Case SV212 and SV216 Vibratory Roller Operator's Manual 6-28740NA - PDF DOWNLOAD

TABLE OF CONTENTS

SECTION 1 - TO THE OWNER/SAFETY .................................................................................................... 1-1 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 ............................................................................. 1-6 Safety rules .............................................................................................................................................. 1-7 Personal safety ......................................................................................................................................... 1-8 Read Operators Manual .......................................................................................................................... 1-14 Decals .................................................................................................................................................... 1-15 Hand signals .......................................................................................................................................... 1-22 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 ................................................................................................................ 2-6 Front upper control functions ................................................................................................................. 2-12 Right-hand arm control functions ........................................................................................................... 2-13 Operator’s seat ....................................................................................................................................... 2-16 Accessory functions ............................................................................................................................... 2-19 SECTION 3 - OPERATING INSTRUCTIONS .............................................................................................. 3-1 Before operating the machine .................................................................................................................. 3-1 Operating the machine ............................................................................................................................. 3-2 Run in period ............................................................................................................................................ 3-3 Starting the engine ................................................................................................................................... 3-4 Shutting down the engine ......................................................................................................................... 3-7 Engine emergency shut down .................................................................................................................. 3-8 Machine travel and direction of travel ...................................................................................................... 3-9 Parking the machine .............................................................................................................................. 3-12 Tilting the operator’s compartment ......................................................................................................... 3-14 Opening and closing the engine hood .................................................................................................... 3-18 Driving the machine on rough ground .................................................................................................... 3-21 ROPS frame removal and installation (optional) .................................................................................... 3-22 Cab removal and installation .................................................................................................................. 3-23 Adapting the smooth drum for tamping compaction (optional) ............................................................... 3-23 Transporting the machine ...................................................................................................................... 3-27 Handling the machine ............................................................................................................................ 3-30 Towing the machine ............................................................................................................................... 3-31 Filling the tires with liquid ballast ............................................................................................................ 3-34 Operating the machine in special conditions .......................................................................................... 3-37 Dozer blade (if fitted) .............................................................................................................................. 3-39

TABLE OF CONTENTS

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS............................................................... 4-1 Hourmeter .................................................................................................................................................4-1 Servicing interval table .............................................................................................................................4-2 Fluids and lubricants .................................................................................................................................4-4 Fluid and lubricant capacities and specifications ......................................................................................4-6 Environment .............................................................................................................................................4-6 Grease points ...........................................................................................................................................4-7 Levels .....................................................................................................................................................4-11 Engine ....................................................................................................................................................4-14 Cooling system .......................................................................................................................................4-16 Fuel system ............................................................................................................................................4-19 Air filter ...................................................................................................................................................4-24 Hydraulic system ....................................................................................................................................4-29 Drum .......................................................................................................................................................4-34 Transmission ..........................................................................................................................................4-36 Axle .........................................................................................................................................................4-38 SECTION 5 - MAINTENANCE/ADJUSTMENTS ......................................................................................... 5-1 Engine fan ................................................................................................................................................5-1 Engine alternator and fan belt ..................................................................................................................5-2 Engine air intake system ..........................................................................................................................5-5 Radiator and oil cooler ..............................................................................................................................5-5 Shock absorbers/Mounting blocks ............................................................................................................5-6 Engine valve clearance ............................................................................................................................5-8 Operator’s compartment and engine hood tilting system strainer ..........................................................5-11 Drum vibration frequency .......................................................................................................................5-12 vibration shock absorber ........................................................................................................................5-13 Cleaning the machine .............................................................................................................................5-14 Operator’s compartment intake air dust filter ..........................................................................................5-15 Scrapers .................................................................................................................................................5-18 Hardware torque specifications ..............................................................................................................5-19 Engine troubleshooting ...........................................................................................................................5-20 SECTION 6 - ELECTRICAL SYSTEM ......................................................................................................... 6-1 Fuses ........................................................................................................................................................6-1 Batteries ...................................................................................................................................................6-2 Booster batteries ......................................................................................................................................6-3 SECTION 7 - STORAGE .............................................................................................................................. 7-1 Storing the machine ..................................................................................................................................7-1

TABLE OF CONTENTS

SECTION 8 - SPECIFICATIONS ................................................................................................................. 8-1 Engine ...................................................................................................................................................... 8-1 Steering .................................................................................................................................................... 8-1 Capacities ................................................................................................................................................ 8-1 Electrical system ...................................................................................................................................... 8-1 Wheels ..................................................................................................................................................... 8-1 Travel ....................................................................................................................................................... 8-1 Travel speed ............................................................................................................................................ 8-2 Vibration ................................................................................................................................................... 8-2 Weights .................................................................................................................................................... 8-2 Performance levels (SV212) .................................................................................................................... 8-3 Maximum compacted lift thickness at optimal working conditions (SV212) ............................................. 8-3 Performance levels (SV216) .................................................................................................................... 8-4 Maximum compacted lift thickness at optimal working conditions (SV216) ............................................. 8-4 Equipment ................................................................................................................................................ 8-5 Noise and vibration levels ........................................................................................................................ 8-5 Overall machine dimensions (with smooth drum) .................................................................................... 8-6 Overall machine dimensions (with tamping drum) ................................................................................... 8-7 Overall machine dimensions (with tamping drum and dozer blade) ......................................................... 8-8 SECTION 9 - ALPHABETICAL INDEX ....................................................................................................... 9-1

TABLE OF CONTENTS

NOTES

SECTION 1

24

TO THE OWNER/SAFETY 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 using or servicing the machine before (you yourself or other people) being fully aware of the instructions given in this manual concerning safety, operation and maintenance. Use only operators who have proved their ability to operate and maintain this machine in a correct, safe manner.

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

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

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

1-2

SECTION 1 - TO THE OWNER/SAFETY

RIGHT, LEFT, FRONT AND REAR OF THE MACHINE As used in this manual, the terms "right", "left", "front" and "rear" indicate the sides of the machine as seen from the operator’s seat.

A. B. C. D.

A

FRONT REAR RIGHT-HAND SIDE LEFT-HAND SIDE

D

C

B CS00M511

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

1-4

SECTION 1 - TO THE OWNER/SAFETY

ROPS FRAME (optional)

CD00M010

5

NOISE LEVELS EXTERNAL This decal shows the value in decibels of the noise level outside the machine. See “Noise and vibration levels” in the “Specifications” Section.

CS99A856

6 INTERNAL (with door closed) This decal shows the value in decibels of the noise level inside the operator's compartment (without vibration). See “Noise and vibration levels” in the “Specifications” Section.

CS98K503

7

1-5

SECTION 1 - TO THE OWNER/SAFETY

IDENTIFICATION OF THE MAIN COMPONENTS OF THE MACHINE Model SV212 and SV216 vibratory rollers come in three different versions: - Smooth drum version - Tamping drum version - Tamping drum version with dozer blade The smooth drum version can be fitted with an optional tamping compaction attachment. See “Adapting the smooth drum for tamping compaction” in the “Operating Instructions” Section.

11

9

10

16 24

20

19

22

15

14

2 8 1

23

3

3

4

21

18

17

6

13

5

7

12

CS00M503

8 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

1-6

Drum chassis Vibratory drum Scrapers Machine articulation Machine chassis Drive axle Fuel tank Batteries ROPS frame (optional) Hydraulic reservoir Cab

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

Engine hood Engine Radiator Oil cooler Operator's compartment Travel pomp Vibration pomp Exhaust system Air filter Hydraulic oil filter Air-conditioning (optional) Dozer blade (if fitted) Tamping feet (if fitted)

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.

CS00M516

9

1-7

SECTION 1 - TO THE OWNER/SAFETY

PERSONAL SAFETY Safety Decals on this machine use the words Danger, Warning or Caution, which are defined as follows:

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

• The first panel indicates the nature of the hazard.

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

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

1-8

as

and

SECTION 1 - TO THE OWNER/SAFETY

BEFORE USING THE MACHINE 1.

2.

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

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

3.

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

4.

Operating the machine requires your full attention, and caution on the part of the operator can avoid accidents. Get to know the abilities and the limitations of the machine and also the space required for its operation. There are some areas of poor visibility within the working range of the machine. Have someone guide you for all work where visibility is not perfect.

5.

Grease, oil, mud or (in winter) 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.

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 and fire extinguisher within easy reach on board. Make sure the fire extinguisher is regularly serviced in conformity with the manufacturer’s instructions.

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

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

1-9

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.

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

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

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.

1-10

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 fitted).

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

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

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

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

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

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.

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.

1-11

SECTION 1 - TO THE OWNER/SAFETY

MAINTENANCE AND ADJUSTMENTS 1.

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

3.

When servicing the machine wear suitable clothing.

4.

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

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 (optional) 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 fitted).

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.

1-12

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.

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 with water.

INTERNAL: drink large amounts of water or milk.

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

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

2.

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

19. It is mandatory to observe the instructions and the servicing intervals for the fire extinguisher.

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.

3.

Always use a non-inflammable solvent for cleaning parts.

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

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

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

ROPS PROTECTIVE STRUCTURE (optional) 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.

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 inflammable gases, make sure that there is adequate ventilation.

5.

Make sure there is always a fire extinguisher within easy reach on board the machine. Make sure the fire extinguisher is regularly serviced in conformity with the manufacturer’s instructions.

6.

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

7.

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

1-13

SECTION 1 - TO THE OWNER/SAFETY

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

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

BC00G075

12

1-14

SECTION 1 - TO THE OWNER/SAFETY

DECALS

!

!

WARNING

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

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

Never use solvents, petrol, etc.

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

3

9 10 11

1

12 13 14

2

16 4

7 5

6

15

17

8

CS00M503

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

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

1-15

SECTION 1 - TO THE OWNER/SAFETY

BASIC READ OPERATOR’S MANUAL

1

Left front of steering column.

Part number : 382622A1

382622A1

14 ROLL OVER/USE SEAT BELT

2

Left front of steering column.

Part number : 321-7030

3217030

15 EMERGENCY EXIT

3

Left front top corner of right door.

Part number: 329051A1

329051A1

16

1-16

SECTION 1 - TO THE OWNER/SAFETY

GENERAL HAZARDOUS AREA

4

Left/right rear sides drum structure.

Part number : 283606A1

283606A1

17 CRUSH-BLADE LOCK (IF FITTED)

5

Left/right front sides drum structure.

Part number : CV003

CV003

18 BASIC CRUSH HAZARD

6

Move to chassis above articulation joint both sides of machine.

Part number : 323694A1

323694A1

19

1-17

SECTION 1 - TO THE OWNER/SAFETY

CRUSH HAZARD STEERING LOCK LINK

7

Left/right sides chassis.

