STA LUBRICATION & MAINTENANCE MANUAL VVW 3415 - PDF DOWNLOAD

LUBRICATION AND MAINTENANCE MANUAL

VVW 3415

Table of Contents Table of Contents

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

3.1. Specifications of Charging Liquids..................................................................................................................................... 4 3.1.1.

3.1.2.

3.1.3.

3.1.4.

Motor Oil ............................................................................................................................................................... 4 Fuel ....................................................................................................................................................................... 5 Lubricating Grease .............................................................................................................................................. 5 Transmission Oil .................................................................................................................................................. 5

3.2. Filling fluids

................................................................................................................................................................ 6

3.3. Plan of Lubrication ............................................................................................................................................................ 7 3.4. Safety and other Precautions for Maintenance................................................................................................................... 8 3.4.1. Safety during Maintenance ................................................................................................................................. 9 3.4.2. Fire precautions during changes of fills .............................................................................................................. 9 3.4.3. Environmental and sanitary precautions .......................................................................................................... 10 3.4.3.1. Environmental precautions ............................................................................................................................... 10 3.4.3.2. Sanitary precautions .......................................................................................................................................... 11

3.5. Specific steps of lubrication and maintenance ................................................................................................................. 12 Every 8-16 hours or daily ................................................................................................................................................ 13 3.5.1.

3.5.2.

3.5.3.

3.5.4.

3.5.5.

3.5.6.

3.5.7.

3.5.8.

Oil level in engine .............................................................................................................................................. 14 Inspection of engine air cooling ........................................................................................................................ 14 Air filter and indicator inspection ....................................................................................................................... 15 Oil level check in the gearbox ........................................................................................................................... 15 Fill up fuel ........................................................................................................................................................... 16 Inspection of safety devices and brake ............................................................................................................. 17 Checking level of water in sprinkler tanks, and filling up ................................................................................. 18 Inspection of suspension system ...................................................................................................................... 18

Every 50 hours – 14 days ............................................................................................................................................... 19 3.5.9. Drum drive .......................................................................................................................................................... 20 3.5.10. Tire pressure ...................................................................................................................................................... 20

Every 100 hours – 1 month............................................................................................................................................. 21 3.5.11. Vibrator drive belt ............................................................................................................................................... 22 3.5.12. Steering undercarriage ..................................................................................................................................... 23

Every 250 hours – after 3 months................................................................................................................................... 24 3.5.13. Changing oil and oil filter .................................................................................................................................. 25 3.5.14. Checking and setting up valves ........................................................................................................................ 26 3.5.15. Checking and cleaning of engine cooling ........................................................................................................ 27 3.5.16. Check tightness of screws ................................................................................................................................. 28 3.5.17. Chain drive ......................................................................................................................................................... 28

Every 500 hours – after 6 months................................................................................................................................... 29 3.5.18. Change of fuel filter, cleaning of fuel tank ......................................................................................................... 30 3.5.19. Cleaning and replacement of air filter .............................................................................................................. 31 3.5.20. Checking the vibrator clutch and travel shift ..................................................................................................... 32 3.5.21. Oil change in the gearbox ................................................................................................................................. 34

2

Lubrication and Maintenance Manual Every 1000 hours – after 1 year ..................................................................................................................................... 35 3.5.22. Vibrator oil change ............................................................................................................................................. 36

Maintenance as needed .................................................................................................................................................. 37 3.5.23. Water separator check ....................................................................................................................................... 38 3.5.24. Scrappers adjustment........................................................................................................................................ 38 3.5.25. Rubberized handles of steering undercarriage ............................................................................................... 39 3.5.26. Cleaning the machine ....................................................................................................................................... 39

3.6. Record of performed procedures ..................................................................................................................................... 40 3.7. Malfunctions and their remedies ..................................................................................................................................... 44 3.7.1.

3.7.2.

3.7.3.

3.7.4.

Engine ................................................................................................................................................................ 44 Machine travel ................................................................................................................................................... 45 Vibration ............................................................................................................................................................. 45 Safety equipment ............................................................................................................................................... 46

3

3.1. Specifications of Charging Liquids Viscosity

3.1.1.

Motor Oil

The use of quality motor oil and the correct period between changes is important for extending the life of the engine.

Classification of oils Oils are classified by performance and quality. They are specified according to the American Petroleum Institute, API, and the Committee of Common Market Automobile Constructors, CCMC. Applicable oil quality by: API-CD-CE-CF4 CCMC-D4-D5-PD2 For lower performance classes API-CC CCMC-D1 the period between changes must be halved.

