STA VH 700 VH 1000 Maintenance and Lubrication Manual - PDF DOWNLOAD

MAINTENANCE AND LUBRICATION MANUAL VH 700 VH 1000

CONTENT CONTENT

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

3.1. Fills specification ............................................................................................................................................................. 4 3.1.1.

3.1.2.

3.1.3.

3.1.4.

3.1.5.

3.1.6.

3.2. Fills

Engine oil ............................................................................................................................................................. 4 Fuel ....................................................................................................................................................................... 5 Hydraulic oil ......................................................................................................................................................... 6 Lubricating grease ............................................................................................................................................... 7 Coolant ................................................................................................................................................................. 7 Screen washer liquid ........................................................................................................................................... 7

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

3.3. Lubrication program ........................................................................................................................................................ 10 3.4. Safety and other regulations at the machine maintenance................................................................................................ 12 3.4.1. Safety at machine maintenance ........................................................................................................................ 13 3.4.2. Fire regulations when changing the working fills ............................................................................................. 14 3.4.3. Ecological and hygienic fundamentals ............................................................................................................. 15 3.4.3.1. Hygienic fundamentals ...................................................................................................................................... 15 3.4.3.2. Ecological fundamentals ................................................................................................................................... 16

3.5. Individual operations of lubrication and maintenance ....................................................................................................... 17 After 20 motorhours or daily ........................................................................................................................................... 18 3.5.1. Inspection, engine coolant level ....................................................................................................................... 19 3.5.2. Inspection, topping oil in engine ....................................................................................................................... 20 3.5.3. Inspection, cleaning fuel filter ............................................................................................................................ 21 3.5.4. Inspection, cleaning the radiator ....................................................................................................................... 22 3.5.5. Inspection, engine drive belt ............................................................................................................................. 22 3.5.6. Inspection of cooling fan .................................................................................................................................... 23 3.5.7. Inspection of the air filter dust vent .................................................................................................................... 23 3.5.8. Inspection, refilling the fuel amount .................................................................................................................. 24 3.5.9. Inspection of the oil amount in hydraulic circuit ............................................................................................... 25 3.5.10. Refilling the sprinkling water tank ..................................................................................................................... 25 3.5.11. Inspection of warning and checking devices ................................................................................................... 26

After 250 motorhours (after 3 months) ........................................................................................................................... 27 3.5.12. Change of the oil and engine oil filter ............................................................................................................... 28 3.5.13. Inspection of engine cooling circuit .................................................................................................................. 30 3.5.14. Inspection of engine intake manifold ................................................................................................................ 31 3.5.15. Inspection of pressure switch of air cleaner ..................................................................................................... 32 3.5.16. Checking oil level in gearbox ............................................................................................................................ 33 3.5.17. Inspection of the accumulators status ............................................................................................................... 34 3.5.18. Stirrups placing bearings – lubrication ............................................................................................................. 36 3.5.19. Central bearing of drums - lubrication .............................................................................................................. 36 3.5.20. Driving pins – lubrication ................................................................................................................................... 37 3.5.21. Suspensions pins – lubrication ......................................................................................................................... 37 3.5.22. Carriages’ rubber steels – nuts re-tightening ................................................................................................... 37 3.5.23. Sprinkler filter - cleaning .................................................................................................................................... 38

After 500 motorhours (after 6 months) ........................................................................................................................... 39 3.5.24. Replacing fuel filters .......................................................................................................................................... 40 3.5.25. Inspection of the coolant concentration ............................................................................................................ 42 3.5.26. Inspection and adjusting of gearbox belt.......................................................................................................... 43

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MAINTENANCE AND LUBRICATION MANUAL After 1000 motorhours (after 1 year) .............................................................................................................................. 45 3.5.27. Inspection, adjusting the engine valves clearance .......................................................................................... 46 3.5.28. Engine belt inspection ....................................................................................................................................... 48 3.5.29. Exhaust system check ....................................................................................................................................... 50 3.5.30. Gearbox oil change ........................................................................................................................................... 51 3.5.31. Oil change in the vibrator .................................................................................................................................. 52 3.5.32. Inspection of the attenuator set ......................................................................................................................... 53 3.5.33. Cleaning of the water tanks ............................................................................................................................... 53

After 2000 motorhours (every 2 years) ........................................................................................................................... 55 3.5.34. Exchange of cooling liquid ................................................................................................................................ 56 3.5.35. Cleaning of fuel tank .......................................................................................................................................... 57 3.5.36. Oil and filter exchange in the hydraulic system ................................................................................................ 58 3.5.37. Cleaning and replacing air cleaner filter element. ........................................................................................... 62 3.5.38. Cleaning water separator of the fine fuel filter .................................................................................................. 65 3.5.39. Radiator cleaning ............................................................................................................................................... 65 3.5.40. Purging fuel system ........................................................................................................................................... 66 3.5.41. Cleaning of the cab ventilation air filter ............................................................................................................ 68 3.5.42. Adjusting of the scrapers ................................................................................................................................... 68 3.5.43. Machine cleaning .............................................................................................................................................. 69 3.5.44. Checking the screw connections tightness ...................................................................................................... 70 3.5.45. Adjusting the vibrator’s frequency ..................................................................................................................... 73

3.6. Records of done acts ...................................................................................................................................................... 74 3.7. Seeking the faults........................................................................................................................................................... 78 3.7.1.

3.7.2.

3.7.3.

Searching the engine faults .............................................................................................................................. 78 Defects of electrical wiring ................................................................................................................................. 80 Faults in hydraulic system ................................................................................................................................. 82

Appendixes – scheme .............................................................................................................................................................. 84 Electrical installation – scheme VH 700 .......................................................................................................................... 84 Electrical installation – scheme - VH 1000 ..................................................................................................................... 90 Hydraulic scheme - VH 700 ............................................................................................................................................. 96 Hydraulic scheme - VH 1000 .......................................................................................................................................... 98

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3.1. Fills specification Viscosity

3.1.1.

Engine oil

Using of quality engine lubricating oil and proper exchange interval are dominant for the engine life-cycle.

Quality The oil are divided on the output class and quality class.

They are specified due to the API (American Petroleum Institute) and CCMC (Committee of COMMON Market Automobile Constructors).

