.

NOTE: As the drain fitting is screwed on the drain plug, just before it is secured it releases a valve in the plug to allow fluid to drain out.

CD01G318

68

4-33

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS 6.

Disconnect suction hose (D) and the cover (E) with the suction strainer.

7.

Remove the suction strainer from the suction pipe. Wash the suction strainer with pressure air from inside.

IMPORTANT: Be sure to protect your face before using compressed air.

8.

Check the condition of the suction strainer, replace the strainer in case of need.

9.

Mount the strainer on the suction pipe.

E

D

CD00N044

69 10. 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 entire upper cover (G) with the filler (B).

11. Reassemble the cover with the suction pipe.

Lubricate the O-ring with clean oil. If the entire upper cover (G) has been removed, use a new Teflon sealing strip.

12. Replace the hydraulic filter. See "Hydraulic filter cartridge replacement".

B

G

CD00N044

70 DRAINING (SV212, SV216) 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.

Install the drain hose on the drain valve (C).

3.

Place a receptacle of a suitable capacity under the reservoir, open the valve (C) and allow the hydraulic fluid to drain.

NOTE: The wider the valve (C) is opened, the higher the flow will be. Do not unscrew the valve (C) completely.

4.

Once all the hydraulic fluid has been drained, close the valve (C) and remove the drain hose.

C CD00N045

71

4-34

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS 5.

Remove the suction hose (D), the cover (E) with the suction pipe (F) and the strainer.

6.

Check the condition of the reservoir. Clean the reservoir and rinse it with clean hydraulic fluid if foreign matter is found inside. For better accessibility, the cover (G) and filler cap (B) may be removed.

7.

Clean the strainer with diesel fuel and dry it with compressed air. Replace the strainer if it is damaged.

IMPORTANT: Be sure to protect your face before using compressed air.

8.

Replace the sealing and install the cover (G) and filler cap (B) if they have been removed.

9.

Install the strainer and the cover (E) with the suction pipe (F) and the suction hose (D). Check the condition of the seals and clean or replace them, if necessary.

F

B

E

D

G CD00N044

72

10. Replace the hydraulic filter. See "Hydraulic filter replacement".

HYDRAULIC FILTER CARTRIDGE REPLACEMENT Irrespective of the normal, 2000 hours replacement interval for the hydraulic filter, it is also necessary to replace it if the hydraulic fluid is changed, or any of the hydraulic components (cylinders, pump etc.) are replaced ... In addition replace the hydraulic filter, if the warning lamp on the front console comes on.

SV208, SV210

CT04G001

73 SV212, SV216

CS03G010

74 4-35

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS 1.

Change the filter cartridge on the filtration block.

CD01G316

75 2.

Dismantle the filter housing with the filter cartridge using wrench 27 and take out the cartridge.

3.

Carefully clean the housing.

4.

Clean the contact surface of the filtration block on the lower side.

5.

Check the condition of sealing rings and lubricate them with clean oil

6.

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

7.

Check that the warning lamp on the front console is not alight.

CD01G317A

76

CHECKING THE OIL TEMPERATURE SENSOR 1.

Dismantle the sensor (H) and clean the contact.

2.

Dip the sensor into warm oil of known temperature and read oil temperature on the gauge on the dash.

3.

Replace the sensor if not operating properly.

H

CD00N046

77

4-36

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS FILLING THE HYDRAULIC SYSTEM There are two possible ways of filling the hydraulic system: 1. With a hydraulic reservoir filler station (see your Dealer for this device).

2. Without a filler station.

It is recommended to use a filler station as this has the effect of flushing out any foreign matter in the system and the lifetime of all components is thereby extended.

With the filler station: 1.

Connect the filler station quick connector to the machine quick connector.

CD00N047

78 2.

Install the drain pipe on the valve.

3.

Place a receptacle with a suitable capacity and open the valve.

4.

Using the filler station, fill the tank with suitable hydraulic fluid until clean fluid runs out of the drain hose (approximately 15 litres/3.95 gal US).

5.

Shut OFF the valve and remove drain hose.

6.

Fill the hydraulic reservoir completely and then remove the filler station.

7.

Start and run the engine at low idle and perform a number of operations with the machine. Shut down the engine and check the level using the sight glass (A). Add fluid if necessary. See "Level in reservoir".

CD01G318

79

4-37

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS 8.

Make sure the warning lamp on the front console is not alight.

SV208, SV210

CT04G001

80 SV212, SV216

CS03G011

81 Without the filler station: IMPORTANT: It is not recommended to use this method because slight traces of dirt will always remain in the hydraulic circuit and this will contaminate the new fluid poured in. When this method is adopted it will also be necessary to reduce the oil change interval to 1000 hours or once a year.

1.

Make sure the valve is properly shut.

CD01G318

82

4-38

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS 2.

Remove the protection plate and the filler cap (B).

3.

Fill the reservoir with suitable fluid until it comes up to the strainer located in the filler neck.

4.

Install the cap (B) and the protection plate.

5.

Start and run the engine at low idle and perform a few operations with the machine. Shut down the engine and check the level using the sight glass (A). Add fluid if necessary.

6.

Make sure the warning lamp on the front console is not alight.

B

CD00N044

83

4-39

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS DRUM SERVICE SPECIFICATIONS Oil level check.............................................................................................Every 250 hours or every 3 months Oil change....................................................................................................Every 2000 hours or every 2 years Oil capacity (SV208, SV210) .......................................................................................... 6.7 litres (1.77 gal US) Oil capacity (SV212, SV216) ............................................................................................... 8 litres (2.1 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), the plug with the sloping base - is in the upper position.

3.

Shut down the engine and remove the starter switch key.

A

CD00N049

84 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).

B

CD00N028

85

4-40

SECTION 4 - SERVICING INTERVALS/LUBRICATION/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 (C) 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 (C).

C B

CD00N028

86 5.

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

6.

Once the oil is completely drained, install the drain plug (C).

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

CD00N049

87

4-41

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS TRANSMISSION SERVICE SPECIFICATIONS Oil level check.............................................................................................Every 250 hours or every 3 months Oil change.......................................................................................................Every 1000 hours or once a year (after the first 100 run in hours) Oil capacity (SV208, SV210) .......................................................................................... 2.5 litres (0.66 gal US) Oil capacity (SV212, SV216) ............................................................................................ 4.2 litres (1.1 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 drain plug (C) is in the lower most position.

3.

Shut down the engine and remove the starter switch key.

4.

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

5.

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

6.

Install the plugs (A) and (B).

SV208, SV210

A

B

C

CD01G160

88 SV212, SV216

A

B

C

CD00N029

89

4-42

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS OIL CHANGE IMPORTANT: Drain 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 (C) is in the lower position.

3.

Shut down the engine and remove the starter switch key.

4.

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

5.

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

6.

Once the oil is completely drained, install the drain plug (C).

7.

Replace the plug seals.

8.

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

9.

Install the plugs (A) and (B).

SV208, SV210

C

CD01G214

90

A

B

CD01G160

90 SV212, SV216

A

B

C

CD00N029

91

4-43

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS PLANETARY REDUCTION GEARS SERVICE SPECIFICATIONS Oil level check.............................................................................................Every 250 hours or every 3 months Oil change....................................................................................................Every 1000 hours or every 2 years (after the first 100 run in hours) Oil capacity (SV208, SV210) .......................................................................................... 2.5 litres (0.66 gal US) Oil capacity (SV212, SV216) .......................................................................................... 2.8 litres (0.74 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 plug (A) is in the upper position.

3.

Shut down the engine and remove the starter switch key.

4.

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

5.

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

6.

Install the plugs (A) and (B).

7.

Repeat steps 2 to 6 for the other reduction gear.

B

A

CD01A006

92

OIL CHANGE IMPORTANT: Drain 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 plug (A) is in the lower position.

3.

Shut down the engine and remove the starter switch key.

4.

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

5.

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

B

A

CD01A007

93

4-44

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS 6.

When draining is completed, start the engine and move the machine so the plug (A) is in the upper position.

7.

Shut down the engine and remove the starter switch key.

8.