Fig. 1- Diagram of viscosity

4

Since oil varies its viscosity with temperature, ambient temperature and manner of operation is decisive for the selection of SAE (Society of Automotive Engineers) viscosity class.

Exceeding the low temperature limit is not detrimental for the engine, however, starting may become difficult.

Exceeding the high temperature limit may last for a short time only, since lubricating qualities are lowered.

We recommend using oils as shown in Fig. 1 depending on the manner of operation and ambient temperature for manual starting.

Lubrication and Maintenance Manual

3.1.2.

Fuel

3.1.3.

For fuel use diesel according to

Lubricating Grease

For greasing synthetic grease with lithium content should be used according to NLGI 2 (National Lubricating Grease Institute, part 2) – see lubricating points in Plan of Lubrication.

CEN EN 590 or DIN EN 590 DIN 51 601 BS 2869 A1 and A2 ASTM D 975-88; 1-D and 2-D NATO Code F-54 and F-75

3.1.4.

VV-F-800: DF-A, DF-1 and DF-2 Normal diesel fuel contains less than 0.5% of sulfur. When fuel with 0.5 to 1% of sulfur is used, periods between oil changes must be halved. When using diesel fuels with more than 1% of sulfur, the engine manufacturer should be consulted regarding the periods between oil changes.

Winter fuel At temperatures below freezing normal diesel fuel deposits paraffin wax in the engine fuel system. These paraffin waxes may cause defects and inhibit the engine. For this reason use winter diesel fuel at temperature below the freezing point. Usually, diesel fuel is changed at the service station seasonally. At freezing temperature additives or petrol oil may be mixed in to improve low temperature properties as advised by the manufacturer.

The amount of added petrol fuel at different temperature ranges is as follows:

The low est am bie nt temperature at s ta rting °C (°F)

R atio of pe trol in diesel fuel summ er

w inter

0 (32 )÷ -10 (14 )

20 %

-

-1 0 (14)÷ -1 5 (5)

30 %

-

-1 5 (5)÷ -20 (-4)

50 %

20 %

-2 0 (-4)÷ -30 (-2 2)

-

50 %

Transmission Oil

Fill transmission with turbine oil TB 32 – turbine oil of kinetic viscosity 32 sq.mm per second at 40 degrees C. Viscosity class to ISO – VG 32.

It is possible to use hydraulic oil of same viscosity to ISO – VG 32.

In difficulties with shifting travel direction, see ”Note” in the Driver’s Manual, chapter 2.8.2., use oil of viscosity class to ISO VG 22 [22 sq.mm per second at 40 degrees C (104 degrees F)].

Maintain periods between oil changes!

When working with the roller at ambient temperatures below freezing use oils with lower viscosity to ISO VG 22.

Never apply transmission oil.

Mix only in the fuel tank.

First pour specified amount of additive or petrol oil into the tank, then fill up fuel. Winter fuel mixtures are flammable just as summer fuel.

Observe fire regulations!

5

3.2. Filling fluids

S e c ti o n - fi ll Engine - motor oil API-C D; CE see chapter 3.1.1.

Use

T y p e o f f il l

summ er

SAE 15W /40

summer (transition period)

SAE 10W /40

w inter

SAE 5W/3 0

above freezing

summ er

point

diesel

Fue l tank, see chapte r 3.1.2.

1,5 l (0,4 gal U S)

4,8 l (1,27 gal U S) below freezing point

G earbox

w inter diesel 1. TB - 32

1. turbine oil 2. hy draulic oil

A m o u n t o f fi ll

2. Hy dr. oil year round

hydraulic

3 l (0,8 gal U S)

motor 32 to ISO VG 32 Vibrator- engine oil

Travel drive - lubricating grease Chain drive n- lubricating grease Steering undercarriage lubricating grease

Water tank 2 x

6

year round

year round

year round

year round

above freezing point

SAE 15W /40

1 l (0,26 gal US)

to plan of

30 cm 3 ( 1 ,8 in 3 ) in

lubrication

one grease point

to plan of lubrication

as needed

to plan of

30 cm 3 (1,8 in 3 ) in

lubrication

one grease point

w ater

2x28 l (2x7,5gal U S)

Ic o n

3.3. Plan of Lubrication

Lubrication and Maintenance Manual

Fig. 2 - Plan of Lubrication

7

3.4. Safety and other Precautions for Maintenance

8

Lubrication and Maintenance Manual 3.4.1.

Safety during Maintenance

3.4.2.

Fire precautions during changes of fills

Perform lubrication, maintenance, and adjustments

• by trained personnel.

• in time periods listed in the table for lubrication, or during technical check-up.

• following safety rules of ”Operation Instruction for Roller VVW 3415”.