Acceptable oils due : API CE CCMC D5 If oil of class CE is not available, then class CC or CD oil may be used. Intervals between changes must be cut to half, however.

Considering that the oil viscosity is changing with the temperature, is dominant for the viscosity class SAE (Society of automotive engineers) the ambient temperature and the kind of use the machine on the working place.

The overrun the lower temperature limit doesn’t cause the engine damages, can only cause the difficult engine starts.

The overrun of the upper temperature limit due to the decreasing the oil lubricating abilities could not be for a longer time.

Is recommended to use the universal wide-scope oil to prevent the oil exchanges because of the ambient temperature changes.

Recommended oil for all seasons is SAE 15W-40, see Fig. 1 (e.g., Cummins Premium Blue, in the Czech Republic M7ADSIII). For easier starts at temperatures below 0 °C (32 °F), the engine manufacturer recommends oils SAE 10W-30, see Fig. 1.

Conditions of the oil exchange

Fig. 1 - Diagram of Viscosity

4

Regularly change the oil in intervals according to the table after 500Mh (MPH). If we don’t reach the oil exchange interval within one year, change the oil irrespectively to the number of motorhours after 1 year.

MAINTENANCE AND LUBRICATION MANUAL Winter fuel

3.1.2.

Fuel

As an engine fuel is used the diesel oil :

• CEN EN 590 or DIN/EN 590 (proposal) • DIN 51 601 • BS 2869 (1998) : 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 Common fuel for the diesel engines contains the sulfate amount under 0,5% of weight, when using the fuel with bigger sulfate amount 0.5 – 1 % is necessary to decrease the oil exchange intervals to one half.

Under lower temperatures under 0 °C (32 °F) by the common diesel fuel the causes the separation of paraffins in the machine fuel system. Separated paraffins can cause the faults even disable the machine’s operations.

In that case , under ambient temperatures under 0 °C (32 °F) use the winter diesel fuel.

The diesel fuel is usually changed by the distributors due to the year season.

When using the summer diesel fuel under temperatures near the 0 °C (32 °F) mix to the diesel fuel the kerosene for improving the lower-temperature qualities.

The dependence of the temperature to the added kerosene amount shows the diagram – Fig.2.

Sufficient anti-freeze quality we can reach also by adding the additive to the fuel for improving the liquidity (fuel additives).

Do the mixing only in the tank. Fill first the tank with determined amount of kerosene, then replenish with the fuel.

The mixtures of winter fuels are equally flammable as the gas itself – keep the fire regulations !

It is strictly required to use above specified brands of diesel fuel only.

Usage of different fuel (like Bio-fuels, or Light heating oils of any kind) is strictly PROHIBITED.

Fig. 2 - Diagram of Mixing

„Su

per

die

sel

“

Ambient Content of mixed kerosene

5

3.1. Fills specification 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 - Comparison Table Of 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.!

MAINTENANCE AND LUBRICATION MANUAL 3.1.4.

Lubricating grease

3.1.6.

For the machine lubrication is necessary to use the plastic lubricant with content of lithium due to the regulation NLGI-2 according to the lubrication schedule table.

3.1.5.

Screen washer liquid

As a fill for the screen washer tank use the mixture of water and concentrated cleaning antifreeze agent for screen washers of cars in the ratio given by the manufacturer of the agent.

Coolant

The engine cooling system is filled yearly by the manufacturer using the antifreeze liquid composed of 40% of ethylene-glycol coolant and 60% of water for temperatures to -23 °C (-10 °F). For the cooling system fills we can use also the propylene-glycol cooling liquids.

The water for this mixture use modified de-mineralized or distilled. The scope of use by different content of ethyleneglycol or propylene-glycol in the antifreeze liquid shows the following table:

Ethylene-glycol

Propylene-glycol

40 % = -23 °C (-10 °F)

40 % = -21 °C (-6 °F)

50 % = -37 °C (-34 °F)

50 % = -33 °C (-27 °F)

60 % = -54 °C (-65 °F)

60 % = -49 °C (-56 °F)

68 % = -71 °C (-90 °F)

68 % = -63 °C (-82 °F)

Don’t use the portion of antifreeze cooling agent in the coolant bigger than 50%, if it isn’t really necessary.

Never use the portion bigger than 68% !

Use the antifreeze agents harmless to the environment.

We don’t recommend the mutual mixing of antifreeze agents. Mixing the different cooling liquids can cause the lost of anti-corrosion qualities.

When mixing the antifreeze agent of the nitride base with agent of the amine base, raise the harmful nitroamines.

Check the portion of antifreeze cooling agent in the cooling liquid before the winter season using the refractometer (hydrometer).

7

3.2. Fills Fills - VH 700 Part – fill Engine – engine oil Due to the chap. 3.1.1.

Kind of fill

Fill amount l (gal US)

SAE 15W/40 – whole season

9,5 (2,5)

Fuel tank – diesel fuel Due to chap. 3.1.2

Summer diesel fuel over 0 °C (32 °F) Winter diesel fuel under 0 °C (32 °F) Modified summer diesel fuel – due to chapter 3.1.2

160 (42,3)

Hydraulic system – hydraulic oil due to chap. 3.1.3.

Hydraulic oil with the kinematic viscosity 68 mm2/s

65 (17,2)

Carriage bearings, driving cylinder stirrups bearings, suspension – lubricating grease due to chap. 3.1.4

Plastic lubricant with the lithium contents due to the regulation NLGI-2*

Engine cooling set – coolant due to chap. 3.1.5

All season coolant Fridex G48 (CASTROL ANTI-FREEZE) + water for temperat. down to -25 °C (-13 °F).

Vibration carriage – engine oil

SAE 15W/40 – whole year

Battery

Distilled water

Screen washer tank

Water + cleaning agent (antifreeze) – whole year

2,75 (0,72)

Front sprinkling tank

Water

530 (140)

Rear sprinkling tank

Water

480 (127)

* - NLGI (National Lubricanting Grease Institute)

8

When necessary

18 (4,76)

4x2 (4x0,53)

When necessary

Symbol

MAINTENANCE AND LUBRICATION MANUAL Fills - VH 1000 Part – fill Engine – engine oil Due to the chap. 3.1.1.

