STA Roller VH 1700 LUBRICATION AND MAINTENANCE MANUAL - PDF DOWNLOAD

LUBRICATION AND MAINTENANCE MANUAL

VH 1700

Contents: Contents:

................................................................................................................................................................ 2

3.1. Specifications ................................................................................................................................................................ 4 3.1.1.

3.1.2.

3.1.3.

3.1.4.

3.1.5.

3.1.6.

3.1.7.

3.2. Fills

Motor oil ................................................................................................................................................................ 4 Fuel ....................................................................................................................................................................... 5 Hydraulic oil ......................................................................................................................................................... 6 Transmission oil ................................................................................................................................................... 6 Grease .................................................................................................................................................................. 6 Coolant ................................................................................................................................................................. 7 Windshield washer fluid ...................................................................................................................................... 7

................................................................................................................................................................ 8

3.3. Lubrication schedule ......................................................................................................................................................... 9 3.4. Safety and other precautions during maintenance ............................................................................................................ 10 3.4.1. Safety during maintenance ............................................................................................................................... 11 3.4.2. Fire prevention when changing service liquids ............................................................................................... 12 3.4.3. Environmental and health regulations ............................................................................................................. 13 3.4.3.1. Health regulations ............................................................................................................................................. 13 3.4.3.2. Ecological regulations ....................................................................................................................................... 14

3.5. Specific lubrication and maintenance procedures............................................................................................................. 15 After 20 hours or daily .................................................................................................................................................... 16 3.5.1.

Inspection and adding motor oil ....................................................................................................................... 17 3.5.2. Inspection and refill of coolant in radiator ......................................................................................................... 18 3.5.3. Inspection and cleaning of fuel filter ................................................................................................................. 18 3.5.4. Inspection and cleaning of the radiator ............................................................................................................ 19 3.5.5. Inspection of engine belts ................................................................................................................................. 19 3.5.6. Inspection of cooling fan .................................................................................................................................... 20 3.5.7. Inspection of dust valve of the air filter .............................................................................................................. 20 3.5.8. Checking fuel level, and adding fuel ................................................................................................................ 21 3.5.9. Checking oil level in the hydraulic loop tank .................................................................................................... 22 3.5.10. Filling sprinkling tank ......................................................................................................................................... 22 3.5.11. Inspection of warning and control devices ....................................................................................................... 23 3.5.12. Inspection of safety labels and markings.......................................................................................................... 24

After 250 working hours or 3 months .............................................................................................................................. 25 3.5.13. Engine oil and oil filter change ......................................................................................................................... 26 3.5.14. Inspection of engine cooling ............................................................................................................................. 28 3.5.15. Inspection of engine intake manifold ................................................................................................................ 28 3.5.16. Inspection of vacuum switch of the air filter ...................................................................................................... 29 3.5.17. Inspection of oil level in the vibrator ................................................................................................................. 30 3.5.18. Inspection of oil level in the drum reducer ........................................................................................................ 31 3.5.19. Inspection of batteries........................................................................................................................................ 32 3.5.20. Sprinkling filter - cleaning .................................................................................................................................. 34 3.5.21. Lubrication of steering joint bearings ................................................................................................................ 35 3.5.22. Lubrication of steering pins ............................................................................................................................... 36 3.5.23. Lubricating pins of scrapers .............................................................................................................................. 36 3.5.24. Lubrication of hinge pins ................................................................................................................................... 36

2

LUBRICATION AND MAINTENANCE MANUAL After 500 working hours (after 6 months) ....................................................................................................................... 37 3.5.25. Replacement of fuel filters ................................................................................................................................. 38 3.5.26. Inspection of anti-freeze fluid ............................................................................................................................ 40

After 1000 working hours (after 12 months) ................................................................................................................... 41 3.5.27. Inspection, adjustment of engine valves .......................................................................................................... 42 3.5.28. Inspection of engine belt ................................................................................................................................... 45 3.5.29. Inspection of exhaust system. ........................................................................................................................... 46 3.5.30. Oil change in drum reducer. .............................................................................................................................. 46 3.5.31. Inspection of rubberized metal parts ................................................................................................................. 48 3.5.32. Cleaning of water tanks ..................................................................................................................................... 49

After 2000 hours of service (after 2 years) ..................................................................................................................... 50 3.5.33. Change of cooling fluid ..................................................................................................................................... 51 3.5.34. Inspection of damper of engine torsion vibrations ........................................................................................... 52 3.5.35. Vibrator oil change ............................................................................................................................................. 52 3.5.36. Cleaning of fuel tank .......................................................................................................................................... 53 3.5.37. Oil and filter change in the hydraulic loop ........................................................................................................ 54

Maintenance as needed .................................................................................................................................................. 58 3.5.38. Cleaning and replacement of air filter cartridge ............................................................................................... 59 3.5.39. Cleaning of fuel separator ................................................................................................................................. 61 3.5.40. Venting the fuel system ...................................................................................................................................... 62 3.5.41. Cleaning of the radiator ..................................................................................................................................... 64 3.5.42. Adjustment of vibrating frequency ..................................................................................................................... 64 3.5.43. Scrapers adjustment .......................................................................................................................................... 66 3.5.44. Cleaning of filter in the cabin ventilation .......................................................................................................... 67 3.5.45. Cleaning the roller ............................................................................................................................................. 67 3.5.46. Inspection of screw joints .................................................................................................................................. 68

3.6. Maintenance records ...................................................................................................................................................... 72 3.7. Identifying defects .......................................................................................................................................................... 76 3.7.1.

3.7.2.

3.7.3.

Appendix

Identifying engine defects ................................................................................................................................. 76 Electrical wiring defects ..................................................................................................................................... 79 Defects in hydraulic system ............................................................................................................................... 80

.............................................................................................................................................................. 82

Electrical installation ........................................................................................................................................................ 82 Diagram of hydraulics ...................................................................................................................................................... 90

3

3.1. Specifications Viscosity

3.1.1.

Motor oil

The use of high quality motor oil and its regular change are important for the life of the engine.

Quality Oils are classified by their quality and performance, and are specified by API (American Petroleum Institute) and CCMC (Committee of Common Market Automobile Constructors).

Applicable oils by classification: API CE CCMC D5 Where CE oils are not available, CC or CD oils may be used. Change intervals must be lowered, however.

Since oils change viscosity with temperature, ambient temperature and mode of application for the site of application are important factors for the determination of viscosity class SAE (Society of automotive engineers). The engine will not be damaged by the use of lower temperature limits, only difficulties with starting the engine may be experienced.

Exceeding the upper temperature limit causes lower lubrication capabilities, and shouldn’t last too long.

It is advisable to use universal multi-range oils to limit oil changes because of ambient temperature variations.

Recommended oil for year-round use is SAE 15W-40, to diagram in Fig. 1, like Cummins Premium Blue. For easier starts at temperatures below 0 °C (32 °F), the engine manufacturer recommends SAE 10W-30, to diagram in Fig. 1.

Conditions for oil change Change oil regularly in intervals of Table for 25o service hours, or at least once a year, whichever comes first.

Fig. 1 - Diagram of Viscosity

4

LUBRICATION AND MAINTENANCE MANUAL Winter fuel

3.1.2.

Fuel

At temperatures below 0 °C (32 °F),the diesel fuel produces paraffin wax in the fuel system. Such waxes may cause a defect and prevent the engine from working.

Thus, at temperatures below 0 °C (32 °F) use winter fuel..

Use diesel fuel ·

CEN EN 590 or suggested DIN/EN 590

·

DIN 51 601

·

BS 2869 (1988): A1 and A2

·

ASTM D 975-88: 1-D and 2-D

·

VV-F-800C: DF-A, DF-1 and DF-2

·

NATO code F-54 and F-75

Regular fuel for diesel engines contains less than 0.5% of sulfur by weight. When using fuels with sulfur content 0.5% to 1%, oil change intervals must be lowered to one half.

Service stations usually replace naphtha according to season.

When using summer diesel fuel at 0°C (32 °F), mix petroleum with naphtha to improve low temperature properties.

The relation of petroleum additives with temperature is indicated in diagram, Fig. 2.

Sufficient anti-freeze effects may be achieved with fuel additives for improving viscosity.

Mix in the tank. First, fill with the specific amount of petroleum and then fill with fuel.

Mixtures of winter fuels are equally flammable as gasoline – observe fire regulations.

It is not allowed to use other fuels, like bio-naphtha, mixed bio-naphtha, LTO, than fuels as specified.

Fig. 2 - Diagram of Mixing

„Su

per

die

sel

“

Ambient temperature Content of mixed kerosene

5

3.1. Specifications Synthetic Hydraulic Oil

3.1.3.

Hydraulic oil

For use in the hydraulic system of the machine, only highquality hydraulic oils of output class according to ISO 6743/HV (equal to DIN 51524 part 3 HVLP; CETOP RP 91 H).

The machines are filled with hydraulic oil of kinetic viscosity 68 mm 2/s at 40 °C (104 °F) ISO VG 68 by the manufacturer. This particular oil is suited for applications in the widest range of ambient temperatures.

At high ambient temperatures, when the oil temperature reaches continual 90 °C (194°F), we recommend replacing the oil with one of kinetic viscosity 100 mm 2/s - HV 100 (BP BARTRAN HV 100; ESSO UNIVIS N 100, etc.)

Should it be required to start the machine at temperatures below –8 °C (18 °F) lasting more than one month, replace oil in the hydraulic system with one of kinetic viscosity 46 mm2 /s - viscosity class HV 46.

At temperatures below –13°C (9°F), replace oil with one of kinetic viscosity 32 mm 2/s - viscosity class HV 32, such as BP BARTRAN HV 32, ESSO UNIVIS N 32, etc.).

Fig. 3 - Comparing table of the hydraulic oils

The hydraulic system may be filled with synthetic oil under the following conditions: PANOLIN - HLP Synth 15/22/32/68 is a fully synthetic, highly efficient oil, and according to VDMA 24´568 is classified in HESS . It satisfies standard DIN 51524 Part 2 and 3. The requirements for resistance against aging are exceeded by far. Accidental spills are destroyed by microorganisms found in water or soil. During operation, one has to be careful to avoid its mechanical contamination by wear, dust, etc.. Oil must not exceed contamination class 17/14 (to ISO 4406) Water content due to condensation may not exceed 0.1%.

The fluid must be checked regularly by taking samples, as specified in table below.Taking of such samples must be done in accordance with instructions supplied by the PANOLIN Laboratory, or preferrably, let PANOLIN take the samples directly.