Part number : CV006

CV006

20 CRUSH HAZARD PIVOT LOCK

8

Left/right sides chassis.

Part number : CV005

CV005

21 DO NOT WELD ON MACHINE

9

Inside left access door.

Part number : CV002

CV002

22

1-18

SECTION 1 - TO THE OWNER/SAFETY

HOT SURFACE HAZARD

10

Inside left access door.

Part number : 283608A1

283608A1

23 BASIC REMOVE KEY/READ SERVICE MANUAL

11

Inside left access door.

Part number : CV004

CV004

24 ENTANGLEMENT HAZARD FAN

12

Both sides of radiator support.

Part number : 332512A1

332512A1

25

1-19

SECTION 1 - TO THE OWNER/SAFETY

ENTANGLEMENT HAZARD BELT

13

Both sides of radiator support.

Part number : 388112A1

388112A1

26 HOT LIQUID HAZARD

14

Both sides of radiator support.

Part number : 384258A1

384258A1

27 STARTER - START FROM SEAT

15

Frame edge next to starter.

Part number : 321-7040

3217040

28

1-20

SECTION 1 - TO THE OWNER/SAFETY

RUNOVER HAZARD

16

Rear, slightly left of hitch.

Part number : CV001

CV001

29 BATTERY EXPLOSION/SERVICE

17

On battery mounting plate centered between batteries.

Part number : 412471A1

412471A1

30

1-21

SECTION 1 - TO THE OWNER/SAFETY

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

START THE ENGINE

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

PDE0002A

SHUT DOWN THE ENGINE

31

PDE0003A

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

PDE0002

32 PDE0003

34

1-22

SECTION 1 - TO THE OWNER/SAFETY

GO THIS FAR

EMERGENCY STOP Wave hands back and forth.

PDE0004A

35 ALL STOP AND HOLD

PDE0005

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

PDE0004

36 STOP Wave hands back and forth.

PDE0008A

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

PDE0005A

37 PDE0008

40

1-23

SECTION 1 - TO THE OWNER/SAFETY

NOTES

1-24

SECTION 2

28

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 it and use the steps and access handles. Keep the steps and access handles clean and remove all traces of grease, oil, mud and (in winter) ice.

D F CS00M503

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.

2

8

11

10

4

12 13 14

15 16 17

3

28

6 5

19A 19

26

20

25 18

24

23 63

64 22

1 27

21

7 9

38

40

35

39

34 62 37 36 33

CS00M504

4

2-2

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES 1. Starter switch

21. Rotating beacon control (optional)

2. Fuel level gauge

22. Hazard warning signal control

3. Engine coolant solution temperature gauge 4. Engine tachometer

23. Instrument lighting, front working lamp and front and rear position light control

5. Hydraulic fluid temperature gauge

24. Rear working lamp control

6. Hourmeter

25. Horn control

7. Power socket

26. Turn indicator control

8. Diagnostic socket

27. Engine throttle control

9. Indicator lamp for turn indicators

28. Fuse compartment

10. Air filter restriction warning lamp

33. Right-hand control arm

11. Hydraulic oil filter restriction warning lamp

34. Direction of travel and travel speed lever

12. Direction of travel neutral position indicator lamp

35. Drum vibration control

13. Drum vibration indicator lamp

37. Selector for slow speed ranges

14. Machine braking warning lamp

38. Emergency stop control

15. Hydraulic fluid level warning lamp

39. Operator’s seat

16. Battery charge warning lamp

40. Steering wheel

17. Engine oil pressure warning lamp

62. Emergency brake control

18. Drum vibration selector control

63. Dozer blade control (if fitted)

19. Drum anti-slip control

64. Auxiliary lamp control

36. Speed type control

19A.Differential locking control (optional) 20. Heater/ventilation control

2-3

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES

45

42

29

30

31

43

32

44

44 41

CS00M506

5

53

48

47 49

63

39

52 50

46

51 39A

46 55

58 54 CS00M505

65

57 59

56

60 6

2-4

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES 29. Front windshield wiper control

51. Beverage holder

30. Rear windshield wiper control

52. Heater control

31. Cab blower control

53. Operator’s compartment air intake

32. Windshield washer control

54. Side compartment

39. Operator’s seat

55. Battery master switch

39A.Operator’s seat pivoting lever

56. Operator’s compartment tilting control

41. Operator’s compartment lighting

57. Engine hood opening/closing control

42. Storage compartment

58. Emergency pump lever

43. Sun visor

59. Emergency pump

44. Rear view mirrors

60. Tilting control fuse

45. 46. Air vents

63. Dozer blade control (if fitted)

47. Front windshield wiper

65. Storage net

48. Rear windshield wiper 49. Windshield washer reservoir 50. Fire extinguisher

2-5

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

3

4

6

5

1 CS00M512

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 the "Operating Instructions" Section.

NOTE: This key is also used to lock the cab doors and the side compartment door (54).

IMPORTANT: Before starting the engine, make sure that the direction of travel lever (34) 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

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 throttle control (27).

5. HYDRAULIC FLUID TEMPERATURE GAUGE The hydraulic fluid temperature when working should be between 50°C (122°F) and 60°C (140°F). The minimum permitted temperature is 25°C (77°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 Intervals/ Lubrication/Fluids" Section.

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES

10

8

7

9

12

11 13

CS00M512

8

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

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

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.

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 the "Servicing Intervals/ Lubrication/Fluids" Section.

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 the "Servicing Intervals/ Lubrication/Fluids" Section.

12. DIRECTION OF TRAVEL NEUTRAL POSITION INDICATOR LAMP This indicator lamp comes on when the direction of travel lever (34) 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 (35) is operated. See "Right-hand arm control functions".

2-7

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES

16

14

15

17

CS00M512

9

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 (34). When the direction of travel lever is in the "0" position (Neutral) this warning lamp comes on after 2 seconds and the machine brakes are automatically applied. When the direction of travel lever (34) 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 (38) and the emergency brake control (62) 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 the "Servicing Intervals/Lubrication/Fluids" Section.

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

2-8

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 (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 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 (1) and find the cause of the problem.

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.

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES

18

20

19 19A

CS00M512

10

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 (35), see "Right-hand arm control functions".

19. DRUM ANTI-SLIP CONTROL This two-position control is used to select the drum anti-slip function. When the switch is pushed forwards, the drum anti-slip function is inoperative. When the switch is pressed backwards, the anti-slip function is obtained and the switch lights up.

IMPORTANT: This control should only be used when the machine is being loaded onto a trailer. See "Transporting the machine" in the "Operating Instructions" Section. Before engaging the drum anti-slip function, make sure the speed type control (36) is in low speed position and never use the drum vibration control (35) to engage drum vibration.

19A.DIFFERENTIAL LOCKING CONTROL (OPTIONAL) This two-position control is used to lock or unlock the differential. When the switch is pushed forward the differential is unlocked. When the switch is pushed backwards, the differential is locked. In the differential locked position, this switch lights up. See "Operating the machine on rough ground" and "Transporting the machine" in the "Operating Instructions" Section.

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 (52). See "Accessory functions".

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

2-9

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES

21 22

23

24

CS00M512

11

21. ROTATING BEACON CONTROL (OPTIONAL) This two-position control is used to switch the rotating beacon 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 “Power socket”.

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.

2-10

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.

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES

28

26

27

64

25

CS00M512

12

25. HORN CONTROL When this switch is pressed and held completely backwards, 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 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.

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

64. 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.

2-11

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES FRONT UPPER CONTROL FUNCTIONS 29

30

31

32

CS00M507

13

29. 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.

30. 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.

31. CAB BLOWER CONTROL This is a four-position control used to operate the cab blower.

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

(2): Medium.

(3): Fast.

!

WARNING

!

The lower supplies fresh air from the outside. Use the blower to ventilate the cab when the windows are closed.

32. 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.

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

2-12

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES RIGHT-HAND ARM CONTROL FUNCTIONS 33. 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 lever located at the front of the arm. 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.

33

34

!

WARNING

!

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.

CS00M514

14 34. 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 "0" position (Neutral), 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 (36) and (37). 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.

IMPORTANT: When the lever is in the "0" (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.

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

NOTE: To start the engine, it is imperative for the lever (34) to be in the "0" (Neutral) position, otherwise starting is impossible. See "Starting the engine" in the "Operating Instructions" Section.

2-13

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES

35. 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".

35

36

IMPORTANT: To engage vibration, the lever (34) has to be operated. It is not possible to engage vibration if the lever (34) is in the "0" (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", item 27.

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

CS00M514

15

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

36.TYPE OF SPEED CONTROL 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 (37), depending on the work which has to be carried out.

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

Once the type of speed has been defined, use the lever (34) to move the machine. Note that the travel speed also depends on the angle to which the lever (34) 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.

2-14

!

WARNING

!

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.

!

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.

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES 37. LOW 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 (36) is in the "Low speed" position.

See "Travel speed" in the "Specifications" Section 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 (34) to move the machine. Note that the travel speed also depends on the angle to which the lever (34) is tilted.

38

37

62

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

CS00M514

16 38. 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 (1) is impossible or if there is an operating problem with the direction of travel lever (34). 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 (1), see "Engine emergency stop" in the "Operating Instructions" Section.

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

NOTE: To start the engine, it is essential for the button (38) to be in the raised position, otherwise it is impossible to start. See "Starting the engine" in the "Operating Instructions" Section.

62. 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 moving backwards). Place the direction control lever (34) 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 (34) is operated.

2-15

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES OPERATOR’S SEAT For correct operation of the machine with maximum efficiency and comfort, adjust the seat (39) 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 ADJUSTING THE SUSPENSION Pull the lever forward to reduce the hardness of the suspension. Push the lever backwards to increase the hardness of the suspension.

CI01C503

17 ADJUSTING THE FORE AND AFT POSITION Pull the control upwards, hold it there, slide the seat to the chosen position, then release the control.

CI01C504

18 ADJUSTING THE ANGLE OF THE SEAT BACK To change the angle of the seat back, hold the lever up while moving with the seat back to the desired position, then release the lever.

CI01C505

19

2-16

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES ADJUSTING THE LUMBAR SUPPORT Turn the knob to obtain good support for your back.

CI01C506

20 ADJUSTING THE ANGLE OF THE ARM RESTS Raise the arm rest, turn the knob to reach the desired angle, then lower the arm rest.

CI01C507

21 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

22

!

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.

2-17

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES PIVOTING LEVER 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 (39A) and then pivot the seat to the right until the lever engages. Carry out the same procedure to return it to the driving position.