• with the machine placed on a level and firm surface,

• In view of fire danger, applied flammable fluids are subdivided into the following danger classes: II. danger class – diesel fuel IV. danger class – mineral oils, lubricating grease

• Oil change must done in place, which is removed from areas endangered by explosion or fire.

secured against spontaneous roll (brake), and accidental starting.

• The place must be provided with notices forbidding

• with notice board attached to the undercarriage han-

• The workplace must be arranged to catch the quantity

dle ”The machine is out of order”.

• when the machine is standing and the engine has cooled of.

• with the engine running (adjustments), with another person present that has access to the emergency controls and is constantly in touch with the mechanic doing the adjustments, so that the engine may be switched off immediately should the need arise.

• after the machine, the lubrication points, and serviced areas have been cleaned.

• using tools that are in good shape.

• by replacing parts with new ones. The manufacturer is

smoking and open flame. of flammable fuel equal to the largest size of the container.

• The place must have fire extinguishers on hand.

• For handling oils and diesel use containers like metal drums, barrels, cans, and metal canteens.

• Transportation containers must be properly closed in storage.

• The containers must have only one opening, stored with the opening up, and secured against leaks and dripping.

• The containers must be indelibly marked showing the contents and danger classification.

not responsible for damages caused by using other components and parts.

• with adequate illumination of the entire machine during limited visibility.

• with all covers and safety elements in place after they have been removed during maintenance.

• with all connections, nuts and bolts that were removed during maintenance tightened and checked with specified torque.

• and use recommended fills after the machine warmed up adequately – watch out for getting burnt.

9

3.4. Safety and other Precautions for Maintenance 3.4.3.

Environmental and sanitary precautions

The user is obligated to comply while operating and maintaining the equipment with general sanitary and environmental precautions and regulations pertaining to the situation, as issued for the territory of operations.

3.4.3.1. Environmental precautions The contents of individual systems of the machine and some of its parts become waste with properties bearing certain risks to the environment, when the machine has been placed out of service and disassembled.

This type of waste includes mainly -

organic and synthetic lubricants, oils, and fuels

-

cleaning and conservation matters

-

all removed filters and cartridges

-

all used and discarded hydraulic and fuel hoses, rubberized metal, and other parts of the machine soiled by above named products.

The listed matters and parts must be dealt with after discarding them according to applicable national regulations for the protection of environment and health.

10

Lubrication and Maintenance Manual 3.4.3.2. Sanitary precautions • Oil products and lacquers including thinners are inju-

Applicable regulations During lubrication and maintenance the following regulations and standards must be complied with:

rious to health. Workers coming in contact with such products during operations and maintenance must observe general sanitary precautions of health protection, and safety and sanitary instructions issued by the manufacturer of such products.

Abroad

We draw your attention particularly to

Applicable regulations for flammable liquids

–

skin protection when working with oils and lacquers

Regulations and laws for health and environment protection applicable to these operations.

–

thorough hand washing at the end of work and before meals. Protect your hands with suitable cosmetic creams

Valid regulations pertaining to the handling of dangerous matters and waste.

–

when working with oils and fuels comply with operation instructions issued for the machine,

Valid regulations for work safety, and health protection during operations and maintenance.

Applicable regulations for fire protection.

• Oil products and lacquers including organic thinners, cleaning and conservation means should be preserved in original containers properly marked. Do not allow storage in unmarked bottles and other cans resulting in dangerous interchange. Most dangerous is their interchange for food or drink.

• Should the skin, soft tissues, or eyes be affected, or vapors inhaled, apply immediately first aid. In case of accidental consumption seek out immediately medical help.

• While working with the machine use ear protectors of appropriate type and manufacture.

11

3.5. Specific steps of lubrication and maintenance Lubrication, maintenance, and set-up should be done regularly in specific time periods depending on the number of working hours shown in the Operation Record Book.

Removed or loose bolts, plugs, and screw connections should be tightened using torque of tables in chapter 3.5.16, unless indicated otherwise in particular cases.

This manual describes only basic data on the engine, other are to be found in the service and maintenance engine manuals supplied with the machine documentation.

Follow instructions of the Operation and Maintenance Engine Manual!

After first 25 hours of new machine operation or after General Overhaul 3.5.13. Change oil and filter in the engine 3.5.14. Check and adjust valves

After first 50 hours of new machine operation or after General Overhaul 3.5.11. Check the belt tension on the vibrator 3.5.17. Check tension of chain drive

After first 250 hours of new machine operation or after General Overhaul 3.5.20. Check clutch in the vibrator and the travel gearshift 3.5.21. Change oil in gearbox 3.5.22. Change oil in vibrator

12

Lubrication and Maintenance Manual Every 8-16 hours or daily Fig. 3

13

3.5. Specific steps of lubrication and maintenance Every 8-16 hours or daily 3.5.1.

Every 8-16 hours or daily

Oil level in engine

3.5.2.