Schedule of samples

Normal use

Extreme conditions

1. inspection

500 h

250 h

2. inspection

1000 h

500 h

subsequent inspections

1000 h or 1x a year

500 h or 1x year

Brand name

Sort of oil

Output class on ISO 6743/HV

HV (HVLP)

Viscosity class on ISO 6743/4, DIN 51519

VG 68

Transition from mineral oils onto synthetic ones must be done in compliance with VDMA 24´569

Viscosity class on CETOP RP 91H

HV 68

When filling older motors with PANOLIN HLP Synth the residual level of mineral oils may not be higher than 8% of the total volume of the fill.

AGIP

AGIP ARNICA 68

AVIA

AVILUB HVI 68

BP

BARTRAN HV 68

CASTROL

HYSPIN AWH 68

CHEVRON

EP 68 HV

ELF

HYDRELF 68

ESSO

UNIVIS N 68

FINA

HYDRAN HV 68

FUCHS

RENOLIN MR 68 HV

MOBIL

MOBIL DTE 16

ÖMV

HLP - M 68

SHELL

TELLUS T 68

TEXACO

RANDO OIL HD CZ 68

TOTAL

EQUIVIS ZS 68

6

Mixing PANOLIN HLP Synth oil with other biologically neutralized oils, such as unsaturated synthetic esters or vegetable oils, is not allowed!

When filling biologically fast neutralized oils, mixing with up to 2% of the tank content is allowed Transition to other types of oil, or mixing with other types of oil, should be consulted with the manufacturer or PANOLIN Comp.!

LUBRICATION AND MAINTENANCE MANUAL 3.1.4.

Transmission oil

For the lubrication of the gearbox in the drum use quality oils to API GL-5 of SAE 80W/90 rating.

For greasing vibrator bushings use the following lubricants Manufacturer

Make of lubricant

PARAMO ESSO SHELL BP

CLP 100 SPARTAN EP 100 OMALA 100 ENERGOL GR - XP 100

3.1.6.

Coolant

The radiator is filled by the manufacturer with antifreeze of 40% glycol and 60% water good for ambient temperatures down to -23 °C (-10 °F). In addition, propylene glycol may be used.

Use demineralized or distilled water in these mixtures.

The proportion of ethylene glycol or propylene glycol in the antifreeze for different temperature ranges is Ethylene-glycol

Propylene-glycol

40% = -23 °C (-10 °F)

40% = -21 °C (-6 °F)

These lubricants comply with

50% = -37 °C (-34 °F)

50% = -33 °C (-27 °F)

DIN 51 517 Part 3 * AGMA no. 2 EP to no. 8 EP ** * Deutsche Industrie Normen ** American Gear Manufacturers Association

60% = -54 °C (-65 °F)

60% = -49 °C (-56 °F)

68% = -71 °C (-90 °F)

68% = -63 °C (-82 °F)

3.1.5.

Do not use proportions higher than 50% in antifreeze mixtures, unless absolutely necessary, however, never more than 68%.

Grease

Use synthetic grease with lithium to NLGI-2*, as indicated in the lubrication schedule.

Use environmental friendly chemicals.

We do not recommend mixing different chemicals, since anti-corrosion properties may be lost.

* - NLGI (National Lubricanting Grease Institute)

When nitride and amino-based antifreeze fluids are mixed, the result is a chemical dangerous to health.

Check the efficiency of the antifreeze with a gravity meter before the onset of cold weather.

3.1.7.

Windshield washer fluid

In the washer use mixture of water and concentrated antifreeze cleaning fluid in a ratio recommended by the manufacturer.

7

3.2. Fills

Section - fill

Type of fill

Engine - motor oil, to Chapter. 3.1.1

SAE 15W/40 - year -round

Fuel tank - naphtha, chapter 3.1.2

Qty of fill liters (US gal.)

14,2 (3,75)

Summer naphtha above freezing point Winter naphtha above 0 °C (32°F)

370 (98)

Modified summer naphtha, to 3.1.2 Hydraulic system hydraulic oil, see Ch. 3.1.3

Hydraulic oil of kinetic viscosity 46 sq.mm per second

100 (26,5)

Bearings of hinge and drum of steering, chapter 3.1.4

Synthetic grease with lithium to NLGI-2*

as needed

Engine radiator assembly - coolant see chapter 3.1.5

Mixture antifreeze and water, year- round

26,5 (7)

Vibration drums transmission oil

Type oil - see chapter 3.1.4.

Drum gearbox transmission oil

SAE 80W/90 API GL-5

4,5 (1,2)

Battery

Distilled water

as needed

Windshield washer

Water and antifreeze cleaning

2,75 (0,72)

Front sprinkling tank

Water

520 (137)

Rear sprinkling tank

Water

520 (137)

* - NLGI (National Lubricanting Grease Institute)

8

2x22 (2x5,8)

Make

3.3. Lubrication schedule

LUBRICATION AND MAINTENANCE MANUAL

Fig. 4 - Lubrication plan

9

3.4. Safety and other precautions during maintenance

10

LUBRICATION AND MAINTENANCE MANUAL 3.4.1.

Safety during maintenance Do all maintenance work:

Perform lubrication, maintenance, and adjustments

• using trained personnel, • as scheduled in table, or during inspection of technical conditions,

• as specified in safety, fire, ecological, and health regulations in Operations Manual VH 1700 roller,

• after the machine, lubrication points, and spots for maintenance or repair have been washed,

• with the machine on a firm, flat surface, • wedged against spontaneous movement, • with electrical breaker off, locked batteries cover, and ignition key removed, and with notice ”Machine under repair fixed to the dashboard,

• with machine cooled off, • using undamaged tools,

with the key removed (engine stopped) with electrical wiring disconnected, and the battery compartment locked Let a professional do work that requires the engine running.

With adjustment and service work finished, re-check the function of all safety equipment.

Before arc welding, disconnect all elements containing semiconductors, like the alternator, service hours counter, all control units under the dashboard, etc.

Ground the welding equipment as close to the point of welding as possible.

• with zero hydrostatic pressure, and to valid regulations,

• by replacing defective or worn out parts with new, original ones. The manufacturer is not responsible for damages caused by the use of unauthorized parts.

• with satisfactory illumination at night and poor visibility,

• with covers and safety elements re-installed, • with connectors and bolts tightened to specified torque, and inspection of tightness of connectors that were loosened during maintenance,

• after the fills warmed up by the operation of the machine, preferably in rest – watch out for being burnt – use recommended fills.

11

3.4. Safety and other precautions during maintenance 3.4.2.

Fire prevention when changing service liquids

All flammable liquids are separated into classes as far as fire danger is concerned II

danger class - naphtha

IV danger class - mineral oils, grease, antifreeze mixture

• Perform oil change in a place that doesn’t interfer with an area endangered by explosion or fire.

• The place must be provided with notices ”No Smoking.

Do not use open flame!”

• The working area must be of dimensions that would be sufficiently large to collect the amount of flammable liquid equal to that of the largest shipping container.

• The place must be equipped with portable fire extinguishers.

• When handling oil or naphtha, use metal barrels, canisters, or metal cans.

• Shipping containers must be firmly closed, when stored.

• Containers with one opening must be stored with the opening up, and secured against leaks and seepage.

• The containers must be marked indelibly showing the content and danger class.

12

LUBRICATION AND MAINTENANCE MANUAL 3.4.3.

Environmental and health regulations

The user is obligated to observe general regulations and laws of health and environment protection valid in the area of operating and maintaining the roller.

3.4.3.1. Health regulations Oil products, coolants, battery contents, and lacquers incl. thinners are health injurious chemicals. Workers that are exposed to these products must observe general rules of safety and health protection, and those issued by the manufacturers of these products.

We draw your attention particularly to the following precautions: -

skin and eyes protection when working with batteries

-

skin protection when working with oils, lacquers, and coolants,

-

thorough washing of hands at the end of work, before meals. Apply suitable protection cream.

-

when working with chemicals, follow instructions for the operation of the machine,

• Oil products, coolants, contents of batteries, lacquers and thinners, cleaning and preservation chemicals should be stored in original, properly marked containers. Do not allow these materials to be stored in unmarked bottles or other containers, because of danger through interchange. Particularly dangerous is the possibility of mistaking them for food or drink.

• Should the skin, mucous membrane, or eyes be affected or vapors be inhaled, apply first aid immediately.

See your doctor immediately, should you consume accidentally any of the products.

• When working with the roller, wear always ear protectors of suitable type and make.

13

3.4. Safety and other precautions during maintenance 3.4.3.2. Ecological regulations The contents of all systems and some parts become dangerous waste when discarded after disassembly or replacement/change.

Particularly the following items belong in this waste category:

Related regulations During lubrication and maintenance, the following regulations and standards must be particularly observed:

Work safety and health protection for the operation and maintenance of machinery Fire prevention

-

organic and synthetic grease, oils, and fuel

-

coolants

-

batteries and their content

Health and environment protection as applied to this type of work

-

air-conditioners contents

Dangerous materials and waste

-

cleaning and preservation chemicals

-

all replaced filters and cartridges

-

all removed hydraulic and fuel hoses, rubberized metal parts, and other elements soiled by abovementioned products.

The above-listed materials and parts must be disposed off according to locally valid environment and health protection regulations.

14

Inflammable materials

3.5. Specific lubrication and maintenance procedures Lubrication and maintenance are performed at regular intervals determined by the number of service hours as indicated on the working hours counter.

Removed or loosened screws, bolts, threaded connectors in the hydraulic loops, etc. are to be tightened using torque values of tables in Chapter 3.5.46, unless a specific value is listed for that particular operation.

This manual lists only basic information on the engine. Complete data are listed in the Engine Instructions and Maintenance Manual supplied with the equipment.

Follow instructions in the Engine Instructions and Maintenance Manual!

After 100 service hours of a new machine (after General Overhaul) perform 3.5.30. Very first oil change in the drum reducer

15

3.5. Specific lubrication and maintenance procedures After 20 hours or daily Fig. 5

16

LUBRICATION AND MAINTENANCE MANUAL After 20 hours or daily 3.5.1.

Inspection and adding motor oil

• Perform before starting – the roller must be horizontal on a firm, flat surface

• If the engine was running, wait about 5 minutes for the oil to run off in the crankcase.

• Pull out the oil stick (1), Fig. 6, wipe off with lint free

After 20 hours or daily • Remove cap (1) and add oil through the filler, Fig. 7.

Recheck level after about 1 minute, when oil has reached the crankcase.

• Add oil of the same type.

• Inspect tightness of the engine, correct if necessary.

• Inspect the engine for damaged and/or missing parts, and general shape.

cloth.