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

9.

Replace the plug seals.

B

A

10. Install the plugs (A) and (B).

11. Repeat steps 2 to 10 for the other reduction gear.

CD01A006

94

4-45

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS

NOTES

4-46

SECTION 5

26

MAINTENANCE/ADJUSTMENTS WARNING AND CONTROL DEVICES SERVICE SPECIFICATIONS Check ............................................................................................................................ Every 10 hours or daily SV208, SV210

7 12 11 10

6 9

8

1

2

3

4

5

13

CT04G011

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

1.

Operate switches (1), (2), (3), (4), (5), (6) and (7) to be sure the road lights, working lights and horn are functioning correctly.

2.

Turn the starter switch key (8) to position "I" (contact) and make sure lamps (9), (10), (11) and (12) light up.

3.

Warning lamp (9) should go out after 3 seconds.

4.

Turn the starter switch key (8) to position "II" (start). Lamps (9) and (15) should go out.

5.

While driving the machine, press the emergency stop button (13). The engine should stop, the brakes should be applied and lamp (11) should light up.

5-1

SECTION 5 - MAINTENANCE/ADJUSTMENTS

SV212, SV216

7

9 8

12 10

11

13

14

15

1

2

3

4

5

6

16

CD01G319A

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

1.

Operate switches (1), (2), (3), (4), (5), (6) and (7) to be sure the road lights, working lights and horn are functioning correctly.

2.

Turn the starter switch key (8) to position "I" (contact) and make sure lamps (9), (10), (11), (12), (13), (14) and (15) light up.

3.

ECM warning lamps (9), (10), (11), (12) should go out after 3 seconds.

5-2

4.

Turn the starter switch key (8) to position "II" (start). Lamp (15) should go out.

5.

While driving the machine, press the emergency stop button (16). The engine should stop, the brakes should be applied and lamp (14) should light up.

SECTION 5 - MAINTENANCE/ADJUSTMENTS ENGINE FAN SERVICE SPECIFICATIONS Visual check .................................................................................................................. Every 10 hours or daily Check that the fan is working properly. The hub must turn freely and without end play. If damage is found as any parts are missing, replace the fan. See your Dealer.

CD02B102

3

CRANKCASE BREATHER TUBE (SV208, SV210) SERVICE SPECIFICATIONS Check/Clean .................................................................................................................. Every 10 hours or daily Inspect in the breather tube for sluge, debris or ice the tube.

Inspect the tube more frequently in icy conditions.

CT04G004

4

5-3

SECTION 5 - MAINTENANCE/ADJUSTMENTS ENGINE ALTERNATOR AND FAN BELT SERVICE SPECIFICATIONS Visual check................................................................................................................... Every 10 hours or daily Tension check .................................................................................................Every 1000 hours or once a year 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

5 TENSION CHECK 1.

Press the center of the belt with your finger, exerting a pressure of about 10 kg (22 lb).

CD00N050

6 2.

The maximum deflection should be between 9.5 mm (3/8 in) to 13 mm (1/2 in).

PDE0090

7

5-4

SECTION 5 - MAINTENANCE/ADJUSTMENTS 3.

If the belt has to be replaced, use a tool to lift the idler and remove the belt.

4.

Check the fan is working correctly (the hub must turn freely and show no signs of end play).

5.

Install a new belt.

CD00N052

8

5-5

SECTION 5 - MAINTENANCE/ADJUSTMENTS TIRES AND WHEELS SERVICE SPECIFICATIONS Tire pressure check...................................................................................................................Every 100 hours Wheel nut torque.........................................................................................Every 500 hours or every 6 months Torque specification ............................................................................................................... 540 Nm (400 ft lb)

!

WARNING

!

A burst tire can cause serious injury. Regularly check the condition of the tires and always maintain the recommended inflation pressure. When checking pressure or inflating a tire, never stand in front of the tire. Always face the tread. Always use an inflation cage when the wheel is removed from the machine. Keep all other people in the area away. Never weld close to a tire. The tire must be removed for all welding operations.

TIRE PRESSURE IMPORTANT: Be sure to wear face protection before using compressed air.

1.

Remove the dust caps.

2.

Connect a pressure gauge to the valves (A). Inflation pressure should be 1.6 bar (23.2 psi).

3.

Add air if necessary.

4.

Install the dust caps.

NOTE: In order to increase wheel load and lower the machine’s center of gravity, the tires may be filled with liquid ballast. See "Filling the tires with liquid ballast" in Section 3.

5-6

A

CD00N020

9

SECTION 5 - MAINTENANCE/ADJUSTMENTS TORQUE Wheel nuts (B) should be tightened to a torque of 165 Nm (122 ft lb).

WHEEL REPLACEMENT 1.

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

2.

Place blocks on each side of the drum.

3.

Loosen the nuts (B) on the wheel to be removed.

4.

Use suitable lifting equipment to raise the rear of the machine and install supports under the rear frame.

5.

Remove the nuts (B) and then remove the wheel.

6.

Install a new wheel, making sure the tire tread is facing in the right direction.

7.

Install and tighten the nuts (B) to a torque of 165 Nm (122 ft lb).

8.

Remove the supports from under the rear frame.

9.

Lower the machine to the ground.

B

CD01G277

10

10. Remove the blocks from under the drum.

11. Check the pressure of the new tire.

5-7

SECTION 5 - MAINTENANCE/ADJUSTMENTS ENGINE AIR INTAKE SYSTEM SERVICE SPECIFICATIONS 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.

A

C

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

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

B CD00N054

11

RADIATOR AND 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.

Clean the radiator and oil cooler as follows: 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 approved cleaning solution.

IMPORTANT: The use of trichlorethylene is strictly forbidden.

2.

5-8

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

CD02B102

12

SECTION 5 - MAINTENANCE/ADJUSTMENTS SHOCK ABSORBERS/MOUNTING BLOCKS SERVICE SPECIFICATIONS Check ............................................................................................................. Every 1000 hours or once a year Check the condition of the various shock absorbers and mounting blocks shown below (rubber, metal components, hardware, etc.). If these are damaged, replace its.

DRUM

CD01J020

13 OPERATOR’S COMPARTMENT (front)

CD01G282

14 OPERATOR’S COMPARTMENT (rear)

CD01G284

15

5-9

SECTION 5 - MAINTENANCE/ADJUSTMENTS ENGINE (front)

CD00N058

16 ENGINE (rear)

CD00N059

17

5-10

SECTION 5 - MAINTENANCE/ADJUSTMENTS ENGINE VALVE CLEARANCE (SV208, SV210) SERVICE SPECIFICATIONS Check ................................................................Every 1000 hours or once a year, see your CUMMINS Dealer IMPORTANT: The valve clearance should be measured while the engine is cold.

1.

Disconnect the air inlet lines loading to the turbocharger and valve covers.

CD01G320

18 2.

Remove the blanking plug from the engine flywheel casing.

CD01G321

19 3.

Install the engine turnover tool (Cummins Number 3824591).

4.

Use the engine turnover tool to rotate the engine slowly and find the Top Dead Center position.

CD00N062A

20

5-11

SECTION 5 - MAINTENANCE/ADJUSTMENTS 5.

When the engine is in Top Dead Center Position, the valve rocker arms for valves (E, I) will be free.

I CD01G322

E 21

6.

Use a feeler gauge to measure the valve clearance at the intake (I) and exhaust valves (E) in the order shown: Intake (I): 0.25 mm (0.010 in).

Exhaust (E): 0.50 mm (0.020 in).

7.

If the clearance is not correct, loosen the rocker arm locking nut and use a screwdriver to turn the adjustment screw and obtain the proper clearance. Tighten the locking nut to a torque of 24 Nm (18ft lb) and check the clearance once more.

CD00N065

22 8.

Check and adjust clearances of remaining valves.

9.

After tightening the locking nut recheck clearances.

CD00N066A

23

5-12

SECTION 5 - MAINTENANCE/ADJUSTMENTS 10. Make a mark on the torsion vibration damper and turn the crankshaft by 360°.

CD01G323

24 11. Check and adjust clearances of remaining valves.