Kind of fill

Fill amount l (gal US)

SAE 15W/40 – whole season

9,5 (2,5)

Fuel tank – diesel fuel Due to chap. 3.1.2

Summer diesel fuel over 0 °C (32 °F) Winter diesel fuel under 0 °C (32 °F) Modified summer diesel fuel – due to chapter 3.1.2

210 (55,5)

Hydraulic system – hydraulic oil due to chap. 3.1.3.

Hydraulic oil with the kinematic viscosity 68 mm2/s

70 (18,5)

Carriage bearings, driving cylinder stirrups bearings, suspension – lubricating grease due to chap. 3.1.4

Plastic lubricant with the lithium contents due to the regulation NLGI-2*

Engine cooling set – coolant due to chap. 3.1.5

All season coolant Fridex G48 (CASTROL ANTI-FREEZE) + water for temperat. down to -25 °C (-13 °F).

18,8 (4,96)

Vibration carriage – engine oil

SAE 15W/40 – whole year

4x2 (4x0,53)

Battery

Distilled water

Screen washer tank

Water + cleaning agent (antifreeze) – whole year

2,75 (0,72)

Front sprinkling tank

Water

660 (174)

Rear sprinkling tank

Water

640 (169)

Symbol

When necessary

When necessary

* - NLGI (National Lubricanting Grease Institute)

9

3.3. Lubrication program Fig. 4 - Lubrication program - VH 700

10

MAINTENANCE AND LUBRICATION MANUAL Fig. 4 - Lubrication program - VH 1000

11

3.4. Safety and other regulations at the machine maintenance

12

MAINTENANCE AND LUBRICATION MANUAL 3.4.1.

Safety at machine maintenance

The lubrication, maintenance and adjusting provide :

• always at engine stolling • with expertly trained personnel • to the dates showed in the lubrication table or by the technical status check according to safety, fire, ecological and hygienic regulations mentioned in the Operational manual for the VH 700/VH 1000 roller

• after cleaning the machine, lubricating areas and maintenance or repair areas

• on the machine placed on solid flat area • on machine secured against spontaneous movement

After finishing the adjusting or maintenance check the function of all security devices !

Before doing the welding works using electrical circuit on the machine is compulsory to disconnect all elements containing semiconductors from the electrical installation, it is: engine alternator, motorhour counter, all driving units under the dashboard and so on.

The welding instrument’s ground place as near to the welded place as possible.

(scotchs)

• with disconnected electrical installation using the disconnector and with removed key from the switch box

• after placing the warning table “Machine is out of order” on the dashboard

• on the cooled machine parts • using the suitable non-damaged instruments • under zero pressure in the hydrostatic delivery system and due to the valid regulations

• by replacing the fault or worn parts by new ones, original-made. The manufacturer is not responsible for damages caused by using of non-original parts!

• by decreased visibility and in the night using the sufficient lighting of the whole machine

• by necessary remove of the covers and safety elements with their mounting back after finishing the work

• by re-tightening the screw connections – by the tightening moment and connections tightness check

• when changing the working fills after their warm up – avoid the burn ups – use recommended fills only

13

3.4. Safety and other regulations at the machine maintenance 3.4.2.

Fire regulations when changing the working fills

From the view point of fire danger are the flammable liquids used on the machine divided into classes of hazard : II

hazard class - diesel fuel

IV hazard class – mineral oils, lubricating greases, antifreeze mixture.

• The place for exchange the oils must be placed such way to don’t overlap to the areas with danger of explosions, fire.

• It must be signed by the tables and marks with “No smoking” signs and signs prohibiting the use of naked fire.

• The manipulation area must be designed such way to catch the amount of flammable liquid equal to the capacity of the largest vessel, transport container.

• The place must be equipped with the hand extinguishers fire.

• For the oil, diesel fuel manipulation, use the vessels as the steel barrels, cans, sheet metal jugs.

• The transport vessels must be properly closed during the storage.

• The vessels must be with only one outlet, stored always with the outlet up and secured against the flow out and drains.

• The vessels must be marked by non-removable writing showing the contents and the flammable class.

14

MAINTENANCE AND LUBRICATION MANUAL 3.4.3.

Ecological and hygienic fundamentals

When operating and maintenance the machine, the machine’s user is obliged to keep the general fundamentals of health protection and the environment protection, and keep the laws, regulations and prescripts relative to this problems and valid in the territory of using the machine.

3.4.3.1. Hygienic fundamentals Oils, radiator, brake systems and accumulators fillings, cleaning and conserving agents and paints including thinners are harmful materials. Workers in contact with these products during the driving or maintenance of the machine are obliged to obey the common rules of the selfhealth protection and follow the safety and hygienic manuals from the manufacturers of this products.

We warn of: -

eyes and skin protection when working with accumulators

-

skin protection when working with oils, paints and coolants

-

proper washing the hands after finishing the work and before the meal, treat the hands with appropriate reparation cream

-

when working with the working fills obey the maintenance manual

• Oils, radiator, brake systems and accumulators fillings, cleaning and conserving agents and paints including organic thinners and also cleaning and conserving agents always keep in original properly signed vessels. Don’t allow the storing of these materials in non-signed vessels and other bottles due to danger of exchange. Extremely dangerous is a possibility of exchange with meal or drinkables.

• In the case of accidental stain of the skin, mucous membranes, eyes or of inhalation of the vapor, apply immediately first aid. In such case find the emergency first aid by the doctors.

• When working with the machine use the ears protectors always of convenient kind and design.

15

3.4. Safety and other regulations at the machine maintenance 3.4.3.2. Ecological fundamentals The fillings of individual machine systems and also some parts are after blackout (dismounting, fills exchange) the risk garbage for the environment.

To this category of waste products belongs : -

organic and synthetic lubricants, oils and fuels

-

cooling liquids

-

accumulator fills and accumulators themselves

-

the conditioner systems fillings

-

cleaning and conserving materials

-

all dismounted filters and filter inserts

-

all used and blackouted hydraulic and fuel pipes, rubber steels and other machine parts, contained by materials mentioned above.

With materials and parts listed above we must manipulate after blackout according to the appropriate national regulations for individual environment parts protection and according to the health protection regulations.

16

Related regulations When doing the lubrication and maintenance we must mainly the following regulations and standards :

Foreign : Valid regulations for the work safety and health protection during the operations and maintenance the machine Valid regulations for the fire prevent Valid regulations for the flammable liquids Valid regulations and laws for the environment and health protection relative to this area Valid regulations for the manipulation with dangerous staffs and waste material

3.5. Individual operations of lubrication and maintenance The lubrication and maintenance is done in regularly repeated intervals due to daily counting the numbers on the motorhours counter.

