Sd110 Operator Manual Eng_gb_20026436

Transcript

sd110 operator's manual SD110 Serial No. 5233258001- English CST English Ref. no. Pub 20026436 2010.03 Volvo, India SD110 Foreword This Operator's Manual is intended as a guide for the correct use and maintenance of the machine. Therefore, study it carefully before starting and operating the machine, or before carrying out any preventive maintenance. Keep the manual in the manual box, so that it always is at hand. Replace it immediately if it is lost. The manual describes the applications for which the machine primarily is intended and is written to apply for all markets. We therefore ask you to disregard the sections which are not applicable to your machine or to the work for which you use your machine. OPERATOR'S MANUAL Table of contents Presentation NOTICE If this manual includes more than one machine, the information applies to all machines, unless otherwise stated. Many hours are spent on design and production to make a machine that is as efficient and safe as possible. The accidents which occur in spite of this, are mostly caused by the human factor. A safety conscious person and a well maintained machine make a safe, efficient and profitable combination. Therefore, read the safety instructions and follow them. We continually strive to improve our products and to make them more efficient through changes to their design. We retain the right to do this without committing ourselves to introduce these improvements on products, which have already been delivered. We also retain the right to change data and equipment, as well as instructions for service and other maintenance measures without prior notice. Instrument panels Other controls Operating instructions Safety regulations It is the operator's obligation to know and follow the applicable national and local safety regulations. The safety instructions in this manual only apply to cases when there are no national or local regulations. WARNING The warning symbol above appears at various points in the Operator's Manual together with a warning text. Read the text carefully, your safety depends on it! It is the obligation of the operator to make sure that all warning decals are in place on the machine and that they are readable. Operating techniques Safety when servicing Service and maintenance CAUTION Indicates a potentially hazardous situation which may result in machine damage. NOTICE Is used to notify of installation, operation, or maintenance information which is important but not hazard related. Specifications Alphabetical index Get to know the capacity and limits of your machine! Ref. No. PUB 20026436-A 2011.10 Copyright © 2010, Volvo Construction Equipment Customer Support. All rights reserved. Foreword 2 Identification numbers Identification numbers Enter the product identification number (PIN) of machine, manufacturer code and engine serial number. These numbers must be specified when contacting the manufacturer to order spare parts. For positions and explanation of the PIN plate, see page Product plates. Manufacturer Volvo India Private Limited 7 & 8, Peenya Industrial Area Bangalore- 560058. PIN of machine Manufacturer code Engine serial number Please send comments about the Operator’s Manual to [email protected] Table of contents 3 Table of contents Foreword ................................................................. 1 Identification numbers ......................................................... 2 Table of contents ..................................................... 3 Presentation ............................................................ 5 Machine view ..................................................................... 13 CE-marking, EMC-directive ............................................... 16 Product plates ................................................................... 17 Information and warning decals ........................................ 19 USA federal clean air act ................................................... 23 Instrument panels .................................................. 26 Other controls ........................................................ 30 Controls ............................................................................. 30 ROPS ................................................................................ 31 Operator comfort ............................................................... 32 Operating instructions ............................................ 33 Safety rules when operating .............................................. 33 Measures before operating ............................................... 57 Starting engine .................................................................. 61 Hydraulic system, warming up .......................................... 62 Vibration ............................................................................ 63 Operating ........................................................................... 64 Braking .............................................................................. 66 Stopping ............................................................................ 67 Measures after operating .................................................. 68 Parking .............................................................................. 69 Measures in case of machine failure ................................. 71 Retrieving and towing ........................................................ 76 Transporting machine ........................................................ 81 Operating techniques ............................................ 84 Eco driving ......................................................................... 85 Signalling diagram ............................................................. 86 Safety when servicing ............................................ 88 Service position ................................................................. 92 Before service, read .......................................................... 95 Preparations before service ............................................ 102 Entering, leaving and climbing the machine .................... 103 Fire prevention ................................................................ 104 Handling hazardous materials ......................................... 109 Handling line, tubes and hoses ....................................... 115 Table of contents 4 Service and maintenance .................................... 116 General inspection of machine ........................................ 124 Engine ............................................................................. 125 Fuel system ..................................................................... 131 Engine air cleaner ........................................................... 133 Cooling system ................................................................ 141 Electrical system ............................................................. 144 Transmission ................................................................... 156 Axles ................................................................................ 158 Brake system ................................................................... 163 Steering system ............................................................... 164 Wheels ............................................................................ 165 Drum ................................................................................ 167 Hydraulic system ............................................................. 174 Greasing .......................................................................... 180 Lubrication and service chart .......................................... 184 Specifications ...................................................... 188 Recommended lubricants ................................................ 189 Service capacities and change intervals ......................... 195 Brake ............................................................................... 197 Wheels ............................................................................ 198 Drum ................................................................................ 199 Specifications .................................................................. 200 Machine weights .............................................................. 204 Dimensions ...................................................................... 205 Service history ................................................................. 208 Alphabetical index ............................................... 211 Presentation 5 Presentation Description, complete machine WARNING Persons who do not follow the safety instructions and do not pay attention to the warnings in this service manual must make sure that their work method is safe. Otherwise, there is a serious risk of serious accidents and, at worst, fatalities. V1100904 SD110 compactor machine Machine description: SD110 The SD110 is a single-drum vibratory soil compactor, is powered by a Volvo D5D GA E3 water cooled diesel engine, driving three hydraulic pumps. First pump powers propulsion system, second pump powers the vibration system and the third pump powers steering system. Engine rpm is controlled by the throttle lever. Machine forward, reverse direction and speed is controlled by propulsion control lever and machine dual speed is controlled by two speed switch. Drum vibration frequency and amplitude is controlled by vibration control lever. Machine steering action is controlled by steering wheel. The compactor uses the positioning of the propulsion control lever to STOP position as a service brake. An independent spring applied hydraulically released axle brake serves as a parking brake. Standard equipment includes an emergency switch to shut down the engine and apply the parking brake in an emergency situation. Roll-over protective structure (ROPS), railing assembly and seat belt provides operator safety. NOTICE For a complete listing of currently supplied / available standard and option features contact your nearest Volvo authorized dealer. Presentation 6 Engine The SD110 series compactor is powered by 99 kw (133 hp) Volvo D5D GA E3 water cooled diesel engine. A dry type, two-stage air cleaner system provides clean air to the engine. A dust discharging evacuator valve is provided on the air cleaner. Air filter clog indicator is provided on the control console. When it glows, it indicates that air filtration system needs attention. The engine rpm is controlled by the throttle lever located at right side of the operator seat. Electric starter and belt driven alternator are standard. Engine shutdown is by an ignition key or an emergency switch in case of emergency. Main Frame The machine is built with rear frame assembly and a front frame assembly, connected by a swivel frame with two articulation pins and one oscillation pin. The rear frame is a welded assembly on which hydraulic tank, fuel tank, battery compartment, control valves, engine assembly with propulsion pump, vibration pump, steering pump and axle with tyre assembly are mounted. The front frame is a welded assembly on which drum assembly and scraper bar are mounted. Drum Drum fitted with the machine is a smooth drum. Vibration is transmitted to the drum by an eccentric assembly which is mounted inside the drum and is powered by a hydraulic vibration motor. Amplitude and frequency of drum vibration is controlled through vibration control lever. NOTICE Drum drive and pad foot is a option, Contact your nearest Volvo dealer for more information. Controls All operator controls, gauge and indicators are provided in the operator compartment for operator’s convenience and comfort. The propulsion control lever, vibration control lever and engine throttle lever are located on the right side of the operator seat. The control console has control switches, light switches, indicators, hourmeter, emergency switch, ignition key switch, mobile charger plug, fuel gauge and steering control unit mounted on it. Transmission The machine is equipped with a hydrostatic transmission and hydraulic motor which consists of the drive engine and an adjustable flow pump in a closed hydraulic circuit. The speed of the machine and the direction of machine travel is controlled by Presentation 7 the FSR propulsion control lever, engine speed selector and a speed selector switch. Vibration System The drum vibration system consists of an eccentric assembly mounted internally and is powered by an hydraulic motor. This system has dual amplitude capability. Selection of high or low amplitude is by operating the vibration control lever provided on the right side of the operator seat. High amplitude is recommended for thick lift compaction while low amplitude is for thinner lift and sensitive compaction area. Operator can select different vibration frequencies for high or low amplitude depending on the requirement. To have a different drum vibration frequency with high amplitude, vibration control lever to be operated in forward direction, similarly to have different drum vibration frequency with low amplitude, vibration control lever to be operated in backward direction. To stop the drum vibration, vibration control lever should be in neutral position. Gradeability Gradeability of this machine is the result of a powerful torquebalanced hydrostatic propulsion system, which includes machine two–speed range capability and use of the high engine rpm selection. Engine low rpm selection is for idling only. The machine’s low speed range is recommended for compacting while the high speed range for travelling. Brake The standard parking brake is a part of the axle and is designed to use as a parking brake/emergency brake. The parking brake is spring applied and hydraulically released. Loss of engine power for any reason or loss of hydraulic pressure to the brake circuit will allow the parking brake to apply. The positioning of the propulsion control lever to “STOP” position acts as a service brake. Drum drive motor will have additional spring applied hydraulically released brake in case of machine with drum drive option. See page Service and maintenance of this operator’s manual for additional information. Serviceability Machine maintenance and service, as described in Service and maintenance of this operator’s manual, will require placing