CD00N066A

25 12. Install the turbocharger air intake hose. Install the valves covers and tighten the screws to a torque of 24 Nm (18 ft lb).

CD00N068

26

5-13

SECTION 5 - MAINTENANCE/ADJUSTMENTS ENGINE VALVE CLEARANCE (SV212, SV216) SERVICE SPECIFICATIONS Check................................................................ Every 1000 hours or once a year, see your CUMMINS Dealer IMPORTANT: The valve clearance should be measured while the engine is cold.

1.

Remove the turbocharger air intake hose and remove the valve covers.

CD00N061

27 2.

Remove the blanking plug from the engine flywheel casing.

3.

Install the engine turnover tool (Cummins Number 3824591).

4.

Use the engine turnover tool to rotate the engine slowly and press in the timing pin.

CD00N062

28 5.

When the timing pin engages in the camshaft pinion, number 1 cylinder is in Top Dead Center Position.

CD00N063

29

5-14

SECTION 5 - MAINTENANCE/ADJUSTMENTS 6.

Remove the timing pin from the camshaft pinion.

CD00N064

30 7.

Use a feeler gauge to measure the valve clearance at the intake valves (I) and exhaust valves (E) in the order shown above: Intake (I): 0.25 mm (0.010 in).

Exhaust (E): 0.50 mm (0.020 in).

8.

If the clearance is not correct, loosen the rocker arm locking nut and use a screwdriver to turn the adjustment screw and obtain the proper clearance. Tighten the locking nut to a torque of 24 Nm (18 ft lb) and check the clearance once more.

9.

Place alignment marks on the crankshaft pulley and the timing gear cover.

CD00N065

31

10. Use the turnover tool to rotate the engine 360° until the alignment marks are opposite each other once again.

CD00N066

32

5-15

SECTION 5 - MAINTENANCE/ADJUSTMENTS 11. Check the clearance of the other valves in the order shown above and make any necessary adjustments as explained in Steps 7 to 8.

12. Install the blanking plug in the engine flywheel casing.

CD00N067

33 13. Install the turbocharger air intake hose. Install the valve covers and tighten the screws to a torque of 24 Nm (18 ft lb).

CD00N068

34

5-16

SECTION 5 - MAINTENANCE/ADJUSTMENTS OPERATOR’S COMPARTMENT AND ENGINE HOOD TILTING SYSTEM STRAINER (if equipped) SERVICE SPECIFICATIONS Check and clean.......................................................................................... Every 2000 hours or every 2 years and whenever the hydraulic fluid is changed 1.

Drain the hydraulic reservoir. See "Hydraulic fluid replacement" in Section 4.

2.

Place a receptacle of an appropriate size (about 10 litres) under the assembly (B).

3.

Remove the mounting screws (A) and remove the unit (B) from under the hydraulic reservoir.

A B CD01G285

35 4.

Remove the strainer (C) from the suction pipe (D).

5.

Clean the strainer (C) in clean fuel and dry it with compressed air.

D

IMPORTANT: Be sure to wear face protection when using compressed air.

6.

Check the condition of the strainer (C) and replace it if necessary.

7.

Install the strainer (C) in the suction pipe (D).

8.

Check the condition of the seal (E) and replace it if necessary.

9.

Install the unit (B) and tighten the mounting screws (A). Make sure there are no leaks.

C E

CD00N069A

36

10. Fill the hydraulic reservoir. See "Filling the hydraulic system" in Section 4.

5-17

SECTION 5 - MAINTENANCE/ADJUSTMENTS DRUM VIBRATION FREQUENCY SERVICE SPECIFICATIONS Check...........................................................................................................Every 2000 hours or every 2 years CHECK The drum vibration frequency should be checked while the machine is traveling and the drum is vibrating.

1.

Connect a frequency measuring instrument to the shock absorber plate on the drum (to obtain this instrument, see your Dealer) and take the reading.

2.

The frequency values should be: For SV208/SV210 models: - with high amplitude: 30 Hz (1800 vpm) - with low amplitude: 40 Hz (2400 vpm) For SV212 model: - with high amplitude: 32 Hz (1920 vpm) - with low amplitude: 35 Hz (2100 vpm) For SV216 model: - with high amplitude: 29 Hz (1740 vpm) - with low amplitude: 35 Hz (2100 vpm)

IMPORTANT: Be careful not to invert the frequencies.

Low frequency must correspond to high amplitude and vice-versa.

3.

If the values measured by the test instrument are not in conformance with those shown above, then adjustment should be made. Contact your Dealer.

IMPORTANT: It is imperative to observe the values specified by the manufacturer.

5-18

CD00N070

37

SECTION 5 - MAINTENANCE/ADJUSTMENTS VIBRATION SHOCK ABSORBER SERVICE SPECIFICATIONS Check .......................................................................................................... Every 2000 hours or every 2 years Check the alignment of the marks (A) on the two surfaces of both parts of the vibration shock absorber. If the marks (A) are more than 1.59 mm (1/16 in) out of alignment, the shock absorber needs to be changed.

See your Dealer.

A

A

CD00N072

38

CLEANING THE MACHINE SERVICE SPECIFICATIONS 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 horizontal 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.

5-19

SECTION 5 - MAINTENANCE/ADJUSTMENTS OPERATOR’S COMPARTMENT INTAKE AIR DUST FILTER (Cab version) SERVICE SPECIFICATIONS Clean............................................................................................................................................ Once a month IMPORTANT: If the machine is used in dusty conditions, reduce the cleaning intervals.

1.

Remove the protection grill (A).

A

CD01G286

39 2.

Remove the filter (B).

3.

Clean the filter (B) in a detergent solution.

4.

If the filter (B) is damaged or too dirty, change it.

5.

Install the filter (B) and the protection grill (A).

B

CD01G287

40

5-20

SECTION 5 - MAINTENANCE/ADJUSTMENTS AIR-CONDITIONING (if equipped) The air-conditioning system components require regular servicing. Respect these service intervals to ensure the correct operation and full effectiveness of the air-conditioning system. The air-conditioning system contains a gas which is subject to strict regulations. Any failures in the system must be repaired as quickly as possible.

!

WARNING

!

Never perform any service work on the air-conditioning circuit. Consult an approved specialist for any service work required.

NOTE: Use the air-conditioning at least once a week, if only for a short time. See "Air-conditioning controls" in Section 2.

SERVICE SPECIFICATIONS Check ........................................................................................................................................ Every 3 months Clean the condenser ........................................................................................................................... Regularly CHECK 1.

With the engine running, check the condition of the refrigerant liquid visually through the receiver/ dryer filter sight glass. The sight glass should be clean, without any signs of mist, shaded areas or bubbles.

CD00N073

41 2.

Check the compressor drive belt tension. Press in the center of the belt with your finger. The maximum amount of deflection measured should be between 10 mm (0.4 in) and 15 mm (0.6 in). Also check the condition of the belt. If it is worn or damaged, replace it.

CD00N074A

42

5-21

SECTION 5 - MAINTENANCE/ADJUSTMENTS 3.

Remove the evaporator drain hose, clean it and check its condition. If it is damaged, change it.

CD00N075

43 CLEANING THE CONDENSER Dry dust: use compressed air.

Mud: use a hose.

Greasy deposits: use suitable cleaner.

IMPORTANT: The use of trichlorethylene is strictly forbidden.

IMPORTANT: Be sure to wear face protection before using compressed air.

CD00N076

44

5-22

SECTION 5 - MAINTENANCE/ADJUSTMENTS SCRAPERS SERVICE SPECIFICATIONS Check .................................................................................................................................................. Regularly IMPORTANT: Be sure to keep the clearance between the drum and the scrapers to the dimensions given below. If the scrapers are too close at one end of the drum the machine will tend to steer towards that side, thereby causing damage.

SMOOTH DRUM Check the clearance between the scrapers and the drum. The distance must be 15 mm (0.6 in). If necessary, loosen the mounting hardware, move the holder (1) towards the drum until the clearance is 15 mm (0.6 in) and then re-tighten the mounting hardware.