• Insert fully, pull out, and read oil level.

• The level should be between the marks on the stick.

• L-mark is the lowest possible limit, H-mark is the top limit.

Use recommended oils only as in Chapter 3.1.1.

• The distance between L and H represents 0.95 l (1 U.S. Quart) of oil.

Do not use the engine, if oil level is not correct.

Fig. 6

Fig. 7

H

MAX.

L

MIN.

1

1

17

3.5. Specific lubrication and maintenance procedures After 20 hours or daily 3.5.2.

Inspection and refill of coolant in radiator

After 20 hours or daily 3.5.3.

Inspection and cleaning of fuel filter

• Check before starting the engine.

• Perform before starting the engine – the roller must be horizontal on a firm, flat surface.

• Check level visually, see Fig. 8.

• Maintain level between ”MIN” and ”MAX” • Should you find a large loss of fluid, check for tightness in the system, and repair.

• Add antifreeze only as specified in Chapter 3.1.6.

• If the filter contains dirt or water, it must be cleaned while the engine is not running.

• Loosen the bottom nut (1) and tilt the bracket (2) to the side, Fig. 9.

• Remove glass (3), and clean it.

• Reinstall.

• Intervals between cleanings depend on the dirt content in the fuel.

Remove the radiator cap when temperature drops below 50° C (120°° F), otherwise there is danger of being scalded by steam or fluid under pressure.

Observe fire regulation – danger of fire When working on fuel systems do not use open flame and don’t smoke Keep fuel from dripping.

Do not use additives in the radiator against leaks in the system.

Do not pour cold fluid into a hot engine. The engine block may crack.

Fig. 8

Fig. 9

3 2 1

18

LUBRICATION AND MAINTENANCE MANUAL After 20 hours or daily 3.5.4.

Inspection and cleaning of the radiator

After 20 hours or daily 3.5.5.

Inspection of engine belts

• Inspect visually with the engine not running.

• Inspect visually, when the engine is not running before work and after.

• Disconnect batteries at the breaker.

• Check for damage. Fissures at right angles to the belt are not serious. The belt must be replaced, if fissures are longitudinal , Fig. 12.

• Check seals of the engine radiator and the oil cooler, Fig. 10. On machines with air-conditioning check condenser seals.

• If dirt deposits are visible, blow pressurized air through the radiator from the cooling fan outwards, Fig. 11.

Fig. 10

Fig. 11

Fig. 12

19

3.5. Specific lubrication and maintenance procedures After 20 hours or daily 3.5.6.

Inspection of cooling fan

After 20 hours or daily 3.5.7.

Inspection of dust valve of the air filter

• Inspect visually while the engine is not running,Fig. 13.

• If damaged (broken off pieces, tears, deformation, etc.), replace.

• Inspect visually while the engine is not running.

• The valve (1), Fig. 14, discharges dust by itself when the engine is running.

• Check whether the valve is not damaged or missing, Fig. 15.

• Occasionally, clean the output slit.

• Remove caked dust by squeezing the upper part of the slit.

Do not operate the machine, if dust valve appears damaged, as in Fig. 15.

Fig. 13

Fig. 14

1

20

LUBRICATION AND MAINTENANCE MANUAL After 20 hours or daily

After 20 hours or daily 3.5.8.

Checking fuel level, and adding fuel

• Do before starting the engine, which should be placed on a horizontal, flat, and firm surface.

• Check quantity of fuel, and add, if indicator lights up.

• Clean fuel tank and fuel filler hose, Fig. 16.

• Fill the tank only to the bottom rim of the fuel filler tube.

• Use only clean, recommended fuel per 3.1.2.

• Observe cleanliness during work.

• Volume of fuel tank is 370 l (98 gal US). Full tank is usually good for about 10 to 25 hrs of service, depending on the load and type of driving.

• Do not run out of fuel, otherwise the entire fuel system must be vented with great effort. See 3.5.40.

Do not use open flame and do not smoke!

Do not add fuel in closed areas.

Add fuel only with the engine stopped.

Do not spill fuel!

Fig. 15

A

Fig. 16

B 1

C

D

A - Broken B - Torn C - Stays open D - Missing

21

3.5. Specific lubrication and maintenance procedures After 20 hours or daily 3.5.9.

Checking oil level in the hydraulic loop tank

After 20 hours or daily 3.5.10. Filling sprinkling tank • Add water while the engine is off, the machine must be

• Check with engine stopped, and the machine horizontally on a firm, flat surface.

• Open left engine cover.

placed horizontally on a flat, firm surface.

• Fill with clean water through the fill lock (1).

• Fill through sieve (2) in the fill hole, Fig. 18.

• Check oil level through the sight glass.

• Maintain level within the low and high marks, Fig. 17.

• Oil level must be always visible in the inspection hole of the sight glass.

• Should there be a larger loss of oil, find the reason and repair. Causes of oil loss may be due to loose joints, faulty hydraulic hoses, leaks in hydraulic generators or hydraulic motors, etc.

• Add as necessary fresh, clean oil of same type, per Chapter 3.1.3, to procedure of 3.5.37.

Call service, if defect discovered during warranty period.

The fill hose to the hydraulic tank has been sealed by the manufacturer, and its opening is not allowed during the warranty period.

With removed seal, warranty is void.

Do not loosen hydraulic loop sections under pressure!

Damaged parts must replaced by identical new parts.

Fig. 17

Fig. 18

1

MAX MIN

22

2

LUBRICATION AND MAINTENANCE MANUAL After 20 hours or daily

After 20 hours or daily

3.5.11. Inspection of warning and control devices

Signal the start of the engine by the horn!

Check whether the start of the engine may injure anybody!

• Switch on battery breaker.

• Check lights and beacon, switches 32, 33, 34, 35,and

Sound the warning horn before starting moving, and wait a while for everybody to leave the vicinity around and underneath the roller in time!

36, Fig. 19.

• Check warning horn (11) and directional lights (12), (28), Fig. 19, 20.

• Turn ignition key to position ”1” - lubrication indicator

Make sure that the area in front and behind the machine is free of people!

(24), park break indicator (25), neutral (27), and charging indicator (30) are on, Fig. 19.

During operations check continually the instruments and indicators on the dashboard!

• Start the engine. Lubrication (24) and charging (30) indicators turn off, Fig. 19.

• Start moving and switch on emergency brake, Fig. 20.

Remove possible defects!

The machine stops and the engine turns off. Brake indicator (25) turns on.

• Check back-up horn, if installed, when ignition is on.

Fig. 19

Fig. 20

24 25

28

12

30 34

27 11

10

32 33

35

36

23

3.5. Specific lubrication and maintenance procedures After 20 hours or daily 3.5.12. Inspection of safety labels and markings • Do before starting the engine.

• Check the condition of safety labels and markings, and whether missing.

24

After 20 hours or daily

LUBRICATION AND MAINTENANCE MANUAL After 250 working hours or 3 months Fig. 21

25

3.5. Specific lubrication and maintenance procedures After 250 working hours or 3 months 3.5.13. Engine oil and oil filter change

After 250 working hours or 3 months • Remove filter (2), Fig. 23.

• Clean seat of filter seal.

• Drain oil when the temperature of the coolant has reached 60 °C (140 °F). ·

• Place the roller horizontally on a flat, firm surface.

• Stop the engine and switch battery off.

• Have a container of about 15 liters ready.

• Unscrew plug (1), Fig. 22 and let oil drain.

• Fill new filter with fresh motor oil.

• Lubricate oil seal, screw filter in, and tighten well by hand.

• Check seal of the drain plug, replace defective one.

• Check thread, and clean seat of plug seal.

• Install plug with torque 50 Nm (37 ft.lb.)

• Clean area around the filter.

Fig. 22

Fig. 23

1 2

26

LUBRICATION AND MAINTENANCE MANUAL After 250 working hours or 3 months

After 250 working hours or 3 months

• Pour fresh motor oil through filling pipe (3), Fig. 24.Total quantity of oil is 14,5 l (3,75 gal US).

Change oil at least every year, even if 250 working hours haven’t been reached

• Start the engine and let it idle for about 2 - 3 min.

• Stop the engine, wait 3 minutes for oil to run off into the

Draining hot oil may cause scalding.

crankcase Check oil level and add more up to the upper mark on the stick, Fig. 25.

Use recommended filters only

• Check tightness.

Use only oils recommended in Chapter 3.1.1.

Don’t strip threads and filter seals by tightening them too much.

Catch drained oil before it seeps into ground.

Salvage oil as required.

Store discarded filters in a container, and dispose of them without affecting the environment.

Fig. 24

Fig. 25

3

H

MAX.

L

MIN.

4

27

3.5. Specific lubrication and maintenance procedures After 250 working hours or 3 months

After 250 working hours or 3 months

3.5.14. Inspection of engine cooling

3.5.15. Inspection of engine intake manifold

• Place the roller on a firm, flat surface.

• Place the roller on a firm, flat surface.

• Stop the engine and disconnect battery.

• Stop the engine and disconnect batteries.

• Inspect connections of the cooling system. Check

• Check tightness of engine intake manifold.

whether rubber pieces are not damaged and hose clips are not missing.

• Check engine and oil radiator fins, whether clean.

• If dirty, follow chapter ”Maintenance as needed” 3.5.41.

• Check whether hoses and elbow (1) are not damaged (tears, fractures, etc.) and whether clips (2) are not missing, Fig. 26.

• Check expansion bag of air filter.

• Do not use the roller, if the expansion bag of the air filter and the intake hose are damaged.

Fig. 26

1 2

28

LUBRICATION AND MAINTENANCE MANUAL After 250 working hours or 3 months 3.5.16. Inspection of vacuum switch of the air filter

After 250 working hours or 3 months The worker on the machine

• Remove cover of air filter on the hood and cover the opening with a piece of heavy paper.

Inspection is performed by two workers, one on the machine, the other in the cabin, in the following sequence:

The worker in the cabin

• Increase speed to 1800 RPM. The worker on the machine

• Secure steering hinge against machine turning, see Driver’s Manual, 2.9.1.

• Check whether indicator (29) lights up, Fig. 27.

• Then turn engine off.

• Wedge the drums against movement and signal the cabin worker thereafter.

The worker on the machine

• Return the machine to its original state.

The worker in the cabin

• Upon the signal of the outside worker, preset speed (3) to full extent left of symbol ”turtle”. The roller is secured against movement, Fig. 27.

• If indicator (29) didn’t light up, find and correct reason for it (faulty bulb, contact, cable, vacuum switch (3)), Fig. 28.

• Start the engine.