Dismounted or unscrewed screws, plugs, worm connections of the hydraulic etc. retighten by the tightening moment due to the tables mentioned in the chap. 3.5.44. else otherwise specified by the different value at respective operation.

Within this manual are mentioned only the basic information about the engine, other information are mentioned in the manual for the manipulation and maintenance of the engine, which is part of the documentation delivered with the machine.

Obey the instruction mentioned in the manipulation and maintenance manual !

After 50 first motorhours of new machine (after GR) do according to: 3.5.23. Cleaning of sprinkling water pump filter

After 250 first motorhours of new machine (after GR) do according to: 3.5.26. Check of the strain and adjusting of gearbox spur belt - valid for VH 700

17

3.5. Individual operations of lubrication and maintenance After 20 motorhours or daily Fig. 5

18

MAINTENANCE AND LUBRICATION MANUAL After 20 motorhours or daily 3.5.1.

After 20 motorhours or daily

Inspection, engine coolant level

• Check before starting – the machine must be leveled on firm and flat ground.

• Check level visually, see Fig. 6.

• Maintain level between marks “MIN” and “MAX”.

• Should there be unusual drops in level, look for leaks in the cooling system, and repair.

• Top up with anti-freeze coolant only, of the same formula, see Chapter 3.1.6.

Remove the radiator cap only when engine temperature drops below 50 degrees C (120 degrees F). At higher temperatures there is danger of injury by hot steam or by the coolant due to internal pressure.

Do not use additives to engine coolants to prevent radiator leaks!

Do not pour cold liquid into hot engine!

Engine castings may be damaged.

Fig. 6

MAX

MIN

19

3.5. Individual operations of lubrication and maintenance After 20 motorhours or daily 3.5.2.

Inspection, topping oil in engine

After 20 motorhours or daily • Lift the lid in the floor, Fig. 8.

• Top oil by pouring it through the neck, Fig. 9, after plug

• Do before starting – the machine must be leveled on firm and straight ground.

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

• Pull oil stick (1), Fig. 7, clean with lint- free rag.

• Reinsert to full stop and pull out again. Read off oil

(1) was removed. Wait a minute or so for the oil to run off and check level.

• Use same make of oil.

• Check tightness of engine, if necessary, repair.

• Inspect the engine for damaged or missing parts and for changes in appearance.

level.

• Maintain level between marks on the stick.

• The lower mark L (Low) indicates the lowest oil level, Use only recommended oils as specified in Chapter 3.1.1.

H (High) the highest.

• The distance between the two marks corresponds to 0.95 liters (1 US quart).

Fig. 8

Do not start the engine unless oil level is correct.

1

Fig. 7

Fig. 9

1 1

20

MAINTENANCE AND LUBRICATION MANUAL After 20 motorhours or daily 3.5.3.

After 20 motorhours or daily

Inspection, cleaning fuel filter

• Check visually before start.

• If there is water or dirt present in the fuel filter, clean while the engine is off.

• Close fuel intake valve (1) at the bottom of the fuel tank Fig. 10.

• Loosen lower nut (1), fold shackle (2) aside, Fig. 11.

• Remove glass (3) with sieve (4).

• Clean glass and rinse sieve.

Danger of fire – follow fire prevention regulations.

• Re-assemble.

While working on the fuel system, do not use open flame, do not smoke.

• Open fuel valve.

• Cleaning periods depend of fuel purity.

Fig. 10

Prevent fuel from spilling.

Fig. 11

1

4 3

2 1

21

3.5. Individual operations of lubrication and maintenance After 20 motorhours or daily 3.5.4.

Inspection, cleaning the radiator

• Do by visual means under engine turned off after finishing the works or before starting.

• Disconnect the electrical installation of the machine using the disconnector.

• Check the engine radiator lamellas and oil radiator cleanness. When the machine is equipped with the air conditioning, check the condenser lamellas Fig. 12.

After 20 motorhours or daily 3.5.5.

• Inspect visually before starting or after shutting off the engine.

• Inspect for damage. Fissures perpendicular to the belt are not significant. The belt must be replaced, Fig. 13, if lengthwise splits, fringed edges, or torn pieces are detected.

• When soated, blow the radiator by pressure air in the direction from the cooling fan to outside.

Fig. 12

22

Inspection, engine drive belt

Fig. 13

MAINTENANCE AND LUBRICATION MANUAL After 20 motorhours or daily 3.5.6.

Inspection of cooling fan

After 20 motorhours or daily Fig. 15 - VH 700

• Visual inspection before starting or with the engine off, Fig.14.

• If damaged (such as broken off parts, breaks, deformation, etc.) replace fan.

3.5.7.

Inspection of the air filter dust vent

• Do by visual means before starting the engine or under

1

engine turned off.

• The valve (1) Fig. 15 is cleared automatically when the machine is running.

• Check if the valve is not damaged or missing Fig. 16.

• Clean the outlet slot sometimes.

• Remove the clotted dust by pressing the upper slot part.

Fig. 15 - VH 1000

Don’t manipulate the machine if the dust valve shows the marks of damages due to Fig. 16.

1

Fig. 14

Fig. 16

A

B

C

D

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

23

3.5. Individual operations of lubrication and maintenance After 20 motorhours or daily 3.5.8.

After 20 motorhours or daily

Inspection, refilling the fuel amount

• Do before starting the engine - the machine must stand horizontally on solid, flat base.

• Check the fuel amount at the fuel gauge. When the indicator in fuel gauge gets on, refill the fuel !

• Clean the tank plug (1) and the filling neck Fig. 17.

• Unlock tank and turn tank plug, see Fig. 17.

• Fill the tank only to lower border of the filling neck pipe.

• Use the clean recommended fuel only due to chapter 3.1.2.

• During the work, keep the place clear.

• Size of fuel tank – see Chapter 3.2. - Filling. The fuel tank average sufficiency is for approx. 20-25 motorhours according to the engine loading and way of driving.

• Don’t spend the whole fuel tank. If you do so, you are obliged to do the laborious de-aeration of whole fuel system.

When working, don’t smoke and use the naked fire.