NOTE: If it is not possible to reduce the clearance to 15 mm (0.6 in), remove the hardware and the scraper (2), install them in the next holder orifice so as to be able to obtain a clearance of 15 mm (0.6 in) and then tighten the hardware.

1

CD01A009

45 TAMPING DRUM Check the clearance between the scrapers and the drum. The distance must be 25 mm (1 in). If necessary, loosen the mounting hardware, move the scraper (2) towards the drum until the clearance is 25 mm (1 in) and then re-tighten the mounting hardware.

NOTE: The rear scrapers are longer than the front ones. When it becomes necessary to replace rear scrapers, use them to replace scrapers at the front of the drum and install new scrapers at the rear.

2

CD01A008

46

5-23

SECTION 5 - MAINTENANCE/ADJUSTMENTS HARDWARE TORQUE SPECIFICATIONS SERVICE SPECIFICATIONS 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

5.8

2 (1)

4 (3)

7 (5)

16 (12)

31.5 (23)

53 (39)

78.5 (58)

113 (83)

172 (127)

226 (167)

284 (209)

392 (289)

8.8

3 (2)

6 (4)

10 (7)

22.5 (17)

44 (32)

75 (55)

118 (87)

165 (122)

245 (181)

314 (231)

392 (289)

549 (405)

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)

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

!

WARNING

!

The self-locking nuts must be changed systematically used 3 times only.

5-24

SECTION 5 - MAINTENANCE/ADJUSTMENTS ENGINE TROUBLESHOOTING PROBLEM

Engine does not star or shuts down.

POSSIBLE CAUSE

SOLUTION

Defective starter switch (starter does not run)

Check switch

Defective rotation of starter (starter rotates slowly)

Discharged batteries, starter problems, contaminated or loose wiring connectors

Incorrect viscosity of engine oil

Inspect and replace as necessary

Incomplete air bleeding of fuel system

Completely bleed air

Engine too cold (cold weather)

Preheat the intake air or warm up the coolant

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.

Low hydraulic fluid

Refill

Blown fuses

Replace

Blown diode

Replace

Bad relay under front console

Replace

Bad solenoid on left side of engine

See your Dealer

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.

See your Dealer

Excessive oil

Disassemble and repair, replace parts

Excessively low oil viscosity

Replace with correct oil viscosity

Excessive cooling by radiator

Adjust

Incorrect fuel injection timing Low compression

Exhaust from engine is black or dark gray.

See your Dealer

Improper fuel

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

5-25

SECTION 5 - MAINTENANCE/ADJUSTMENTS

PROBLEM

Excessive engine oil consumption.

Unusual noise (fuel or mechanical).

Engine overheating (coolant temperature is too high).

POSSIBLE CAUSE

SOLUTION

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

Low coolant

Refill

Coolant leakage

Repair

Worn or damaged belt

Replace

Incorrect mixture of anti-freeze solution

Replace

Defective radiator Broken fan Defective thermostat

See your Dealer

Defective water pump Defective water temperature gauge Incorrect belt tension

Defective battery charging.

Adjust

Electrical wiring problems

Repair

Defective battery

Replace

Defective regulator Defective alternator

5-26

See your Dealer

SECTION 6

6

ELECTRICAL SYSTEM FUSES IMPORTANT: Before changing a fuse, place the battery master switch in horizontal position (system switched off). Never replace a fuse with a fuse of different amperage.

CD00M004

47 The fuses are located in the compartment in the front console.

F1 (Upper fuse) Front and rear work lamps, front parking lights and tail lights, auxiliary work lamps, instrument illumination, lifting the hood and operator’s compartments, illumination of license plates ............................................. 20 A F2 Service power socket, cab illumination, warning horn, turn indicators and beacon, radio receiver ................................................... 10 A F3 Brake, engine shut down, travel, vibration, brake lights, back up alarm, hydraulic oil level indicator, vibration switch indicator, brake indicator, travel lever neutral position indicator lamp .......................................................... 7.5 A F4 ASC (Anti-Slip Control) .............................. 10 A F5 Engine coolant thermometer, hydraulic oil temperature gauge, fuel level, tachometer, hourmeter, warning lamps for maintenance, stop engine, engine oil pressure, water in fuel, air filter restriction, battery charge, hydraulic oil level and hydraulic filter restriction .................... 15 A F6 Ventilator and heater fan, front and rear wiper, front and rear windshield washer............... 15 A F7 Air conditioning (if equipped) ..................... 20 A F8 Reserve ..................................................... 20 A

CS03G012

1

6-1

SECTION 6 - ELECTRICAL SYSTEM Fuse for operator’s compartment and engine hood tilting........................................................................... 50 A This fuse is located in the side compartment on the left-hand side of the machine.

CS00M505

2

CD01G272

3 Engine fuses located in the right-hand compartment.

F10, F11, F12 Power supply engine electronics ...........................................................7.5 A F13, F14 Power supply relay injection valve ...................................................................10 A Fuse F15............................................... reserve

F10

F11

F12

F13

F14 F15

CD03G002

4

6-2

SECTION 6 - ELECTRICAL SYSTEM BATTERIES SERVICE SPECIFICATIONS Electrolyte level check ................................................................................ Every 250 hours or every 3 months and whenever the warning lamp on the front console comes on See "Battery charge warning lamp" in Section 2 NOTE: If the machine needs to be started with booster batteries, see "Booster batteries".

!

WARNING

!

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

- The electrolyte in the batteries can cause serious burns. Batteries contain sulphuric acid. Avoid contact with skin, eyes and clothing.

Antidote: EXTERNAL: rinse thoroughly with water and remove soiled clothes.

INTERNAL: do not induce vomiting. Rinse the mouth out with water. Seek medical advice.

EYES: rinse thoroughly with water for 15 minutes and seek medical advice.

- A spark or a light can cause the hydrogen in a battery to explode. To prevent explosion, proceed as follows: - When disconnecting the battery cables, always disconnect the negative (-) cable first.

- When reconnecting the 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.

- Batteries give off explosive gases. Keep all flames, sparks and cigarettes away. Ensure adequate ventilation when charging batteries or when using in a confined place. Always protect your eyes when working near batteries.

- 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 batteries removed from the machine.

- Open the plugs before recharging.

- Connect the batteries correctly after completed recharging.

- Do not disconnect the battery with the engine running.

- Disconnect wires of +B and +D terminals from the alternator before welding.

- Do not run the alternator with the wire disconnected from the +B terminal and a connected +D terminal.

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

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

6-3

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 master switch.

3.

Clean the surface of batteries.

4.

Check the condition of terminals and clean them. Slightly coat the terminals with grease (ensure good contact).

CD01G326

5 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 batteries.

7.

Keep the batteries dry and clean.

IMPORTANT: The 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.

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

6-4

A

CD00N030

6

SECTION 6 - ELECTRICAL SYSTEM BOOSTER BATTERIES

!

WARNING

!

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

Connect starter cables following the instruction below.

Check that the voltage of booster batteries is compatible with the machine’s electrical system (24 volts).

1.

Remove the terminal protection caps.

2.

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

3.

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

+

CD02B103

7

6-5

SECTION 6 - ELECTRICAL SYSTEM

NOTES

6-6

SECTION 7

2

STORAGE STORING THE MACHINE PREPARATION FOR STORAGE

PERIODIC CHECKS

The following procedure applies when the machine is to be stored for three months or more. Store the machine on flat, level ground, with the drum in alignment with the machine 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.

1.

The electrolyte level in the batteries 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.

Close the drain taps and fill the cooling system with coolant.

2.

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

4.

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

3.

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

5.

Clean or change the air filter.

4.

Change the fuel filter.

6.

Drain the cooling system, leave the drain taps open and do not tighten the radiator cap.

5.

Install the batteries.

6.

Grease the machine completely.

7.

Use the master switch to disconnect the electrical system.

7.

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

8.

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

8.

Check all levels and add as necessary.

9.

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

9.

Paint any areas where the paintwork has been damaged.