• Do before starting the engine – the machine must be standing on flat and firm surface.

• If the engine was running recently, wait for 3 minutes

Inspection of engine air cooling

• With the engine stopped check visually cool air intake openings (1) and the cylinder ribbing (2) whether soiled by heavy dirt or dust, etc. Clean, see Fig.6.

to let the oil settle.

• Clean dirt around the dipstick opening.

• Remove dipstick (1) and wipe with cloth free of lint – Fig. 4.

• Insert dipstick fully and pull it out again to check the level.

• Keep the level between marks on the dipstick, Fig. 4.

• The distance between marks corresponds to 0.4 l (0.1 US gals).

• Remove cap (2) and pour oil through the opening, Fig. 5.

• Wait about a minute until oil settles, and recheck.

Fig. 5

• Check for any leaks in the engine and correct if necessary.

Fill with oil of the same kind according to table in chapter 3.2.

2

Do not use the engine, should the level be below the low mark on the dipstick.

Fig. 4

Fig. 6

MA X

2 2 MI N

1

14

1

Lubrication and Maintenance Manual Every 8-16 hours or daily 3.5.3.

Air filter and indicator inspection

• Check air intake opening whether soiled by heavy dirt, dust, or leaves, etc. Clean, see Fig. 7.

• Check the indicator of filter element – green stripe in

Every 8-16 hours or daily 3.5.4.

Oil level check in the gearbox

• Stop the engine, clean the area around the dipstick, pull out dipstick, wipe, reinsert, pull out again and read off oil level, see Fig. 9.

the middle must be visible, see Fig. 8.

Fig. 7

Fig. 8

Fig. 9

15

3.5. Specific steps of lubrication and maintenance Every 8-16 hours or daily 3.5.5.

Fill up fuel

• Before starting the engine clean the area around fuel tank lid and check level when the lid has been removed, fill up if necessary. Maintain fuel level at least half full, see Fig. 10.

Use only clean fuel and clean canisters. Do not spill fuel. Refrain from smoking or using open flame.

Fig. 10

16

Every 8-16 hours or daily

Lubrication and Maintenance Manual Every 8-16 hours or daily 3.5.6.

Inspection of safety devices and brake

Every 8-16 hours or daily Fig. 11

%

Brake function inspection – shifting in neutral

• Control brake on a slope!

• For your own sake stand beside the machine.

9

• Start the engine.

• Shift working gear (turtle), Fig. 11.

• Adjust normal revolutions by lever (2) to the middle position, Fig. 12.

• Press brake lever (5), Fig. 13.

• Shift to forward by travel control (3), see Fig. 12.

• When the machine is moving release brake lever – the machine must stop and travel control shifts to neutral.

• The brake must hold the roller on a grade of 45 % (24 degrees ).

Fig. 12

9

3

If a defect is found call service and don’t use the machine!

9 2 Safety devices check

• Stand beside the machine for your own safety.

• With the engine running and working gear shifted (turtle), start moving backwards

• Thereafter press the safety bumper by hand forward, see Fig. 13.

• The machine must stop immediately.

• When the bumper is pressed all the way to the handle

Fig. 13

(1), the roller must start moving forward.

1

• If the equipment is not functional, check the flexible

3

rods and the clutch on the controller (3).

9 Should it be impossible to correct the situation, call service!

Make sure that nobody is standing close by in front or back of the machine while checking.

6

17

3.5. Specific steps of lubrication and maintenance Every 8-16 hours or daily 3.5.7.

Checking level of water in sprinkler tanks, and filling up

Every 8-16 hours or daily 3.5.8.

Inspection of suspension system

• Visually check daily the condition of rubberized metal • Clean the lid and the area around, remove the lid and check water level, Fig. 14. Fill up with clean water from a clean canister.

pieces on the engine platform (1), Fig. 15, and the undercarriage (2), Fig. 16. Fissures on the rubber surface of up to 10 mm deep are allowed. A rubberized piece with a fissure deeper than this must be replaced.

The life of the suspension system deteriorates considerably, when the machine is operated with one or more damaged pieces.