Fig. 27

29

3

29

3.5. Specific lubrication and maintenance procedures After 250 working hours or 3 months

After 250 working hours or 3 months 3.5.17. Inspection of oil level in the vibrator

Follow the above-described sequence!

Do not start before the outside worker signals!

When stepping on the machine use ladder or a suitable platform, and be extremely careful.

Do nothing else in the cabin and do not leave the driver’s seat!

To cover the opening, don’t use thin paper. The suction intake may be plugged.

• Place the roller horizontally on a firm, flat surface, with drain plug (1) at the bottom, Fig. 29.

• Stop the engine and disconnect batteries.

• Clean around the filling, control, and drain plugs.

• Unscrew control plug (2), Fig. 29.

• The oil level in the vibrator is correct, if oil starts flowing out.

• Unscrew filling plug (1) and add oil, Fig. 30.

• Use oil of table 3.2.

Observe ecology and prevent oil leaks to ground

Fig. 28

Check after oil cooled off.

3

Fig. 29

Fig. 30

1 2 1

30

LUBRICATION AND MAINTENANCE MANUAL After 250 working hours or 3 months

After 250 working hours or 3 months

3.5.18. Inspection of oil level in the drum reducer • Place roller horizontally on a flat, firm surface.

• Clean control plug (2), remove and check oil level with the stick, Fig. 31, on the right side of the rear drum, and the left side of the front drum.

• Maintain oil level above the bottom mark.

• If necessary, clean plug (1), remove and add oil, Fig. 32.

• Replace plugs and check for tightness of gearbox.

Do not touch hot gearbox and adjacent parts!

Fig. 31

Fig. 32

1

2

1

31

3.5. Specific lubrication and maintenance procedures After 250 working hours or 3 months 3.5.19. Inspection of batteries

After 250 working hours or 3 months Checking the electrolyte

• Check electrolyte density in each cell, Fig. 34.

• Place roller horizontally on a firm, flat surface.

• Stop the engine and disconnect batteries.

• Clean batteries on the surface.

• Check condition of terminals and clamps, clean, Fig. 33.

Grease lightly to get good contact.

• Open plugs of cells and check levels of electrolyte,

• Compare values with table, Fig. 35. The table indicates charge condition at 25 °C (68 °F), and under tropical conditions.

• Should the capacity be insufficient, charge the battery.

• Recharge with the battery removed from the machine.

• Before charging, open cell plugs.

whether at a level of 5 ÷ 15 mm above the plates in all cells, or to the control inserts. The level may be checked using a glass tube.

• A discharged battery may freeze at low freezing tem-

• Add distilled water to cells to reach the required level.

• Connect batteries correctly after charging (polarity),

• Close the batteries.

peratures. Defrost such batteries before recharging, otherwise they may explode. and keep contacts clean and tight.

• Keep batteries clean and dry.

• Demands on batteries in winter are very high. At low temperatures, batteries maintain lower capacity needed for starting the engine than under normal conditions. For that reason, we recommend that batteries and electrolyte levels be checked and/or recharged.

Fig. 34

• If the roller is not to be used for several weeks in winter, remove batteries and store them protected against freezing, lest they be damaged by frost.

Fig. 33

Fig. 35

Density in g/cm3

in °Be (Beume)

Normal Normal Tropics Tropics temperatures temperatures

32

fully charged

1,28

1,23

32°

27°

semi charged

1,2

1,12

24°

16°

exhausted charge immediately!

1,12

1,08

16°

11°

LUBRICATION AND MAINTENANCE MANUAL After 250 working hours or 3 months

After 250 working hours or 3 months

WHEN WORKING WITH BATTERIES OBSERVE THE FOLLOWING:

WHEN WORKING WITH BATTERIES OBSERVE THE FOLLOWING:

Battery electrolyte is a strong acid.

Use rubber gloves and eye protectors for safety.

Disconnect batteries when repairing charging circuit to prevent accidental sparks.

Protect skin and clothing against electrolyte and lead particles.

During removal, disconnect cable from negative terminal first, then from positive.

Should electrolyte enter your eye, wash your eye with water for a few minutes, and seek medical treatment.

Should the electrolyte contact your skin or clothing, undress and wash the spots with soapy water or soda diluted in water as soon as possible, and seek medical treatment.

Drink a lot of water or milk, or magnesium solution, should you consume electrolyte. Seek out medical treatment immediately.

Never add distilled water, unless the battery is to be recharged immediately thereafter. Increased discharge of battery would result.

Never add sulfuric acid (H2SO 4)!

Do not turn batteries upside. The electrolyte may run out of the vents.

Do not disconnect batteries while the engine is running.

When using booster, do not disconnect this source before the battery is connected.

The booster voltage should be 24 V. Before welding, disconnect conductors from terminals ”B+” and ”D+” on the alternator!

Connect the battery by its ”minus” pole to chassis, and ”plus” pole to alternator ”B+”. Opposite connection would damage the entire semiconductor system.

Do not run the alternator without load on terminal ”B+” and connected terminal ”D+”.

Should you spill electrolyte on the ground, wash the spot with water and neutralize with lime.

Recharging batteries releases hydrogen that combines with air to an explosive mixture. Do not handle open flame or light, do not smoke.

Do not produce sparks. Do not handle conductors and electrical devices sparks may result.

Do not check presence of voltage by producing sparks on the chassis.

33

3.5. Specific lubrication and maintenance procedures After 250 working hours or 3 months

After 250 working hours or 3 months

3.5.20. Sprinkling filter - cleaning • Stop the engine and disconnect battery.

• Open cover off water tank (1), Fig. 36.

• Remove sprinkling filter container (1), remove sieve and clean, Fig. 37.

Fill water always through a sieve!

Fig. 37

9

Fig. 36

9

1

1

34

LUBRICATION AND MAINTENANCE MANUAL After 250 working hours or 3 months

After 250 working hours or 3 months

3.5.21. Lubrication of steering joint bearings • Stop the engine and disconnect battery.

• Remove lids, clean grease nipples of -

the upper bearing, Fig. 38.

-

the lower bearing, Fig. 39.

-

Bearings 4x, Fig. 40.

• Keep on feeding grease until fresh grease starts running out.

• Use grease of 3.1.5.

Fig. 39

Fig. 38

Fig. 40

35

3.5. Specific lubrication and maintenance procedures After 250 working hours or 3 months

After 250 working hours or 3 months

3.5.22. Lubrication of steering pins

3.5.23. Lubricating pins of scrapers

• Stop the engine and disconnect battery.

• Stop the engine and disconnect battery.

• Remove lids of nipples, clean surplus grease on nip-

• Remove lids on nipples, clean surplus grease off

ples of both linear hydraulic motors, Fig. 41, 42.

• Keep on feeding grease until fresh grease starts running out.

• Use grease of 3.1.5.

nipples on pins of scrapers, Fig. 43.

• Keep on feeding grease until fresh grease starts running out.

• Use grease of 3.1.5.

3.5.24. Lubrication of hinge pins • Stop the engine and disconnect battery.

• Remove lids on nipples, clean surplus grease off nipples of door hinges, engine covers, sprinkling pump covers.

Fig. 41

• Keep on feeding grease until fresh grease starts running out.

• Use grease of 3.1.5.

Fig. 42

36

Fig. 43

LUBRICATION AND MAINTENANCE MANUAL After 500 working hours (after 6 months) Fig. 44

37

3.5. Specific lubrication and maintenance procedures After 500 working hours (after 6 months) 3.5.25. Replacement of fuel filters

After 500 working hours (after 6 months) • Fill filters with clean fuel and grease O-rings (2), Fig. 47.

• Place the roller on a firm, flat surface.

• Stop the engine and disconnect battery.

• Open right engine cover.

• Screw filter in by hand until seated on the seal, then turn some more by half a turn, Fig. 48.

• Check tightness.

• Clean head of fuel filters, remove filters, Fig. 45.

• Catch escaping fuel in ready containers.

• Clean sealing area of filter bracket, Fig. 46.

• Replace O-ring (1), Fig. 46.

Fig. 45

Fig. 46

1

38

1

LUBRICATION AND MAINTENANCE MANUAL After 500 working hours (after 6 months)

After 500 working hours (after 6 months)

Observe ecological and health rules during replacement!

Observe fire regulations!

Work in ventilated areas without danger of fire!

Prevent fuel from escaping to ground.

Do not smoke and do not use open flame.

Use only recommended filters.

Do not thread filters too tight. Threads and seals may be damaged.

Store used filters in specific containers and handle them without affecting the environment.

Fig. 47

Fig. 48

2

39

3.5. Specific lubrication and maintenance procedures After 500 working hours (after 6 months)

After 500 working hours (after 6 months)

3.5.26. Inspection of anti-freeze fluid • Place the roller horizontally on a firm, flat surface.

• Stop the engine and disconnect battery.

• Drain the required amount of fluid in the density meter, Fig. 49.

• Using the density meter, Fig. 50 siphon a sample of fluid in the filling opening of the expansion container.

• Check at temperature of 20 °C (68 °F), always before the onset of winter.

• The ratio of ethylene glycol or propylene glycol antifreeze in the mixture should be at least 40 % – at ambient temperatures of up to 23 °C (-10 °F).

• Use antifreeze anytime, even when temperatures do not reach below freezing.

• The antifreeze fluid is not only good protection against freezing, it also increases the boiling point. The inhibitors in the fluid protect the cooling system and prolong its service life.

Use work rubber gloves!

Fig. 49

40

Fig. 50

LUBRICATION AND MAINTENANCE MANUAL After 1000 working hours (after 12 months) Fig. 51

41

3.5. Specific lubrication and maintenance procedures After 1000 working hours (after 12 months)

After 1000 working hours (after 12 months) • Insert Cummins no. 3824591 pin with a 1/2” opening

3.5.27. Inspection, adjustment of engine valves

for the key. With this key, the engine can be turned by hand, Fig. 53.

• Place the roller horizontally on a firm, flat surface • Stop the engine and disconnect battery.

• Check and adjust at temperatures below 60 °C (140 °F) - use thermometer in the coolant.

• Locate the top position of cylinder no. 1 by turning the engine and depressing the timing pin simultaneously, Fig. 53.

• See the location of the timing pin on the engine in Fig. 54.

• Remove covers of valves.

• Remove plug (1) in the hole on the wall of flywheel housing where the grooved pin is to be inserted, Fig. 52.

Fig. 53

Fig. 52

Fig. 54

1

42

LUBRICATION AND MAINTENANCE MANUAL After 1000 working hours (after 12 months) • The timing pin falls into the opening of the gear on the camshaft, and cylinder no. 1 is in top position, Fig. 55.