10. Raise the dozer blade and lock it mechanically (if equipped).

11. Remove the starter switch key, place a "Do not operate" label on the console and raise the righthand control arm.

12. Lock the engine hood and the doors.

10. 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

14

SPECIFICATIONS SV208 - SV210 SPECIFICATIONS ENGINE Cummins engine B4.5 - C99 Tier II certified 4 cylindrer diesel 239 CID Federal emission certified

Horsepower, turbocharged: - Gross 100 Hp (75 kW) Air cleaner-dry type, radial seal Fan guard

OPERATOR PROTECTIVE STRUCTURE ROPS / FOPS protection Tiltable operator’s platform with hand rails Left and right side access steps Isolated operator’s platform Power steering One lever control

Rotating vinyl suspension seat w/ armrest and 2" seatbelt Locking tool box Cup & bottle holder Manifest compartment / cargo net Rearview mirror

INSTRUMENTATION Tachometer/hourmeter Parking brake indicator light Engine oil pressure gauge Engine temperature gauge Engine water temperature gauge Fuel gauge Voltmeter

Air cleaner restriction indicator light Alternator charge light Hydraulic oil temperature gauge Horn Emergency stop indicator Differential lock indicator light

CAPACITIES Fuel: 275 litres (72.7 gal US) Engine oil: 11.2 litres (2.96 gal US)

Hydraulic system: 73 litres (19.3 gal US)

CHASSIS Oscillating frame: ±12° Articulating frame: ±36°

Centralized diagnostic access door, lockable Turning radius: Inner (edge): 3090 mm (121.7 in)

DRUM 66" wide x 51" diameter hydrostatic drive Dual frequency vibration

Dual amplitude Auto-vibration control

ELECTRICAL Alternator guard Push button electrically operated tilting hood Push button electrically operated tilting operator’s platform

Halogen worklights, front and rear Batteries: 2 x 12V @ 850 CCA

8-1

SECTION 8 - SPECIFICATIONS WHEELS 14.9 x 24" R3 8PR Diamond Tires liquid ballast to -25°

Tires ballast filling device

OTHER Backup alarm Emergency manual operator platform and hood tilt

Vandalism protection Titable engine hood

TRANSMISSION 4 speed drive selection system Hydrostatic rear driven wheels with interlock control Spring applied, hydraulic release parking brake SV208 Planetary reduction gear Maximum speed (with smooth drum)

2

2

0-11 km/h (0-7 mph)

0-11 km/h (0-7 mph)

45%

45%

Hydrostatic Multi-disc

Hydrostatic Multi-disc

Theoretical gradeability (without vibration) (with smooth drum) Brakes: Service Parking and emergency

SV210

TRAVEL SPEED

1st speed range (work) 1 2 3 2nd speed range

SV208

SV210

0-2.5 km/h (0-1.55 mph) 0-3.5 km/h (0-2.17 mph) 0-4.7 km/h (0-2.92 mph)

0-2.5 km/h (0-1.55 mph) 0-3.5 km/h (0-2.17 mph) 0-4.7 km/h (0-2.92 mph)

0-11 km/h (0-7 mph)

0-11 km/h (0-7 mph)

SV208

SV210

1.7/0.86 mm (0.067/0.034 in) 30/40 Hz (1800/2400 vpm) 145/130 kN (32 597/29 225 ft lb)

1.85/0.96 mm (0.073/0.038 in) 30/40 Hz (1800/2400 vpm) 160/145 kN (35 970/32 597 ft lb)

VIBRATION

Vibration modes Nominal amplitude Frequency Centrifugal force

8-2

SECTION 8 - SPECIFICATIONS WEIGHTS

SV208

SV210

Operating weight

7140 kg (15 741 lb)

8820 kg (19 445 lb)

Operating weight - maximum

7675 kg (16 921 lb)

8935 kg (19 698 lb)

4020 kg (8863 lb)

5315 kg (11 718 lb)

23.9 kg/cm (133.8 lb/in)

31.6 kg/cm (176.9 lb/in)

SV208

SV210

Operating weight

7085 kg (15 620 lb)

8765 kg (19 323 lb)

Operating weight - maximum

7620 kg (16 799 lb)

8880 kg (19 577 lb)

3965 kg (8741 lb)

5260 kg (11 596 lb)

SV208

SV210

Operating weight

7585 kg (16 722 lb)

9265 kg (20 426 lb)

Operating weight - maximum

8120 kg (17 902 lb)

9380 kg (20 679 lb)

Drum load

4555 kg (10 042 lb)

5850 kg (12 897 lb)

Ballast

2x210 kg (2x463 lb)

2x210 kg (2x463 lb)

With smooth drum

Drum load Static linear load With tamping drum

Drum load

With tamping drum and dozer blade

8-3

SECTION 8 - SPECIFICATIONS SV208 - SV210 OVERALL MACHINE DIMENSIONS (with smooth drum)

L

E F

B C

D

A

K

G

H J

CS01A508

1 A.............................................................................................................................................2.560 m (100.8 in) B...............................................................................................................................................1.300 m (51.2 in) C ..............................................................................................................................................0.385 m (15.2 in) D ..............................................................................................................................................0.375 m (14.8 in) E............................................................................................................................................. 2.890 m (113.8 in) F...............................................................................................................................................2.200 m (86.6 in) G ............................................................................................................................................5.195 m (204.5 in) H ..............................................................................................................................................1.680 m (66.1 in) J (SV208) .................................................................................................................................1.880 m (74.0 in) J (SV210) .................................................................................................................................1.930 m (76.0 in) K (SV208) ................................................................................................................................0.095 m (3.74 in) K (SV210) ................................................................................................................................0.120 m (4.72 in) L ...............................................................................................................................................0.025 m (0.98 in)

8-4

SECTION 8 - SPECIFICATIONS SV208 - SV210 OVERALL MACHINE DIMENSIONS (with tamping drum)

E F M B

L

C

D

A

K

G

H J

CS01C501

2 A ............................................................................................................................................ 2.560 m (100.8 in) B .............................................................................................................................................. 1.240 m (48.8 in) C .............................................................................................................................................. 0.385 m (15.2 in) D .............................................................................................................................................. 0.375 m (14.8 in) E ............................................................................................................................................ 2.890 m (113.8 in) F .............................................................................................................................................. 2.200 m (86.6 in) G............................................................................................................................................ 5.195 m (204.5 in) H .............................................................................................................................................. 1.680 m (66.1 in) J (SV208)................................................................................................................................. 1.880 m (74.0 in) J (SV210)................................................................................................................................. 1.930 m (76.0 in) K (SV208) ................................................................................................................................ 0.095 m (3.74 in) K (SV210) ................................................................................................................................ 0.120 m (4.72 in) L............................................................................................................................................... 0.015 m (0.59 in) M.............................................................................................................................................. 1.400 m (55.1 in)

8-5

SECTION 8 - SPECIFICATIONS SV208 - SV210 OVERALL MACHINE DIMENSIONS (with tamping drum and dozer blade)

E F D C B

L A

H

G

J

K CS01C502

5 A.............................................................................................................................................2.560 m (100.8 in) B...............................................................................................................................................1.300 m (51.2 in) C ..............................................................................................................................................0.385 m (15.2 in) D ..............................................................................................................................................1.480 m (58.3 in) E................................................................................................................................................2.870 m (113 in) F...............................................................................................................................................2.200 m (86.6 in) G ............................................................................................................................................5.195 m (204.5 in) H ..............................................................................................................................................1.680 m (66.1 in) J ...............................................................................................................................................2.215 m (87.2 in) K.............................................................................................................................................5.555 m (218.7 in) L ...............................................................................................................................................0.025 m (0.59 in)

8-6

SECTION 8 - SPECIFICATIONS SV212 - SV216 SPECIFICATIONS ENGINE Cummins engine QSB5.9 - C155 Tier II certified 6 cylindrer diesel 5.9 L

Horsepower, turbocharged: - Gross 155 Hp (116 kW) Air cleaner-dry type, radial seal Fan guard

OPERATOR PROTECTIVE STRUCTURE ROPS / FOPS protection Tiltable operator’s platform with hand rails Left and right side access steps Isolated operator’s platform Power steering One lever control