Fig. 15

1

Fig. 14

Fig. 16

2

18

Lubrication and Maintenance Manual Every 50 hours – 14 days Fig. 17

19

3.5. Specific steps of lubrication and maintenance Every 50 hours – 14 days 3.5.9.

Drum drive

Every 50 hours – 14 days 3.5.10. Tire pressure

• Grease each of the 4 greasing nipples on the drum chain drive, Fig. 18, 19, using 30 cu.cm (1.8 cubic inches) of following grease:

Grease - make Benz ina

PM-LA 2

Mobil

Mobi lgr ease SPECIAL

• Maintain tire pressures in line with the grain of compacted material.

• Check using pressure gauge always before starting work on a different type of material, or when the tires a cold.

• Pressures : materials

type

tire pressure kPa (PSI)

fine grain

clay, soil

117 (16,9)

other

gravel, sand

157 (22,6)

Mobi lgr ease MP Mobi lpl ex EP-1 ESSO

Mul ti-Pur pose Grease H

SHELL

Retinax A Alvania Grease No 3

CASTROL

Castrolease LM Spherol Grease RBB 2

Fig. 18

20

Fig. 19

Lubrication and Maintenance Manual Every 100 hours – 1 month Fig. 20

21

3.5. Specific steps of lubrication and maintenance Every 100 hours – 1 month 3.5.11. Vibrator drive belt

Every 100 hours – 1 month Belt tension adjustment

• Loosen bolt (1), Fig. 21.

• Stop the engine.

• Loosen pin (2), Fig. 22.

• Check visually the belt. If considerable damage or

• By pulling on the hexagon (3) at the end of the tension

wear are visible, like deeper fissures, frayed ends, or tears, replace the belt.

• Check tension of the belt. Press with your finger extending a force of about 50 N (11 lbf) on the middle of the longest section of the belt. The depression may be no more than 1.5 to 2 cm (0.6 to 0.8”)

plate (4), Fig. 21, adjust tension.

• Thereafter tighten the bolt and the pin. Check tension.

• Do not overdo – the bearings may be overloaded.

Replacing the belt

• Loosen the bolts and remove the belt cover, loosen bolt (1) and pin (2), move the tension plate (3) with the pulley and replace the belt. Tighten the belt, replace cover and clean grooves of the pulleys.

Check belt tension after 50 working hours!

Fig. 21

Fig. 22

1

4 2 3

22

Lubrication and Maintenance Manual Every 100 hours – 1 month

Every 100 hours – 1 month

3.5.12. Steering undercarriage • Lubricate grease nipples on both sides of the engine revolutions, vibrator, and reversing gear controller, Fig. 23, until new grease starts running out.

• Lubricate one grease nipple of the vertical pin on the steering, Fig. 24, until new grease starts running out.

• Grease both nipples of the rocker with 30 cu.cm (1.8 cu.inches) of fresh grease (Fig. 25).

• Use grease according to table in chapter 3.5.8.

Fig. 23

Fig. 24

Fig. 25

23

3.5. Specific steps of lubrication and maintenance Every 250 hours – after 3 months Fig. 26

24

Lubrication and Maintenance Manual Every 250 hours – after 3 months 3.5.13. Changing oil and oil filter

Every 250 hours – after 3 months • Remove the lid (1), do not damage the hexagon, use proper key, Fig. 28.

• Change oil only when the engine is hot. Otherwise start the engine and let run for about 15 minutes.

• Place the machine horizontally and switch off the engine.

• Have a suitable container ready for the used oil and place it under the oil discharge opening.

• Remove the plug (1) and the oil run out, Fig. 27.

• Replace the old element with a new one (2) with TOP marking up, Fig. 28.

• Check seal ring (3) and install the lid (1), Fig. 29.

• Wipe the area around the plug, install plug with new seal.

• Fill with 1.5 l (0.4 US gals.) of new oil according to chapter 3.2., Fig. 30.

• Clean the oil filter cartridge.

Fig. 27

Fig. 29

3

1

Fig. 28

Fig. 30

1

2

25

3.5. Specific steps of lubrication and maintenance Every 250 hours – after 3 months • Check oil level using dipstick, Fig. 31.

Every 250 hours – after 3 months 3.5.14. Checking and setting up valves

• Start the engine and let idle for 3 minutes.

• Stop the engine, let oil run of and check level after 2 minutes.

• Check tightness of release plug and the oil filter.

• Check and adjust valves when the engine is stopped and cooled down at a temperature of 10 to 30 degrees C (50 to 86 degrees F).

• Remove engine cover.

• Leave the decompression lever (1) in ”0” position, Fig. 32.

• Clean the lid over the valves and remove together with

Do not get burnt by hot oil!

The first oil change in a new engine or after General Overhaul should be done after 25 working hours.

Change oil at least once a year even if the engine hasn’t been working the specified number of hours.

the seals. Always replace with new seals.

• Turn the engine using the starting crank handle until compression point is reached.