• Pull out the timing pin, Fig. 56.

• Measure the lift of the intake and exhaust valves between the touch points of the valve and the cam using feelers, Fig. 57.

After 1000 working hours (after 12 months) • The correct play of valves: -

Intake valves (1) – play 0,25 mm (0,010 in).

-

Exhaust valves (E) - play 0,50 mm (0,020 in).

• Check and adjust per Fig. 58.

• Adjust play to prescribed value by loosening the safety nut and turning the adjustment screw with a screwdriver,Fig. 57.

Fig. 55

Fig. 57

Gear

Timing pin

Gear assembly cover

Fig. 56

Fig. 58

43

3.5. Specific lubrication and maintenance procedures After 1000 working hours (after 12 months)

After 1000 working hours (after 12 months)

• Thereafter tighten safety nut, torque value is 24 Nm (18 ft-lb).

The sequence of cylinders 1 to 6 starts from the cooling fan belt.

• The play is correctly adjusted, when some friction on the feeler is felt.

Before you start turning, make sure that the timing pin was removed.

Prevent damage to the pin.

• Check again after the nut has been tightened.

• Mark the belt, Fig. 59 and turn the crankshaft by 360°.

• Check adjustment of the other valves to Fig. 60.

• Tighten safety nuts and recheck play. Torque value should be 24 Nm (18 ft-lb).

• Replace valve covers and tighten screws with torque of 24 Nm (18 ft-lb) (Fig. 48).

Fig. 59

44

Fig. 60

LUBRICATION AND MAINTENANCE MANUAL After 1000 working hours (after 12 months) 3.5.28. Inspection of engine belt

After 1000 working hours (after 12 months) Fig. 62

Check tension

• Place the roller on a firm, flat surface horizontally.

• Stop the engine and disconnect battery. Apply park brake.

• Measure with your thumb the flexion of the belt on the long side between the pulleys, Fig. 61. Maximum deflection should be 9,5 to 12,7 mm [3/8” to 1/2”].

• To measure tension the Cummins Part No.ST-1293 fixture may be used. The value measured should be 267 to 578 N [60 - 130 lb-ft], Fig. 62.

Wear check

• Deflect the tension pulley by the lever and remove belt, Fig. 63.

• Check visually for wear.

Fig. 63

• Tears at right angle to the belt are not objectionable, Fig. 64.

• Replace belt, if you see longitudinal tears, worn out edges, or larger pieces missing, Fig. 64.

• Install belt.

• Check tightness of screws on the cover of the tension device, Torque should be 43 Nm [32 ft-lb].

Check and tighten the belt with the engine off.

Fig. 61

Fig. 64

45

3.5. Specific lubrication and maintenance procedures After 1000 working hours (after 12 months)

After 1000 working hours (after 12 months)

3.5.29. Inspection of exhaust system

3.5.30. Oil change in drum reducer

• Place the roller on a firm, flat surface horizontally.

• Place the roller on a firm, flat surface horizontally.

• Stop the engine and disconnect battery.

• Do not touch the reducer and parts while hot.

• Check tightness of the exhaust collectors from the

• Clean around the plugs, Fig. 66.

engine to the turbo fan.

• Check exhaust to the muffler, Fig. 65.

• Tighten exhaust pipes with torque of 21 Nm.

• Place a suitable container underneath the plug,Fig. 67.

• Open all plugs and let oil drain.

• Clean plugs.

• Thereafter close drain plug (3).

Fig. 65

Fig. 66

1

2

3

46

LUBRICATION AND MAINTENANCE MANUAL After 1000 working hours (after 12 months)

After 1000 working hours (after 12 months)

• Pour recommended oil through filler (1), Fig. 68.

Change oil for the first time after 100 service hours!

• Check amount of oil with dipstick in control plug (2), Fig. 66. The level must reach the upper mark.

• Replace plugs (1) and (2).

• Check tightness of gearbox.

Do not touch hot parts!

Do not drain hot oil!

Behave ecologically!!!

Fig. 67

Fig. 68

3 1

47

3.5. Specific lubrication and maintenance procedures After 1000 working hours (after 12 months) 3.5.31. Inspection of rubberized metal parts

After 1000 working hours (after 12 months) Fig. 70

• Place the roller on a firm, flat surface horizontally.

• Stop the engine and disconnect battery.

• Check positions of rubberized metal parts, tightness of screws and nuts per table in Chapter 3.5.46.

• Check quality of parts for tears, cohesion of rubber with metal in -

the damping assembly of both drums, Fig. 69, 70.

-

the flexible suspension of the engine, Fig. 71, 72, and the driver’s compartment.

• Have faulty parts replaced by professional service with identical parts from catalogue ND.

Fig. 71

Fig. 69

48

Fig. 72

LUBRICATION AND MAINTENANCE MANUAL After 1000 working hours (after 12 months)

After 1000 working hours (after 12 months) Fig. 74

3.5.32. Cleaning of water tanks • Place the roller on a firm, flat surface horizontally.

• Stop the engine and disconnect battery.

• Remove lock of filler (1), sieve (2) from the filler and clean it, Fig. 73.

• Remove drain plug (1) and drain water, Fig. 74.

• Remove filter box (1) with the sieve, Fig. 75.

• Flush the box and the sieve, clean, and install.

1

• Flush the tank with a stream of water. If necessary, remove the lid of the tank (3), Fig. 73.

• Check the function of sprinkling jets (1), Fig. 76.

Fig. 75

Fill tanks with clean water through the sieve in the filler!

Drain tanks and the sprinkling system always before temperature drop below freezing!

( 1

Fig. 76

Fig. 73

2

1 3

1

49

3.5. Specific lubrication and maintenance procedures After 2000 hours of service (after 2 years) Fig. 77

50

LUBRICATION AND MAINTENANCE MANUAL After 2000 hours of service (after 2 years) 3.5.33. Change of cooling fluid

After 2000 hours of service (after 2 years) • Start the engine and wait until 80 °C (175 °F) is reached. In the meantime, check for leaking coolant.

• Drain the fluid at 60 °C (140 °F).

• Stop the engine.

• Place the roller on a firm, flat surface horizontally.

• Check the level of coolant in the equalizing box,

• Stop the engine and disconnect battery.

• Open radiator by removing the pressure cap (1) on the

Fig. 78.

• Should it be below ”MIN” mark, add fluid to reach ”MAX” mark.

radiator equalizing box, Fig. 78.

• Open drain on the radiator.

• Drain the fluid into a ready container. The quantity of fluid is 27 l (7 gal US).

• Check for damaged hoses or missing clamps in the cooling system of the engine.

When removing the pressure lid, wait for the temperature to drop below 50 °C (120 °F) to avoid being scalded by escaping fluid!

• Check the radiator for damage, leaks, and dirt in the fins.

• Clean as in 3.5.41, and/or repair.

• Refill the system with fresh fluid, Fig. 79 (60 % of water

Observe ecological and health rules during change.

and 40 % of antifreeze).

• Wait for about 2 to 3 minutes until the loop is full.

Use fluid as per Chapter 3.1.6!

• Close the equalizing box with the pressure lid.

Protect your hands with rubber gloves!

Protect your eyes with glasses or goggles!

Liquidate used fluid as specified!

Fig. 78

Fig. 79

1

40 %

60 %

51

3.5. Specific lubrication and maintenance procedures After 2000 hours of service (after 2 years) 3.5.34. Inspection of damper of engine torsion vibrations

After 2000 hours of service (after 2 years) 3.5.35. Vibrator oil change • Change oil while warm.

• Check position of discarded marks on the face of both sections of the damper of torsion vibrations, Fig. 80. If these marks have moved against each other by more than 1.59 mm (1/16”), the damper should be replaced.

• Place the roller on a firm, flat surface for the drain plug (3) to be in its lowest position, Fig. 81.

• Stop the engine and disconnect battery.

• Clean around the plugs.

• Place a suitable container underneath the drain.

• Remove plugs (1, 2, 3) and let the oil drain.

• Thereafter install drain plug (3).

• Pour recommended oil as in table 3.2 through filler (1), Fig. 82.

• Fill up to edge of control hole (2), Fig. 81 – Oil must leak out.

• Install remaining plugs.

Fig. 80

Pay attention to draining hot oil. Do not get scalded!

A

Prevent oil from seeping into the ground!

A A

Fig. 81

Fig. 82

1 2 3

52

LUBRICATION AND MAINTENANCE MANUAL After 2000 hours of service (after 2 years)

After 2000 hours of service (after 2 years)

3.5.36. Cleaning of fuel tank • Place the roller on a firm, flat surface horizontally in a well-ventilated room to avoid fire.

• Stop the engine and disconnect battery.

• Clean when the tank is almost empty – after the fuel level indicator was turned on.

• Remove drain plug (1), Fig. 83, and let remaining fuel run into a ready container underneath it.

• Remove cleaning lid with the fuel indicator. Do not damage the meter.

• Flush the tank with fresh fuel and remove dirt.

• Install drain plug and cover, check seals.

• Vent the fuel system as in chapter 3.5.40.

Observe fire regulations!

Do not use open flame and do not smoke!

Observe ecological and health regulations!

Clean in a ventilated room for fire safety!

Avoid spilling fuel into the ground.

Fig. 83

1

53

3.5. Specific lubrication and maintenance procedures After 2000 hours of service (after 2 years)

After 2000 hours of service (after 2 years)

3.5.37. Oil and filter change in the hydraulic loop

• Thread on the drain valve at the bottom of the tank, Fig.

• We recommend oil change and hydraulic tank cleaning in springtime or before the working season, when the roller has been standing for a period.

85.

• Collect oil in a ready container - the quantity of oil is100 l (26,5 gal US).

• Remove intake hose (1), and lid (2) with the intake pipe and the suction basket, Fig. 86.

• Place the roller on a firm, flat surface horizontally.

• Remove suction basket off the intake pipe.

• Stop the engine and disconnect battery.

• Wash the basket in gasoline and blow out with com-

• Drain oil below 50 °C (122 °F).

• Remove terminal, Fig. 84, insert hose.

pressed air from within.

• Check the condition of the basket and replace it, if the sieve has been damaged.

• Install the basket on the intake pipe.

• Inspect the inside of the tank. Clean thoroughly if dirt is found at the bottom, and flush with fresh oil. The entire top lid (3)can be removed with the filler (4) for easier cleaning.

Fig. 84

• Reinstall lid (2) with the intake pipe and the basket.

Fig. 85

Fig. 86

Lubricate slightly he O-ring. If the upper cover (3) was removed, use fresh Teflon seal strip.