the machine in the service position and need to open the engine hood to access the engine, oil filter, fuel filters, battery, etc. Tilting of the operator’s seat is necessary for servicing hydraulic oil filters. Railings/ROPS/Seat Belt The machine is provided with railings, roll-over protective structure (ROPS) and a seat belt for operator safety. ROPS used Presentation 8 in conjunction with a seat belt will lessen the possibility of death or serious injury in the event of a rollover. NOTICE Before handling the machine, See page 33 . Intended use The machine (soil compactor) is intended to be used only for the compaction of soil. Use of the machine for any other purpose, such as for towing other vehicles or equipment, is contrary to its designated use. The manufacturer and local authorized dealer or distributor cannot be held responsible for any damage resulting from such use. If it is used for other purposes or in potentially dangerous environments, for example explosive atmosphere, flammable environment or areas with dust containing asbestos, etc., special safety regulations must be followed and the machine must be equipped for such use. Contact the manufacturer's local authorized dealer or distributor for further information. The risk of misuse lies entirely with the user. Environmental requirements Be aware of the environment when operating and during service and maintenance of the machine. Always follow local and national environmental legislation applicable to all handling of the machine. Additional Icons NOTICE Some symbols shown in this section may not appear on your machine. Machine specific symbols Symbol Description Symbol Description Drum vibration Anti-wheel spin Drum vibration control Anti-drum spin High amplitude Manual vibration control Presentation 9 Symbol Description Symbol Description Low amplitude Auto vibration control Frequency (vibration) Vibration control Ignition switch Caution Tie-down points and tow points International symbols Symbol Description Symbol Description On/start Seat (lap) belt Off/stop Linear On/Off Rotational Plus (positive) Volume empty Minus (negative) Volume half full Horn Volume full Battery condition Grease Presentation 10 Symbol Description Symbol Description Hourmeter Oil lubrication point Lift point Engine oil temperature Jack or support point Engine coolant Filling or emptying Engine coolant level Read Operator's Manual Coolant temperature Engine oil Engine rotations (rpm) Engine oil pressure Gas inject (cold start) Engine oil pressure – failure Engine air filter Engine oil level Engine air filter – failure Engine oil filter Fan belt – failure Emergency engine stop Reverse direction Engine start Parking brake Engine on/run Brake on Presentation 11 Symbol Description Symbol Description Start switch Brake off Transmission Primer (start aid) Transmission oil level Hydraulic oil High gear Hydraulic oil pressure Low gear Hydraulic oil level Forward direction Hydraulic oil filter Hydraulic oil temperature Control lever – multi-direction Diesel fuel Clockwise rotation Fuel level Counterclockwise rotation Fuel filter Engine electrical preheat Work light Fast speed Presentation 12 Symbol Description Flashing beacon Control lever – dual direction Symbol Description Slow speed Presentation Machine view 13 Machine view Directional terms The terms left and right, when used in this manual, indicate the sides of the machine as seen from the operator seat facing the front of the machine. 1 Front 2 Rear 3 Left 4 Right 1 4 3 2 V11053 79 Machine view Presentation 14 Machine view Location of components 11 12 15 7 17 16 14 13 2 1 3 4 10 5 6 Location Of Components 1 Engine area 2 ROPS 3 Operator control console 4 Articulation lock pin 5 Drum scraper 9 8 V1100949 Presentation Machine view 6 7 8 9 10 11 12 13 14 15 16 17 Drum Torque hub / Drum drive motor Eccentric drive Shock mount Hydraulic tank Emergency stop switch Propulsion and Vibration control Axle and brake assembly Battery Battery disconnect switch Fuel tank Throttle lever Operator's protective structure, component locations 3 4 5 6 2 1 V1104340 Operator's protective structure 1 Railing assembly 2 Seat assembly 3 Roll over protective structure (ROPS) 4 Control group assembly 5 Steering wheel 6 Control box 15 Presentation 16 CE-marking, EMC-directive CE-marking, EMC-directive CE-marking If this machine is CE-marked, this means that, when delivered, the machine meets the applicable “Essential Health and Safety Requirements,” which are given in the EU Machinery Directive, 2006/42/EC. Any person carrying out changes that affect the safety of the machine is also responsible for the same. As proof that the requirements are met, an EU Declaration of Conformity and a sound certificate regarding sound level in dB (A) are supplied with the machine. The sound certificate includes both measured external values and guaranteed sound level. These declarations are issued by Volvo Construction Equipment for each individual machine. This EU declaration also covers attachments manufactured by Volvo Construction Equipment. The documentation is a valuable document, which should be kept safe and retained for at least 10 years. The document should always accompany the machine when it is sold. EU's EMC directive The electronic equipment of the machine may in some cases cause interference to other electronic equipment, or suffer from external electromagnetic interference, which may constitute safety risks. The EU’s EMC-directive about “Electromagnetic Compatibility,” 2004/108/EC, provides a general description of what demands can be made on the machine from a safety point of view, where permitted limits have been determined and given according to international standards. A machine or device which meets the requirements should be CEmarked. Our machines have been tested particularly for electromagnetic interference. The CE-marking of the machine and the declaration of conformity also cover the EMC-directive. If other electronic equipment is fitted to this machine, the equipment must be CE-marked and tested on the machine with regard to electromagnetic interference. Presentation Product plates 17 Product plates Machine identification Manufacturer Volvo India Private Limited, 7 & 8 , Phase 1, Peenya Industrial area, Bangalore- 560058, India. Phone: +91 80 2219 2500 Fax :+91 80 2839 4651 Name & Machine types SD110 Series of Single-Drum, Vibratory Soil Compactors. Serial number and product range The serial number effectivity for the SD110 Series of compactors covered in this manual is outlined below. Compactor Series Effective with Serial Number SD110 Effective from S/N 52332 — 99999 SD110 Effective from S/N 58000 — 99999 Product identification plate The product identification plate is located on the front side of the rear frame, in the articulation area. The product identification plate contains product identification number (PIN). The PIN contains important information about the machine including the model number, the manufacturing code and machine serial number. This information should be recorded and kept in a convenient location for future reference. When ordering spare parts, and in all telephone enquiries or correspondence the PIN must always be quoted. Product identification plate Presentation 18 Product plates Engine, identification Engine identification plate The engine serial number and important information related to engine are available on the name plate which is fixed on crank case. Open the engine hood to access engine identification plate. The following important information should be recorded and kept in a convenient location for reference when contacting the local Volvo authorized service centre while ordering the parts. Engine identification plate Table. Reference numbers: ENGINE TYPE RATING KW/HP @ RPM RATING STD GOVERNING CLASS ENGINE No. Presentation Information and warning decals 19 Information and warning decals The operator should read, understand and follow the information and warning decals which are positioned on the machine. The decals must be kept free from dirt so that they can be read and understood. If they have been lost or no longer are legible, they must be replaced immediately. Refer to the Parts Catalogue for this machine which identifies the proper location and part number (order number) of all decals. Contact your manufacturer’s local authorized dealer or distributor for additional information or assistance as required. Presentation 20 Information and warning decals International decals 1 Do not sit on rail. Never sit on railing around operator compartment. 2 Crush area. Can cause serious injury or death. Install articulation lock pin before servicing. 3 Improper operation of this equipment can cause serious injury or death. Read and understand the operator and safety instructions before operating and servicing. 4 Rotating fan and belt. Can cause serious injury. Do not operate with guards or shields removed. Stop machine before performing maintenance. 5 Rollover of this machine can cause serious injury or death. Do not operate this machine near or on an inclined surface. A rollover can occur. If this machine has a rollover protective structure (ROPS), seat belts must be worn to avoid serious injury or death from being thrown out. Presentation Information and warning decals 21 6 Radiator (expansion tank). Injury can result when removing the expansion tank pressure cap. Steam or fluid escaping from the expansion tank can burn. Inhibitor contains alkali. Avoid contact with skin and eyes. Always shut down the engine and allow to cool before removing the expansion tank pressure cap. Remove the expansion tank pressure cap slowly to relieve pressure. Avoid contact with steam or escaping fluid. 7 WARNING Use of ether may cause explosion or severe injury. This engine is equipped with an electric heater starting aid. Do not use ether. Presentation Information and warning decals 22 Decals/Plates and reflectors V1100949 Location of Decals/Plates REF NO. DECAL QUANTITY LOCATION 1 Checklist 1 Cowling frame 2 Warning: Rollover 1 Steps on hydraulic tank 3 Warning: Do not sit on Rails 2 Railings 4 Lube chart 1 Hydraulic tank 5 Warning: Misoperation 1 Console 6 Warning: Crushing hazard (each on both side) 2 Machine side frame 7 Warning: Runaway machine 1 Console Presentation USA federal clean air act 23 USA federal clean air act The Federal Clean Air Act Section 203.a (3) prohibits the removal of air pollution control devices or the modification of an EPAcertified non-road engine to a non certified configuration. The Federal regulations implementing the Clean Air Act for nonroad engines, 40 CFR 89.1003(a)(3)(i), reads as follows: The following acts and the causing thereof are prohibited: For a person to remove or render inoperative a device or element of design installed on or in a non-road engine vehicle or equipment in compliance with the regulations under this part prior to its sale and delivery to the ultimate purchaser or for a person knowingly to remove or render inoperative such a device or element of design after the sale and delivery to the ultimate purchaser. The law prescribes a fine of up to $2,750 USD for each violation. An example of a prohibited modifications is the recalibration of the fuel system so that the engine will exceed the certified horsepower or torque. You should not make a change to an EPA-certified non-road engine that would result in an engine that does not match the engine configuration certified to meet the Federal Standards. Customer Assistance Volvo Construction Equipment wishes to help assure that the Emission Control System Warranty is properly administered. In the event that you do not receive the warranty service to which you believe you are entitled under the Emission Control System Warranty, you should contact the nearest Volvo Construction Equipment regional office for assistance. Normal non-road engine use The maintenance instructions are based on the assumption that this conventional machine will be used as designated in the operator's instruction manual and operated only with the specified fuel and lubrication oils. Non-road engine maintenance This is a non-road engine of conventional design and any local dealer may perform the necessary non-road emission control maintenance as defined in this manual. Volvo recommends that the purchaser use the service program for the non-road engine, known as preventative maintenance, including the recommended engine emission control maintenance. In order to document that the proper regular maintenance has been performed on the non-road engine, Volvo recommends that the owner keep all records and receipts of such maintenance. These records or receipts should be transferred to each subsequent purchaser of the non-road engine. Presentation 24 USA federal clean air act Service performed by your local dealer Your local dealer is best suited to give you good, dependable service since he has trained service technicians and is equipped with genuine original manufacturer's parts and special tools and the latest technical publications. Discuss your servicing and maintenance requirements with your local dealer. He can tailor a maintenance program for your needs. For scheduled service or maintenance, it is advisable to contact your local dealer in advance to arrange for an appointment to ensure availability of the correct equipment and service technician to work on your machine. In this way you will assist your local dealer in reducing the time required to do service on your machine. Preventive maintenance program In order for the conventional non-road engine to retain the reliability and performance parameters such as noise level and emission levels it had when delivered, it is essential that it receives regularly scheduled service, inspections, adjustments, and maintenance. Fuel system Fuel recommendations: The fuel used must be clean, completely distilled, stable and noncorrosive. Distillation range, cetane level and sulfur content are most important when selecting fuel for optimum combustion and minimum wear. Engine working conditions and ambient temperature influence the selection of the fuel with respect to cold handling properties and cetane levels. In cold weather conditions, below 0 ºC (32 ºF), the use of lighter distillate or higher cetane level fuel are recommended. (Final boiling point maximum 349 ºC (660 ºF) and cetane minimum 45.). In order to avoid excessive sedimentation and to minimize the emissions of sulfur dioxide, the fuel's sulfur content should be as low as possible. The diesel fuels recommended for use shall meet ASTM designation: D 975 no. 1D (C-B) or no. 2D (T-T) with a cetane level above 42 and sulfur content not exceeding 0.05 percent by weight. Check for fuel leaks (with the engine running at high idle): Visually check unions and hose connections. Check the condition of the fuel hoses for: Ageing Cracks Blisters Scuffing Check the condition of the fuel tank: Drain condensation water. Check for cracks. Check for leaks. Check the mounting. Presentation USA federal clean air act 25 Check the turbocharger: Visually check for leaks in the intake hoses and exhaust pipe of the turbocharger. Instrument panels 26 Instrument panels Instrument panels Control box which is mounted on control console has following control switches, emergency stop switch, ignition key switch, fuel level gauge, horn, various indicators mounted on it. Hourmeter and mobile charger plug are mounted on the left side of the control console. 