Don’t refill the fuel in closed buildings.

Don’t refill the fuel under the engine is on.

Don’t spill the fuel.

9

Fig. 17

24

1

MAINTENANCE AND LUBRICATION MANUAL After 20 motorhours or daily 3.5.9.

After 20 motorhours or daily

Inspection of the oil amount in hydraulic circuit

3.5.10. Refilling the sprinkling water tank • Do before starting the engine - the machine must stand

• Do before starting the engine - the machine must stand

horizontally on solid, flat base.

• After opening the cover (1), refill with the pure water

horizontally on solid, flat base.

• Open the left engine cover.

Fig. 19.

• Check the oil level in the sights of the oil gauges (1).

• Fill through the sieve (2) in the tank neck Fig. 20.

• Keep the level between the upper and lower border of both oil gauges Fig. 18.

• The oil level must be always visible in the bottom oil gauge !

• Refill by the oil if necessary chap. 3.1.3.

Fig. 19

1

Fig. 18

Fig. 20

1

2

1

MAX

MIN

25

3.5. Individual operations of lubrication and maintenance After 20 motorhours or daily

After 20 motorhours or daily

3.5.11. Inspection of warning and checking devices

Fig. 22

• Check correct function of warning horn, lights, direction signals, warning lights.

• Switch the key in switch box (15) to the “1” position.

• The lubrication (24), recharging (30), neutral (27), parking brakes (25) indicators will get on.

11

• Try the beacon (36) function fig 21.

10

• Try the warning horn function (11) Fig. 22.

• Start the engine – the lubrication (17) and recharging (13) indicators will get off Fig. 21.

• Run the machine and switch on the emergency brake (10) switch Fig. 22 – the machine will stop and the engine will turn off – the brake indicator (25) will get on.

Fig. 21

A

01

15

B

Detail A

24

36

30

26

2

25

Detail B

27

MAINTENANCE AND LUBRICATION MANUAL After 250 motorhours (after 3 months) Fig. 23

27

3.5. Individual operations of lubrication and maintenance After 250 motorhours (after 3 months)

After 250 motorhours (after 3 months)

3.5.12. Change of the oil and engine oil filter

• Clean the area round the oil filter’s head. Dismount the filter (3) Fig. 26.

• Let the oil out after finishing the work or after decreasing the temperature to 60 °C (140 °F), or with the engine turned on (when driving the machine) wait until the oil temperature reaches the 60 °C (140 °F).

• Place the roller to the horizontal position on a flat, solid base.

• Turn the engine off and disconnect the electric machine installations.

• Clean the contact area for the filter packing.

• Take the new filter, fill it with clean engine oil.

• The rubber filter packing slightly lubricate with oil and screw it back, properly tighten.

• Check the plug (1) packing, change the damaged.

• Check the worm and clean the contact area for the packing.

• Prepare the convenient vessel with capacity approx.

10 l.

• Mount the plug back. Tightening moment 50 Nm (37 ft lb).

• Dismount the lid in engine cover and the engine cover

• Take out the cover in cab floor Fig. 27.

behind the front carriage Fig. 24.

• Dismount the outlet plug (1) Fig. 25 and let the oil flow out.

Fig. 24

Fig. 26

3

Fig. 25

Fig. 27

1

28

MAINTENANCE AND LUBRICATION MANUAL After 250 motorhours (after 3 months)

After 250 motorhours (after 3 months)

• Fill the engine with clean engine oil by the filling neck (2) Fig. 28.

Change the oil always after 1 year even the exchange interval doesn’t reach the 250 work-out motorhours.

• The whole content is 9 l (2,37 gal US) of oil.

• Start the engine and let it run under increased revolu-

When out-flowing the hot oil, watch out for possibility of burn ups.

tions for 2-3 minutes.

• Stop the engine, wait for 5 min. to let the oil flow down

Use recommended filters only.

to the machine van. Then check the proper oil level – if necessary, replenish to upper guideline of the gauge (1) Fig. 29.

Use recommended foils only due to chap. 3.1.1.

• Check the tightness.

Don’t over-tighten the filter, it can cause the worm and packing damage.

Catch the outflowing oil, don’t let it suck in to the ground.

Dispose according the valid regulations.

Used filters store in the individual container and manipulate with them such way to prevent the pollution of the environment.

Fig. 28

Fig. 29

1 2

29

3.5. Individual operations of lubrication and maintenance After 250 motorhours (after 3 months)

After 250 motorhours (after 3 months)

3.5.13. Inspection of engine cooling circuit • Place the machine horizontally on solid, flat base.

• Stop the engine and disconnect the electrical machine’s installation.

• Fold the cab down due to chapter 2.8.12. “Driver’s manual”.

• Do the cooling circuit tightness check. Check if there are not any damaged rubber parts and missing hose braces.

• Check the lamellas purity of the engine radiator and oil cooler Fig. 30.

• If soiled, follow Chapter “Occasional Maintenance”, 3.5.39.

Fig. 31 - VH 700

1

3

Fig. 30

Fig. 31 - VH 1000

3 1

1 2 3

30

MAINTENANCE AND LUBRICATION MANUAL After 250 motorhours (after 3 months)

After 250 motorhours (after 3 months)

3.5.14. Inspection of engine intake manifold • Place the roller level on firm, flat ground.

• Stop the engine and disconnect electrical cables in the equipment.

• Check intake manifold for leakage.

• Check that hoses (1) and elbows (2) are not damaged (tears, breaks), and that clips (3) are not missing, Fig. 31, 32, 33.

• Check the gasket in the air cleaner (1), Fig. 34 – replace if damaged (applicable to VH 700).

• Fold the cabin according to chapter 2.8.12. ”Driver’s Manual”.

• Do not run the equipment, if gasket and suction hose are damaged!

Fig. 32 - VH 700

Fig. 33 - VH 700

3

2

2

3

1

1 3 3

3

Fig. 32 - VH 1000

Fig. 33 - VH 1000

2

3 3

3

3 2

31

3.5. Individual operations of lubrication and maintenance After 250 motorhours (after 3 months) 3.5.15. Inspection of pressure switch of air cleaner • Check while the engine is running.

After 250 motorhours (after 3 months) • When covered, the control bulb indicator of air cleaner condition lights up (29), Fig. 35.