Rotating vinyl suspension seat w/ armrest and 2" seatbelt Locking tool box Cup & bottle holder Manifest compartment / cargo net Rearview mirror

INSTRUMENTATION Tachometer/hourmeter Parking brake indicator light Engine defect warning indicator light Stop engine warning indicator light Fuel gauge Drum vibration indicator light Air cleaner restriction indicator light

Alternator charge light Hydraulic oil temperature gauge Hydraulic oil filter restriction indicator light Horn Emergency stop indicator Hydraulic fluid level warning indicator light

CAPACITIES Fuel: 410 litres (108 gal US) Engine oil: 16.3 litres (4.3 gal US)

Hydraulic system: 90 litres (23.8 gal US)

CHASSIS Oscillating frame: ±10° Articulating frame: ±36°

Centralized diagnostic access door, lockable Turning radius: Inner (edge): 3050 mm (120.1 in)

DRUM 87" wide x 59" diameter hydrostatic drive Dual frequency vibration

Dual amplitude Auto-vibration control

ELECTRICAL Alternator guard Push button electrically operated tilting hood Push button electrically operated tilting operator’s platform

Halogen worklights, front and rear Batteries: 2 x 12V @ 850 CCA

8-7

SECTION 8 - SPECIFICATIONS WHEELS 23.1 x 26" UK5 10PR Tires liquid ballast to -25°

Tires ballast filling device

OTHER Backup alarm Emergency manual operator platform and hood tilt

Vandalism protection Titable engine hood

TRANSMISSION 4 speed drive selection system Hydrostatic rear driven wheels with interlock control Spring applied, hydraulic release parking brake SV212 Planetary reduction gear

SV216

2

2

0-14.5 km/h (0-9 mph)

0-13 km/h (0-8 mph)

Theoretical gradeability (with smooth drum)

77%

69%

Theoretical gradeability (with tamping drum)

74%

69%

Theoretical gradeability (with tamping drum and dozer blade)

68%

63%

Transversal stability - straight (without dozer blade)

36°

37°

Transversal stability - straight (with dozer blade)

37°

38°

Hydrostatic Multi-disc

Hydrostatic Multi-disc

Maximum speed

Brakes: Service Parking and emergency TRAVEL SPEED

SV212

SV216

1st speed range (work) 1 2 3

0-2.5 km/h (0-1.6 mph) 0-3.4 km/h (0-2.1 mph) 0-6.0 km/h (0-3.7 mph)

0-2.4 km/h (0-1.5 mph) 0-3.1 km/h (0-1.9 mph) 0-5.7 km/h (0-3.5 mph)

2nd speed range

0-14.5 km/h (0-9 mph)

0-13.0 km/h (0-8 mph)

SV212

SV216

1.15 mm (0.045 in) 35 Hz (2100 vpm) 206 kN (46 311 ft lb) 1.85 mm (0.073 in) 32 Hz (1920 vpm) 277 kN (62 272 ft lb)

1 mm (0.039 in) 35 Hz (2100 vpm) 237 kN (53 280 ft lb) 2 mm (0.079 in) 29 Hz (1740 vpm) 325 kN (73 063 ft lb)

VIBRATION

Vibration modes 1. Nominal amplitude Frequency Centrifugal force 2. Nominal amplitude Frequency Centrifugal force

8-8

SECTION 8 - SPECIFICATIONS WEIGHTS

SV212

SV216

Operating weight

11 085 kg (24 438 lb)

14 310 kg (31 548 lb)

Operating weight - maximum

12 285 kg (27 084 lb)

15 510 kg (34 194 lb)

7020 kg (15 477 lb)

10 160 kg (22 399 lb)

1200 kg (2646 lb)

1200 kg (2646 lb)

SV212

SV216

Operating weight

11 515 kg (25 386 lb)

14 220 kg (31 350 lb)

Operating weight - maximum

12 715 kg (28 032 lb)

15 420 kg (33 995 lb)

7450 kg (16 425 lb)

10 070 kg (22 201 lb)

1200 kg (2646 lb)

1200 kg (2646 lb)

SV212

SV216

Operating weight

12 425 kg (27 392 lb)

15 130 kg (33 356 lb)

Operating weight - maximum

13 625 kg (30 038 lb)

16 330 kg (36 002 lb)

8690 kg (19 158 lb)

11 310 kg (24 934 lb)

1200 kg (2646 lb)

1200 kg (2646 lb)

With smooth drum

Drum load Ballast With tamping drum

Drum load Ballast With tamping drum and dozer blade

Drum load Ballast

8-9

SECTION 8 - SPECIFICATIONS PERFORMANCE LEVELS (SV212)

With smooth drum (soil compaction) Number of passes

Square output

Working speed km/h: 4.5 (2.8 mph) Correction factor: 0.8

Volumetric Output m3/h (yd 3/h)

m2/h

Compacted lift thickness m (in)

2

(yd /h)

0.2 (8)

2

3960 (4736)

792 (1036)

4

1980 (2368)

396 (518)

594 (777)

6

1320 (1579)

264 (345)

8

990 (1184)

198 (259)

0.3 (12)

0.4 (16)

0.5 (20)

0.6 (24)

396 (518)

528 (691)

660 (863)

792 (1036)

297 (388)

396 (518)

495 (647)

594 (777)

0.7 (28)

0.8 (31)

693 (906)

792 (1036)

With tamping drum (soil compaction) Number of passes

Square output

Working speed km/h: 4.5 (2.8 mph) Correction factor: 0.8

Volumetric Output m3/h (yd 3/h)

m2/h

Compacted lift thickness m (in)

2

(yd /h)

0.2 (8)

2

3960 (4736)

792 (1036)

4

1980 (2368)

396 (518)

594 (777)

6

1320 (1579)

264 (345)

396 (518)

528 (691)

8

990 (1184)

198 (259)

297 (388)

396 (518)

0.3 (12)

0.4 (16)

0.5 (20)

495 (647)

Less economical compaction modes MAXIMUM COMPACTED LIFT THICKNESS AT OPTIMAL WORKING CONDITIONS (SV212)

With smooth drum With tamping drum

8-10

Rockfill

Sand/gravel

Mixed soils

Silt

Clay

0.8 m (31 in)

0.6 m (24 in)

0.5 m (20 in)

0.4 m (16 in)

0.25 m (10 in)

0.5 m (20 in)

0.4 m (16 in)

0.3 m (12 in)

SECTION 8 - SPECIFICATIONS PERFORMANCE LEVELS (SV216)

With smooth drum (soil compaction) Number of passes

Square output

Working speed km/h: 4.5 (2.8 mph) Correction factor: 0.8

Volumetric Output m3/h (yd 3/h)

m2/h

Compacted lift thickness m (in)

2

(yd /h)

0.2 (8)

2

3960 (4736)

792 (1036)

4

1980 (2368)

6 8

0.4 (16)

0.6 (24)

0.8 (31)

396 (518)

792 (1036)

1188 (1554)

1320 (1579)

264 (345)

528 (691)

792 (1036)

1056 (1381)

990 (1184)

198 (259)

396 (518)

594 (777)

792 (1036)

1 (39)

1.2 (47)

1.4 (55)

990 (1295)

1188 (1554)

1386 (1813)

With tamping drum (soil compaction) Number of passes

Square output

Working speed km/h: 4.5 (2.8 mph) Correction factor: 0.8

Volumetric Output m3/h (yd 3/h)

m2/h

Compacted lift thickness m (in)

2

(yd /h)

0.2 (8)

2

3960 (4736)

792 (1036)

4

1980 (2368)

6 8

0.3 (12)

0.4 (16)

0.5 (20)

0.6 (24)

0.7 (28)

396 (518)

594 (777)

792 (1036)

990 (1295)

1320 (1579)

264 (345)

396 (518)

528 (691)

660 (863)

792 (1036)

924 (1208)

990 (1184)

198 (259)

297 (388)

396 (518)

495 (647)

594 (777)

693 (906)

0.8 (31)

792 (1036)

Less economical compaction modes MAXIMUM COMPACTED LIFT THICKNESS AT OPTIMAL WORKING CONDITIONS (SV216)