4

1 2

54

3

LUBRICATION AND MAINTENANCE MANUAL After 2000 hours of service (after 2 years)

After 2000 hours of service (after 2 years)

Replacing filter cartridge

• Replace together with oil change always -

following a major overhaul of the hydraulic loop

-

after repair or replacement of the hydraulic motor or the hydraulic generator

-

when the indicator of the pressure filter (26) of hydraulic oil lit up and temperature of 50 – 60 °C (122 – 140 °F) was reached, Fig. 87.

• Replace filter cartridge in the filtration block, Fig. 88.

• Remove filter container (2) with filter cartridge (3) using wrench 27, and remove the cartridge, Fig. 89.

• Clean thoroughly filter container.

• Clean the seat of the filtration block underneath.

• Insert fresh cartridge in the filter container and screw back – tighten with torque of 40 +10 Nm (30 +7 lb ft).

Fig. 88

Fig. 87

26 Fig. 89

2

3

55

3.5. Specific lubrication and maintenance procedures After 2000 hours of service (after 2 years)

After 2000 hours of service (after 2 years)

Filling the hydraulic system

• Fill to the top, Fig. 92 - disconnect filling equipment.

• Fill using fresh, clean oil in the filling equipment. The

• Start the engine, adjust RPM to 1200, and test the

old oil and dirt from the hydraulic loop, the hydraulic generator, and hydraulic motor will be flushed out. The amount of old oil and dirt in the new fill will decrease, and life expectancy will be prolonged. Machines at the manufacturing plant are filled in the same manner.

• The filling equipment , Fig. 90, must have –

pressure of 6 MPa (870 PSI) at least

–

filtering capacity of 3÷10 µm

machine.

• Check tightness, and/or add oil with the filling equipment.

• Quick-coupler of the filling equipment 2FFN38 GAS F corresponds to FASTER 2FFN38 GAS M quick-coupler of the filling loop.

• The filling equipment and/or the quick-coupler may ordered from the machine manufacturer.

• Slide the filling equipment quick-coupler on the quickcoupler on the right side of the engine compartment, Fig. 91.

• Keep on filling until fresh oil starts escaping from the drain. Collect oil in a catch basin.

• After about 20 l (5,5 gal US) have drained, remove terminal from the drain hole and fix it to the side of the tank, Fig. 84.

Fig. 91

Fig. 90

Fig. 92

56

LUBRICATION AND MAINTENANCE MANUAL After 2000 hours of service (after 2 years)

After 2000 hours of service (after 2 years)

Emergency filling of the hydraulic system

• Use this procedure only in emergencies – the manu-

Attention !

facturer doesn’t recommend it.

• With this procedure, a large amount of used oil remains in the loop, and the life expectancy of hydraulics will be lowered.

• Shorten the oil change interval to 1000 hours or 1 year.

The tank lock is sealed Warranty is void, should the seal be broken before its expiry.

• Fill through filler (4),Fig. 86, the specified type of fresh, clean oil amounting to 100 l (26,5 gal US) as in Fig. 92, to the top.

• Start the engine, adjust RPM to 1200, and test the roller until all loops are full.

• Add oil to level as in Fig. 92.

If the hydraulic motor or the hydraulic generator is defective, internal parts may be destructed, in which case it becomes necessary to clean the hydraulic tank and to remove mechanical debris, before a new aggregate is installed.

Maintain cleanliness, and avoid soiling the system with materials that could cause defects in important parts of the aggregate.

Use cleaners that are lint free.

Close or cover containers with fresh hydraulic oil to prevent dirt or water to affect the fluid.

Do not open the container unnecessarily.

When changing oil, follow ecological and health regulations.

Follow fire regulations.

Draining hot oil may cause scalding Use only recommended filters.

Use only recommended oils of Chapter 3.1.3.

Collect and liquidate drained oil according to regulations.

Do not tighten the filter too hard. The thread and seal may be damaged.

Store used filter in a separate container, and handle it without affecting the environment.

57

3.5. Specific lubrication and maintenance procedures Maintenance as needed Fig. 93

58

LUBRICATION AND MAINTENANCE MANUAL Maintenance as needed 3.5.38. Cleaning and replacement of air filter cartridge

Maintenance as needed • Remove the used cartridge carefully.

• Clean the filter inside and sealing seats in the filter with a cloth.

• The life of the cartridge depends on the environment in which it operates. With the indicator (29) lit up, Fig. 94, the cartridge must be cleaned or replaced, at least during the 12 months of operations.

• Place the roller on a firm, flat surface horizontally.

• Stop the engine and disconnect battery.

• Do not use compressed air to avoid dust entering the intake pipes of the engine.

• Install a new or cleaned cartridge. Check its position and seal.

• Remove safety cartridge (6) , Fig. 96 only when replacing the main cartridge.

• Remove dust valve (1) and clean. Install again, Fig. 95.

• Unscrew nut (1) and remove lid with the main cartridge (2), Fig. 96.

Fig. 95

1

Fig. 94

Fig. 96

29

59

3.5. Specific lubrication and maintenance procedures Maintenance as needed

Maintenance as needed

Cleaning of main cartridge

Main cartridge replacement

• Use only dry compressed air. Its pressure shouldn’t be

• Carefully remove the used cartridge.

more than 5 bar (72 psi). Blow air at a slight angle from within.

• The cartridge may be cleaned only 5 times, when a new one must be used. The cartridge must be replaced by a new one at least once year.

• Check for dust in the old cartridge, which would indicate its tightness in the filter.

• Press the seal of the new cartridge to see if it is flexible, Fig. 97.

• Record each cleaning on the lid of the cartridge.

• Check proper seating of the seal.

• Do not clean a cartridge soiled by carbon soot, replace

• Check connections and pipes whether tight.

only.

• After cleaning, check the cartridge with light whether damaged, and replace it in that case.

• We recommend that a spare cartridge is always on hand. Damaged cartridge is ineffective, and dirt may lower the life expectancy of the engine.

Fig. 97

60

LUBRICATION AND MAINTENANCE MANUAL Maintenance as needed Safety cartridge

Maintenance as needed 3.5.39. Cleaning of fuel separator

• Replace safety cartridge (6), Fig. 96, with a new one -

always when you replace the main cartridge

-

after five cleanings of the main cartridge

-

after two years of use

-

if the indicator lights up after the main cartridge has been cleaned

-

if the main cartridge was damaged.

Change of safety cartridge -

Loosen fixing nut (4).

-

Remove safety cartridge (6).

-

Insert new cartridge and use a new fixing nut (4), Fig. 96.

• If fuel contains dirt as a rule, clean the fuel separator filter.

• Have a can ready for catching the sediment.

• Stop the engine and disconnect battery.

• Turn the separator valve (1) by 4 turns cw until the valve extends by about 25 mm (1") down, Fig. 98. Let fuel drain until clean.

• Push the valve up and turn it back.

• If you drained more than 6 cl (2 oz) of fuel, add fuel to filter as in Chapter 3.5.25, and vent as in Chapter 3.5.40. You will prevent difficulties in starting.

Use correct cartridges Use only original cartridges Do not use damaged cartridges Do not remove the cartridge for inspection Do not judge dirty, used cartridge from its appearance Do not leave the filter open longer than absolutely necessary.

Do not use a filter with damaged lid or body.

Do not hammer out a cartridge Do not clean filter cartridges with gasoline or liquids.

Fig. 98

When washing the machine watch that water doesn’t enter the air filter.

If moisture enters the filter remove and dry out both cartridges.

`

1

61

3.5. Specific lubrication and maintenance procedures Maintenance as needed

Maintenance as needed

3.5.40. Venting the fuel system Venting of the fuel system is done before the first start when -

the fuel filters are not filled with fuel – the filters are changed

-

the fuel pump has been replaced

-

the high-pressure hoses, or the injector have been replaced

-

the machine has been idle for a long time

-

the engine ran out of fuel.

Venting low-pressure pipes and filters

• Loosen venting screw on the fuel filters (1), Fig. 99.

• Pump fuel with pump (2), Fig. 100 until clean, bubblefree fuel starts running out.

• Tighten venting screw with torque of 9 Nm (7 ftlb).

Fig. 99

Fig. 100

1

2

62

LUBRICATION AND MAINTENANCE MANUAL Maintenance as needed

Maintenance as needed

Venting high-pressure pipes and injectors.

• If you finished the above and the engine still didn’t

The pressure of fuel in the highpressure pipes is large and may cause serious injury to skin.

start, vent high-pressure pipes as in Fig. 101, 102.

• Vent by loosening one or more nuts on the injector, and

Do not vent a hot engine. The fuel may run out on hot exhaust pipes and ignite.

by turning the engine the air is pushed out of the highpressure pipes.

• Vent until the engine runs smoothly.

Collect escaping fuel.

• Tighten loose connections with torque of 30 Nm (22 ft-lb).

Do not use open flame during work on the fuel system.

Do not smoke.

If you used the starter for venting, do not turn the engine for more than 30 sec. Wait 2 minutes between starts.

The engine could start. Be careful of safety.

Fig. 101

Fig. 102

63

3.5. Specific lubrication and maintenance procedures Maintenance as needed

Maintenance as needed

3.5.41. Cleaning of the radiator

3.5.42. Adjustment of vibrating frequency

• Place the roller on a firm, flat surface horizontally.

Frequency can be measured in two ways

• Stop the engine and disconnect battery.

1. By a portable device

• Clean with compressed air or water (steam) from the side of the fan.

• Do not use cleaners under high pressure.

• With the machine working in a dusty environment clean more often. The coolant and the hydraulic oil temperature increase with dirty radiator.

• If the radiator is soiled with oil, spray cleaners on the radiator fins.

FAM 012 Geodynamic AB - Sweden ECM Vibrometer VM - Czech. Republic.

• Attach the device (1) on the bracket perpendicularly, Fig. 103 (there is a mark on the sensor indicating the direction of vibration pickup) and read frequency on the display per instructions.

• ECM Vibrometer may be ordered from the machine manufacturer.

2. By reading vibration frequency in Hz units on the multifunctional display on the dashboard. This method is less accurate.

When using cleansers, follow the manufacturer’s instructions.

When the radiator is soiled with oil derivatives (oil, grease), find the cause of fouling.

Do not damage radiator fins when cleaning.

Collect cleaning water in catch basins, and observe ecological regulations.

Fig. 103

1

64

LUBRICATION AND MAINTENANCE MANUAL Maintenance as needed

Maintenance as needed

Frequency adjustment

• Stop the engine and adjust frequency.