14 1 2 3 15 16 17 18 19 20 21 22 4 5 6 7 8 9 23 24 11 10 12 13 V1100601 Control box 1 2 3 4 5 6 7 8 9 10 11 12 13 Two speed switch Beacon light switch (Option) Hazard switch Park brake test switch Park brake switch Front head lamp switch (high / Low beam) Rear working lights switch Position lights switch Turn indicator lights switch Emergency stop switch Ignition key switch Fuel gauge Horn switch 14 15 16 17 18 19 20 21 22 23 24 Air filter clog indicator Seat belt indicator Engine preheat indicator High engine coolant indicator Left turn signal indicator Right turn signal indicator Engine oil low pressure indicator Battery no charge indicator Front light high beam indicator Mobile charger plug Hourmeter 1. Two speed switch It is a two position (HIGH/LOW) rocker switch. A decal is placed on it to show HIGH and LOW position. All compaction work must Instrument panels 27 be done with the switch in the LOW position, while the HIGH speed position is used for travelling. NOTICE The two speed switch position change should be done only when the machine is stationary and on level ground, with the parking brake in the “applied” position. 2. Beacon lamp switch (option) It is two position (ON/OFF) rocker switch. When the switch is positioned to ON , beacon lamp starts flashing and revolving. 3. Hazard switch It is two position (ON/OFF) rocker switch. When hazard switch is positioned to ON , all turn indicating lamps flash simultaneously. NOTICE When hazard switch is on, turn indicating lamps do not work as turn indicators. 4. Parking brake test switch It is a rocker momentary switch, that provides the operator to test the working of parking brake. 5. Parking brake switch It is a rocker switch, that provides the operator with the means to manually engage the parking brake. Red light is provided on the switch which illuminates, when the parking brake switch is in ON position. . NOTICE Machine will not start, if the parking brake switch is in OFF position. 6. Front head lamps switch (high / low beam) It is a three position (HIGH/LOW/OFF) rocker switch. When it is positioned to HIGH activates front lights to high beam, When it is positioned to LOW activates front lights to low beam, when it is positioned to OFF, front lights are off. 7. Rear working lights switch It is a two position (ON/OFF) switch. When it is positioned to ON rear lights are on, when it is positioned to OFF, rear lights are off. 9. Turn light Indicator switch It is a three position (LEFT/OFF/RIGHT) rocker switch. When moved to right, right side indicator lamps of the machine activates and when moved to left, left side indicator lamps of the machine activates. Instrument panels 28 10. Emergency stop switch It connects and disconnects electrical power from vehicle circuits. This provides the operator with a means to shutdown the vehicle operation. When the button is pressed down, the main current is turned off, causing the machine to immediately shutdown and the parking brakes to get engaged. Emergency stop switch should be set to normal position to restart the machine NOTICE Emergency stop switch must be used in case of emergency only . 11. Ignition key switch Ignition key is inserted/removed at the STOP position. Ignition key switch energizes the electrical system to preheat the engine, when turned anti-clockwise to the PREHEAT position. This activity is for engine cold-start Ignition key switch energizes the electrical system, when turned clockwise to the RUN position. When turned further clockwise to the START position the starter motor is engaged. When the ignition key is released the Ignition switch returns to the RUN position automatically, . Turning the ignition key back to the STOP position, turns off the electrical system and stops the engine. 12. Fuel level indicator WARNING Stop the engine before filling fuel. It indicates the fuel level in the fuel tank. It is an analogue gauge, with indication of “E” red colour, “1/2” mark and “F”. If the indicator shows fuel level in “E” red area, fill the fuel. 13. Horn push button Press the horn button to sound the horn and alert personnel to the approaching machine or when changing direction. 14. Air filter clog indicator It glows when air filter is clogged. 15. Seat belt indicator It blinks if operator does not wear the seat belt or seat belt is not put properly. Operator has to wear the seat belt properly. 16. Engine preheat indicator It glows while preheating the engine. 17. Engine coolant indicator It glows when engine coolant temperature is high. Stop the machine immediately and check the coolant level. Instrument panels 29 18. Left turn signal indicator It indicates LEFT turn light indicators are on. It blinks when turn light indicator switch is pressed ‘LEFT’ until it is pressed ‘OFF’. 19. Right turn signal indicator It indicates RIGHT turn light indicators are on. It blinks when turn light indicator switch is pressed ‘RIGHT’ until it is pressed ‘OFF’. 20. Engine oil low pressure indicator It indicates the engine oil pressure is low. 21. Battery no charge indicator It glows, when alternator is not charging the battery. 22. Front lights high beam indicator It glows when front lights high beam switch is ON. 23. Mobile charger plug It is mounted on the left side of control console. This is to facilitate mobile charging. It is directly connected to the battery. It does not work if battery cut-off switch is OFF. 24. Hourmeter It is mounted on the left side of control console. It displays the engine run time in hours with a resolution of 0.1 hour. Other controls 30 Controls Other controls Controls Travel control lever 1 2 V1090832 Propulsion control lever. 1 Propulsion control lever. 2 Vibration control lever. 1 Travel control lever. The Propulsion (TRAVEL) Control lever is located at the right side of the operator’s seat. This control varies machine direction and speed of travel. It also functions as the control for hydrostatic braking. The control has three positions, Forward (F) , Stop (S), and Reverse (R) with variable speed ranges in either direction. To propel the machine forward, gradually move the control to the Forward position. To stop the travel of the machine, move the control slowly back to the Stop (S) position. This also provides hydrostatic braking. To propel the machine in reverse, gradually move the control backward to the Reverse position. To stop the travel of the machine, move the control slowly back to the Stop (S) position. There is also an electrical interlock switch on the control that allows the engine to be started only with the control lever in Stop (S). 2 Vibration control lever (VPM) The Vibration (VPM) Control is located at the right side of the operator’s seat beside the Propulsion (Travel) control lever. The Vibration (VPM) Control lever varies the vibrations per minute of the drum. Vibration control lever helps operator to select high or low amplitude and variable vibration frequency depending on the requirement. To have a varying drum vibration frequency with high amplitude, vibration control lever to be operated in forward direction, similarly to have a varying drum vibration frequency with low amplitude, vibration control lever to be operated in backward direction, and for no drum vibration mode, vibration control lever to be in neutral position. Throttle control The THROTTLE Control is located on the right side of the console in front of operator seat. It is connected to the engine governor thru a cable. Move the control upward to obtain engine “HIGH RPM” and move the control downward to obtain engine “LOW RPM”. Other controls ROPS 31 ROPS ROPS WARNING Risk of crushing. The machine can tip over. This could result in serious injury. Ensure the ROPS is correctly installed. WARNING Structural damage caused by the machine rolling over or by unpermitted modification weakens the cab ROPS. Contact an authorised Volvo dealer workshop if the ROPS has been damaged or modified. The machine is provided with roll-over protective structure (ROPS). ROPS used in conjunction with a seat belt will lessen the possibility of death or serious injury in the event of a rollover. Other controls 32 Operator comfort Operator comfort Operator seat WARNING Adjusting the seat should always be done when the machine is stationary. The machine is equipped with a suspension seat that features two adjustments. The entire suspension seat assembly and attached control console can be positioned forward or reverse by positioning the handle outward, locating the seat and then releasing the handle. Operator comfort, resistance to lowering, can be adjusted by rotating the handle clockwise for more resistance and counterclockwise for less resistance to lowering. Operator's manual, storage Operator's manual storage is located in front of operators seat in the control console. Keep the manual in the storage compartment so that it is always at hand. Operating instructions Safety rules when operating 33 Operating instructions Safety rules when operating Danger zone The danger zone of this machine is the immediate area or zone surrounding the machine, machine accessories or extensions which would allow contact with the machine if the machine, machine accessories or extensions were to move. Trained and authorized personnel must first notify the operator of their presence and are permitted within the danger zone during machine operation. All other persons are not permitted in the danger zone during machine operation. Safety when handling the machine Volvo Construction Equipment is only responsible if: - The machine has been used correctly and has been maintained according to instructions in Service Manuals and the Operator's Manual. - Prescribed service and prescribed inspections have been performed at the stipulated points in time. - The lubricant recommendations in the manual have been followed. - No security seals have been broken by unauthorized persons. - All modifications and repairs have been performed as prescribed by Volvo. - Only Volvo genuine spare parts/accessories or attachments that meet Volvo's requirements have been used. WARNING For safety, observe the following rules. DO NOT operate this machine if the sunshade assembly/ROPS or railing assembly got structurally damaged, shows cracks, is not properly secured as originally installed, or has been involved in a rollover. DO NOT repair, modify, drill, weld on or add attachments to the sunshade assembly/ROPS, railing assembly or on the machine assembly unless authorized in writing by the manufacturer. DO NOT operate the machine unless the seat belt conforming to SAE and/ or ASAE standards is fastened. General The manufacturer cannot ensure for all possible circumstances that might lead up to a potential hazard. Therefore, the combination of warnings listed in this manual and those placed on the machine itself are not intended to be all inclusive. Operators and maintenance personnel must be alert to recognize and avoid potential hazards. They should also have comprehensive training, required skills and necessary tools to properly perform their functions. Operating instructions 34 Safety rules when operating The machine is built in accordance with state-of-the-art standards and recognized safety rules. Nevertheless, its misuse may constitute a risk to life and limb of the user or of third parties, and may cause damage to the machine or other material property. The machine must be used in accordance with its designated use as described in the operating manual. The machine must only be operated by safety-conscious persons who are fully aware of the risks involved in operating the machine. Any functional disorders, especially those affecting the safety of the machine, must be corrected immediately. The machine is designed exclusively for the compaction of soil. Use of the machine for purposes other than that mentioned (such as for towing other vehicles/equipment) is considered contrary to its designated use. The manufacturer/supplier cannot be held liable for any damage resulting from such use. The risk of such misuse lies entirely with the user. Operating the machine within the limits of its designated use also involves compliance with the inspection and maintenance directives contained in the operating manual. Selection and qualification of personnel WARNING Machine operators must have sufficient skills and knowledge of the content in the Operator's Manual before operating the machine. It is important that the operator reads and follows the instructions in the machine's Operator's Manual. An untrained operator may cause serious injuries and fatalities. Never operate a machine for which there is no Operator's Manual available. Learn to understand the warning plates, symbols and operating instructions for the machine before you start operating. Work on and with the machine must be performed by qualified personnel only. Statutory minimum age limits must be observed. Individual responsibilities of the personnel responsible for operation, setup, maintenance and repair of the machine should be stated clearly. Define the machine operator’s responsibilities - also with regard to observing traffic regulations - the operator should have the authority to refuse instructions by third parties that are contrary to safety. Do not allow persons being trained or instructed in the operation or maintenance of the machine to work without permanent supervision by an experienced