39A

CI01C509

23

2-18

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES ACCESSORY FUNCTIONS STEERING WHEEL The steering wheel (40) 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.

40

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

CS00M504A

24 OPERATOR’S COMPARTMENT LIGHTING Located at the upper front right-hand side of the operator’s compartment, the lighting (41) is controlled by a switch incorporated in the lamp base.

41

CS00M506

25 STORAGE COMPARTMENT Located at the upper front left-hand side of the operator’s compartment, this storage compartment (42) 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.

42

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

CS00M506

26

2-19

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES SUN VISOR Attached to the windshield, the sun visor (43) can easily be positioned as required.

43

CS00M506

27 REAR VIEW MIRRORS The rear view mirrors (44) 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.

44

CD00M001

28

2-20

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 (45) and (46) are for the circulation and orientation of the airflow. The vents are opened and closed manually.

45

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

CS00M506

29

46 CS00M505

30 FRONT WINDSHIELD WIPER The front windshield wiper (47) is controlled by the switch (29). See "Front upper control functions".

47

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

CS00M505

31

2-21

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES REAR WINDSHIELD WIPER The rear windshield wiper (48) is controlled by the switch (30). See "Front upper control functions".

48

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

CS00M505

32 WINDSHIELD WASHER RESERVOIR Located at the rear of the operator’s compartment, this reservoir (49) has two electric pumps controlled by the switch (32). 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.

49 CS00M505

33 FIRE EXTINGUISHER Located at the rear of the operator’s compartment, study the operation of the fire extinguisher (50) as soon as you receive the machine. The operating instructions are shown on the fire extinguisher body.

Every month: examine the fire extinguisher and make sure that it is not damaged.

50

Every six months: have the powder removed and have the fire extinguisher refilled by an approved specialist.

Every year: have the fire extinguisher examined by an approved specialist.

CD00M002

34

!

WARNING

!

Observe the instructions and the maintenance intervals for the fire extinguisher.

2-22

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES BEVERAGE HOLDER Located at the rear of the operator’s compartment, the beverage holder (51), when opened, can be used for holding cups, bottles, etc.

51

CD00M002

35 HEATER CONTROL

52

Located on the left of the operator’s seat, and to the rear, the control (52) 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

!

36

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 (53) 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 the "Maintenance/Adjustments" Section.

53

CD00M505

37

2-23

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES SIDE COMPARTMENT Located on the left-hand side of the machine, the compartment (54) gives access to the battery master switch (55) and to the tilting controls (56, 57) 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.

54 CD00M505

38

BATTERY MASTER SWITCH Located in the side compartment, the battery master switch (55), when tilted to the right "0", completely disconnects the batteries from the electrical system (system switched off). In the "1" position, the system is switched on.

55

!

WARNING

!

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

CD00M004

39

OPERATOR’S COMPARTMENT TILTING CONTROL Located in the side compartment, this three-position control (56) 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 "0"). Press and hold the bottom of the switch to return the operator’s compartment to the normal position. To carry out this operation, see "Tilting the operator’s compartment" in the "Operating Instructions" Section.

56 CD00M004

!

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 (58) and the pump (59).

See "Tilting the operator’s compartment" in the "Operating Instructions" Section.

2-24

40

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES CONTROL FOR OPENING AND CLOSING THE ENGINE HOOD Located in the side compartment, the control (57) has three positions. Press and hold the top of the switch, the hood opens. To stop the movement, release the switch (central position "0"). Press and hold the bottom of the switch, the hood closes.

To carry out this operation, see "Opening and closing the engine hood" in the "Operating Instructions" Section.

!

WARNING

!

57

CD00M004

41

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 (58) and the pump (59). See "Opening and closing the engine hood" in the "Operating Instructions" Section.

EMERGENCY LEVER AND MANUAL PUMP Located in the side compartment, the lever (58) and the manual pump (59) are to be used in the event of an operating problem with the tilting controls (56) and (57). See "Tilting the operator’s compartment" and "Opening and closing the engine hood" in the "Operating Instructions" Section.

58

59

CS00M505

42

2-25

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES TILTING CONTROL FUSE Located in the side compartment, the 50 amp fuse (60) protects the tilting controls (56) and (57).

IMPORTANT: Before changing a fuse, place the battery master switch (55) in the "0" position (system switched off).

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

60 CS00M505

43 POWER SOCKET This socket may be used for connecting a rotating beacon (optional) or an inspection lamp.

CD01A005

44 DOZER BLADE CONTROL (if fitted)

III

This lever (63) has four positions: (0) Neutral position (dozer blade stops moving).

(I) Dozer blade lowers.

(II) Dozer blade rises.

(III) Dozer blade is in floating position.

I

0 II

63

The dozer blade will stop moving as soon as the lever (63) is released. The lever automatically returns to neutal position (0) upon release, except when it is in position (III). See “Dozer blade” in the “Operating Instructions” Section.

CS00M505

45

!

WARNING

!

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

2-26

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES STORAGE NET

65

The net (65) is for operator’s personal items.

CD01C169

46 AIR-CONDITIONING CONTROLS (optional) Two controls are used to operate the air-conditioning system.

Control (22A) 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.

Control (22) is used to turn on the air-conditioning and regulate the air flow.

22A

22

This control has four positions: “0”: Off “1”: Low air flow “2”: Medium air flow “3”: High air flow

CD00N011

47

The air-conditioning system will only work while the engine is running, with the heater control (52) in lowered position. The air vent (45, 46) must be open and the cab doors must be closed.

Turn control (22) to one of the three positions and then select the required temperature by turning control (22A). To switch the air-conditioning system off, turn control (22) to “0” position.

NOTE: It is not necessary to alter the position of control (22A) 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 the “Maintenance/Adjustments” Section.

2-27

SECTION 2 - CONTROLS/INSTRUMENTS/ACCESSORIES

NOTES

2-28

SECTION 3

42

OPERATING INSTRUCTIONS BEFORE OPERATING THE MACHINE

!

WARNING

!

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

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

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 the "Servicing Intervals/ Lubrication/Fluids" Section.

2.

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

3.

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

4.

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

5.

Check the correct operation of the windshield wipers.

6.

Check the condition and pressure of the tires.

See "Tires and wheels" in the "Maintenance/ Adjustments" Section.

7.

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

8.

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

9.

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

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. Make yourself aware of the possibilities for evacuating the machine (emergency exit via the lefthand door) in the event that access via the righthand 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. Make yourself 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.

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

3-1

SECTION 3 - OPERATING INSTRUCTIONS OPERATING THE MACHINE

!

WARNING

!

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

When operating the machine observe the following instructions: 1.

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

2.

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

3.

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

4.

5.

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

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.

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

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

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

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

16. Never work with the engine hood open.

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

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

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

20. Avoid running the engine in a confined space. 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.

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.

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.

7.

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

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

8.

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

9.

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

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

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

3-2

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

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

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

27. 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.

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

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

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

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

Check the oil levels and coolant solution levels frequently.

After the first 100 hours Change the oil in the transmission. See “Transmission” in the “Servicing Intervals/Lubrication/Fluids” Section.

Change the oil in the axle. See “Axle” in the “Servicing Intervals/Lubrication/Fluids” Section.

3-3

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

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

1.

Place the battery master switch (55) in the "I" position (system switched on).

55

CD00M004

1 2.

3.

Sit correctly in the operator’s seat (39), check that it is correctly locked in the driving position and fasten your seat belt. See "Operator’s seat" in the "Controls/Instruments/Accessories" Section.

39

Place the right-hand arm (33) in the lowered position.

IMPORTANT: If the arm (33) is not in the lowered position, it is impossible to start the engine.

33 CS00M504A

2 4.

Turn the starter switch key (1) to the "On" position and make sure that the battery charge (16) and engine oil pressure (17) warning lights are on.

16

1

17

CS00M512

3

3-4

SECTION 3 - OPERATING INSTRUCTIONS 5.

Make sure that the direction of travel lever (34) is in the neutral position, with the indicator lamp (12) on the front console alight and the emergency stop button (38) in the raised position.

38 34

IMPORTANT: If the lever (34) is not in the neutral position or if the button (38) is lowered, it is impossible to start the engine.

CS00M514

4 6.

Move the engine throttle lever (27) one quarter of its stroke.

27 CS00M512

5 7.

Make sure that no-one is in the vicinity of the machine, and sound the horn (25) as a safety measure.

25 CS00M512

6

3-5

SECTION 3 - OPERATING INSTRUCTIONS 8.

Turn the key (1) to the 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.

16

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 (16) and engine oil pressure (17) warning lamps go out.

1

17

CS00M512

7 10. Move the engine throttle lever (27) so that the tachometer needle (4) is between 1300 and 1500 rpm.

4

27 CS00M512

8 11. Allow the engine to run until it reaches normal operating temperature. The needle on the temperature gauge (3) should show at least 45°C (113°F).

3

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

CS00M512

9

3-6

SECTION 3 - OPERATING INSTRUCTIONS SHUTTING DOWN THE ENGINE 1.

2.

If drum vibration is being used, press the push button (35) to stop it and check that the indicator lamp (13) on the front console is out.

35

Place the direction of travel lever (34) in the "0" position (neutral) and make sure that the indicator lamp (12) on the front console has come on.

34

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

CS00M514

10 3.

Place the engine throttle lever (27) in the idle speed position.

4.

Run the engine at idle for about 1 minute.

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

5.

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

1 27 CS00M512

11 6.

If you have to leave the operator’s compartment, raise the arm (33) and remove the starter switch key (1).

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

33

CD01C128

12

3-7

SECTION 3 - OPERATING INSTRUCTIONS ENGINE EMERGENCY SHUT DOWN In the event of emergency, or if it is impossible to shut down the engine by means of the starter switch key (1), or if an operating problem with the direction of travel lever (34) occurs, immediately press the button (38). The engine will stop, the machine’s brakes are automatically applied and the indicator lamp (14) on the front console comes on.

34 38

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 (38) in the direction of the arrow, make sure that the direction of travel lever (34) 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 (38) to be in the raised position, otherwise it is impossible to start.

3-8

CS00M514

13

SECTION 3 - OPERATING INSTRUCTIONS MACHINE TRAVEL AND DIRECTION OF TRAVEL Before any travel, make sure that no obstacle or person is in front of or behind the machine and make sure also that 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 that it is locked mechanically (if fitted).

In the event of poor visibility, use the controls (23) and (24) 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 (36) showing the "Hare" symbol.

2.

Make sure, by means of the control (35) that drum vibration is switched off (the indicator lamp (13) on the console should be out).