Low amplitude Loosen safety nut (3) and by turning the upper screw of the hydraulic generator (1) adjust to required value 60Hz (3000VPM), tighten safety nut, Fig. 104. By turning the screw out frequency increases, and vice-versa.

High amplitude

Adjust with the engine off.

Loosen safety nut (3). Turn lower screw (2) until frequency of 45 Hz (2700 VPM) is reached, tighten nut (3), Fig. 105.

By turning the screw out frequency increases, and viceversa.

Fig. 104

Fig. 105

1

3

3 2

65

3.5. Specific lubrication and maintenance procedures Maintenance as needed

Maintenance as needed

3.5.43. Scrapers adjustment • Place the roller on a firm, flat surface horizontally.

• Stop the engine and disconnect battery.

• Loosen three screws (1).

• Turn scraper with the hexagon (2), Fig. 106, until the plastic wiper (3), Fig. 107, is pressed against the drum with torque of 300 Nm.

• Secure scrapers in the position by tightening screws (1).

• When the scraper is worn and the effect lost, adjust again to provide for guaranteed scrapping of the drum, or slide the wiper out by loosing screws (4), Fig. 107.

When transporting the roller for a considerable distance while the scrapers are not in use, we recommend loosening the scrapers to a position where no scraping is taking place.

Fig. 106

Fig. 107

1 4

1

66

2

1

4

4

3

LUBRICATION AND MAINTENANCE MANUAL Maintenance as needed 3.5.44. Cleaning of filter in the cabin ventilation

Maintenance as needed 3.5.45. Cleaning the roller • After work, clean the roller of all major grime.

• Clean regularly once a month, or more if working in a dusty environment.

• Remove cover grid (1) on the outside rear wall of the

• Clean completely at least once a week. After work on homogenous, cement or lime stabilized soils, clean daily.

• Do not use aggressive and easily combustible clea-

cabin, Fig. 108.

• Replace filter (2) with the filtration element (3), Fig.

ners, like gasoline.

• Stop the engine and disconnect battery.

109.

• Shake out the element and wash it in soapy water. Use a new one if damaged or soiled too much.

• When using steam cleaner do not expose electrical parts and insulating material to direct streams of steam. Cover such spots.

• When washing the roller, watch out that water doesn’t enter air filter through the grill on the rear wall of the cabin.

• Prior to cleaning with pressurized water, steam, etc., cover all openings that the cleaners could enter, like engine intake, battery compartment. Thereafter remove such covers.

Fig. 109

Fig. 108

1

2

1

67

3.5. Specific lubrication and maintenance procedures Maintenance as needed

Maintenance as needed

3.5.46. Inspection of screw joints • Check regularly whether any screws are loose.

• Use torque wrenches.

Fig. 110 - Table of screw tightening moments with metric worm.

TIGHTENING MOMENT For the screws For the screws For the screws 5.8 (5 S) 8.8 (8 G) 10.9 (10 K) Worm

Nm

lb-ft

Nm

lb-ft

Nm

lb-ft

M4

2

1

3

2

4

3

M5

4

3

6

4

8

6

M6

7

5

10

7

14

10

M8

16

12

22,5

17

32,5

24

M10

31,5

23

44

32

62

46

M12

53

39

75

55

105

77

M14

79

58

118

87

165

122

M16

113

83

165

122

226

167

M18

172

127

245

181

343

253

M20

226

167

314

232

441

325

M22

284

209

392

289

559

412

M24

392

289

549

405

755

557

M27

520

384

716

528

1020

752

• Values in the table apply to torque on dry threads, with friction coefficient of 0,14, and not on greased threads.

68

Safety lock nuts may be retightened 3 times only.

LUBRICATION AND MAINTENANCE MANUAL Maintenance as needed Fig. 111 - Table of insert nuts tightening moments with tightening “O” circle – the hoses

Tightening moments for the sliding nuts with the tightening circle “O” – hoses Nm

lb-ft

Size spanner

Worm

Hose

Nominal

Min

Max

Nominal

Min

Max

14

M12x1.5

6

20

15

25

15

11

18

17

M14x1.5

8

38

30

45

28

22

33

19

M16x1.5

8

45

38

52

33

28

38

51

43

58

38

32

43

10 22

M18x1.5

10 12

24

M20x1.5

12

58

50

65

43

37

48

27

M22x1.5

14

74

60

88

55

44

65

15 30

M24x1.5

16

74

60

88

55

44

65

32

M26x1.5

18

105

85

125

77

63

92

36

M30x2

20

135

115

155

100

85

114

166

140

192

122

103

142

22 41

M36x2

46

25 28

50

M42x2

30

240

210

270

177

155

199

50

M45x2

35

290

255

325

214

188

240

M52x2

38

330

280

380

243

207

280

42

69

3.5. Specific lubrication and maintenance procedures Maintenance as needed

Maintenance as needed

Fig. 112 - Table of tightening moments for necks with tightening edge, or with flat packing

Fig. 113 - Table of tightening moments for plugs with flat packing

Tightening moments for the necks

70

Tightening moments for the plugs

G-M

Nm

lb -ft

G -M

Nm

lb -ft

G 1/8"

25

18

G 1/8"

15

11

G 1/4"

40

30

G 1/4"

33

24

G 3/8"

95

70

G 3/8"

70

52

G 1/2"

130

96

G 1/2"

90

66

G 3/4"

250

184

G 3/4"

150

111

G 1"

400

295

G 1"

220

162

G 11/4"

600

443

G 11/4"

600

443

G 11/2"

800

590

G 11/2"

800

590

M 10 x 1

25

18

M 10 x 1

13

10

M 12 x 1,5

30

22

M 12 x 1,5

30

22

M 14 x 1,5

50

37

M 14 x 1,5

40

30

M 16 x 1,5

60

44

M 16 x 1,5

60

44

M 18 x 1,5

60

44

M 18 x 1,5

70

52

M 20 x 1,5

140

103

M 20 x 1,5

90

66

M 22 x 1,5

140

103

M 22 x 1,5

100

74

M 26 x 1,5

220

162

M 26 x 1,5

120

89

M 27 x 1,5

250

184

M 27 x 1,5

150

111

M 33 x 1,5

400

295

M 33 x 1,5

250

184

M 42 x 1,5

600

443

M 42 x 1,5

400

295

M 48 x 1,5

800

590

M 48 x 1,5

500

369

LUBRICATION AND MAINTENANCE MANUAL Maintenance as needed

Maintenance as needed

71

3.6. Maintenance records

Date

72

Number of hours

Event

LUBRICATION AND MAINTENANCE MANUAL

Date

Number of hours

Event

73

3.6. Maintenance records

Date

74

Number of hours

Event

LUBRICATION AND MAINTENANCE MANUAL

Date

Number of hours

Event

75

3.7. Identifying defects Considering the complexity of the machine it is practically impossible to identify the defect precisely without the use of diagnostic equipment, and to effect repairs. In no case should you try to establish the defect and repair it by yourself.

Address the service department of the manufacturer, in case of a defect.

For effective communication with service regarding the identification of defects, follow Chapter 3.7.2.

3.7.1.

Identifying engine defects

Defect

Possible cause

Remedy

Engine cannot be started, starter turning

No fuel

Add fuel and/or vent fuel system

Fuel system not tight

Check connections for tightness, repair.

Add fuel with manual pump

Air locks in fuel system

Vent fuel system

Filters and lines soiled

Clean lines and change filters

Filters and lines filled with paraffin in winter

Clean, replace filters and use winter fuel

The starter turns slowly, battery discharged or contacts oxidized, Clamp not tight

Check battery, add electrolyte. Clean contacts, tighten clamps and grease-

Heavy oil used in winter

Use oils suited to ambient temperature

Engine stopped by the engine shutoff solenoid, hydraulic oil level signal lamp lights.

Add hydraulic oil to specified level

Engine stopped by the engine shutoff solenoid.

Check solenoid voltage Y4 and fuse F5, cables, relay K6, contacts

Output valve on the injector pump

Let manufacturer’s service check

76

LUBRICATION AND MAINTENANCE MANUAL

Defect

Possible cause

Remedy

Engine cannot be started, starter doesn’t turn

Wiring disconnected, Engine indicator doesn’t light up

Connect wiring by turning the breaker

Condition for roller travel not provided

Folding arm with travel control lifted, or push-button of emergency brake depressed

Travel control is not in neutral, and indicator of neutral is not on.

Place controller in neutral

Faulty battery or wiring

Check voltage of battery, contacts, wiring to starter

Starter

Check wiring, pinion pushed out

Ignition box

Check function and wiring in ignitionwiring, relay K5, switch S15 and S16, wiring of plugs

Mechanical defect on the engine, clutch or hydrostatic devices

Check whether engine turns by means of crankshaft belt

Lack of coolant

Stop the engine immediately, add fluid, find cause of leak, and repair.

Radiator plugged up

Remove dirt

Tension arrangement faulty, or belt broken

Repair, replace belt

Thermostat not working properly

Check thermostat, or replace

Cooling loop is heavily soiled

Clean cooling loop

Defective injectors

Let professional service check

Incorrectly adjusted fuel dosage delivery

Let professional service adjust

Too high ambient temperature

Limit working time and let engine cool off

Incorrectly adjusted start of injection

Let professional service check

Oil level too low

Add oil

Oil leaks

Stop the engine immediately, check joints in oil loop, repair if necessary.

Oil in engine of incorrect viscosity for actual ambient temperature

Replace oil with recommended one

Engine overheated

Let engine cool off. Find cause

Engine overheats

Engine not properly lubricated. Lubrication indicator is on.

77

3.7. Identifying defects

Defect

Possible cause

Remedy

Engine runs irregularly and at low power

Air locks in fuel system

Vent, repair leaks

Defective injectors

Let professional service check

Incorrect valve setting

Let professional service check

Broken injector pipe

Let professional service check

Incorrectly adjusted pump

Let professional service check

Increased vacuum in intake manifold

Check vacuum switch, and/or replace pads

Oil level in engine too high

Decrease level to upper mark o dipstick

Incorrect compression due to burnt or broken piston rings

let rings be checked in professional service shop, or adjust valves

High consumption of oil

Oil system leaks

Repair

Piston ring loose, or engine worn out

Let professional service check

Engine’s power too low

Fuel filters soiled

Replace filters

Incorrectly adjusted valves

Adjust

Plugged up injectors, or not adjusted to proper pressure

Let professional service check

Incorrectly adjusted injection pump, fuel injection advance, cylinder compression, or turbo fans.