person. Work on the electrical system and equipment of the machine must be done only by a skilled electrician or by instructed persons under the supervision and guidance of a skilled electrician and must be in accordance with electrical engineering rules and regulations. Operating instructions Safety rules when operating 35 Work on the mainframes, brake, hydraulic and steering systems must be performed by skilled personnel with special knowledge and training for such work. Organizational measures STOW manuals in the manual pouch/box provided on the machine. Manuals must always be available at the site where the machine is used. OBSERVE AND INSTRUCT the user in all other generally applicable legal and mandatory regulations relevant to accident prevention and environmental protection. These compulsory regulations may also deal with the handling of hazardous substances, issuing and/or wearing of personal protective equipment, and traffic regulations. SUPPLEMENT operating instructions with detailed working instructions pertaining to the specific work location. ALWAYS be sure that persons entrusted with work on the machine have read the operating instructions and in particular the chapter on safety before beginning work. Reading the instructions after work has begun is too late. This is especially important for persons who work only occasionally on the machine, e.g. during set up or maintenance. MAKE CERTAIN personnel are working in compliance with the operating instructions and are alert to risks and safety factors. ALWAYS tie back or otherwise secure long hair, wear close-fitting garments and avoid wearing jewelry such as rings. Injury may result from clothing, hair, or jewelry being caught up in the machinery. USE protective equipment wherever required by the circumstances or by law. OBSERVE all safety instructions and warnings attached to the machine. BE SURE all safety instructions and warnings attached to the machine are complete and perfectly legible. STOP the machine immediately in the event of any malfunction. REPORT the malfunction to the proper authority/person. NEVER provide service or maintenance to the machine unless the drum and wheels are adequately chocked, articulation lock bar/pin is in locked position, and parking brake is applied. NEVER make any modifications to the machine which might affect safety without the manufacturer’s approval. This applies to the installation and adjustment of safety devices and valves as well as to welding work on load bearing elements. ALWAYS ADHERE to prescribed intervals or those specified in the operating instructions for routine checks and inspections. Safety when operating on public roads Road signs, traffic restricting arrangements and other safety devices, which may be required when considering traffic speed and intensity or other local conditions, must be used. Operating instructions 36 Safety rules when operating Rotating warning beacon may be used: - on vehicle during road maintenance work - when the vehicle constitutes a hindrance or impedes other traffic - when working on or by the side of the roadway. Electrocution hazard DANGER Risk of electrocution Working near or making contact with overhead power lines may lead to electrical flash-over and electrocution. Always keep the minimum clearance from overhead power lines. Operating the machine near overhead power lines requires special precautions. Electrical flash-over may occur and cause serious injury to the operator and may also damage the machine and attachments even at great distances from the overhead power lines. See page No.55 for overhead power line minimum clearances and procedures when operating near overhead power lines. Safety rules when operating General This machine has been carefully designed and built to provide a safe working environment when all safety warnings are understood and followed. Prior to starting, operating or maintaining the machine, read and understand this manual, particularly the safety instructions. Contact supervisor or manufacturer’s local authorized dealer or distributor with any questions. Never guess about how to safely operate and maintain this equipment. Make sure the machine is operated and maintained only by safety-conscious persons who have been authorized, properly trained, and have the required skills and tools to do their jobs. All personnel must be alert to, recognize, and avoid potential hazards associated with performing their work. Always wear or use proper personal protective equipment while operating or maintaining the machine. Operate the machine only when it is in good condition. Any functional disorders, especially those affecting the safety of the machine, must be corrected immediately. The machine must be used in accordance with its designated use as described in this operation and maintenance manual. Make sure the machine is used only as intended by the manufacturer. Use of the machine for any other purpose, such as for towing other vehicles or equipment, is contrary to its designated use. See page No. 8 for an explanation of the intended use. The manufacturer and local authorized dealer or distributor cannot be held responsible for any damage resulting from such use. The risk of such misuse lies entirely with the user. Operating instructions Safety rules when operating 37 Selection and qualification of personnel Make sure only qualified personnel work on and with the machine. Statutory minimum age limits must be observed. Describe clearly the responsibilities of individuals who operate, setup, maintain and repair the machine. Define the machine operator responsibilities for safe machine operation, including observing traffic regulations. The operator should have the authority to refuse instructions by third parties that are contrary to safe practices. Do not allow persons being trained or instructed in the operation or maintenance of the machine to work without continuous supervision by an experienced person. Allow only skilled electricians, or persons instructed by them, to work on the electrical system or electrical components of the machine. All electrical work must be performed in accordance with electrical engineering guidelines and local regulations. Be sure that work on the machine chassis, brake, hydraulic and steering systems is performed only by skilled personnel trained to perform such work. Organizational measures Always make this operation and maintenance manual available where this machine is used. Store it in the compartment provided on the machine. Observe and instruct users of the machine in all generally applicable legal and mandatory regulations relevant to accident prevention and environmental protection. These compulsory regulations may also deal with the handling of hazardous substances, the issuing and/or wearing of personal protective equipment, and traffic regulations. Supplement operating instructions with detailed work instructions for specific work activities and locations. Always be sure that persons who operate or work on the machine have read the operating instructions and especially, the safety information. Reading the instructions after work has begun is too late. This is especially important for persons who only occasionally work on the machine, such as during set up or maintenance. Make certain personnel work in compliance with the operating instructions and are alert to risks and safety factors. Be aware of personal safety hazards. Always tie back or otherwise secure long hair, and wear close-fitting garments. Avoid wearing jewellery such as rings, bracelets and necklaces. Injury may result from clothing, hair, or jewellery being caught in the machinery. Use personal protective equipment whenever required by work circumstances or by law. Observe all safety instructions in this manual and on decals attached to the machine. Operating instructions 38 Safety rules when operating Be sure all safety Warning and instruction decals attached to the machine are complete and readable. Stop the machine immediately in the event of any malfunction. Report the malfunction to the proper supervisory personnel. The continued operation of a machine that is not working properly may cause extensive damage to the machine or significantly increase hazards to operating personnel due to abnormal operating conditions. Never perform service or maintenance on the machine in any manner other than that which is described in this manual. Never make any modifications, additions or conversions to the machine which might affect safety without the manufacturer’s approval in writing. This applies to the installation and adjustment of safety devices and valves as well as to welding work on loadbearing components. Always adhere to prescribed intervals listed in the operating instructions and maintenance instructions for routine checks, inspections and maintenance procedures. Performing scheduled preventive maintenance consistently will extend the life of the machine. Observe all fire fighting procedures. Mandatory safety measures Never clean, lubricate or service the machine when it is running. Do not operate the machine while under the influence of drugs or alcohol. Always use personal protective equipment, such as hard hats, safety shoes, eye and ear protection, while operating or maintaining the machine. Do not wear radio or music headphones while operating the machine. Do not wear jewellery while operating the machine. Replace any guards and shields removed, mount them securely, and clear all maintenance tools before starting the engine after maintenance. Contact supervisor, or any manufacturer’s authorized dealer or distributor, if there are any questions about the operation or maintenance of this machine. Never guess – always check! Remember, failure to adhere to these safety instructions may result in serious injury or even death. Pre-start inspection Inspect the machine daily. Ensure that routine maintenance and lubrication procedures are dutifully performed. Repair or replace any malfunctioning, broken, or missing parts. Refer to the preventive maintenance schedule located in maintenance instructions in this manual. Operating instructions Safety rules when operating 39 Verify that all safety warning and instruction decals are in place and readable. These instructions are as important as any other equipment on the machine. Refer to the decal location drawing in the safety section of this operation and maintenance manual at safety related decals. Ensure that all safety and protective devices are in place and in good working order. Use caution when refuelling. Never fill the fuel tank with the engine running, while the machine is located near an open flame, or while operating personnel are smoking. Smoking is prohibited within 15 m (50 feet) of the machine while refuelling. Always fill the fuel tank either outside or in an adequately ventilated room. Always wipe up any spilled fuel. Check for any maintenance and repair warning tags placed on the machine. Do not operate the machine until repairs have been made and the warning tags have been removed by authorized personnel. Remove any dirt, debris or foreign material from the operator platform to reduce the danger of slipping. Know the location of the emergency stop (E-Stop) switch. Know the capabilities and limitations of the machine with respect to speed, gradeability, steering, and braking. Be aware of the dimensions of the machine. This includes the height and width of the overall machine, as well as the transporter dimensions and weight. Working within dangerous areas Check for dangerous conditions in the work area, such as holes, banks, underground culverts, manhole covers, water melt pits, or curb and street boxes. Avoid any operation that might sacrifice safety. This machine should only be brought into service where the machine is applicable to the situation and conditions of the construction site. This includes the stability and condition of the ground, width of the driving lane, and any objects which would interfere with the movement of the machine both above ground level and below ground level such as curbstones or ditches. Safety instructions governing operation Avoid any operating mode or procedure that might sacrifice safety. Avoid any operation that might risk machine stability. Ensure that all necessary precautions are taken to ensure that the machine is used only when in a safe and reliable condition. Operate this machine only if all safety and protective devices originally provided by the manufacturer are in place and in good condition. This includes removable safety devices, emergency shut off equipment, soundproofing elements and exhausts. Operating instructions 40 Safety rules when operating Make sure there is sufficient clearance when moving the machine through tunnels, underpasses, and under power lines. Make sure bridges are rated to hold the weight of this machine before crossing them. Check the machine at least once each shift for damage and report damage to your supervisor. If the machine is not operating properly, shut down the machine immediately. The continued operation of a machine that is not working properly may cause additional damage to the machine or significantly increase the hazards to operating personnel due to abnormal operating conditions. Check the surrounding area for pedestrians. Make sure no one is in danger or at risk before starting the machine or setting it in motion. Check that braking, steering, signalling and lighting systems are fully functional before moving the machine. Check that accessories have been safely stowed away before setting the machine in motion. Observe all the valid traffic regulations when traveling on public roads. Always make sure the machine is in a condition that meets those regulations. Always keep a safe distance away from the edges of building pits and slopes. Always secure the machine to prevent inadvertent movement and unauthorized use before leaving it. Provide an observer when loading and unloading the machine from a truck or trailer, or lifting it with a crane. Starting Always use hand rails and steps to get on and off the machine. Always maintain a three-point contact when climbing onto or off of the machine as shown. Always wear the seat belt when operating the machine. Read and follow all safety warning and instruction decals. Turn on the lighting system in conditions of poor visibility and after dark. Check the surrounding area for pedestrians. Make sure no one is in danger or at risk before starting the machine or setting it in motion. Before attempting to start the engine, Ensure that the forwardstop-reverse (FSR) propulsion control lever is in the S (stop) position. Watch the indicators during start-up and shutdown procedures in accordance with the operating instructions. See operating instructions in this manual. Before starting the engine, ensure that the parking brake control is in the “applied” position, See page No. 26 for parking brake control details. Operating instructions Safety rules when operating 41 Start the engine only while at the operator console. Boost starting WARNING Never boost-start the machine by connecting directly to the starter motor. This may result in uncontrolled machine movements. When using another machine to boost-start, it must not touch the machine that is being started. Avoid equipment damage by making sure that the machine receiving a boost-start does not come in contact with the machine supplying the boost-start. Never boost-start a frozen battery, it will explode. Be aware that lead acid batteries generate explosive gases while charging. Keep sparks, flames and lighted smoking materials away from batteries. Always wear eye protection when working on or near batteries. Follow these procedures when boost-starting the machine. 