• Should the bulb not light up, check cause (faulty bulb, contact, wires, pressure switch (1)), Fig. 36.

• Increase engine revolutions to about 1500 1/min (RPM).

• Cover momentarily the opening in the air cleaner input manifold - following removal of grid (1), cover suction intake, Fig. 34.

Use heavy paper – light paper may plug up suction opening!

Fig. 35

D Fig. 34

1

Detail

29

32

MAINTENANCE AND LUBRICATION MANUAL After 250 motorhours (after 3 months)

After 250 motorhours (after 3 months) 3.5.16. Checking oil level in gearbox • Position roller horizontally on a firm and flat surface.

• Open and secure the right engine cover.

• Check oil level with the dipstick in the upper plug (1), Fig. 37.

• If needed fill up to top dipstick mark.

Maintain oil level at the top mark!

Fig. 36

Fig. 37

1

1

33

3.5. Individual operations of lubrication and maintenance After 250 motorhours (after 3 months) 3.5.17. Inspection of the accumulators status

After 250 motorhours (after 3 months) Checking the electrolyte status :

• Measure the electrolyte consistency in each cells • Place the roller horizontally on solid, flat base.

• Stop the engine and disconnect the electrical machine’s installation.

• Clean the accumulators’ surface e.g. by water and dry them out.

• Check the poles and clamps status. Clean the accumulator poles and clamps Fig. 38. Slightly lubricate the clamps by grease (attend to a good contact).

• Check electrolyte level in battery, whether the level reaches 5 to 15 mm above the plates in all cells, or the level of control inserts. The level may checked with a glass rod.

• The cells with lower electrolyte level refill with distilled water to specified level.

• Close the accumulators.

• Keep the accumulators dry and clean.

Fig. 39.

• Compare measured values with table Fig. 40. The table indicates battery charge at 25 °C (68 °F) and in the tropics.

• In case of non-sufficient accumulator capacity recharge the accumulators.

• The accumulator recharge do outside the machine.

• Before recharging, open the accumulator plugs.

• The run-down accumulator can freeze up already at few grades under zero. Before recharging, let the accumulator defrost otherwise it can explode when recharging.

• After recharging, connect the accumulators properly (same poles), attend to a good contact.

Fig. 39

• The requirements for the accumulators are extremely high in winter season. The accumulators have only part of their capacity needful for starting the machine at lower temperatures comparing with the capacity during normal conditions. For that case we recommended to check the battery electrolyte status and necessary recharge.

• If the machine is not used during heavy frost weather during a few weeks, dismount the accumulators and store them such way to protect them against the frost.

Otherwise they can be damaged by the frost.

Fig. 38

Fig. 40

Density in g/cm3

in °Be (Beume)

Normal Normal Tropics Tropics temperatures temperatures

34

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°

MAINTENANCE AND LUBRICATION MANUAL After 250 motorhours (after 3 months)

When manipulating with the accumulators, keep these regulations !!!

The accumulator electrolyte is a strong acid. When manipulating with the accumulators, use the protective rubber gloves and means for eye protection.

Protect the skin and clothes against stain with the electrolyte or lead elements.

When contact the eyes with the electrolyte immediately wash the afflicted eye by the water stream for a few minutes. Then find the professional doctor’s help.

When stained the skin or clothes by the electrolyte, wear off the clothes, wash the afflicted places by soap water or by the cooking soda and water solution - find the doctor’s help.

When consume the electrolyte, drink the maximal amount of milk or water, the solution of burnt flash powder with water, immediately find the doctor’s help.

Never replenish with the distilled water the cells, if there is not any following work with the machine or recharging out of the machine. It can cause increased discharge of the accumulator.

After 250 motorhours (after 3 months)

When manipulating with the accumulators, keep these regulations !!!

Disconnection of the accumulators have not be done under the engine is on.

The accumulator battery must e connected with the “minus” pole to the ground and “plus” pole to alternator output “B+”. Reverse connection can cause the damage of whole semiconductor device.

Alternator must not be started for idle run - it is with disconnected cable from the “B+” grip and connected “D+” grip.

When starting using the auxiliary power supply is prohibited to disconnect that supply sooner than the machine accumulators are connected.

Watch out for the starting voltage of auxiliary power supply (for 12 V).

Before welding on the machine, the cables from “B+” and “D+” alternator grips must be disconnected.

To replace a battery with a new one consult your dealer or use an SHD (super heavy duty) battery type.

Never replenish the acid (H2SO4).

Don’t turn the accumulators, the electrolyte can flush away from deaeration accumulator leaks.

When spilled the acid (electrolyte), wash the afflicted place by water and neutralize by lime.

When recharging the accumulators, the hydrogen is released and raising with the mixture with air the explosive, easily combustible mixture. Don’t manipulate with the naked fire, naked light, don’t smoke.

Don’t provide actions producing the sparks. Don’t manipulate with conductors and electrical devices and instruments – it can cause the sparks.

Is prohibited to check the live wire by sparking on the machine’s ground.

If you do any repairs on the recharging circuit, disconnect the accumulator to prevent the accidental shorts.

When dismounting, disconnect the minus pole cable first (-), then the plus (+).

35

3.5. Individual operations of lubrication and maintenance After 250 motorhours (after 3 months) 3.5.18. Stirrups placing bearings – lubrication • Take out the covers of pins’ lubrication heads (1) – clean the lubrication head Fig. 41.

• Fill with the grease due to chap. 3.1.6. until there is

After 250 motorhours (after 3 months) 3.5.19. Central bearing of drums - lubrication • Remove covers of lubrication heads (1) - clean lubrication head, Fig. 42.

• Fill with grease according to chapter 3.1.6 by about 1/2 of the content of the grease gun supplied as accessory with the machine.

flowing new lubrication grease out.

Attention!

Rollers with undivided drums have no central bearing and are not greased.

Fig. 41

Fig. 42

1

36

1

MAINTENANCE AND LUBRICATION MANUAL After 250 motorhours (after 3 months)

After 250 motorhours (after 3 months) 3.5.22. Carriages’ rubber steels – nuts retightening

3.5.20. Driving pins – lubrication • Take out the covers of pins’ lubrication heads (1) –

• Check the rubber steels nuts tightening using the

clean the lubrication head Fig. 43.

• Fill with the grease due to chap. 3.1.6. until there is

moment key Fig. 45.