35

IMPORTANT: Never operate the control (35) when in high speed.

36

CS00M514

14 3.

Use the lever (27) to increase engine speed.

27 CS00M512

15

3-9

SECTION 3 - OPERATING INSTRUCTIONS 4.

Move the machine forwards or in reverse by means of the direction of travel lever (34). The indicator lamp (12) on the front console will go out.

34

NOTA: Travel speed depends on the angle to which the lever (34) is tilted. It can be released at any time and will remain in position at the chosen speed.

5.

Steer the machine by means of the steering wheel (40).

IMPORTANT: Do not use the engine throttle control lever (27) to increase travel speed.

6.

To stop travel, place the lever (34) in the neutral position; the indicator lamp (12) on the front console will come on. After 2 seconds, the machine’s brakes are automatically applied and the indicator lamp (14) also comes on. If necessary, shut down the engine, see "Shutting down the engine".

CS00M514

16

IMPORTANT: During machine travel never tilt the switch (36) 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 (36).

2.

Choose one of the three speed ranges to suit the type of work to be carried out, using the selector (37).

3.

36

Carry out Steps 2 to 6 in "High speed travel".

37

NOTE: During travel, it is possible at any time, if conditions so permit, to change to high speed by means of the switch (36).

CS00M514

17

3-10

SECTION 3 - OPERATING INSTRUCTIONS 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 (18).

18

CS00M512

18 3.

Place the engine throttle lever (27) in the maximum speed position.

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

27 CS00M512

19 4.

Set the machine in motion by means of the direction of travel lever (34); the indicator lamp (12) on the front console will go out. Then operate the push-button (35); the indicator lamp (13) on the front console will come on and the drum will begin to vibrate.

35 34

NOTE: The speed of travel depends on the angle to which the lever (34) is tilted. It can be released at any time and it will remain in position at the chosen speed.

5.

6.

To stop drum vibration, press the push button (35) again. The indicator lamp (13) on the front console will go out.

Carry out Steps 5 and 6 of "High speed travel".

CS00M514

20

3-11

SECTION 3 - OPERATING INSTRUCTIONS PARKING THE MACHINE 1.

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

2.

Place the drum in line with the machine.

3.

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

4.

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

5.

Shut down the engine, see "Shutting down the engine" and remove the starter switch key (1).

1 CS00M512

21 6.

It is mandatory to raise the right-hand arm (33).

33

CD01C128

22 7.

Operate the lever (39A) to unlock the operator seat pivot (39) and pivot the seat to the right until it engages. Leave the operator’s compartment.

!

WARNING

39

!

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.

39A

CS00M516

23

3-12

SECTION 3 - OPERATING INSTRUCTIONS 8.

Switch off the electrical system by means of the battery master switch (55).

9.

Make sure the engine hood is correctly locked, then lock the doors of the cab and the side compartment (54).

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

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

55

CD00M004

24

3-13

SECTION 3 - OPERATING INSTRUCTIONS TILTING THE OPERATOR’S COMPARTMENT The operator’s compartment can be tilted forward in order to provide access to some of the machine’s components.

!

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.

TILTING FORWARDS 1.

Unscrew the operator’s compartment rear retaining nuts.

CD00M006A

25 2.

Open the side compartment door (54).

54 CS00M505

26

3-14

SECTION 3 - OPERATING INSTRUCTIONS 3.

Place the battery master switch (55) in the "I" position (system switched on).

4.

Press and hold down the top of the switch (56) until the operator’s compartment is completely tilted, then release the switch (56).

NOTE: The movement can be stopped at any time by releasing the switch (56).

5.

55

If necessary, place the battery master switch (55) in the "0" position (system switched off) and close the side compartment door (54).

CD00M004

56 27

TILTING BACKWARDS 1.

Open the side compartment door (54) and make sure the battery master switch (55) is in the "I" position (system switched on).

2.

Press and hold down the bottom of the switch (56) until the operator’s compartment is totally resting on the machine, then release the switch (56).

55

NOTE: The movement can be stopped at any time by releasing the switch (56).

3.

4.

If necessary, place the battery master switch (55) in the "0" position (system switched off) and then close the side compartment door (54).

56 CD00M004

28

Screw down and tighten the operator’s compartment rear retaining nuts.

IMPORTANT: It is mandatory to ensure that the operator’s compartment is correctly fastened down before using the machine. If this is not done and the machine rolls over a fatal accident could be caused.

CD00M006A

29

3-15

SECTION 3 - OPERATING INSTRUCTIONS NOTA: This operation is protected by the 50 amp fuse (60).

60

CS00M505

30 MANUAL TILTING If an operating failure occurs, it is, nevertheless, possible to tilt the operator’s compartment manually.

1.

Remove the lever (58) from under the operator’s seat.

58

CS00M505

31 2.

Install the lever (58) in the hand pump (59).

59

CD01C170

58 32

3-16

SECTION 3 - OPERATING INSTRUCTIONS 3.

Use the locking device (D) and clip (E) to lock the valve spool (C) either in: (A) corresponding to rearward tilting of the operator’s compartment.

(B) corresponding to forward tilting of the operator’s compartment.

4.

Using the lever (58), pump manually in both directions.

5.

Once the operation is completed, remove the clip (E) and locking device (D).

6.

Remove and put back the lever (58).

A C D

E CD01C171

33

B

E

C

D

CD01C172

34

3-17

SECTION 3 - OPERATING INSTRUCTIONS OPENING AND CLOSING THE ENGINE 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.

OPENING 1.

Open the side compartment door (54).

54 CS00M505

35 2.

Place the battery master switch (55) in the "I" position (system switched off).

3.

Press and hold the top of the switch (57) until the hood opens completely, then release the switch (57).

57

NOTE: The movement can be stopped at any time by releasing this switch (57).

4.

55

If necessary, place the battery master switch (55) in the "0" position and then close the side compartment door (54).

CD00M004

36

3-18

SECTION 3 - OPERATING INSTRUCTIONS CLOSING 1.

Open the door of the side compartment (54) and make sure that the battery master switch (55) is in the "I" position (system switched on).

2.

Press and hold down the bottom of the switch (57) until the hood closes completely, the release the switch (57).

NOTA: The movement can be stopped at any time by releasing the switch (57).

3.

55

If necessary, place the battery master switch (55) in the "0" position (system switched off) and then close the door of the side compartment (54).

57 CD00M004

37 NOTA: This operation is protected by the 50 amp fuse (60).

60

CS00M505

38 MANUAL OPENING AND CLOSING If an operating failure occurs, it is, nevertheless possible to open or close the hood manually.

1.

Remove the lever (58) from under the operator’s seat.

58

CS00M505

39

3-19

SECTION 3 - OPERATING INSTRUCTIONS 2.

Install the lever (58) in the hand pump (59).

59

58 CD01C170

40 3.

Use the locking device (J) and clip (K) to lock the valve spool (H) either in: (F) Corresponding to engine hood opening.

(G) Corresponding to engine hood closing.

4.

Using the lever (58), pump manually in both directions.

5.

Once the operation is completed, remove the clip (K) and locking device (J).

6.

Remove and put back the lever (58).

F

H

K

J CD01C173

41

G K H

J CD01C174

42

3-20

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 prevent this phenomenon, switch on the differential locking control (if fitted).

Press the rear of the switch (19A), this will activate the differential lock and the switch (19A) will light up. To unlock the differential, press the front of the switch (19A), and the switch light will go out.

19A

IMPORTANT: The differential lock can only be engaged during slow travel.

!

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.

CS00M512

43

IMPORTANT: If it is necessary to apply the machine’s brakes immediately (for example, on a slope), place the direction of travel lever (34) in neutral position and then press the emergency brake switch (62).

34

62 CS00M514

44

3-21

SECTION 3 - OPERATING INSTRUCTIONS ROPS FRAME REMOVAL AND INSTALLATION (optional)

!

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 (1).

2.

Screw the two lifting eyes (A) into the top of the ROPS frame (9).

3.

Secure the slings to the lifting eyes (A).

4.

Remove the 16 mounting screws and washers (B).

5.

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

6.

Carefully raise and remove the ROPS frame (9) and then lower it gently to the ground.

A

9

B

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 (9) around the cab.

3.

Install and tighten the 16 mounting screws and washers (B) to a torque of 549 Nm (4854 in lb).

4.

Remove the slings and lifting eyes (A).

3-22

CS00N509

45

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

REMOVAL 1.

Remove the lower cab mounting hardware.

2.

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

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.

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 (3) and clean the drum surface.

3.

Use lifting equipment with hooks and chains.

3

3

CS00M503

46

3-23

SECTION 3 - OPERATING INSTRUCTIONS 4.

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

5.

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

47 6.

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).

7.

Remove the hooks (A) from the first segment.

8.

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

48 9.

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

A

CD00N002

49

3-24

SECTION 3 - OPERATING INSTRUCTIONS 10. 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

50 11. 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).

E C

12. 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.

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

B

D C CD00N004

51

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

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

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

17. 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.

18. 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).

3-25

SECTION 3 - OPERATING INSTRUCTIONS 19. Install all the fastening hardware on the third segment, making sure there is a gap of 26 mm (1.02 in) between each segment.

20. Remove all the fixing clamps (B).

21. Tighten all hardware to a torque of 314 Nm (2776 in lb).

CD00N004

52 22. Use the fastening hardware from the scrapers already removed to install the special scrapers (3) supplied with the segments. Tighten the hardware to a torque of 314 Nm (2776 in lb).

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

REMOVAL 1.

Remove the special scrapers (3).

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 (2776 in lb).

3-26

3

3

CS00M503

53

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 (19) or, if fitted, the differential lock (19A) and make sure drum vibration is disengaged.

5.

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

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 (1) and raise the right-hand control arm (33).

9.

Make sure the doors and hood are properly locked.

CD95M248

54

10. Fold the rear view mirrors (44) inwards.

3-27

SECTION 3 - OPERATING INSTRUCTIONS 11. 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

55 12. 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

56 13. Use blocks and chains to fasten the machine to the trailer.

14. 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.

3-28

CS00N510

57

SECTION 3 - OPERATING INSTRUCTIONS UNLOADING 1.

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

2.

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

58 3.

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).

4.

Adjust the rear view mirrors (44).

5.

Lower the right-hand control arm (33), make sure all controls are in neutral and start the engine.

6.

Make sure the drum anti-slip function (19), or, if fitted, the differential lock (19A) is engaged.

7.

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

8.

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

9.

Release the dozer blade if necessary (if fitted).

A

B E D CS00N511

59

10. Disengage the drum anti-slip function (19), or, if fitted, release the differential lock (19A).

3-29

SECTION 3 - OPERATING INSTRUCTIONS HANDLING THE MACHINE

!