1 Connect the Positive (+) terminal of the booster battery to the Positive (+) terminal of the discharged battery. 2 Connect the Negative (–) terminal of the booster battery to the best ground point on the machine, away from the battery. 3 Follow all recommended engine starting procedures. 4 Remove the booster cables in the reverse order of their connection as soon as the engine has started. Operating Make sure no person or obstruction is in your line of travel before moving the machine. Look in all directions before changing your direction of travel. Never climb on or off the machine while it is operating or moving. Use extreme caution and be observant when operating the machine in close quarters or in congested areas. No riders. Never carry passengers. Know the hand signals used (required) for particular machine operations and machine travel, and know who has the responsibility for signalling. Know the area in which you are working. Familiarize yourself with work site obstructions and any other potential hazards in the area. Always remain seated with the seat belt on when operating the machine whether compacting, travelling, or loading and unloading. Close all sound baffles during operation. Do not work in the vicinity of overhanging banks or on grades that could cause the machine to slide or roll over. Avoid side hill travel. Always operate up and down slopes. Never change to a lower gear on a slope; always change before Operating instructions 42 Safety rules when operating reaching it. Always keep the FSR propulsion control lever in low speed range close to the S (stop) position when climbing or descending hills. Never allow anyone to stand within the machine’s articulation area when the engine is running. Control the machine travel speed with the FSR propulsion control lever. Control engine speed with the throttle control. Always perform compacting operations at high engine speed. Do not tow the machine except as explained in the operating instructions of this manual. Do not run the engine in a closed building for an extended length of time. Exhaust fumes can kill. Read and follow all safety warning and instruction decals. Stopping Always park the machine on solid level ground. If this is not practical, park the machine at a right angle to the slope and block the drum and wheels. Reduce the travel speed by moving the FSR propulsion control lever slowly toward the S (stop) position. To stop the machine, slowly push the FSR propulsion control lever to the S (stop) position. Apply the parking brake. Install the articulation lock pin. Position the throttle control to “idle rpm”. Turn ignition switch to OFF, and lock all lockable compartments. Always be sure that all control switches are in the OFF position and that the engine is shut down before leaving the machine. Always retract the seat belt fully before leaving the operator station. Always mount and dismount the machine using walkways, steps and handrails provided. Never jump from the operator platform to the ground. Always maintain a “three-point contact” when climbing on or off the machine. Refer to safety rules for starting. Use proper flags, barriers, and warning devices to warn others of the machine, especially when parking in areas of heavy traffic. Maintenance Follow the start-up and shutdown procedures set forth in the operating instructions before performing any work on the machine. This includes the operation, conversion or adjustment of the machine and its safety oriented devices, and any work related to maintenance, inspection and/or repair. Ensure that the maintenance area is adequately secured as outlined below. Secure the machine against inadvertent starting, if it is completely shut down for maintenance and repair work. See page No. 92 Operating instructions Safety rules when operating 43 for procedure to secure the machine for maintenance and repair work. Check de-energized parts for the presence of power. Ground or short circuit any parts found to contain residual power. Insulate adjacent live parts and elements. Check and inspect machine electrical equipment at regular intervals. Faults, such as loose connections or scorched cables, must be corrected immediately. Lifting the machine – When raising the machine off the ground, apply the parking brake. Attach the lifting apparatus only to the machine’s designated lifting points using properly rated lifting straps, cables, or chains. Use spreader bars to ensure equal weight distribution during lifting as well as avoid contact with the machine. Use care when attaching and securing lifting tackle to individual parts and large assemblies being moved for replacement purposes to avoid the risk of accidents. Use lifting gear that is in proper operating condition and with adequate lifting capacity. Never work or stand under suspended loads. NOTICE Lifting the machine must only be carried out by trained personnel. Perform maintenance and repair work only if the machine is positioned on stable and level ground and has been secured to prevent movement. Keep all platforms and standing surfaces free from mud, dirt, snow and ice. Always use the correct tools and workshop equipment when performing maintenance on the machine. Clean the machine at the end of each workday while it is still warm. Clean the machine, especially connections and threaded unions, of any traces of oil, fuel or preservatives before carrying out maintenance or repair. never use aggressive detergents. Use lint free cleaning rags. Cover or tape all openings which – for safety and functional reasons – must be protected against water, steam or detergent penetration before cleaning the machine with water, steam jet (high pressure cleaning) or detergents. Special care must be taken with electric motors and switch gear cabinets. Ensure during cleaning of the machine that temperature sensors do not come into contact with hot cleaning agents. Remove all covers and tapes applied for that purpose after cleaning the machine. Examine all fuel, lubricant, and hydraulic fluid lines for leaks, loose connections, chafe marks and damage after cleaning. Repair or replace faulty parts immediately. Tighten any screwed connections that have been loosened during maintenance and repair. Operating instructions 44 Safety rules when operating Replace and check any safety devices removed during setup, maintenance or repair activities. Do this immediately upon completion of the maintenance and repair activity. Avoid servicing, cleaning, or examining the machine with the engine running, whenever possible. Do not perform service or maintenance on the machine unless the drum and wheels are adequately blocked, the articulation lock pin is in the locked position, and the parking brake is applied. Be sure the machine is adequately secured to prevent movement, See page No. 92. Never fill the fuel tank of the machine with the engine running. Do not permit sparks, open flames or smoking within 15 m (50 feet) of the machine while refuelling. Always wipe up any spilled fuel. Do not alter the engine governor settings from those indicated in the engine manual and the engine option plate. Always replace damaged or lost warning and instruction decals. It is dangerous to operate the machine without these decals. Refer to the parts manual for the proper location and part number of all decals. Disconnect the battery cables when working on the electrical system. Be sure the battery area is well ventilated (clear of fumes) should it be necessary to connect a jump battery or battery charger. Fumes from the battery can ignite by a spark and explode. Be sure the battery charger is turned off when making the connections if battery charging is required. Inspect and check the machine’s electrical equipment at regular intervals. Faults, such as loose connections or scorched cables must be corrected immediately. Inspect hydraulic hose assemblies visually at regular intervals. Replace them if they show signs of chafing, cracking, brittleness, deformation, blistering, leakage, fitting separation, corrosion or other damages which may affect their function and strength. Inspect hydraulic hoses and screwed connections regularly. Look for leaks and signs of damage. Replace faulty parts immediately. Remember that hot hydraulic fluid will cause serious burns. Wait for hot hydraulic fluid to cool down before disconnecting hydraulic lines. Do not work on hydraulic lines while the engine is running and the system is under pressure. The hydraulic fluid remains under pressure long after the engine has been stopped. Do not work on any hydraulic hose or fitting until the pressure has been relieved correctly. Never use your hands to check for hydraulic leaks when inspecting an hydraulic system. Use a piece of cardboard to check for leaks, and always wear gloves and eye protection while checking. Operating instructions Safety rules when operating 45 Remember that fluid penetration from a pin-hole leak can cause serious injury or death. Get immediate treatment if hydraulic fluid has been injected under your skin. Depressurize the hydraulic system sections to be serviced before servicing them. Follow the manufacturer’s instructions for the specific equipment involved. Lay and fit hydraulic lines properly. Ensure that no connections are interchanged. The fittings, lengths and quality of the hoses must comply with the technical requirements. Observe all product related safety regulations when handling oil, grease and other chemical substances. Ensure that all consumable and replaced parts are disposed of in an environmentally safe manner and in accordance with local guidelines and regulations. Use only original fuses with the specified current rating. Switch off the machine immediately if trouble occurs in the electrical system. Allow only a skilled electrician, or instructed person working under the supervision and guidance of a skilled electrician, to work on the electrical system of the machine. All work must be done in accordance with electrical engineering guidelines and local regulations. Remove electrical power to components of the machine before performing inspection, maintenance and repair work. Follow established lockout, tagout procedures. Be careful when handling hot fluid or parts to avoid burning or scalding. Wear appropriate personal protective equipment. Use only genuine original equipment manufacturer’s replacement parts. This will protect the warranty and ensure the safe operation and optimum performance of the machine. Welding safely on the machine Proper welding procedures are necessary in order to avoid damage to the electronic controls and to the bearings. Allow only qualified and authorized personnel to weld, flame cut or perform any grinding work on the machine. There may be a risk of explosion and fire. Clean the machine before starting welding, flame cutting and grinding operations. Remove dust and other flammable substances and make sure that the premises are adequately ventilated to avoid the risk of fire and explosion. Make sure all welding work is carried out by fully trained, instructed, qualified and authorized personnel. All regulations and safety stipulations must be strictly adhered to as well as the generally recognized standards for performing welding work. Disconnect the battery cables when welding on the machine. Ensure the clamp on the earth cable (ground) has a good contact near the joint to be welded. Operating instructions 46 Safety rules when operating Ensure that the welding current does not flow through any bearings. Transporting, towing, and roading Securing the machine for transport – When securing the machine for transport, use only the designated tie-down locations to fasten the to the transport vehicle. Decals on the machine indicate the locations to tie the machine down. Use only properly rated tiedowns and securing equipment. Place blocks at the front and rear of the machine while securing to the transport vehicle. If the transport vehicle will be stationary for an extended period of time without being moved, do not remove the blocks until transporting the machine. Use only appropriate means of transport and lifting gear of adequate capacity. Entrust to experienced persons only the fastening of loads and the instructing of crane operators. The personnel giving the instructions must be within sight or sound of the operator. Do not attempt to load the machine on the transporters without knowledge and experience with the operation of the machine. Always use a ramp when loading the machine on the transporter. Be sure ramps are of adequate strength, low angle, and proper height and width. Be sure that the transporter is on level ground when loading the machine. Use proper blocks in front and rear of the wheels of the transporter when loading the machine. Ensure the transporter is on level ground. Approach the transporter loading ramps squarely to make sure the machine does not drop off the side of the ramp. Keep the transporter deck clean of clay, oil, mud, ice, frost and other material that can become slippery. Use proper blocks to secure the drum and rear wheels of the machine once it