With smooth drum With tamping drum

Rockfill

Sand/gravel

Mixed soils

Silt

Clay

1.4 m (55 in)

0.9 m (35 in)

0.75 m (30 in)

0.55 m (22 in)

0.3 m (12 in)

0.75 m (30 in)

0.55 m (22 in)

0.35 m (14 in)

8-11

SECTION 8 - SPECIFICATIONS SV212 - SV216 OVERALL MACHINE DIMENSIONS (with smooth drum)

L

E F

B C

D

A

K

G

H J

CS01A508

3 A................................................................................................................................................ 2.820 m (111 in) B...............................................................................................................................................1.500 m (59.1 in) C ..............................................................................................................................................0.420 m (16.5 in) D ..............................................................................................................................................0.430 m (16.9 in) E............................................................................................................................................. 3.030 m (119.3 in) F...............................................................................................................................................2.500 m (98.4 in) G ............................................................................................................................................5.686 m (223.9 in) H ..............................................................................................................................................2.200 m (86.6 in) J (SV212) .................................................................................................................................2.450 m (96.5 in) J (SV216) .................................................................................................................................2.500 m (98.4 in) K (SV212) .................................................................................................................................. 0.118 m (4.6 in) K (SV216) ..................................................................................................................................0.142 m (5.6 in) L (SV212)......................................................................................................................................0.025 m (1 in) L (SV216)...................................................................................................................................0.040 m (1.6 in)

8-12

SECTION 8 - SPECIFICATIONS SV212 - SV216 OVERALL MACHINE DIMENSIONS (with tamping drum)

E F M B

L

C

D

A

K

G

H J

CS01C501

4 A ................................................................................................................................................2.820 m (111 in) B .............................................................................................................................................. 1.440 m (56.7 in) C .............................................................................................................................................. 0.420 m (16.5 in) D .............................................................................................................................................. 0.430 m (16.9 in) E ............................................................................................................................................ 3.030 m (119.3 in) F .............................................................................................................................................. 2.500 m (98.4 in) G............................................................................................................................................ 5.686 m (223.9 in) H .............................................................................................................................................. 2.200 m (86.6 in) J (SV212)................................................................................................................................. 2.450 m (96.5 in) J (SV216)................................................................................................................................. 2.500 m (98.4 in) K (SV212) .................................................................................................................................. 0.118 m (4.6 in) K (SV216) .................................................................................................................................. 0.142 m (5.6 in) L (SV212) .................................................................................................................................. 0.020 m (0.8 in) L (SV216) .................................................................................................................................. 0.028 m (1.1 in) M.............................................................................................................................................. 1.640 m (64.6 in)

8-13

SECTION 8 - SPECIFICATIONS SV212 - SV216 OVERALL MACHINE DIMENSIONS (with tamping drum and dozer blade)

E F D C B

L A

H

G

J

K CS01C502

5 A................................................................................................................................................ 2.820 m (111 in) B...............................................................................................................................................1.440 m (56.7 in) C ..............................................................................................................................................0.420 m (16.5 in) D ..............................................................................................................................................1.640 m (64.6 in) E............................................................................................................................................. 3.030 m (119.3 in) F...............................................................................................................................................2.500 m (98.4 in) G ............................................................................................................................................5.686 m (223.9 in) H ..............................................................................................................................................2.200 m (86.6 in) J ............................................................................................................................................. 2.950 m (116.1 in) K.............................................................................................................................................6.094 m (239.9 in) L (SV212)...................................................................................................................................0.020 m (0.8 in) L (SV216)...................................................................................................................................0.028 m (1.1 in)

8-14

SECTION 9 ALPHABETICAL INDEX A

E

Accessory functions .......................................... 2-29 Adapting the smooth drum for tamping compaction ................................................... 3-25 Air filter.............................................................. 4-26 Air filter restriction warning lamp................. 2-7, 2-13 Air vents ............................................................ 2-31 Air-conditioning ................................................. 5-21 Air-conditioning controls .................................... 2-38 Anti-freeze/Anti-corrosion .................................... 4-5 ASC differential lock - warning lamp ......... 2-10, 2-18 ASC function ..................................................... 3-14 Auxiliary lamp control ...................... 2-10, 2-14, 2-17

Electrical control for opening and closing the engine hood ............................................ 2-35 Electrical system....................................6-1, 8-1, 8-7 Emergency brake control................................... 2-23 Emergency stop control..................................... 2-23 Engine.................................................4-15, 8-1, 8-7 Engine air intake system...................................... 5-8 Engine alternator and fan belt.............................. 5-4 Engine coolant solution temperature gauge......... 2-6 Engine defect - warning lamp ............................ 2-17 Engine diagnostics ............................................ 2-12 Engine diagnostics switch.................................. 2-17 Engine emergency shut down ............................. 3-8 Engine fan ........................................................... 5-3 Engine fuse box................................................. 2-37 Engine oil ............................................................ 4-4 Engine oil pressure warning lamp........................ 2-8 Engine speed control......................................... 2-16 Engine tachometer .....................................2-6, 2-12 Engine throttle control........................................ 2-11 Engine troubleshooting...................................... 5-25 Engine valve clearance ............................5-11, 5-14 Environment ........................................................ 4-6 Equipment ..................................................8-3, 8-11

B Batteries.............................................................. 6-3 Battery charge warning lamp...................... 2-8, 2-14 Battery master switch ........................................ 2-34 Before operating the machine ............................. 3-1 Beverage holder................................................ 2-33 Booster batteries ................................................. 6-5 C Cab blower control ............................................ 2-19 Cab door ............................................................. 2-1 Cab removal and installation ............................. 3-24 Capacities .................................................... 8-1, 8-7 Cleaning the machine........................................ 5-19 Controls/Instruments/Accessories ....................... 2-1 Cooling system.................................................. 4-17 Crankcase breather tube (SV208, SV210) .......... 5-3 D Decals............................................................... 1-14 Diagnostic socket ....................................... 2-7, 2-13 Direction of travel and travel speed lever........... 2-21 Direction of travel neutral position indicator lamp ........................................ 2-7, 2-13 Dozer blade....................................................... 3-43 Dozer blade control ........................................... 2-36 Driving the machine on rough ground................ 3-22 Drum ................................................................. 4-40 Drum and wheel anti-slip control (ASC)...... 2-9, 2-15 Drum anti-slip control ................................. 2-9, 2-15 Drum vibration control ....................................... 2-21 Drum vibration frequency .................................. 5-18 Drum vibration indicator lamp..................... 2-7, 2-13 Drum vibration selector control ................... 2-8, 2-14

F Fast travel ..................................................3-9, 3-11 Filling the tires with liquid ballast........................ 3-38 Fluid and lubricant capacities............................... 4-6 Fluid and lubricant specifications ......................... 4-6 Fluids and lubricants............................................ 4-4 Front console control functions (SV208, SV210).. 2-6 Front console control functions (SV212, SV216) 2-12 Front upper control functions ............................. 2-19 Front windshield wiper ....................................... 2-32 Front windshield wiper control ........................... 2-19 Fuel ..................................................................... 4-5 Fuel filter ........................................................... 4-21 Fuel level gauge .........................................2-6, 2-12 Fuel system ....................................................... 4-20 Fuse compartment ...................................2-11, 2-17 Fuses .................................................................. 6-1 G Grease ................................................................ 4-5 Grease points ...................................................... 4-7 9-1

SECTION 9 - ALPHABETICAL INDEX

H

O

Hand signals...................................................... 1-24 Handling the machine........................................ 3-33 Hardware torque specifications.......................... 5-24 Hazard warning signal control...................2-10, 2-16 Heater control.................................................... 2-33 Heater/blower control..................................2-9, 2-15 Hood ................................................................. 3-21 Horn control..............................................2-10, 2-16 Hourmeter ...........................................2-6, 2-12, 4-1 Hydraulic fluid...................................................... 4-5 Hydraulic fluid level warning lamp...............2-8, 2-14 Hydraulic fluid replacement................................ 4-33 Hydraulic fluid temperature gauge ..............2-6, 2-12 Hydraulic oil filter restriction warning lamp ..2-7, 2-13 Hydraulic system ............................................... 4-32