Let professional service check

Engine smokes too much

Other information regarding possible defects is listed in the Engine Manual supplied with the roller.

78

LUBRICATION AND MAINTENANCE MANUAL 3.7.2.

Electrical wiring defects

Travel system

• Indicator of soft stop – start flashes (31), Fig. 114.

Control and cabling system

• Display on dashboard (14) shows ”ERROR”, Fig. 114.

• Red diode STATUS (A) on control unit (2) on the left side underneath the dashboard flashes, Fig. 116.

• Red diode flashes STATUS (A), Fig. 115, on control unit (1) under the dashboard (dashboard must be unfolded).

STATUS diodes on the control unit signal in code, which indicates the type of defect.

Fig. 115

1

A Fig. 114

31

Fig. 116

A 14

2

79

3.7. Identifying defects 3.7.3.

Defects in hydraulic system

Defects in hydraulic system are tested by measuring pressure in that hydraulic loop, where defect appears.

Values of pressured measured in hydraulic loops Attached terminals

*

-

** -

80

Measured pressure

Max. pressure in safety valves in MPa (PSI)

1

Pressure in travel loop forward

38 (5510)

2

Pressure in travel loop back

38 (5510)

3

Pressure in vibration loop (small amplitude)

38 (5510)

4

Pressure in vibration loop (large amplitude)

38 (5510)

5

Supplemental pressure in vibration loop *

2,2 (319)

6

Pressure in steering loop **

25 (3625)

7

Supplemental pressure in loops

2,2 (319)

Measured with vibration on This pressure appears only when turning of the drum is blocked, and with max. engine revolutions.

LUBRICATION AND MAINTENANCE MANUAL Location of connecting terminals of measured pressures in hydraulic loops Fig. 119

Connecting terminal 1 of travel hydraulic generator, Fig. 117.

5

Connecting terminal 2 of travel hydraulic generator, Fig. 118.

3

Connecting terminal 3÷5 of flushing valve on the frame under the hydraulic tank, Fig. 119.

4

Connecting terminal 6 in steering loop – steering block on the frame, Fig. 120.

Connecting terminal 7 of supplemental pressure in loops – on the block of hydraulic oil pressure filter, Fig. 121.

Fig. 117

Fig. 120

6 1

Fig. 118

Fig. 121

7

2

81

Appendix Electrical installation Description A1 A2 A3 A4 A5 A6 A7 B1 B2 B3 B4 B5 B6 E1 E 2,3 E 4,5 E 6,7 E 8,9 E 10,11 E 12,13 E 14,15 E 16,17 E 18,19 E 20 F 1-12 G 1,2 G3 H1 H2 H3 H4 H5 H6 H7 H8 H9 H 10 H 11 H 12 H 13 H 14 H 15 K1 K 2-8 M1 M2 M3 M4 M5 M6 M7 M8 P1 P2 P3 P4 Q1 R1

82

Directional lights flasher (custom accessory) Brake timer Travel electronics Steering electronics Travel control Display Sensor of hinge angle turning the roller RPM sensor of the engine RPM sensor of front travel hydraulic motor RPM sensor of vibration hydraulic motor Temperature sensor of engine coolant Temperature sensor of hydraulic oil Fuel level floater Instruments illumination Front silhouette lights (custom accessory) Rear lights (custom accessory) Front headlights Rear lights Cabin illumination Left directional lights (custom accessory) Right directional lights (custom accessory) Side lights (custom accessory) Rear drum illumination (custom accessory) Warning beacon (custom accessory) Fuses – heat melting Batteries Alternator Directional lights indicator (custom accessory) Horn Vibrator switch indicator Back-up horn (custom accessory) Hydraulic oil level indicator Neutral position indicator Control of soft start and stop Sprinkling indicator Fuel low level indicator Battery charger indicator Engine lubrication indicator Plugging of hydraulic oil filter indicator Air filter plugging indicator Park brake indicator Coolant level indicator Breaker Auxiliary relay Engine starter Motor of front drum sprinkling Motor of rear drum sprinkling Motor of front windshield wiper Motor of rear windshield wiper Motor of windshield washer Motor of rear windshield washer Fan Thermometer of engine coolant Thermometer of hydraulic oil Operating hours counter Fuel gauge Battery breaker Potentiometer of frequency adjustment (custom accessory)

R2 R3 R4 R 5,6 R 7-16 S1 S2 S3 S4 S5 S6 S7 S8 S9 S 10 S 11 S 12 S 13 S 14 S 15 S 16 S 17 S 18 S 19 S 20 S 21 S 22 S 23 S 24 S 25 S 26 S 27 S 28 S 29 S 30 S 31 S 32 S 34 S 35 V 1-5 X1 X 2-39 X 40 X 41,42 Y1 Y2 Y3 Y4 Y5 Y6 Y7 Y8 Y9 Y 10

Potentiometer of sprinkling intervals Potentiometer of maximum travel speed of the roller Potentiometer of direction steering (steering wheel) Resistors with shunts Resistors Ignition box Front headlights switch Rear lights switch Warning lights switch (custom accessory) Directional signals switch (custom accessory) Side illumination switch (custom accessory) Warning beacon switch (custom accessory) Horn button Fast travel switch Double-switch of differential lock Vibration switch Vibration switch on travel controller Vibration service button Back-up horn switch in travel controller Emergency brake button Neutral position switch in the travel controller Floater in the hydraulic oil tank Switch of protection against over-revving the engine Soft start and stop button Sprinkling switch Engine lubrication pressure switch Pressure switch of hydraulic oil filter plugging Vacuum switch of air filter plugging Park brake pressure switch Front windshield wiper switch Rear wiper switch Washer button Fan switch Air-conditioning switch (custom accessory) Air-conditioning thermostats (custom accessory) Pressure fuse of air-conditioning (custom accessory) Position switch for heater control (custom accessory) Park brake button Sensor of coolant level Diodes Accessory plug Interconnecting plugs Fork of CAN BUS Diagnostic plugs Solenoid valve of fast travel of front drum Solenoid valve of fast travel of rear drum Vibration pump power valve Solenoid valve for stopping the engine Solenoid valve of park brake Travel pump power valve Solenoid for blocking the direction potentiometer Steering wheel) Solenoid valve of steering right Solenoid valve of steering left (custom accessory) Solenoid clutch of air-conditioning compressor

Fig. 122 - Electrical installation

FRONT SILHOUETTE LIGHTS

FRONT HEADLIGHTS

REAR LIGHTS

83

LUBRICATION AND MAINTENANCE MANUAL

REAR LIGHTS

RIGHT REAR DIRECTIONAL LIGHTS RIGHT FRONT DIRECTIONAL LIGHTS

SIDE LIGHTS

REAR DRUM ILLUMINATION

WARNING BEACON

HORN

FAST TRAVEL OF FRONT DRUM FAST TRAVEL OF REAR DRUM

Appendix

LEFT REAR DIRECTIONAL LIGHTS

Fig. 122 - Electrical installation

84 LEFT FRONT DIRECTIONAL LIGHTS

Fig. 122 - Electrical installation

VIBRATION PUMP POWER VALVE

BACK-UP HORN

HYDRAULIC OIL LEVEL

PARK BRAKE

85

LUBRICATION AND MAINTENANCE MANUAL

STOPPING THE ENGINE

RPM SENSOR OF FRONT TRAVEL HYDRAULIC MOTOR

RONT DRUM SPRINKLING REAR DRUM SPRINKLING

DIAGNOS. PLUG

RPM SENSOR OF THE ENGINE

TRAVEL ELECTRONICS

SOLENOID OF STEERING WHEEL

Appendix

Fig. 122 - Electrical installation

86 TRAVEL PUMP POWER VALVE

Fig. 122 - Electrical installation

VALVE OF STEERING RIGHT VALVE OF STEERING LEFT

TEMPERATURE SENSOR OF ENGINE COOLANT TEMPERATURE SENSOR OF HYDRAULIC OIL OPERATING HOURS COUNTER

FUEL GAUGE BATTERY CHARGER INDICATOR ENGINE LUBRICATION HYDRAULIC OIL FILTER AIR FILTER PARK BRAKE PRESSURE SWITCH

87

LUBRICATION AND MAINTENANCE MANUAL

ANG

DIAGNOS. PLUG

SENSOR OF HINGE LE TURNING THE ROLLER

STEERING ELECTRONICS

RPM SENSOR OF VIBRATION HYDRAULIC MOTOR

REAR WIPER

FFRONT WINDSHIELD WASHER REAR WINDSHIELD WASHER

FAN

AIR-CONDITIONING THERMOSTATS PRESSURE FUSE OF AIR-CONDITIONING CLUTCH OF AIR-CONDITIONING COMPRESSOR

Appendix

FRONT WINDSHIELD WIPER

Fig. 122 - Electrical installation

88 SENSOR OF COOLANT LEVEL

LUBRICATION AND MAINTENANCE MANUAL

89

Appendix Diagram of hydraulics Description 1 - Travel hydraulic generator

90R100 SAUER

2 - Vibration hydraulic generator

90R100 SAUER

3 - Travel hydraulic motor

51C080 SAUER

4 - Vibration hydraulic motor

90M055 SAUER

5 - Steering hydraulic generator

Q17/17R.54600

6 - Steering linear hydraulic motor

PHM 90/45/325 AXL

7 - Linear hydraulic motor of lifting

PHM 20/12/175 AXL

8 - Manual equipment for hydraulic lifting of the hood

1009

9 - Hydraulic lock

RVJ-05-M/BJ HYTOS

10 - Steering block

729-0061 HYTOS

11 - Flushing valve

ID.Nr.760389 SAUER

14 - Suction basket

AS080-01 HYTOS

15 - Filtration block

729-0060 HYTOS

16 - Filler

LE. 0817-01 ARGO

17 - Level meter

03/130

18 - One-way valve

VJ2-16-050-02

19 - Combination cooler

34306 EMMEGI

20 - Thermostat

7038-55

21 - Testing quick-coupler

SKK20-9/16UNF PE STAUFF

22 - Filling quick-coupler

2FFN38GASM – SAMEC FASTER

23 - Quick-coupler

2FFJ14GASF – SAMEC FASTER

24 - Quick-coupler

2FFJ14GASM – SAMEC FASTER

25 - Thermometer sensor

90

Fig. 123 - Diagram of hydraulics

LUBRICATION AND MAINTENANCE MANUAL

91

STAVOSTROJ a.s.

549 01 Nové Město nad Metují tel: +420-441/ 476 111

fax: +420-441/470 405

Issued by:

Literature Department of

STA Stavostroj a.s.

Nové Město nad Metují

© 1 / 2002