• Check valve clearance between the rocker (1) and the head of the valve (2) with feeler (3), Fig. 33.

• When the clearance is correctly set, slight drag must be felt on the feeler when sliding between the rocker and the valve.

Fig. 31

Valve clearance

mm (inches)

intake valve

0.1(0.004)

exhaust valve

0.2 (0.008)

Fig. 32

MA X

MI N

26

1

Lubrication and Maintenance Manual Every 250 hours – after 3 months Adjustment of valve clearance

• Adjust valve clearance by loosening nut (4) and tur-

Every 250 hours – after 3 months 3.5.15. Checking and cleaning of engine cooling

ning screw (5), Fig. 33.

• Loosen nut (4) using key (1) and screwdriver (2), and

• Check before starting the motor.

turn adjustment screw, Fig. 34.

• Simultaneously control clearance, Fig. 33 – the gauge must feel considerable resistance.

Presence of dust

• Clean dry and air-blow the air conduits, around the

• Tighten the nut and check adjusted gap.

cylinder, cylinder head, and the fan blades, Fig. 35.

• Replace cover using new seal, and tighten uniformly.

• Let the engine run for a while and check tightness.

Presence of oil deposits

• Clean around the air cooling system using detergent according to the manufacturer’s instructions, then hose down with pressurized water stream, and dry with jet of air immediately.

• Correct sources of soiling by oil and leaks.

• Install parts of air cooling system.

Fig. 33

• Immediately thereafter start the engine and let run for the engine to warm up and dry out, to prevent corrosion.

3 1

5

4

2

Fig. 34

Fig. 35

2

2 1

2

1

1

27

3.5. Specific steps of lubrication and maintenance Every 250 hours – after 3 months

Every 250 hours – after 3 months

3.5.16. Check tightness of screws

3.5.17. Chain drive

• Check all accessible screws and nuts on the undersi-

• Remove cover off chain drive on the left side of the

de of the machine, steering undercarriage, installed accessories, mainly the installation of the engine and gearbox to the mounting plate.

Table of torque Torque For screws

For screws

For screws

5.8 (5 S) *

8.8 (8 G) *

10.9 (10 K) *

Thread

Nm

lb-ft

Nm

lb-ft

Nm

lb-ft

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

machine and check tension of chain.

• Loosen bolts of tension plate (1) and tighten chain. The chain must run loose on tensor (2). The deflection in the longest section may be equal to the thickness of the chain when depressed by finger of force 20 to 30 N (4.4 – 6.6 lbf). Check the gap (3-5 mm) between the chain and the muffler (3), Fig. 36.

• Remove dirt from the chain and lubricate with grease of chapter 3.5.8. Check sealing around the cover and install cover.

Check chain tension on a new machine or after General Overhaul after the first 50 hours of operations.

* - Strength class of screws – as indicated on the screw head

• Use torque wrench.

• The values shown in the table are those of a dry thread, not applicable to oiled threads.

Fig. 36

3-5 mm

3

2

28

1

Lubrication and Maintenance Manual Every 500 hours – after 6 months Fig. 37

29

3.5. Specific steps of lubrication and maintenance Every 500 hours – after 6 months

Every 500 hours – after 6 months

3.5.18. Change of fuel filter, cleaning of fuel tank

• Place a container underneath the filter and fuel hoses to collect escaped fuel.

• Remove fuel hoses from both sides of the fuel filter (1) • The time period between filter changes depends on its contamination by fuel used. The period may be extended or shortened considerably.

• We recommend to clean the fuel tank as well by

and replace with a new fitter (2) with the arrow oriented in the direction of flow, Fig. 38.

• Remove clamp, tighten the screw of the water separator, add fuel, and check tightness of hoses.

flushing it using clean fuel and thus removing deposited contamination.

• Change the filter when there is only a small amount of fuel in the tank, or when the tank is empty and being cleaned. Drain the tank contents into a handy container by opening the bolt according to Chapter 3.5.23.

• If some fuel remains in the tank, clamp the output hose.

Fig. 38

1 2

1

30

Watch for humidity and clean work process.

Observe fire regulations, do not smoke – danger of fire.

Lubrication and Maintenance Manual Every 500 hours – after 6 months

Every 500 hours – after 6 months

3.5.19. Cleaning and replacement of air filter

The element may be cleaned only twice. It must be replaced after two years of operations.

• Check regularly the indicator of filter condition (1), Fig. 39.

• The green stripe (2) of the indicator will be covered up, when the filter element is soiled, Fig. 39.

• In that case clean the element (replace) even before the regular 500 hrs maintenance.

• Clean carefully the outside and the lid of the filter.