• Tightening moment 75 Nm (55 lb ft).

flowing new lubrication grease out.

3.5.21. Suspensions pins – lubrication • Take out the covers of lubrication heads, clean the lubrication heads.

• Consequently lubricate the lubricators of cab doors, windows, engine covers according to lubrication schedule.

• After folding the mask – front, rear – suspensions (1) Fig. 44.

• Use the lubrication grease according to chap. 3.1.6.

Fig. 44

Fig. 43

Fig. 45

1

1

37

3.5. Individual operations of lubrication and maintenance After 250 motorhours (after 3 months)

After 250 motorhours (after 3 months)

3.5.23. Sprinkler filter - cleaning • Remove screws holding the front and rear masks, Fig. 46.

• Shut off water valve (3).

• Remove container on sprinkler filter (1), remove mesh (2), and clean, Fig. 47.

Fig. 46

Fig. 47

2 1

38

MAINTENANCE AND LUBRICATION MANUAL After 500 motorhours (after 6 months) Fig. 48

39

3.5. Individual operations of lubrication and maintenance After 500 motorhours (after 6 months) Before staring the works, fold out the cab due to chapter 2.8.12. “Driver’s manual”.

After 500 motorhours (after 6 months) 3.5.24. Replacing fuel filters • Place the machine level on a firm and flat surface.

• Stop the engine and disconnect electrical wiring.

• Close fuel intake valve Fig. 49.

• Open the right engine cover.

• Clean the top of fuel filters.

• Remove filters.

• Prevent fuel from escaping.

• Clean the sealing surface of filter holders Fig. 50.

• Replace O-ring (1) Fig. 50.

Fig. 49

Fig. 50

1

40

1

MAINTENANCE AND LUBRICATION MANUAL After 500 motorhours (after 6 months)

After 500 motorhours (after 6 months)

• Fill filters with clean fuel and grease O-rings (2), Fig. 51.

Follow environmental regulations and health precautions!

• Turn filter in by hand until seated on the seal, and then one half of a turn, Fig. 52.

Observe fire prevention rules!

• Open fuel intake valve, Fig. 49.

Work in ventilated rooms without fire danger.

• Check for tightness!

Prevent fuel from leaking into the ground.

Do not smoke and extinguish open flames.

Use only recommended original filters.

Do not tighten filters forcefully, threads and seals could be damaged.

Store used filters in a separate container, and handle them without affecting the environment.

Fig. 51

Fig. 52

2

41

3.5. Individual operations of lubrication and maintenance After 500 motorhours (after 6 months) 3.5.25. Inspection of the coolant concentration • Place the roller horizontally on solid, flat base.

• Stop the engine and disconnect the electrical machine’s installation.

• Measure coolant concentration using refractometer Fig. 53. Release the needed amount of fluid into the refractometer from the radiator valve (1), Fig. 54.

• When using density meter Fig. 55, suck a sample of

After 500 motorhours (after 6 months) • Do the check always before the winter season.

• The portion of ethylene-glycol or propylene-glycol agent in the antifreeze coolant is min. 40 % for ambient temperatures of -23 °C (-10 °F).

• The coolant with antifreeze agent use in all climatic zone even on places where the temperatures are not dropping under 0 °C (32 °F). The coolant serves not only as a cooling system protection against the frost, but also increases the boiling point temperature. The inhibitors contained in the coolant protect the parts of engine cooling system and prolong their lifetime.

fluid from the neck of the expansion tank Fig. 56.

Measure at fluid temperature 20 °C (68 °F).

Fig. 53

Fig. 55

Fig. 54

Fig. 56

1

MAX 1

42

MIN

MAINTENANCE AND LUBRICATION MANUAL After 500 motorhours (after 6 months)

After 500 motorhours (after 6 months)

3.5.26. Inspection and adjusting of gearbox belt Valid for VH 700 • Place the roller horizontally on solid, flat base.

• Stop the engine and disconnect the electrical machine’s installation.

• Open right cover of engine.

• Remove belt cover Fig. 57.

• Measure belt tension (slack) when cold!

• Place the test stick (1) (provided with the machine) and mark depth of insertion at the upper edge of the hole, Fig. 58.

• Slide load (2) on stick (1) and mark new position after the belt has run through. Read off stick (1) graduation the distance between marks (condition of belt tension), Fig. 59.

Fig. 58

1

Fig. 57

Fig. 59

2 1

12-14 mm 0,47-0,55•in

↓

43

3.5. Individual operations of lubrication and maintenance After 500 motorhours (after 6 months)

After 500 motorhours (after 6 months)

Adjust if necessary :

• Unscrew 6 screws Fig. 60.

• Unscrew the contra-nut (1) and by the screw (2) do the adjusting Fig. 61.

After adjusting mount the protective cover back !

Fig. 60

Fig. 61

2 1

44

MAINTENANCE AND LUBRICATION MANUAL After 1000 motorhours (after 1 year) Fig. 62

45

3.5. Individual operations of lubrication and maintenance After 1000 motorhours (after 1 year)

After 1000 motorhours (after 1 year)

Before starting the works on the machine fold down the cab according to chapter 2.8.12. “Driver’s manual”.

• Remove covers of valves and plug (1) on the flywheel

3.5.27. Inspection, adjusting the engine valves clearance • Place the roller horizontally on solid, flat base.

• Stop the engine and disconnect the electrical machine’s installation.

casing opening, where the grooved pin is inserted, Fig. 63.

• Insert into the opening grooved pin Cummins No. 3824591 with 1/2” hole for the imbus key. Using the key the engine may be turned manually, Fig. 64.

• Find the top position of No.1 cylinder by turning slowly the engine using the grooved pin, simultaneously pressing down the timing pin, Fig. 64.

• The location of the timing pin is visible on Fig. 65.

• The inspection or adjusting provide on cooled engine

• When the timing pin meshes the opening in the gear

below 60 °C (140 °F) - check on the coolant thermometer

on the camshaft, cylinder No.1 is in its top position of compression cycle, Fig. 66.

Fig. 63

Fig. 65

%

1

Fig. 64

Fig. 66

Gear

Timing pin

Gear assembly cover

46

MAINTENANCE AND LUBRICATION MANUAL After 1000 motorhours (after 1 year) • Pull out timing pin Fig. 67.