is loaded onto the transporter. Shut the engine down, apply the parking brake, and lock all lockable compartments. Ensure the articulation lock pin is secured in the locked position before transporting the machine. Know the overall height of the machine and transporter. Observe height and weight regulations, and at overhead objects be sure you can safely pass beneath them. Refer to operating instructions of this manual for proper brake release procedures. Obey all traffic regulations and be sure that the proper clearance flags, lights, and warning signs, including the “Slow Moving Vehicle” emblem, are properly displayed when moving the machine on public access roads. Know the approximate stopping distance at any given speed. Operating instructions Safety rules when operating 47 Never turn corners at excessive speeds. Look in all directions before reversing direction of travel. Position the machine on the transporter centred from side to side and apply the brake. Refer to operating instructions of this manual for proper towing instructions. Safe operation of the machine Pre Start Inspection INSPECT your machine daily. Ensure that the routine maintenance and lubrication are being dutifully performed. Have any malfunctioning, broken, or missing parts repaired or replaced before use. VERIFY that all instruction and safety labels are in place and readable. These are as important as any other equipment on the machine. NEVER fill the fuel tank with the engine running, while near an open flame, or while smoking. ALWAYS wipe up any spilled fuel. CHECK for WARNING tags placed on the machine. DO NOT operate the machine until repairs have been made and the WARNING tags have been removed by authorized personnel. Never smoke when refueling or expose diesel fuel to open flames Check the seat belt regularly for wear or damage. Inspect belt hardware and fabric. Replace if hardware is damaged or if strap is nicked, frayed or loose stitching is found. Check that mounting hardware is tight. CLEAN any foreign material from the operator’s platform to reduce the danger of slipping. KNOW the location of the Emergency Shut-Down Control if the machine is so equipped. ALWAYS know the capabilities and limitations of your equipmentspeed, gradeability, steering, and braking. Check the seat belt regularly for wear or damage BE AWARE of the dimensions of your machine height and weight, as well as your transporter dimensions and weight. Operating instructions 48 Safety rules when operating CHECK for any job site conditions that could be dangerous such as; holes, banks, underground culverts, manhole covers, water meter pits, curb and/or street boxes. Safety precautions AVOID any operational mode that might sacrifice safety. TAKE all necessary precautions to ensure that the machine is used only when in a safe and reliable condition. OPERATE the machine only if all protective and safety oriented devices, such as removable safety devices, emergency shut off equipment, soundproofing elements and exhausts, are in place and fully functional. START the machine from the driver’s seat only and always wear the seat belt. WATCH the indicators during start up and shutdown procedures in accordance with the operating instructions. MAKE SURE no one is at danger or risk before starting up or setting the machine in motion. CHECK that braking, steering, signalling and lighting systems are fully functional before starting work or travelling with the machine. CHECK that accessories have been safely stowed away before setting the machine in motion. OBSERVE the valid traffic regulations when travelling on public roads and ways and MAKE SURE the machine is in a condition compatible with these regulations. ALWAYS SWITCH ON the lighting system in conditions of poor visibility and after dark. MAKE SURE there is sufficient clearance when crossing underpasses, bridges and tunnels or when passing under overhead lines. ALWAYS KEEP at a distance from the edges of building pits and slopes. AVOID any operation that might be a risk to machine stability. NEVER CHANGE the speed on a slope, always change before reaching it. On sloping terrain, always adapt your travelling speed to the prevailing ground conditions. ALWAYS SECURE the machine against inadvertent movement and unauthorized use before leaving the driver’s seat. Operating instructions Safety rules when operating 49 Starting ALWAYS USE three point contact, hand rails and steps to get on and off the machine. READ and FOLLOW ALL instruction decals. Always maintain a three-point contact when climbing on or off of the machine ALWAYS be seated with the lap-type seat belt on when operating the machine. The seat and seat belt is designed for use by one adult, not more. BEFORE starting the engine, ENSURE that the propulsion control lever is in the “STOP” position. Seat belt must be fastened at all times when operating the machine BEFORE starting the engine, ENSURE that the parking brake control is in the “Applied” position. START the engine from the operators position only. WARNING Never boost-start the machine by connecting directly to the starter motor. This may result in uncontrolled machine movements. When using another machine to boost-start, it must not touch the machine that is being started. NOTICE Severe injury or death could result from the machine lurching forward or backward and running over the person/s attempting to jump start the machine. Normal safety devices are bypassed when jump starting directly to the starter or starter solenoid. NEVER jump start a frozen battery, as it will explode. While charging, lead acid batteries generate explosive gases. Operating instructions 50 Safety rules when operating KEEP SPARKS, flames and lighted smoking materials away from batteries. While charging, lead acid batteries generate explosive gases. ALWAYS wear safety glasses when working on or near batteries. Do not smoke near batteries PROCEED as follows when jump starting the machine: Connect the Positive (+) terminal of the booster battery to the Positive (+) terminal of the discharged battery. Connect the Negative (-) terminal of the booster battery to the best ground point of the machine away from the battery. Follow all recommended engine starting procedures. Remove the jumper cables in the reverse order of their connection as soon as the engine has started. Operating ALWAYS make sure that no person or obstruction is in your line of travel before starting the machine in motion. NEVER CLIMB onto or off of the machine while it is in motion. ALWAYS remain seated with the seat belt on when operating the machine whether compacting, travelling, or loading/unloading. USE EXTREME CAUTION and be very observant when operating in close quarters or congested areas. NEVER carry passengers. CLOSE all sound baffles during operation. KNOW the area in which you are working. Familiarize yourself with work site obstructions and any other potential hazards in the area. KNOW and USE the hand signals required for particular jobs and know who has the responsibility for signalling. DO NOT work in the vicinity of overhanging banks or on grades that could cause the machine to slide or roll over. AVOID side hill travel. ALWAYS operate up and down slopes. ALWAYS keep the two speed switch in low speed position and propulsion control lever in low speed range close to the STOP position when climbing or descending hills. NEVER allow anyone to stand within the machine's articulation area when the engine is running. USE the left hand side provision as an emergency exit in case of a rollover of a machine . ALWAYS LOOK in all directions BEFORE changing your direction of travel. DO NOT attempt to control compactor travel speed with the throttle control. When operating the compactor maintain the engine speed at full “Operating rpm.” For towing a machine, See page No. 76, and the instructions in the machine Operator's Manual. DO NOT run the engine in a closed building for an extended length of time. EXHAUST FUMES CAN KILL. Operating instructions Safety rules when operating 51 Accidents WARNING Only the operator, seated in the operator's seat, may be in the cab when operating. All other personnel must keep at a safe distance from the machine. Accidents and also incidents should be reported to the site management immediately. If possible leave the machine in position. Only take necessary action so as to reduce the effect of damage, especially personal injuries. Avoid action which may make an investigation more difficult. Take part in the emergency plan for the working site or other instructions about measurements in case of accidents. Wait for further instructions from the site management. Operator duties WARNING Machine operators must have sufficient skills and knowledge of the content in the Operator's Manual before operating the machine. It is important that the operator reads and follows the instructions in the machine's Operator's Manual. An untrained operator may cause serious injuries and fatalities. Never operate a machine for which there is no Operator's Manual available. Learn to understand the warning plates, symbols and operating instructions for the machine before you start operating. 1 Read and understand the Operator's manual. 2 NEVER make any modifications to the machine which might affect safety without the VOLVO’s approval. This applies to the installation and adjustment of safety devices and valves as well as to welding work on load bearing elements. 3 The machine is designed exclusively for the compaction of soil. Use of the machine for purposes other than that mentioned (such as for towing other vehicles/equipment) is considered contrary to its designated use. The VOLVO/ supplier cannot be held liable for any damage resulting from such use. The risk of such misuse lies entirely with the user. 4 The machine operator's must operate the machine in such a way that the risk of accidents is minimised both for the operator, other road users and person present at the work site 5 Never allow an untrained or unqualified person to operate the machine 6 The machine operator must be thoroughly familiar with how to operate and maintain the machine and should undergo required training on the machine. 7 The machine operator must follow the rules and recommendations given in the operator's manual, but also pay attention to any statutory and national regulations or specific requirements or risks that apply on the work site. Operating instructions 52 Safety rules when operating 8 The machine operator must be thoroughly rested and must never operate the machine under the influence of alcohol, medicine or other drugs. 9 The machine operator must be in charge of the working area of the machine, Prevent person from walking or standing near the machine while operating the machine .. 10 Do not allow persons being trained or instructed in the operation or maintenance of the machine to work without permanent supervision by an experienced person. Accidents 1 Accidents and also incidents should be reported to the site management immediately. 2 If possiable leave the machine in proper position. 3 Only take necessary action in order to reduce the effect of damage, especially personal injuries. Avoid action which may make an investigation more difficult. Machine operator safety 1 AVOID any operational mode or procedure that might sacrifice safety. 2 TAKE all necessary precautions to ensure that the machine is used only when in a safe and reliable condition. 3 The machine must be operational, i.e fault which can cause accidents must be rectified. 4 ALWAYS wear or use the proper safety items required for your personal protection. 5 ALWAYS tie back or otherwise secure long hair, wear closefitting garments and avoid wearing jewelry such as rings. Injury may result from clothing, hair, or jewelry being caught up in the machinery. 6 CHECK the seat belt regularly for wear or damage. Inspect belt hardware and fabric. Replace if hardware is damaged or if strap is nicked, frayed or loose stitching is found. 7 USE protective equipment wherever required by the circumstances or by law. 8 OBSERVE all safety instructions and warnings attached to the machine. 9 OBSERVE all safety instructions and warnings attached to the machine. 10 BE SURE all safety instructions and warnings attached to the machine are complete and perfectly legible. 11 STOP the machine immediately in the event of safety relevant malfunction or change in machine behavior during operation. REPORT the malfunction to the proper authority/person. 12 NEVER provide service or maintenance to the machine unless the drum and wheels are adequately chocked, articulation lock bar/pin is in locked position, and parking brake is applied. 13 ALWAYS SWITCH ON the lighting system in conditions of poor visibility and after dark. 14 MAKE SURE there is sufficient clearance when crossing underpasses, bridges and tunnels or when passing under overhead lines. 15 ALWAYS KEEP at a safe distance from the edges of building pits and slopes. 16 AVOID any operation that might be a risk to machine stability. 17 NEVER CHANGE to a lower speed on a slope always change before reaching it. On sloping terrain, always adapt your travelling speed to the prevailing ground conditions. Operating instructions Safety rules when operating 53 18 ALWAYS SECURE the machine against inadvertent movement and unauthorized use before leaving the driver’s seat. 19 During electrical storms, do not enter or exit the machine. If you are off the machine, stay well away from the machine until the storms passes. If you are in the machine, remain seat with the machine stationary until the storm passes. Do not touch controls or anything metals. 20 AVOID personnel injury by making sure the compactor does not touch the other machine while it is being jump started. 21 NEVER jump start a frozen battery, as it will explode. While charging, lead acid batteries generate explosive gases. 22 KEEP SPARKS, flames and lighted smoking materials away from batteries. While charging, lead acid batteries generate explosive gases. 