• Remove nut (1) off the filter lid, Fig. 40.

• Remove the element (1), Fig. 41.

• Clean the inside of the filter housing. Do not use compressed air!

• Shake out the element to remove dust. when using compressed air, direct it from the inside opening outwards. The air pressure should be lower than 0.5 MPa.

Fig. 40

• Replace with a new element always when the filter has been soiled by greasy contaminants!

• Check the tightness of the lid.

• Do not weld or solder a damaged housing or the lid.

Should you find the metal parts warped, dented, or the sealing faces damaged, replace the filter with a new one.

Fig. 39

1

Fig. 41

1 2

1

31

3.5. Specific steps of lubrication and maintenance Every 500 hours – after 6 months

Every 500 hours – after 6 months

3.5.20. Checking the vibrator clutch and travel shift

Refrain from having vibration on needlessly.

• Place the roller on a soft area (clay, sand) and place

When finished with checking, switch vibration off immediately!

wedges under the wheels.

• Shift into neutral – gearshift lever on the lid of the gearbox positioned as in Fig. 42.

• Start the engine.

Checking vibrator clutch

• Release clutch (1) by rod (3) and slide it out from the lever opening (2), Fig. 43.

• Move rod (3) aside.

• Pull the force gauge (4) connected behind the vibration lever (2) on the gearbox, Fig. 44.

• Check the force needed to engage the vibrator clutch from the disengage position to engage position – the machine starts vibrating.

Fig. 43

• The resulting force on the vibration controller (4) must indicate a value of 8 to 9 kp, e.g. 78 to 98 N (1.8 to 2.2 lbf).

3 2

1

Fig. 42

Fig. 44

N

%

3

4

32

2

Lubrication and Maintenance Manual Every 500 hours – after 6 months

Every 500 hours – after 6 months

Checking travel direction clutch

• Pull the force gauge connected behind the travel direction controller (3), Fig. 45 (force gauge behind the controller in both directions) and check force needed to engage travel direction backwards and forward from neutral.

Perform the first check of the control force on a new machine or after General Overhaul after 250 hours of operations!

• The resulting force on the reversing lever must indicate a value of 11 to 13 kp, e.g. 108 to 128 N (2.4 to 2.8 lbf)

• Should the force be outside the specified range, let the roller manufacturer adjust it to specified value.

Fig. 45

%

%

3

33

3.5. Specific steps of lubrication and maintenance Every 500 hours – after 6 months

Every 500 hours – after 6 months

3.5.21. Oil change in the gearbox

Do not get scalded by hot oil!

• Change oil when the oil is warm and the machine idle.

The very first oil change on a new machine or after General Overhaul should be done after 250 hours of operations.

• Place the machine on a level surface.

• Loosen the intake plug (1) on the lid of the gearbox, Fig. 46.

Only specified oil must be used!

• Release the drain plug (2), Fig. 47 and let oil drain into a handy container. Tighten the drain plug.

• Fill the gearbox with clean diesel fuel (petroleum) and let idle for 3 minutes, drain thereafter.

• Tighten plug (2), fill with specified amount of oil according to Chapter 3.2.

• Check level of new oil, Fig. 48.

• Replace intake plug (1).

Fig. 47

2

Fig. 48

Fig. 46

1

34

Lubrication and Maintenance Manual Every 1000 hours – after 1 year Fig. 49

35

3.5. Specific steps of lubrication and maintenance Every 1000 hours – after 1 year 3.5.22. Vibrator oil change • Change oil when warm and the machine idle.

• Place the roller on a gentle slope to have the right side of the machine leaning down (the drain plug lower).

• Place a suitably shaped tub through the opening in the side frame underneath the drain plug.

• Loosen the drain plug (1) and the intake plug (2), see Fig. 50, collect the drained oil in the tub.

• Close the drain hole, position the roller upright and fill with specified oil according to Chapter 3.2.

The very first oil change on a new machine or after General Overhaul should be done after 250 hours of operations.

Do not get scalded by hot oil!

Fig. 50

2

1

36

Every 1000 hours – after 1 year

Lubrication and Maintenance Manual Maintenance as needed Fig. 51

37

3.5. Specific steps of lubrication and maintenance Maintenance as needed

Maintenance as needed

3.5.23. Water separator check

3.5.24. Scrappers adjustment

• Before tanking fuel release the screw of the water

• Check distance between scrappers and the surface of

separator (1) on the fuel tank, and let water sediment run out into a handy container, see Fig. 52. The drain screw (1) shouldn’t be loosened completely, leave it in for about two turns.

the drum. Adjust to 5 mm (0.2”) above the drum surface, loosening screws Fig. 53.