• Measure clearance of intake and exhaust valves between contact areas of valves and the rocker arm with feeler gauge, Fig. 68.

• Adjust valves correctly Intake valve (I) – gap 0.25 mm (0.010”) Exhaust valve (E) – gap 0.50 mm (0.020”)

After 1000 motorhours (after 1 year) • Thereafter tighten counter-nut with torque of 24 Nm (18 ftlb.)

• Gap has been correctly adjusted, when resistance can be felt on the feeler gauge.

• Check thereafter again.

• Mark the belt Fig. 70 and turn the shaft by 360°.

• Check and adjust par Fig. 69.

• Adjust gap to specified value by loosening counter-nut and turning set-up screw using a screwdriver, Fig. 68.

Before turning make sure that the timing pin is out, and prevent its damage.

Fig. 67

Fig. 69

Fig. 68

Fig. 70

47

3.5. Individual operations of lubrication and maintenance After 1000 motorhours (after 1 year) • Check and/or adjust gaps of the remaining valves, see

After 1000 motorhours (after 1 year) 3.5.28. Engine belt inspection

Fig. 71.

• Tighten counter-nuts and recheck gaps, with torque of 24 Nm (18 ftlb.)

• Replace valve covers and tighten bolts to torque 24 Nm (18 ftlb). Install air intake manifold.

• Cylinder sequence is 1 to 4 from the fan belt.

Tension inspection

• set the machine level on a firm and even ground.

• Shut the engine, disconnect electrical wiring, and apply parking brake.

• Check the belt by finger in the spot where the distance between the pulleys is largest, Fig. 72.

• The largest deflection is 9.5 to 12.7 mm (3/8 to 1/2”).

To measure the tension use Cummins fixture P/N ST1293. The value should be 267 to 578 N (60 to 130 lbf), Fig. 73.

Fig. 72

Fig. 71

48

Fig. 73

MAINTENANCE AND LUBRICATION MANUAL After 1000 motorhours (after 1 year)

After 1000 motorhours (after 1 year)

Inspection of wear

• Fold tension pulley and using a lever replace belt, Fig. 74.

• Check the belt visually and inspect regularly its wear.

• Fissures across the belt are not objectionable.

• Belts with lengthwise fissures, frilled edges, or torn out pieces must be replaced, Fig. 75.

• Replace belt.

• Check tightness of bolts on the cover. Use torque 43 Nm (32 ftlb.).

Work on the belt with the engine off!

Fig. 74

Fig. 75

49

3.5. Individual operations of lubrication and maintenance After 1000 motorhours (after 1 year)

After 1000 motorhours (after 1 year)

3.5.29. Exhaust system check • Place the roller horizontally on solid, flat base.

• Stop the engine and disconnect the electrical machine’s installation.

• Check exhaust pipes for tight connection to the engine, Fig. 76.

• Check exhaust pipes to the muffler, Fig. 77.

• Tightening moment of collective exhaust piping – 21 Nm.

Fig. 76 - VH 700

Fig. 77 - VH 700

Fig. 76 - VH 1000

Fig. 77 - VH 1000

50

MAINTENANCE AND LUBRICATION MANUAL After 1000 motorhours (after 1 year)

After 1000 motorhours (after 1 year)

3.5.30. Gearbox oil change Valid for VH 1000 • Position the machine horizontally on a firm and flat surface.

• Open and secure the right engine cover.

• Remove cover in the frame underneath the engine.

• Disconnect the connector (1) boost valve, see Fig. 78.

• Remove input lid (2) Fig. 79 and drain plug (1) Fig. 78 – catch oil in a suitable container.

• Replace drain plug.

• Fill with 0,8 l (0,21 US gal) of oil according to Tab. 3.2. and check with dipstick on input lid.

Catch oil in a container and do not let it run freely on the ground!

Oil level must reach the upper mark on the dipstick!

Fig. 78

Fig. 79

3

2

1

51

3.5. Individual operations of lubrication and maintenance After 1000 motorhours (after 1 year)

After 1000 motorhours (after 1 year) Fig. 81

3.5.31. Oil change in the vibrator • Do the oil change when the oil is warm.

• Place the roller horizontally on solid, flat base.

• Turn the carriages such way to set the mark (1) to the lowest position and the inlet plug (2) up Fig. 80.

• Stop the engine and disconnect the electrical machine’s installation.

• Place the appropriate vessel under outlet plug (2).

• Unscrew both plugs and let the oil flow out.

• After outflow mount the outlet plug (2) back.

• Through the filling hole fill 2 l of recommended engine oil according to chapter 3.2.

• Mount the plug (2).

• Check the oil level after filling. Unscrew the oil level plugs on the left side both drums Fig. 81, right side of drum Fig. 82 and right side of front drum Fig. 83.

Fig. 82

! Watch out for the burn ups when outflowing the hot oil. ! Attend to ecology !!!

Fig. 80

Fig. 83

2

1

52

MAINTENANCE AND LUBRICATION MANUAL After 1000 motorhours (after 1 year)

After 1000 motorhours (after 1 year)

3.5.32. Inspection of the attenuator set

3.5.33. Cleaning of the water tanks

• Check the rubber-steels status, consistency of the

• Place the roller horizontally on solid, flat base.

steel with rubber.

• Carriages’ attenuator set Fig. 84.

• Driver’s post Fig. 85.

• Exchange the damaged.

• Stop the engine and disconnect the electrical machine’s installation.

• Dismount the tank filling seal (1) Fig. 86.

• Open the water outflow valve (1) Fig. 87.

• Check the tightness of screws and nuts.

Fig. 84

Fig. 86

1

Fig. 85

Fig. 87

1

53

3.5. Individual operations of lubrication and maintenance After 1000 motorhours (after 1 year)

After 1000 motorhours (after 1 year)

• Dismount the mask Fig. 88.

• Shut off water valve (1).

• Dismount the sprinkling filter vessel (2) with the sieve (3) Fig. 89.

• Wash and clean the vessel and sieve, mount them back.

• Exchange the sieve from filling neck Fig. 90, clean it.

• Wash the tank by water stream.

Fill the tank with clean water through the sieve in filling neck !

The tanks and sprinkling system empty always before the temperature drop below 0 °C (32 °F) !

Fig. 88

Fig. 90

Fig. 89

1

3 2

54