23 ALWAYS wear safety glasses when working on or near batteries. Handling hazardous materials The following information is provided to assist the machine owners and operators. Further information may be obtained by contacting the local manufacturer’s authorized distributor. The following substances, shown in below, are contained in or emitted by this machine and may be hazardous to health if exposed to or used incorrectly. Substance Precaution Antifreeze Avoid ingestion, skin contact and breathing fumes Hydraulic oil Avoid ingestion, skin contact and breathing fumes Engine lubricating oil Avoid ingestion, skin contact and breathing fumes Preservative grease Avoid ingestion, skin contact and breathing fumes Rust preventive Avoid ingestion, skin contact and breathing fumes Engine fuel Avoid ingestion, skin contact and breathing fumes Battery electrolyte Avoid ingestion, skin contact and breathing fumes SAE gear oil Avoid ingestion, skin contact and breathing fumes The following substances may be produced during the operation of this machine and may be hazardous to health. Substance Precaution Engine exhaust fumes Avoid breathing fumes Engine exhaust fumes Avoid buildup of fumes in confined spaces Electric motor dust (brushes/ insulation) Avoid breathing during maintenance Operating instructions 54 Safety rules when operating Battery disposal WARNING The battery electrolyte contains caustic sulphuric acid. If this comes in contact with your skin rinse it off with soap and lots of water. If acid has come in contact with your eyes or other sensitive parts of your body rinse off with lots of water and seek medical advice as quickly as possible. Batteries contain substances dangerous to your health and the environment. Dispose of batteries marked with the symbol shown below according to local and national regulations. Remember battery electrolyte is corrosive. Do not dispose as general trash. Electrocution hazard WARNING Working near power lines may lead to electrical flash-over. Remain in the machine while it is in contact with the power line. Do not touch any metal surfaces in the cab. Warn personnel outside the machine not to touch it. When operating the machine, maintain a safe distance from overhead electric lines. If work is to be carried out close to overhead lines, keep this machine away from them. Observe the following procedure if your machine comes in contact with electric power lines: Stay in the operator seat. Do not touch any part of the machine. Warn other workers to stay away and not touch any control or any other part of the machine. If contact can be broken, drive the machine away from the danger zone. If contact cannot be broken, stay in the operator seat until told that the power is off. Failure to obey this Warning could result in electrocution or death. Suffocation hazard WARNING Exhaust fumes contain carbon monoxide, a colorless, odorless gas, which is fatal when inhaled in a confined area. Avoid breathing exhaust fumes and be sure engine operation will not cause a concentration of toxic emissions. Breathing exhaust fumes from internal combustion engines can lead to loss of consciousness, carbon monoxide poisoning and suffocation. Never operate internal combustion engines in an enclosed area with poor ventilation. Failure to obey this Warning could result in carbon monoxide poisoning and death. Operating instructions Safety rules when operating 55 Power lines, minimum clearance DANGER Risk of electrocution Working near or making contact with overhead power lines may lead to electrical flash-over and electrocution. Always keep the minimum clearance from overhead power lines. High voltage is lethal and may be powerful enough to destroy machine and attachments. Always contact your local authority before starting work operations near overhead power lines. Operating the machine near overhead power lines requires special precautions. Consider all overhead power lines to be 'live' with electric power, even those that are supposed to be without electric power. Contact with overhead power lines may cause the power to trip out temporarily and power may be re-energised automatically without warning. Electrocution is possible if anyone touches both the machine and the ground. Always be aware of the very serious risk if your machine comes in contact with high voltage. Remember that the voltage in the power line determines the safety distance. Electrical flashovers may damage the machine and injure the operator at relatively great distances from the power line. Always keep the minimum clearance from overhead power lines, see the table below. Minimum clearance from overhead power lines Voltage of overhead power lines Volt (V) Minimum distance m ft up to 50,000 3 10 50,000 to 69,000 4 13 69,000 to 138,000 5 16.4 138,000 to 250,000 6 20 250,000 to 500,000 8 26 500,000 to 550,000 11 35 550,000 to 750,000 13 43 more than 750,000 14 46 Know the location and voltage of all overhead power lines at the job site before operating the machine. Contact your local authority if there is any question whether the power lines are energised or their voltage. Keep the following in mind to ensure safety when operating: Operate the machine at slower than normal operation in the vicinity of power lines. Consider the long-span power line, which can sway and reduce the clearance. Pay attention when travelling over uneven ground that could cause the machine to lose balance. Operating instructions 56 Safety rules when operating Keep all persons away from the machine whenever it is close to power lines. Prohibit persons from touching the machine or its load before it is confirmed to be safe. If your machine comes in contact with overhead power lines Stay in the operator seat while the machine is in contact with the power line. Warn personnel outside the machine not to touch any part of the machine and to stay away. Stay in the operator seat and lower any raised parts in contact with the overhead power lines, or drive the machine out of the overhead power lines if you can. If contact cannot be broken, stay in the operator seat until told that the power is off. If you need to get out because of fire, jump out as far as you can without touching any wires or the machine — keep upright and away. Find out what actions need to be taken if a person has been exposed to an electrical flashover. Failure to follow this instruction can result in electrocution or death! Operating instructions Measures before operating 57 Measures before operating Safety when handling the machine Volvo Construction Equipment is only responsible if: - The machine has been used correctly and has been maintained according to instructions in Service Manuals and the Operator's Manual. - Prescribed service and prescribed inspections have been performed at the stipulated points in time. - The lubricant recommendations in the manual have been followed. - No security seals have been broken by unauthorized persons. - All modifications and repairs have been performed as prescribed by Volvo. - Only Volvo genuine spare parts/accessories or attachments that meet Volvo's requirements have been used. WARNING For safety, observe the following rules. DO NOT operate this machine if the sunshade assembly/ROPS or railing assembly got structurally damaged, shows cracks, is not properly secured as originally installed, or has been involved in a rollover. DO NOT repair, modify, drill, weld on or add attachments to the sunshade assembly/ROPS, railing assembly or on the machine assembly unless authorized in writing by the manufacturer. DO NOT operate the machine unless the seat belt conforming to SAE and/ or ASAE standards is fastened. General The manufacturer cannot ensure for all possible circumstances that might lead up to a potential hazard. Therefore, the combination of warnings listed in this manual and those placed on the machine itself are not intended to be all inclusive. Operators and maintenance personnel must be alert to recognize and avoid potential hazards. They should also have comprehensive training, required skills and necessary tools to properly perform their functions. The machine is built in accordance with state-of-the-art standards and recognized safety rules. Nevertheless, its misuse may constitute a risk to life and limb of the user or of third parties, and may cause damage to the machine or other material property. The machine must be used in accordance with its designated use as described in the operating manual. The machine must only be operated by safety-conscious persons who are fully aware of the risks involved in operating the machine. Any functional disorders, especially those affecting the safety of the machine, must be corrected immediately. The machine is designed exclusively for the compaction of soil. Use of the machine for purposes other than that mentioned (such Operating instructions 58 Measures before operating as for towing other vehicles/equipment) is considered contrary to its designated use. The manufacturer/supplier cannot be held liable for any damage resulting from such use. The risk of such misuse lies entirely with the user. Operating the machine within the limits of its designated use also involves compliance with the inspection and maintenance directives contained in the operating manual. Selection and qualification of personnel WARNING Machine operators must have sufficient skills and knowledge of the content in the Operator's Manual before operating the machine. It is important that the operator reads and follows the instructions in the machine's Operator's Manual. An untrained operator may cause serious injuries and fatalities. Never operate a machine for which there is no Operator's Manual available. Learn to understand the warning plates, symbols and operating instructions for the machine before you start operating. Work on and with the machine must be performed by qualified personnel only. Statutory minimum age limits must be observed. Individual responsibilities of the personnel responsible for operation, setup, maintenance and repair of the machine should be stated clearly. Define the machine operator’s responsibilities - also with regard to observing traffic regulations - the operator should have the authority to refuse instructions by third parties that are contrary to safety. Do not allow persons being trained or instructed in the operation or maintenance of the machine to work without permanent supervision by an experienced person. Work on the electrical system and equipment of the machine must be done only by a skilled electrician or by instructed persons under the supervision and guidance of a skilled electrician and must be in accordance with electrical engineering rules and regulations. Work on the mainframes, brake, hydraulic and steering systems must be performed by skilled personnel with special knowledge and training for such work. Organizational measures STOW manuals in the manual pouch/box provided on the machine. Manuals must always be available at the site where the machine is used. OBSERVE AND INSTRUCT the user in all other generally applicable legal and mandatory regulations relevant to accident prevention and environmental protection. These compulsory regulations may also deal with the handling of hazardous substances, issuing and/or wearing of personal protective equipment, and traffic regulations. Operating instructions Measures before operating 59 SUPPLEMENT operating instructions with detailed working instructions pertaining to the specific work location. ALWAYS be sure that persons entrusted with work on the machine have read the operating instructions and in particular the chapter on safety before beginning work. Reading the instructions after work has begun is too late. This is especially important for persons who work only occasionally on the machine, e.g. during set up or maintenance. MAKE CERTAIN personnel are working in compliance with the operating instructions and are alert to risks and safety factors. ALWAYS tie back or otherwise secure long hair, wear close-fitting garments and avoid wearing jewelry such as rings. Injury may result from clothing, hair, or jewelry being caught up in the machinery. USE protective equipment wherever required by the circumstances or by law. OBSERVE all safety instructions and warnings attached to the machine. BE SURE all safety instructions and warnings attached to the machine are complete and perfectly legible. STOP the machine immediately in the event of any malfunction. REPORT the malfunction to the proper authority/person. NEVER provide service or maintenance to the machine unless the drum and wheels are adequately chocked, articulation lock bar/pin is in locked position, and parking brake is applied. NEVER make any modifications to the machine which might affect safety without the manufacturer’s approval. This applies to the installation and adjustment of safety devices and valves as well as to welding work on load bearing elements. ALWAYS ADHERE to prescribed intervals or those specified in the operating instructions for routine checks and inspections. WARNING For safety, observe the following rules. V1065709 - Read the Operator's manual. - Carry out daily service. In cold weather, make sure that the freezing point of the coolant is sufficiently low and that the lubricating oil is intended for winter use. - Clean the dust around engine, battery and cooler. - Check the level of hydraulic fluid, refill if required. - Check that there is sufficient fuel in the fuel tank. - Check that there are no faulty, loose parts or leaks, which can cause damage. - Check that the battery disconnected switch is switched on. - Check for cracks on frame. - Check that hoods and covers are closed. - Make sure fire extinguisher if equipped is fully charged. - Inspect steps and handholds for damage or loose parts. Make necessary repairs if needed. - Check that there are no persons in the vicinity of the machine. - Adjust the operator seat and fasten the seat belt. - Adjust and clean the mirrors. Operating instructions 60 Measures before operating - Inspect working and other lights for proper operation. - Travel alarm should be on before operating the machine. - Inspect the failure of gauges in the instrument panels. Operating instructions Starting engine 61 Starting engine NOTICE BEFORE starting the engine, ENSURE that the propulsion (travel) control is in the “STOP” position and parking brake control is in the “Applied” position. WARNING Remove all unauthorised personnel from the working area of the machine. Keep a good lookout in all directions to avoid running into personnel or objects. Do not touch control levers or switches during start. Sound the horn before beginning operation. CAUTION Do not crank the starting motor for more than 15 seconds to avoid overheating the motor. Wait 30 seconds before a new attempt. CAUTION If the engine sounds or runs strangely or if strong vibrations arise, the ignition switch must be turned to stop position immediately. Position the Throttle Control Lever to the “Low” or “Idle RPM” Make sure the Parking Brake Switch is in applied position. Place Vibration Control Lever in “OFF” position. Pull up on the Emergency Stop Switch Turn the key to run position. Sound the horn and let other workers and bystanders know you are starting the machine. Turn the key to the starting position. Release the key when the engine has started. NOTICE Allow the engine to run at low or idle rpm for a few minutes before normal operation. Never rise the engine during the warm up period. Warm up the machine. Operating instructions 62 Hydraulic system, warming up Hydraulic system, warming up CAUTION Do not rush the warming up of the oil, as forced warming up may damage the machine. The oil in the hydraulics of the machine is used for operating the hydraulic cylinders of the equipment as well as the hydraulic motors for travelling. When the oil is cold it is viscous. The hydraulic functions of the machine therefore operate slower than when the oil is warm. If one or more of the machine functions are forced against the end-of-stroke position without having first warmed up the system, this may result in malfunctions. It is important that the oil in the hydraulic system is properly warmed up before operating the machine. Apply the parking brake and leave the engine idling so that the oil in the engine, transmission, hydraulic system and axles is warmed up and becomes sufficiently fluid to provide proper lubrication. To race the engine immediately after it has been started may also endanger the lubrication and cooling of the turbocharger with great risk of bearing seizure as a consequence. Moving the machine a short distance (for example when loading onto or off a trailer) can be done without a complete warm up. These operations must be executed with great care. In such situations, the engine speed must not exceed 1200 rpm. 1 Apply the parking brake. 