WARNING

!

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

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

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

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

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

A

A

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

NOTA: The values followed by an asterisk on this illustration are for the SV216 model.

3-30

CS00N513

60

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. The manufacturer’s warranty does not apply to incidents or accidents which occur during towing. Where possible, carry out the repairs at the site. The machine must be towed very slowly, over a short distance and only if it is really unavoidable. 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, caravans, tank, etc.

CD00N005

61

CD00N006

62

3-31

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

1.

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

C

B

A

CD00N007

63 2.

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

D E

CD00N008

64 3.

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

D E

A

CD00N009

65

3-32

SECTION 3 - OPERATING INSTRUCTIONS 4.

It is now necessary to short-circuit the travel circuit. The travel pump has two multi-purpose main relief valves. Use a 27 mm (11/16") hex. wrench to unscrew the center body of each valve (F) three complete turns counterclockwise.

5.

Turn the starter switch key (1) to the “1” (contact) position.

6.

Mount the emergency hand pump lever on the emergency hand pump and operate the pump until the brake warning lamp (14) on the front console goes out. The brakes are then released and the machine may be towed.

NOTA: Because of possible leaks, pressure in the brake lines may drop while towing is in process. If the brake warning light (14) comes on, renew the pressure.

!

WARNING

F

F

CD00N010

66

!

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.

7.

Once the towing operation is completed, return all hoses to their original position and put the lever back under the operator’s seat.

3-33

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 slaked lime and unslaked calcium chloride (CaCl2) or magnesium chloride (MgCl2). See the table below giving the quantities to be used for preparing 100 litres of solution.

Solution volume

Unslaked calcium chloride

Slaked lime

Water

Freezing point

Added weight

Litres (gal US)

Kg (lb)

Kg (lb)

Litres (gal US)

°C (°F)

Kg (lb)

100 (26.4)

23.6 (52.1)

0.42 (0.92)

90 (23.8)

-18 (0)

114 (251.5)

100 (26.4)

27.8 (61.4)

0.48 (1.0)

90 (23.8)

-25 (-13)

118 (260.5)

100 (26.4)

30.8 (68)

0.50 (1.1)

90 (23.8)

-30 (-22)

121 (267)

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

!

Always add the calcium chloride to the water, never the opposite.

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.

3-34

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 the filler hose supplied in place of the plug (B).

7.

Place the container or filler pump at a higher level and commence the filling operation. The total amount of liquid ballast to add per tire is 508 litres (133.9 gal US).

8.

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

9.

Repeat the filling operation for the other tire.

B A

CD00N020

67

10. Remove the dust cap from the valve (A) and then inflate the tire to the recommended pressure. See “Tire pressures” in the “Maintenance/Adjustment” Section. Install the dust cap.

11. Inflate the other tire.

12. Reinstate the wheel hydraulic motor braking system.

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

In countries where there is no risk of the liquid ballast freezing, it is possible to use a solution consisting of water and copper sulphate. For each 100 litres (26.4 gal US) of water, add 0.5 kg (1.1 lb) of copper sulphate. A total of 500 litres (132 gal US) will be needed for each tire.

3-35

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 the filler hose supplied in place of the plug (B).

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”.

3-36

CD00N020

68

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 all corporal risks for the operator.

OPERATING THE MACHINE AT LOW TEMPERATURES

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 using hydraulic oil depends on its viscosity, as per below: 32 mm2/s: 15°C (59°F) 46 mm2/s: 25°C (77°F) 58 mm2/s: 32°C (90°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 TEMPERATURES AND HIGH HUMIDITY LEVELS When the machine is used in hot climates, where the humidity is high, the engine will suffer some loss of power. As heat and humidity are two different factors, their effect on engine power can be resumed as follows: 1.

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.

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

2.

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.

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

In hot countries, where hydraulic oil temperature regularly reaches more than 80°C (176°F), thicker oil should be used (68 mm2/s).

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.

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.

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

4.

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

5.

Use winter-grade fuel.

6.

Check the battery charge level.

3-37

SECTION 3 - OPERATING INSTRUCTIONS 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, ask your Dealer to make the necessary adjustment to the injection pump.

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 the “Servicing Intervals/ Lubrication/Fluids” Section.

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. The manufacturer’s warranty does not cover damage caused by vibrations.

3-38

SECTION 3 - OPERATING INSTRUCTIONS DOZER BLADE (if fitted)

!

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 on the dozer blade using the locking pins.

2.

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

3.

Start up the engine.

A B

CD01C0157

69 4.

Use the speed control (36) to engage slow speed position and choose a suitable speed range using the speed range selector (37).

5.

Set engine speed to full (or near full) throttle.

36 37

CS00M514

70 6.

Lower the dozer blade to ground by shifting the control lever (63) 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

63

CS00M505

71

3-39

SECTION 3 - OPERATING INSTRUCTIONS 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.

C

D

Return the dozer blade control lever (63) to the “0” position.

CD01C158

72 9.

Shift the travel control (34) - forward to move forward with the machine.

34

CS00M514

73 10. Lower the dozer blade to the required cutting depth by shifting the control lever (63), 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

63

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

74

3-40

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 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

75 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

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

F G

NOTE: The cutting edges of the blade are removable.

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

!

WARNING

F

!

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.

CD01C160

77

3-41

SECTION 3 - OPERATING INSTRUCTIONS

NOTES

3-42

SECTION 4

40

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 fitted).

- 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.

6

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.

CS00M512

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 20 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

4-14

Engine oil

4-16

Coolant

4-19

Fuel tank

4-28

Air filter dust ejector

5-1

Engine fan

5-1

Lights, turn indicators, rotating beacon, horn

5-2

Engine alternator belt and fan

4-29

Hydraulic oil reservoir

5-3

Tire pressure

4-7

Articulations and dozer blade (if fitted)

4-14

Engine oil filter

4-28

Air filter restriction warning lamp

4-34

Drum

4-36

Transmission

C

4-38

Axle

C

5-5

Engine air intake system

5-5

Coolant radiator

6-2

Batteries (electrolyte/connections)

4-20

Fuel filters

5-4

Wheel nut tightening torque

5-6

Shock absorbers/Mounting blocks

5-8

Engine valve clearance

4-30

Hydraulic fluid

4-33

Hydraulic filter

5-11

Operator’s compartment and engine hood tilting strainer

5-12

Drum vibration frequency

5-13

Vibration shock absorbers

4-2

Note

2000

1000

500

100

Service points

20

see page

250

Intervals in hours

For servicing specifications

A

E/F

F

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS

Note

2000

1000

500

Service points

100

20

see page

250

Intervals in hours

For servicing specifications

4-21

Fuel circuit

D

4-25

Air filter primary element

G

4-25

Air filter secondary element

H

5-14

Machine wash

I

5-15

Operator’s compartment intake air dust filter

B

5-15

Air conditioning (optional)

K

5-17

Air conditioning condenser (optional)

L

5-18

Scrapers

J

5-19

Hardware torque specifications

J

2-22

Fire extinguisher

M

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

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 light (11) comes on on the console or imperatively every 2000 hours.

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

NOTE G: Clean or replace when the air filter restriction lamp (10) lights up on the front console or imperatively after one year or cleaning five times.

NOTE H: Replace imperatively every 2 years or after cleaning the primary element five times and replace if the air filter restriction lamp (10) remains alight on the front console after cleaning or replacing the primary element.

NOTE I:

Once a week minimum.

NOTE J: Check regularly.

NOTE K: Check every 3 months.

NOTE L: Clean regularly.

NOTE M: Every month, examine the fire extinguisher; Every 6 months, have the fire extinguisher refilled of powder by an approved specialist; Every year, have the fire extinguisher examined by an approved specialist.

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: API CE - CCMC D5 NOTE: In certain countries, if CE grade oils are not to be found, it is possible to use CC/CD grade oils, but in this case the oil must be changed more frequently.

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.

CS00N532

2 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.

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

The type of fluid use depends on ambient temperature:

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

ISO VG46: Temperate climates (-8°C to +40°C) (-17.6°F to +104°F) ISO VG68: Hot climates (0°C to +80°C) (32°F to +176°F)

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.

TRANSMISSION OIL Use extreme pressure type oil, of the API GL5 SAE 80W90 category.

GREASE Use extreme pressure grease of the NLGI grade 2 category.

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

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

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

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

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

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

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

Drain off water and impurities regularly.

4-5

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

Fluids and lubricants

Capacity

Engine

SAE 15W40 - 10W30 - 5W30 oil

16.3 litres (4.3 gal US)

Hydraulic system

ISO VG46 - VG68 oil

90 litres (23.8 gal US)

Transmission

API GL5 - SAE 80W90 oil

4.2 litres (1.1 gal US)

Axle

API GL5 - SAE 80W90 oil

2.8 litres (0.74 gal US)

Fuel system

Grade N°2 fuel

410 litres (108.3 gal US)

Machine articulation

NLGI grade 2 grease

as needed

Cooling system

Coolant - Water - Anti-freeze

25 litres (6.6 gal US)

Drum vibration

SAE 15W40 - 10W30 - 5W30 oil

8 litres (2.1 gal US)

Batteries

Distilled water

as needed

Windshield washers

Water - Anti-freeze

2.75 litres (0.72 gal US)

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...............................................................................................................................NLGI grade 2 Remove the caps from the grease fittings (if fitted), use the grease pump supplied and stop as soon as the grease begins to escape. Remember to reinstall the caps.

MACHINE ARTICULATION 6 grease points.

CI01C510

3

CI01C513

4

4-7

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS STEERING CYLINDERS 4 grease points.

CI01C514

5 OPERATOR’S COMPARTMENT TILTING CYLINDER 2 grease points.

CI01C515

6 ENGINE HOOD OPENING CYLINDERS 4 grease points.

CI01C516

7

4-8

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS CAB DOOR HINGES 6 grease points.

CI01C517

8 ENGINE HOOD HINGES 2 grease points.

CI01C518

9 OPERATOR’S COMPARTMENT TILTING HINGES 2 grease points.

CI01C519

10

4-9

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS SIDE COVER HINGER 2 grease points.

CI01C520

11 DOZER BLADE (if fitted) 6 grease points.

CD01C155

12

CD01C156

13

4-10

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

CD00N022

14 COOLANT See “Cooling system”.

CD00N025

15 FUEL See “Fuel system”.

CD00N026

16

4-11

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS EVERY 100 HOURS HYDRAULIC FLUID See “Hydraulic system”.