Operating the machine in close proximity of building, underground conduits and cables.....................................................3-41 Operating the machine in special conditions ......3-41 Operating the machine in very dusty conditions ......................................................3-41 Operator’s compartment air intake .....................2-33 Operator’s compartment and engine hood tilting system strainer .....................................5-17 Operator’s compartment electrical tilting control ..................................................2-34 Operator’s compartment intake air dust filter (cab version)..............................5-20 Operator’s compartment lighting ........................2-29 Operator’s seat ..................................................2-24 Overall machine dimensions (with smooth drum)................................ 8-4, 8-12 Overall machine dimensions (with tamping drum and dozer blade)..... 8-6, 8-14 Overall machine dimensions (with tamping drum)............................... 8-5, 8-13

I Identification of the main components of the machine................................................. 1-5 Indicator lamp for turn indicators.................2-7, 2-13 Instrument lighting, front and rear light and front working lamp control..............2-10, 2-16 L Levels................................................................ 4-11 Location of controls, instruments and accessories .............................................. 2-2 M Machine articulation locking............................... 3-29 Machine braking warning lamp ...................2-7, 2-14 Machine travel and direction of travel (SV208, SV210) .............................................. 3-9 Machine travel and direction of travel (SV212, SV216) ............................................ 3-11 Maintenance indicator lamp ............................... 2-18 Maintenance/Adjustments ................................... 5-1 Manual pump and lever ..................................... 2-35 Maximum compacted lift thickness at optimal working conditions .................8-9, 8-10 O Operating instructions.......................................... 3-1 Operating the machine ........................................ 3-1 Operating the machine at high altitudes............. 3-41 Operating the machine at low temperatures ...... 3-41

9-2

P Parking the machine ..........................................3-15 Performance levels .................................... 8-9, 8-10 Personal safety ....................................................1-7 Planetary reduction gears ..................................4-44 Power socket .................................... 2-6, 2-13, 2-36 Preparing the machine for use at low temperatures .................................................3-41 R Radiator and oil cooler .........................................5-8 Read Operators Manual.....................................1-13 Rear view mirrors...............................................2-30 Rear windshield wiper........................................2-32 Rear windshield wiper control ............................2-19 Rear working lamp control ....................... 2-10, 2-16 Releasing the transmission and wheel hydraulic motor brakes ..................................3-35 Right, left, front and rear of the machine ..............1-3 Right-hand arm control ......................................2-20 Right-hand arm control functions .......................2-20 ROPS frame removal and installation ................3-23 Rotating beacon control ............................. 2-9, 2-15 Rotating beacon socket .....................................2-36 Run in period .......................................................3-2

SECTION 9 - ALPHABETICAL INDEX

S

V

Safety rules ......................................................... 1-6 Scrapers ........................................................... 5-23 Servicing interval table ........................................ 4-2 Servicing intervals/Lubrication/Fluids................... 4-1 Shock absorbers/Mounting blocks....................... 5-9 Shutting down the engine.................................... 3-7 Side compartment ............................................. 2-34 Slow travel with vibration .......................... 3-10, 3-12 Slow travel without vibration ..................... 3-10, 3-12 Specifications ............................................... 8-1, 8-7 Starter switch ............................................. 2-6, 2-12 Starting the engine (SV208, SV210).................... 3-3 Starting the engine (SV212, SV216).................... 3-5 Starting up after storage ...................................... 7-1 Steering ....................................................... 8-1, 8-7 Steering wheel .................................................. 2-29 Steps and access handles .................................. 2-1 Stop engine - warning lamp............................... 2-17 Storage ............................................................... 7-1 Storage box....................................................... 2-37 Storage compartment........................................ 2-29 Storage net ....................................................... 2-37 Storing the machine ............................................ 7-1 Sun visor ........................................................... 2-30

Vibration .......................................................8-2, 8-8 Vibration levels ...........................................8-3, 8-11 Vibration shock absorber ................................... 5-19 W Warning and control devices ............................... 5-1 Water in fuel - warning lamp .............................. 2-18 Weights ........................................................8-2, 8-8 Wheel replacement.............................................. 5-7 Wheels .........................................................8-1, 8-7 Windshield washer control................................. 2-19 Windshield washer reservoir.............................. 2-32 Work speed range selector................................ 2-22

T Tilting control fuse ............................................. 2-36 Tilting the operator’s compartment and hood..... 3-16 Tilting the operator’s compartment and hood using the electric hydraulic system ....... 3-19 Tire pressure....................................................... 5-6 Tires and wheels ................................................. 5-6 To the owner/safety............................................. 1-1 Towing points.................................................... 3-34 Towing the machine .......................................... 3-34 Transmission..................................................... 4-42 Transmission oil .................................................. 4-5 Transporting the machine.................................. 3-31 Travel........................................................... 8-1, 8-7 Travel over hard or compacted ground.............. 3-41 Travel speed ................................................ 8-2, 8-8 Travel speed switch .......................................... 2-22 Troubleshooting according to flashing codes (SV212, SV216)............................................ 3-13 Troubleshooting switch...................................... 2-17 Turn indicator control................................ 2-10, 2-16 Type, serial number and year of manufacture ..... 1-4 9-3

SECTION 9 - ALPHABETICAL INDEX

NOTES

9-4

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: COOLING SYSTEM Check the coolant levels.

Check for leaks.

FUEL SYSTEM

HYDRAULIC SYSTEM Check the oil level.

Replace the hydraulic oil filter.

GENERAL

Check for leaks.

Look for oil leaks and loose parts.

Drain water and sedimant from the fuel tanks.

Check tire pressure.

ELECTRICAL SYSTEM

Tighten all hose clamps.

Check battery.

Check wheel nut torque.

Check operation of starter, alerrnator, and instruments.

Check brake operation.

Check operation of all lamps.

LUBRICATION Lubricate all pivot points.

ENGINE

Check the control lever for correct operation.

SAFETY Inspect the ROPS. Check the safety decals and replace if necessary.

Check Condition of drive belt.

Check the operator restraint system.

Check engine oil level.

Make sure the machine has the operators manual in the manual storage compartment.

Check engine speed at idle and at full throttle.

Service air cleaner.

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: COOLING SYSTEM Check the coolant levels.

Check for leaks.

FUEL SYSTEM

HYDRAULIC SYSTEM Check the oil level.

Replace the hydraulic oil filter.

GENERAL

Check for leaks.

Look for oil leaks and loose parts.

Drain water and sedimant from the fuel tanks.

Check tire pressure.

ELECTRICAL SYSTEM

Tighten all hose clamps.

Check battery.

Check wheel nut torque.

Check operation of starter, alerrnator, and instruments.

Check brake operation.

Check operation of all lamps.

LUBRICATION Lubricate all pivot points.

ENGINE

Check the control lever for correct operation.

SAFETY Inspect the ROPS. Check the safety decals and replace if necessary.

Check Condition of drive belt.

Check the operator restraint system.

Check engine oil level.

Make sure the machine has the operators manual in the manual storage compartment.

Check engine speed at idle and at full throttle.

Service air cleaner.

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

CASE TECHNICAL MANUALS Manuals are available from your Dealer for the operation, service and repair of your machine. For prompt convenient service, contact your Dealer for assistance in obtaining the manuals for your machine.

Your Dealer can expedite your order for operators manuals, parts catalogs, service manuals and maintenance records.

Always give the Machine Name, Model and P.I.N. (product identification number) or S.N. (serial number) of your machine so your Dealer can provide the correct manuals for your machine

CALIFORNIA Proposition 65 Warning

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling.

NOTE: Case, LLC. reserves the right to make improvements in design or changes in specifications at any time without incurring any obligation to install them on units previously sold.

Printed in U.S.A.

CASE, LLC. 700 STATE STREET RACINE, WI 53404 U.S.A.

CNH America LLC 700 STATE STREET RACINE, WI 53404 U.S.A.

Part Number North American English Printed in U.S.A.

6-39011NA September 04 Lep