• First water starts running out, then fuel. Let a small amount of fuel run out to make sure that all water is out, then tighten the screw.

Fig. 52

Fig. 53

1

5 mm 0,2 in

38

Lubrication and Maintenance Manual Maintenance as needed 3.5.25. Rubberized handles of steering undercarriage

Maintenance as needed 3.5.26. Cleaning the machine • After finishing work clean the machine of all raw con-

• In case the steering handle has dropped down considerably (fatigue, rubber torn), replace both pieces immediately, Fig. 54.

tamination.

• Clean the entire machine once a week.

• Do not use aggressive, flammable means, unfriendly to the environment.

• Clean with water or steam in designated places, where contaminants may be collected, to prevent their escape in surface and subsurface waters (drinking water supply), and sewers.

Clean with the engine stopped and with brakes on.

Fig. 54

39

3.6. Record of performed procedures

Date

40

Number of hours

Procedure performed

Lubrication and Maintenance Manual

Date

Number of hours

Procedure performed

41

3.6. Record of performed procedures

Date

42

Number of hours

Procedure performed

Lubrication and Maintenance Manual

Date

Number of hours

Procedure performed

43

3.7. Malfunctions and their remedies 3.7.1.

Engine

Malfunction

Probable cause

Remedy

Engine turns, doesn't start

Revolutions controller in STOP or in idle

Set controller to maximum

Injection pump doesn't supply fuel

Fill up fuel, check systematically fuel assembly, hoses, filter, fuel pump

Insufficient compression: incorrectly set

Check gaps, adjust

valves Seized valves - loose in seats, cylinder

Contact service

and piston rings worn

At low temperature

Injection out of order

Check injection

Doesn't reach temperature limit for

Observe instructions for cold starts

starting Fuel gelled

Check whether fuel flowing out through drain plug. Warm up fuel system, drain, and fill with stable fuel for given temperature

Low revolutions - thick motor oil

Change oil

Fuel cleaner plugged

Replace

Fuel line cut

Check fuel line

Engine stops

Out of fuel, fuel line faulty (loose

Add fuel, check lines, replace filter,

spontaneously during operation

connections), plugged filter, injection pump faulty, or other mechanical fault

contact service

Engine losing power and

Out of fuel, plugged filter, insufficient fuel tank ventilation, fuel line not tight,

Add fuel, replace filter, clean tank ventilation, check connections, block

revolutions

revolutions controller in improper position

controller

Engine losing power, black

Air filter plugged, improper setting of valves, faulty injection

Clean filter, adjust valves, check injector

Engine starts and stops immediately

exhaust

44

Lubrication and Maintenance Manual 3.7.2.

Machine travel

Malfunction

Probable cause

Remedy

Machine doesn't move, gearshift

Chain off drive

Remove cover, adjust chain

OK

(replace) tension

Machine doesn't move, direction gear operates, gearshift doesn't work

Faulty pull-rod

Check rod, replace

Fault in pull-rod connection

Check connection to controls, repair connection

Clutch plates worn (clutch slides)

Adjust clutch - contact service

Heavy oil in gearbox

Change oil

Travel clutch not adjusted

Adjust clutch - contact service

Malfunction

Probable cause

Remedy

Machine doesn't vibrate

Broken belt

Change

Machine doesn't vibrate, vibration lever moves OK, vibration cannot be shifted in

Faulty pull rod

Check pull rod, replace

Faulty connection in pull rod

Check connection of pull rod with levers, repair

Clutch plates worn (clutch slides)

Adjust clutch - contact service

Reverse shift not holding in travel position with cold machine

3.7.3.

Vibration

45

3.7. Malfunctions and their remedies 3.7.4.

Safety equipment

Malfunction

Probable cause

Remedy

Faulty assembly protecting the driver against being pressed backwards

Faulty pull rod

Check pull rod, replace

Connection on reverse lever stuck

Remove, clean, and grease

Faulty brake pull rod

Replace - contact service

Faulty controller

Contact service

When brake released, neutral doesn't shift, machine keeps on moving (travel lever into mid-position

Faulty connection between brake and reverse lever in gearbox

Contact service

When shifting from forward to backwards, brake lever doesn't need to be pressed again

Faulty controller

Contact service

Not possible to shift backwards at working speed (turtle). Note! with shift in transport speed (rabbit), backwards shift is blocked

Faulty controller

Contact service

Machine brake cannot be released

46

Lubrication and Maintenance Manual

47

STAVOSTROJ a.s.

549 01 Nové Město nad Metují tel: +42 0-441/476 111

fax: +42 0-441/470 405

Issued by:

Literature Department of

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© 3 / 2000