CD00N027

17 EVERY 250 HOURS OR EVERY 3 MONTHS DRUM VIBRATION OIL See “Drum”.

CD00N028

18 TRANSMISSION OIL See “Transmission”.

CD00N029

19

4-12

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS EVERY 250 HOURS OR EVERY 3 MONTHS BATTERY ELECTROLYTE See “Batteries” in the “Electrical System” Section.

CD00N030

20 AXLE OIL See “Axle”.

CD01A006

21

4-13

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS ENGINE SERVICE SPECIFICATIONS Engine oil level check .................................................................................................... Every 20 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 ..................................................................................................................... 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 (1).

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).

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.

ENGINE OIL CHANGE REPLACEMENT

AND

OIL

CD00N022A

22

FILTER

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 (1).

2.

Remove the oil filler cap (B).

B

CD00N023

23

4-14

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS 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 80 Nm (60 ft lb).

C

CD00N024

24 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.

B

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 (16.3 litres/4.3 gal US).

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.

D CD00N023A

25

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

4-15

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS COOLING SYSTEM SERVICE SPECIFICATIONS Coolant reservoir level check......................................................................................... Every 20 hours or daily Coolant concentration check.......................................................................Every 500 hours or every 6 months Drain ............................................................................................................ Every 2000 hours or every 2 years Cooling system capacity .................................................................................................... 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 (1).

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

26

4-16

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

C

IMPORTANT: Always carry out this check before winter.

The minimum proportion of anti-freeze (ethylene-glycol or propylene-glycol) in the coolant solution is 40%. This will afford circuit protection down to -23°C (-9.4°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.

B

C

CD00N032

27

DRAINING 1.

Park the machine on flat, level ground, stop the engine and remove the starter switch key (1).

Allow the engine to cool.

2.

Remove the coolant reservoir plug (D).

D

CD00N032

28 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.

CI01C521

29

4-17

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

Use the coolant solution orifice (D) to fill the system with coolant (25 litres/6.6 gal US) until it comes up to the edge of the filler.

IMPORTANT: Use a suitable coolant solution.

2.

Install the plug (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 (1).

5.

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

4-18

D

A CD00N025

30

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS FUEL SYSTEM SERVICE SPECIFICATIONS Check the fuel level ....................................................................................................... Every 20 hours or daily Fill the fuel tank .............................................................................................................. Every 20 hours or daily or whenever the warning lamp (8) on the front console comes on Replace the fuel filters ................................................................................ Every 500 hours or every 6 months Clean the fuel tank.......................................................................................... Every 1000 hours or once a year Fuel tank capacity........................................................................................................ 410 litres (108.3 gal US) Type of fuel .............................................................................................................. See “Fluids and lubricants” FUEL LEVEL Use the fuel level gauge (2) 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.

2

FILLING THE FUEL TANK 1.

Park the machine on flat, level ground, shut down the engine and remove the starter switch key (1).

!

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 plug (A) and the filler neck (B) with a clean cloth.

3.

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

4.

Fill the tank up to the bottom edge of the filler neck (B) and install the plug (A).

CS00M512

31

A B

IMPORTANT: Use appropriate fuel.

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

CD00N026

32

4-19

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS FUEL FILTERS 1.

Park the machine on flat, level ground, shut down the engine and remove the starter switch key (1).

2.

Clean the area around the filter heads.

3.

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

CD00N037

33 4.

Apply a fine coat of oil or grease to the seals of the new filters.

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

5.

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

IMPORTANT: Do not use the filter wrench.

Overtightening can damage the filters and seals.

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

PH08325

34

4-20

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS 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.

Loosen the screw (G) on the fuel filters.

G

CD00N037

35 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 (7 ft lb).

F

CD00N038

36

4-21

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS 3.

Loosen the screw (H) on the injection pump.

4.

Turn the starter switch key (1) to contact position.

5.

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

H

CD00N040

37 6.

Loosen the injectors connections, run the starter motor until clean, bubble-free fuel flows out and the 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.

BLEEDING THE SEDIMENT FILTER

CD00N041

38

If dirt 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.

CD00N039

39

4-22

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

Run the machine without refilling the tank until the warning lamp (8) lights up on the front console.

2.

Park the machine on flat, level ground, shut down the engine and remove the starter switch key (1).

3.

Put the battery master switch (55) in “0” position (system switched off).

4.

Place a receptacle with a capacity of approximately 50 litres (13.2 gal US) 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).

K

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

1.

Remove the batteries.

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.

5.

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

CD00N042

J 40

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

4-23

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 If the air filter restriction warning lamp (10) comes on while the engine is running, it is necessary to check the air filter elements.

10

CS00M512

41 SERVICE SPECIFICATIONS Primary element: clean or replace when the restriction warning lamp (10) 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 (10) stays on after replacing or cleaning the primary element.

Dust ejector: check every 20 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.

4-24

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS REMOVING THE ELEMENTS 1.

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

CI01C522

42 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

43 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.

PE08311

44

4-25

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS 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

45 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.

PDE0378

46 INSTALLING THE ELEMENTS 1.

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

CI01C523

47

4-26

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS 2.

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

CI01C524

48 3.

Make sure the dust ejector functions correctly.

CD00N035

49 Start and run the engine at low speed and check that the restriction warning lamp (10) is not alight.

10

CS00M512

50

4-27

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

51 RESTRICTION WARNING LAMP Check that the restriction warning lamp (10) functions correctly.

1.

Start the engine.

2.

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

3.

The restriction warning lamp (10) must come on.

If it does not, look for the cause (defective bulb, bad contact, electric cable) and recommence the operation.

CD00N035

52

4-28

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS HYDRAULIC SYSTEM SERVICE SPECIFICATIONS Hydraulic reservoir fluid level check ......................................................................................... Every 100 hours and whenever the warning lamp (15) on the front console comes on Hydraulic fluid replacement ......................................................................... Every 2000 hours or every 2 years Hydraulic oil filter replacement .................................................................... Every 2000 hours or every 2 years and whenever the warning lamp (11) on the front console comes on Hydraulic system capacity ............................................................................................... 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 (1).

2.

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

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.

CD00N027

53 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 warning lamp (15) on the front console is not alight.

B

CD00N044

54

IMPORTANT: During the warranty period for the machine, it is not possible to fill the hydraulic reservoir because it is sealed by the manufacturer. If the hydraulic oil drops to a low level during this period, contact your Dealer. The manufacturer’s warranty becomes null and void if the seal has been broken.

4-29

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 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 (1).

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

55 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.

10. Replace the hydraulic filter. See “Hydraulic filter replacement”.

4-30

F

B

E

D

G CD00N044

56

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS 11. Check that the temperature sender (H) is functioning correctly. Remove the sender (H) and clean the contact points. If the sender (H) is damaged, replace it.

12. Install the sender (H).

13. Fill the system.

H

CD00N046

57 FILLING 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

58

4-31

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS 2.

Install the drain pipe on the valve (C).

3.

Place a receptacle with a capacity of about 20 litres (5.28 gal US) and open the valve (C).

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.

Close the valve (C) and remove the 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 end check the level using the sight glass (A). Add fluid if necessary. See “Level in reservoir”.

8.

C

CD00N045

59

Make sure the warning lamp (15) on the front console is not alight.

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 (C) is properly closed.

C

CD00N045

60

4-32

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 (15) on the front console is not alight.

B

CD00N044

61 HYDRAULIC FILTER 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 ... plus, of course, if ever the warning lamp (11) on the front console comes on.

1.

Using a wrench, turn the base of the filter body counterclockwise and remove it.

2.

Remove the used filter element.

3.

Clean the filter body.

4.

Apply a thin coat of oil to the seal and install the new filter element. Tighten the filter body.

5.

Check that the warning lamp (11) on the front console is not alight.

CD00N048

62

4-33

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 .......................................................................................................................... 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 (1).

A

CD00N049

63 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

64

4-34

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 (1).

4.

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

C B

CD00N028

65 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

66

4-35

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 every 2 years (after the first 100 run in hours) Oil capacity ....................................................................................................................... 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 position.

3.

Shut down the engine and remove the starter switch key (1).

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).

B

A

C

CD00N029

67

4-36

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 (1).

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).

B

A

C

CD00N029

68

4-37

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS AXLE 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 ..................................................................................................................... 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 (1).

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).

A

B

CD01A006

69

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 (1).

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

70

4-38

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 (1).

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.

A

B

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

CD01A006

71

4-39

SECTION 4 - SERVICING INTERVALS/LUBRICATION/FLUIDS

NOTES

4-40

SECTION 5

22

MAINTENANCE/ADJUSTMENTS ENGINE FAN SERVICE SPECIFICATIONS Visual check .................................................................................................................. Every 20 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.

CD00N053

1

LIGHTING AND HORN SERVICE SPECIFICATIONS Check ............................................................................................................................ Every 20 hours or daily Check that the horn, the turn indicators, the position lights, the front and rear work lamps and the rotating beacon are working correctly. Install new bulbs if replacement is necessary.

Place the starter switch key (1) in position “1” (contact) and check that the console lamps come on.

5-1

SECTION 5 - MAINTENANCE/ADJUSTMENTS ENGINE ALTERNATOR AND FAN BELT SERVICE SPECIFICATIONS Visual check................................................................................................................... Every 20 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

2 TENSION CHECK 1.

Press the center of the belt with your finger, exerting a pressure of about 10 kg (22 lb).

CD00N050

3 2.

The maximum deflection should be between 9.5 mm (3/8 in) to 13 mm (1/2 in).

PDE0090

4

5-2

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.

6.

Check the tightness of the idler cover. The torque should be 43 Nm (32 ft lb).

CD00N052

5

TIRES AND WHEELS SERVICE SPECIFICATIONS Tire pressure check .................................................................................................................. Every 100 hours Wheel nut torque ........................................................................................ Every 500 hours or every 6 months

!

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 axle load and low the machine’s center of gravity, the tires may be filled with liquid ballast. See “Filling the tires with liquid ballast” in the “Operating Instructions” Section.

A

CD00N020A

6

5-3

SECTION 5 - MAINTENANCE/ADJUSTMENTS TORQUE Wheel nuts (B) should be tightened to a torque of 540 Nm (400 ft lb).

WHEEL REPLACEMENT 1.

Park the machine on flat, level ground, shut down the engine and remove the starter switch key (1).

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 drive axle.

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 540 Nm (400 ft lb).

8.

Remove the supports from under the drive axle.

9.

Lower the machine to the ground.

10. Remove the blocks from under the drum.

11. Check the pressure of the new tire.

5-4

B

CD00N020A

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

RADIATOR AND OIL COOLER

8

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 perchlorethylene.

IMPORTANT: The use of trichlorethylene is strictly forbidden.

2.

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

5-5

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.)

DRUM

CD00N056

9 OPERATOR’S COMPARTMENT (front)

CD00N057

10 OPERATOR’S COMPARTMENT (rear)

CD00M006

11

5-6

SECTION 5 - MAINTENANCE/ADJUSTMENTS ENGINE (front)

CD00N058

12 ENGINE (rear)

CD00N059

13

5-7

SECTION 5 - MAINTENANCE/ADJUSTMENTS ENGINE VALVE CLEARANCE SERVICE SPECIFICATIONS Check..............................................................................................................Every 1000 hours or once a year 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

14 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

15 5.

When the timing pin engages in the camshaft pinion, number 1 cylinder is in Top Dead Center Position.

CD00N063

16

5-8

SECTION 5 - MAINTENANCE/ADJUSTMENTS 6.

Remove the timing pin from the camshaft pinion.

CD00N064

17 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

18

10. Use the turnover tool to rotate the engine 360° until the alignment marks are opposite each other once again.

CD00N066

19

5-9

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

20 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

21

5-10

SECTION 5 - MAINTENANCE/ADJUSTMENTS OPERATOR’S COMPARTMENT AND ENGINE HOOD TILTING SYSTEM STRAINER SERVICE SPECIFICATIONS Check and clean.......................................................................................... Every 2000 hours or every 2 years and whenever the hydraulic fluid is changed 1.

Remove the mounting screws (A) and remove the unit (B) from under the hydraulic reservoir.

A

B CI01C529

22 2.

3.

Remove the strainer (C) from the suction pipe (D).

D C

Clean the strainer (C) in clean fuel and dry it with compressed air.

IMPORTANT: Be sure to wear face protection before using compressed air.

4.

Check the condition of the strainer (C) and replace it if necessary.

5.

Install the strainer (C) in the suction pipe (D).

6.

Check the condition of the seal (E) and replace it if necessary.

7.

Install the unit (B) and tighten the mounting screws (A). Make sure there are no leaks.

E

CD00N069

23

5-11

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 value should be:

SV212 With high amplitude: 32 Hz (1920 VPM) With low amplitude: 35 Hz (2100 VPM) SV216 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.

IMPORTANT: It is imperative to observe the values specified by the manufacturer.

5-12

CD00N070

24

SECTION 5 - MAINTENANCE/ADJUSTMENTS ADJUSTMENT Adjustment should be made with the engine shut down.

The upper screw (A) is for adjusting the frequency corresponding to high amplitude and the lower screw (B) is for adjusting the frequency corresponding to low amplitude. Loosen the screws to increase frequency.

Tighten the screws to decrease frequency.

1.

Loosen the lock nut (C) and use a screwdriver to turn the adjustment screw until the correct reading is obtained. Then tighten the lock nut (C).

2.

Start the engine and drive the machine with the vibration function switched on. Check the values once again using the test instrument.

A

B

C CD00N071

25

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

26

5-13

SECTION 5 - MAINTENANCE/ADJUSTMENTS 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 the “0” position (system switched off).

Do not use harsh detergents or highly inflammable products.

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

5-14

SECTION 5 - MAINTENANCE/ADJUSTMENTS OPERATOR’S COMPARTMENT INTAKE AIR DUST FILTER 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).

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).

A B

CD00N060

27

AIR-CONDITIONING (optional) 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 the “Controls/Instruments/Accessories” Section.

SERVICE SPECIFICATIONS Check ........................................................................................................................................ Every 3 months Clean the condenser ........................................................................................................................... Regularly

5-15

SECTION 5 - MAINTENANCE/ADJUSTMENTS 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

28 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.

CD00N074

29 3.

Remove the evaporator hose, clean it and check its condition. If it is damaged, change it.

CD00N075

30

5-16

SECTION 5 - MAINTENANCE/ADJUSTMENTS CLEANING THE CONDENSER Dry dust: use compressed air.

Mud: use a hose.

Greasy deposits: use perchlorethylene.

IMPORTANT: The use of trichlorethylene is strictly forbidden.

IMPORTANT: Be sure to wear face protection before using compressed air.

CD00N076

31

5-17

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 20 mm (0.79 in). If necessary, loosen the mounting hardware, move the holder (1) towards the drum until the clearance is 20 mm (0.79 in) and then re-tighten the mounting hardware.

NOTE: If it is not possible to reduce the clearance to 20 mm (0.79 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 20 mm (0.79 in) and then tighten the hardware.

1

CD01A009

32 TAMPING DRUM Check the clearance between the scrapers and the drum. The distance must be 35 mm (1.18 in). If necessary, loosen the mounting hardware, move the scraper (2) towards the drum until the clearance is 35 mm (1.18 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

33

5-18

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).

5-19

SECTION 5 - MAINTENANCE/ADJUSTMENTS ENGINE TROUBLESHOOTING PROBLEM

Engine does not start.

POSSIBLE CAUSE

SOLUTION

Defective starter switch (starter does not run)

Check switch

Defective rotation of starter (starter rotates slowly)

Discharged 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.

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 Improper fuel Exhaust from engine is black or dark gray.

See your Dealer Replace with correct fuel

Incorrect valve clearance

Adjust

Insufficient air intake (air cleaner clogged)

Service the air filter

Defective fuel injection pump Low compression

See your Dealer

Incorrect fuel

Replace with correct fuel

Insufficient air intake

Clean or replace element

Defective fuel injection pump Excessive fuel consumption.

Incorrect spray from fuel injection nozzle Incorrect fuel injection timing Low compression

5-20

See your Dealer

SECTION 5 - MAINTENANCE/ADJUSTMENTS

PROBLEM

Excessive engine oil consumption.

Unusual noise (fuel or mechanical).

Engine overheating (water 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

Water 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

Defective battery charging.

Incorrect belt tension

Adjust

Electrical wiring problems

Repair

Defective battery

Replace

Defective regulator Defective alternator

See your Dealer

5-21

SECTION 5 - MAINTENANCE/ADJUSTMENTS

NOTES

5-22

SECTION 6

4

ELECTRICAL SYSTEM FUSES The fuses are located in the compartment (28) in the front console.

IMPORTANT: Before changing a fuse, place the battery master switch (55) in the “0” position (system switched off). Never replace a fuse with a fuse of different amperage.

28 CS00M512

1 F1 Front and rear work lamps, instrument console lighting, auxiliary work lamps, front marker and tail lights, license plate, lifting and lowering of the hood and the operator’s compartment............................. 20 A F2 Power socket, cab light, horn, turn indicators and radio ............................ 10 A F3 Brakes and brake warning lamp, engine cutout, hydraulic oil gauge, travel, vibration, differential lock, back-up alarm and direction/speed lever neutral position indicateur lamp ......................................... 7.5 A F4 Coolant temperature, hydraulic oil temperature, fuel gauge, speedometer, hourmeter, indicator/ warning lamps for engine oil pressure, air filter restriction, hydraulic filter restriction and battery charging .................................. 10 A F5 Cab blower, heater blower, front and rear windscreen wiper, windscreen washer ...... 15 A F6 Not used (air-conditioning) ........................ 20 A

CD00N077

2

Fuse for operator’s compartment and engine hood tilting, see item 60 of “Location of controls, instruments and accessories”,in the “Controls/Instruments/Accessories” Section ....................................................... 50 A

6-1

SECTION 6 - ELECTRICAL SYSTEM BATTERIES SERVICE SPECIFICATIONS Electrolyte level check ................................................................................Every 250 hours or every 3 months and whenever the warning lamp (16) on the front console comes on 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 (55) must be placed in the “0” position (system switched off).

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

Antidote: EXTERNAL:Rinse with water.

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

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

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

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

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

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

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

ELECTROLYTE LEVEL CHECK Remove the caps (A) and check the level in each cell.

The level should come to between 10 mm (0.4 in) and 15 mm (0.6 in) above the plates. Add distilled water if necessary and install the caps.

A

IMPORTANT: If distilled water is added and ambient temperature is below 0°C (32°F), it will be necessary to charge the batteries or run the engine for approximately two hours so that the electrolyte and distilled water mix perfectly.

NOTE: Make sure the battery poles are clean and greased and that the cable connections are tight.

CD00N030

3

6-2

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.

6-3

SECTION 6 - ELECTRICAL SYSTEM

NOTES

6-4

SECTION 7

2

STORAGE STORING THE MACHINE PREPARATION FOR STORAGE

PERIODIC CHECKS

The following procedure applies when the machine is to be stored for one month or more. Store the machine on flat, level ground, with the 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 machanically (if fitted).

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

8

SPECIFICATIONS ENGINE Make.................................................................................................................................................... Cummins Type.................................................................................................................................................BS.9 - C148 Power rating .........................................................................................................................110.0 kW (148 HP) Standard ........................................................................................................................ ISO 3046/1 (DIN 6271)

STEERING Oscillation angle ..........................................................................................................................................±10° Steering angle .............................................................................................................................................±36° Turning radius: Inner (edge)..................................................................................................................... 3050 mm (120.1 in) Outer (contour) (without dozer blade) ............... (SV212) 5370 mm (211.4 in); (SV216) 5395 mm (212.4 in) Outer (contour) (with dozer blade) ................... (SV212) 5738 mm (225.9 in); (SV216) 5738 mm (225.9 in)

CAPACITIES Fuel.............................................................................................................................. 410 litres (108.3 gal US) Engine oil........................................................................................................................ 16.3 litres (4.3 gal US) Hydraulic system ............................................................................................................. 90 litres (23.8 gal US)

ELECTRICAL SYSTEM Voltage................................................................................................................................................... 24 Volts Batteries ............................................................................................................................................ 2 x 100 Ah

WHEELS Size of tires......................................................................................................................................... 23.1 x 26” Tread (with smooth drum)................................................................................................................. UK5 10 PR Tread (with tamping drum)................................................................................................................ TR1 10 PR

TRAVEL SV212

SV216

Drive axles

2

2

No. of travel speeds

4

4

0 - 14.5 km/h (0-9 mph)

0 - 13 km/h (0-8 mph)

Maximum speed 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

Brakes: Service Parking and emergency

8-1

SECTION 8 - SPECIFICATIONS 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 206 kN (46 311 ft lb) 1.85 mm (0.073 in) 32 Hz 277 kN (62 272 ft lb)

1 mm (0.039 in) 35 Hz 237 kN (53 280 ft lb) 2 mm (0.079 in) 29 Hz 325 kN (73 063 ft lb)

SV212

SV216

Operating weight (CECE)

11 085 kg (24 438 lb)

14 310 kg (31 548 lb)

Operating weight (CECE) - 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 (CECE)

11 515 kg (25 386 lb)

14 220 kg (31 350 lb)

Operating weight (CECE) - 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 (CECE)

12 425 kg (27 392 lb)

15 130 kg (33 356 lb)

Operating weight (CECE) - 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)

VIBRATION Vibration modes 1. Nominal amplitude Frequency Centrifugal force 2. Nominal amplitude Frequency Centrifugal force

WEIGHTS With smooth drum

Drum load (CECE) Ballast With tamping drum

Drum load (CECE) Ballast With tamping drum and dozer blade

Drum load (CECE) Ballast

8-2

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

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)

8-3

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

8-4

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)

SECTION 8 - SPECIFICATIONS EQUIPMENT STANDARD

OPTIONS

Lockable vandal guard Single lever control Both drum and wheels are hydrostatically driven Double mode vibration Interaxle differential lock Articulated chassis Halogen working lamps Tires 23.1 x 26” tread UK 5 (10 PR) Tire ballast water filling device

ROPS protection Tamping foot kit (if not fitted) Air-conditioning Engine air pre-cleaner Tires 23.1 x 26” TR1 (10PR) Tire ballast liquid filling to 0 centigrade C Tire ballast liquid filling to minus 25 centigrade C Compaction indicator Fan safety screen Alternator safety screen Turn indicators Rotating beacon Dozer blade (if not fitted)

NOISE AND VIBRATION LEVELS INTERNAL NOISE

VIBRATION

The acoustic pressure level affecting the driver during travel (measured according to EN 11 202 on sand):

The mean effective value of vibration acceleration:

1) With door closed Using vibration.......................................... 81 dB (A) Without vibration....................................... 78 dB (A) 2) With door open Using vibration.......................................... 91 dB (A) Without vibration....................................... 90 dB (A)

- Transferred to the hands (measured according to ISO 5349 on sand, using vibration): aw < 2.5 m/s2 (vectorial sum).

- Transferred to the body (measured according to EN 1032 on sand, using vibration): aw < 0.5 m/s2 (vectorial sum)

EXTERNAL NOISE Measured according ISO 6393 on concrete, machine stationary............. 108 dB (A)

8-5

SECTION 8 - SPECIFICATIONS OVERALL MACHINE DIMENSIONS (With smooth drum)

L

E F

B C

D

A

K

G

H J

CS01A508

1 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)

8-6

SECTION 8 - SPECIFICATIONS OVERALL MACHINE DIMENSIONS (With tamping drum)

E F M B

L

C

D

A

K

G

H J

CS01C501

2 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)

8-7

SECTION 8 - SPECIFICATIONS OVERALL MACHINE DIMENSIONS (With tamping drum and dozer blade)

E F D C B

L A

H

G

J

K CS01C502

3 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)

8-8

SECTION 9 ALPHABETICAL INDEX A

E

Accessory functions.......................................... 2-19 Adapting the smooth drum for tamping compaction ................................................... 3-23 Air filter ............................................................. 4-24 Air filter restriction warning lamp ........................ 2-7 Air vents............................................................ 2-21 Air-conditioning................................................. 5-15 Air-conditioning controls ................................... 2-27 Anti-freeze/Anti-corrosion ................................... 4-5 Auxiliary lamp control ....................................... 2-11 Axle................................................................... 4-38

Electrical system ................................................. 8-1 Emergency brake control .................................. 2-15 Emergency lever and manual pump ................. 2-25 Emergency stop control .................................... 2-15 Engine........................................................4-14, 8-1 Engine air intake system..................................... 5-5 Engine alternator and fan belt............................. 5-2 Engine coolant solution temperature gauge ....... 2-6 Engine emergency shut down............................. 3-8 Engine fan........................................................... 5-1 Engine oil ............................................................ 4-4 Engine oil pressure warning lamp....................... 2-8 Engine tachometer.............................................. 2-6 Engine throttle control ....................................... 2-11 Engine troubleshooting ..................................... 5-20 Engine valve clearance....................................... 5-8 Environment........................................................ 4-6 Equipment........................................................... 8-5

B Batteries ............................................................. 6-2 Battery charge warning lamp.............................. 2-8 Battery master switch ....................................... 2-24 Before operating the machine ............................ 3-1 Beverage holder ............................................... 2-23 Booster batteries ................................................ 6-3

F C Cab blower control............................................ 2-12 Cab door............................................................. 2-1 Cab removal and installation ............................ 3-23 Capacities........................................................... 8-1 Cleaning the machine....................................... 5-14 Control for opening and closing the engine hood ............................... 2-25 Cooling system ................................................. 4-16 D Decals............................................................... 1-15 Diagnostic socket ............................................... 2-7 Differential locking control .................................. 2-9 Direction indicator control ................................. 2-11 Direction of travel and travel speed lever ......... 2-13 Direction of travel neutral position indicator lamp ................................................. 2-7 Dozer blade ...................................................... 3-39 Driving the machine on rough ground .............. 3-21 Drum................................................................. 4-34 Drum anti-slip control.......................................... 2-9 Drum vibration control ...................................... 2-14 Drum vibration frequency ................................. 5-12 Drum vibration indicator lamp............................. 2-7 Drum vibration selector control........................... 2-9

Fast travel ........................................................... 3-9 Filling the tires with liquid ballast....................... 3-34 Fire extinguisher ............................................... 2-22 Fluid and lubricant capacities and specifications ........................................... 4-6 Fluids and lubricants ........................................... 4-4 Front console control functions ........................... 2-6 Front upper control functions ............................ 2-12 Front windshield wiper ...................................... 2-21 Front windshield wiper control .......................... 2-12 Fuel ..................................................................... 4-5 Fuel filters ......................................................... 4-20 Fuel level gauge ................................................. 2-6 Fuel system....................................................... 4-19 Fuse compartment ............................................ 2-11 Fuses .................................................................. 6-1 G Grease ................................................................ 4-5 Grease points ..................................................... 4-7

9-1

SECTION 9 - ALPHABETICAL INDEX

H

O

Hand signals ..................................................... 1-22 Handling the machine ....................................... 3-30 Hardware torque specifications......................... 5-19 Hazard warning signal control........................... 2-10 Heater control ................................................... 2-23 Heater/blower control.......................................... 2-9 Horn control ...................................................... 2-11 Hourmeter ....................................................2-6, 4-1 Hydraulic filter replacement .............................. 4-33 Hydraulic fluid ..................................................... 4-5 Hydraulic fluid level warning lamp....................... 2-8 Hydraulic fluid replacement............................... 4-30 Hydraulic fluid temperature gauge ...................... 2-6 Hydraulic oil filter restriction warning lamp.......... 2-7 Hydraulic system............................................... 4-29

Operating the machine at high temperatures and high humidity levels................................3-37 Operating the machine at low temperatures .....3-37 Operating the machine in close proximity of building, underground conduits and cables.....................................................3-38 Operating the machine in special conditions.....3-37 Operating the machine in very dusty conditions......................................................3-38 Operator’s compartment air intake ....................2-23 Operator’s compartment and engine hood tilting system strainer ...........................5-11 Operator’s compartment intake air dust filter ....5-15 Operator’s compartment lighting .......................2-19 Operator’s compartment tilting control ..............2-24 Operator’s seat..................................................2-16 Overall machine dimensions ................ 8-6, 8-7, 8-8

I Identification of the main components of the machine .......................................................... 1-6 Indicator lamp for turn indicators......................... 2-7 Instrument lighting, front and rear light and front working lamp control ..................... 2-10 L Legal documents................................................. 1-2 Levels................................................................ 4-11 Lighting and horn ................................................ 5-1 Location of controls, instruments and accessories.............................................. 2-2 Low speed range selector................................. 2-15 M Machine braking warning lamp ........................... 2-8 Machine travel and direction of travel ................. 3-9 Maximum compacted lift thickness at optimal working conditions ..................8-3, 8-4 N Noise and vibration levels ................................... 8-5 Noise levels......................................................... 1-5 O Opening and closing the engine hood .............. 3-18 Operating the machine........................................ 3-2 Operating the machine at high altitudes ........... 3-38

9-2

P Parking the machine .........................................3-12 Performance levels ..................................... 8-3, 8-4 Personal safety ...................................................1-8 Power socket............................................. 2-7, 2-26 Preparing the machine for use at low temperatures ......................................3-37 R Radiator and oil cooler ........................................5-5 Read Operators Manual ....................................1-14 Rear view mirrors ..............................................2-20 Rear windshield wiper .......................................2-22 Rear windshield wiper control ...........................2-12 Rear working lamp control ................................2-10 Releasing the transmission and wheel hydraulic motor brakes ................3-32 Right, left, front and rear of the machine .............1-3 Right-hand arm control......................................2-13 Right-hand arm control functions ......................2-13 ROPS frame removal and installation ...............3-22 Rotating beacon control ....................................2-10 Run in period.......................................................3-3 S Safety rules .........................................................1-7 Scrapers ............................................................5-18 Servicing interval table ........................................4-2 Servicing intructions ............................................4-1

SECTION 9 - ALPHABETICAL INDEX

S Shock absorbers/Mounting blocks...................... 5-6 Shutting down the engine ................................... 3-7 Side compartment ............................................ 2-24 Slow travel with vibration .................................. 3-11 Slow travel without vibration ............................. 3-10 Starter switch...................................................... 2-6 Starting the engine ............................................. 3-4 Starting up after storage ..................................... 7-1 Steering .............................................................. 8-1 Steering wheel.................................................. 2-19 Steps and access handles.................................. 2-1 Storage compartment ....................................... 2-19 Storage net ....................................................... 2-27 Storing the machine............................................ 7-1 Sun visor........................................................... 2-20 T Tilting control fuse ............................................ 2-26 Tilting the operator’s compartment ................... 3-14 Tire pressure ...................................................... 5-3 Tires and wheels ................................................ 5-3 To the owner....................................................... 1-1 Towing points ................................................... 3-31 Towing the machine ......................................... 3-31 Transmission .................................................... 4-36 Transmission oil.................................................. 4-5 Transporting the machine................................. 3-27 Travel.................................................................. 8-1 Travel over hard or compacted ground ............ 3-37 Travel speed....................................................... 8-2 Type of speed control ....................................... 2-14 Type, serial number and year of manufacture.... 1-4 V Vibration ............................................................. 8-2 Vibration shock absorber.................................. 5-13 W Weights............................................................... 8-2 Wheel replacement............................................. 5-4 Wheels................................................................ 8-1 Windshield washer control................................ 2-12 Windshield washer reservoir ............................ 2-22

9-3

NOTES

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