2 Start the engine and let it idle for five minutes. Operating instructions Vibration 63 Vibration Vibration Drum vibration amplitude selection Move the vibration lever to choose desired amplitude setting (High or Low). Select high amplitude for initial or thick soil compaction by moving the vibration lever to High position. Select low amplitude for final or thin layer of soil, and when soil is loose and granular, by moving vibration lever to Low position. V1092791 Vibration lever Drum vibration frequency selection Material Natural Frequency TYPE OF SOIL NATURAL FREQUENCY Sand Uniformly 1900 vpm 32 Hz Sand Graded 1400 vpm 23 Hz Sand Wet 1300 vpm 22 Hz Sandy Gravel Dry 1500–1700 vpm 25–28 Hz 1200 vpm 20 Hz Clay (Pad Foot) Silt Firm 1500–1700 vpm 25–28 Hz Silt Loose 900–1300 vpm 15–22 Hz Operating instructions 64 Operating Operating Operating instructions 1 ALWAYS make sure that no person or obstruction is in your line of travel before starting the compactor in motion. 2 NEVER CLIMB up or climb down the compactor while it is in motion. 3 ALWAYS remain seated with the seat belt on when operating the compactor whether compacting, traveling, or loading/ unloading. 4 USE EXTREME CAUTION and be very observant when operating in close quarters or congested areas. 5 NEVER carry passengers. 6 CLOSE all sound baffles during operation. 7 KNOW the area in which you are working. Familiarize yourself with work site obstructions and any other potential hazards in the area. 8 KNOW and USE the hand signals required for particular jobs and know who has the responsibility for signaling. 9 DO NOT work in the vicinity of overhanging banks or on grades that could cause the compactor to slide or roll over. 10 AVOID side hill travel. ALWAYS operate up and down slopes. ALWAYS keep the propulsion (travel) control lever in low speed range close to the “STOP” position when climbing or descending hills. 11 NEVER allow anyone to stand within the compactor’s articulation area when the engine is running. 12 ALWAYS LOOK in all directions BEFORE changing your direction of travel. 13 DO NOT attempt to control compactor travel speed with the throttle control. When operating the compactor maintain the engine speed at full “Operating rpm.” 14 DO NOT run the engine in a closed building for an extended length of time. EXHAUST FUMES CAN KILL. PROPELLING THE MACHINE 1 Check the travel and work area for people and obstructions. 2 Remove and stow the Articulation Lock Pin in it’s stowed position. 3 Move the throttle Control lever to the low operating RPM.. 4 Position the Two-Speed Control Switch to LOW position. The compactor is to be on solid, level ground and the Parking brake is to be in the applied position. The HIGH speed is to be used only for “roading” the compactor. 5 Push the Parking Brake Switch to Off position, this will release the Brake. 6 Move the Propulsion Control Lever to achieve the desired direction and safe speed of travel as determined by the conditions. The further the control is moved from the S or “STOP” position, the greater the speed in that direction. Return the control to S or “STOP” for normal braking. Operating instructions Operating 65 7 Once the compactor is in motion, move the vibration control lever to the desired eccentric rotation direction and amplitude. NOTICE When the eccentrics are engaged/disengaged, or the direction of rotation is changed, there is a noise clunk that will be heard. This is a normal condition and is caused by the eccentric weights changing position. SHUTDOWN PROCEDURE 1 Move the Vibration Control lever to the stop position. 2 Move the propulsion control lever to S or stop position. 3 Apply parking brake and make sure the parking brake indicator is glowing. 4 Install the Articulation Lock Pin in it’s locked position. 5 Position the throttle control lever to the ‘Idle RPM position. Allow the engine to idle for a few minutes to avoid high internal heat rise and allow for heat dissipation. 6 Turn the Ignition Switch to the OFF position. 7 Choke the machine drum and wheels with suitable wedges. 8 Fill the diesel fuel tank with clean Diesel Fuel to prevent condensation in the tank. 9 Lock all lockable compartments and remove the ignition key. Operating instructions 66 Braking Braking Parking brake, description The parking brake system on this machine consist of a spring applied brake located in the rear axle of the machine. The parking brake is released by hydraulic pressure supplied from the charge pump of the propulsion pump. The parking brake is turned ON and OFF by means of a switch located on the instrumental panel. The parking brake is released when the engine is running and the park brake switch is moved to the OFF position. Once the switch is placed in the OFF position, electrical current is supplied to the brake-destroke valve and valve is actuated. This allows the charge pressure of the charge pump to flow into the brake release circuit. Once the charge relief pressure is obtained, the oil supplied to the brake at the axle via a hydraulic hose will overcome the force of the brake spring. This will in turn release the brake pressure and the machine is free to move as directed. Operating instructions Stopping 67 Stopping Stopping 1 ALWAYS park the compactor on solid level ground. If this is not possible, always park the compactor at a right angle to the slope and chock the wheels and/or drums. 2 AVOID leaving the operator’s platform with the engine running. ALWAYS move the propulsion control lever to “STOP” position , apply the parking brake, install the articulation lock pin, position the throttle control to “low /idle rpm”, turn ignition switch to OFF and lock all lockable compartments. 3 USE proper flags, barriers and warning devices, especially when parking in areas of heavy traffic. Operating instructions 68 Measures after operating Measures after operating Measures after operating Perform the following precautions each day after work in addition to the daily routine maintenance on the lubrication and service chart. NOTICE In any work concerning the operation, conversion or adjustment of the machine and its safety oriented devices or any work related to maintenance, inspection and repair, always observe the start up and shutdown procedures set out in the operating instructions and the information on maintenance work. Fill fuel tank to prevent condensation problems. Clean drum scrapers of accumulated material. If available, lock all vandal protection devices on the machine. Operating instructions Parking 69 Parking Storage Short term Perform this maintenance when the machine will be shut down for a short term (2 weeks or less) parking or storage. 1 Position the machine on level ground. 2 Apply the parking brake. 3 Place all switches and controls in the OFF position. 4 Shut down the engine and remove the key. 5 Remove all valuable items from the machine which can be easily stolen. 6 Close and lock all doors and accessible areas. 7 Place the battery disconnect switch in the OFF position. Long term Perform this maintenance when the machine will be shut down for a long term (more than 2 weeks) parking or storage for an extended period, such as for the off-season. The sequence of the steps may change dependent on storage location. 1 Lubricate the machine. 2 Fill the fuel tank and hydraulic tank to the maximum level. 3 Wash the machine and allow it to dry. 4 Touch up the paint finish to avoid rusting. 5 Position the machine on level ground. 6 Apply the parking brake. 7 Place all switches and controls in the OFF position. 8 Shut down the engine and remove the key. 9 Remove all valuable items from the machine which can be easily stolen. 10 Close and lock all doors and accessible areas. 11 Place the battery disconnect switch in the OFF position. 12 Treat exposed parts with anti-rust agent which can be easily removed at a later date. NOTICE Follow all safety instructions for application and removal of the anti-rust agent provided by the agent manufacturer. 13 Protect the tyres and all exposed rubber components against direct sunlight. 14 Plug exhaust pipe. Prepare machine for use from storage. Perform this maintenance before bringing the machine back into service following storage. 1 Inspect machine for any damage or missing components. Correct as required. 2 Inspect machine for any damage or missing components. Correct as required. 3 Remove all tyres and rubber protective covers Operating instructions 70 Parking 4 Remove anti-rust material. NOTICE Follow all safety instructions for application and removal of the anti-rust agent provided by the agent manufacturer. 5 6 7 8 9 Check all fluid levels and add as necessary. Check tyre pressure and correct if necessary. Check alternator belt tension and correct if necessary. Check air cleaner elements condition. Correct as required Place the battery disconnect switch in the ON position. Operating instructions Measures in case of machine failure 71 Measures in case of machine failure Starting with booster batteries The battery is located at the extreme rear side of the machine, in the battery compartment of the rear frame. See page No. 147 to access the battery. Before connecting the booster cables Before connecting the booster cables, be sure to check the following: Booster cables and clamps must be appropriately dimensioned for the size of the battery. Check booster cables and clamps for damage, corrosion, etc. Make sure that cables and clamps are tightly connected. Make sure that the ignition switch is in OFF position. Make sure that the parking brake is in applied position. Make sure that the propulsion control lever is in STOP position. Make sure that the vibration control lever is in neutral position. Make sure that the battery disconnect switch is in OFF position. The booster battery must have the same voltage as the battery for the engine requiring the jump starting. Make sure that the machines do not come into contact with one another. Connection of the booster cables To start with the booster battery following steps must be followed. WARNING Battery charging generates hydrogen gas, which may be explosive. Short-circuiting, an open flame or a spark near the battery may cause a powerful explosion. Make sure ventilation is adequate when charging batteries. Never smoke near batteries. WARNING Batteries may explode due to the current surge if a fully-charged battery is connected to a completely discharged or frozen battery. Personal injuries may be sustained. 1 Check that the booster battery or any other power source has the same voltage as the battery on the machine. 2 Do not under any circumstances disconnect the cables from the batteries on the machine. 3 Connect the positive (+) terminal of the booster battery to the positive (+) terminal of the battery of the machine to be jump started with a booster cable “A” . 4 Connect the negative (-) terminal of the booster battery to the grounding of the machine to be jump started. NOTICE Make sure that the clamps are tightly connected with the battery terminals. Operating instructions 72 Measures in case of machine failure NOTICE When connecting the cables, make sure that the positive (+) and negative (-) clamps do not touch. A BATTERY OF THE MACHINE TO BE JUMP STARTED BOOSTER BATTERY MACHINE TO BE JUMP STARTED B V1076862 Connection of booster cables 5 Turn the battery disconnect switch to ON position . 6 After the cables are connected, wait 5 minutes before starting the machine. 7 Start the engine with the booster battery, then attempt to start the engine that needs to be jump started. 8 Crank the engine of the machine to be jump started for a maximum of 30 seconds. Wait two minutes between starting attempts. 9 Once the engine has started, turn OFF the machine with booster battery. 10 Remove the negative clamp cable “B” first, then the positive clamp cable “A”. Troubleshooting, general Pre-start check Prior to attempting to start the engine refer to the checklist decal located in the operator area, see page Decal locations for checklist decal location. Failure to follow directions listed on this checklist may prevent the operator from starting the engine. Operating instructions Measures in case of machine failure 73 WARNING Machine operators must have sufficient skills and knowledge of the content in the Operator's Manual before operating the machine. It is important that the operator reads and follows the instructions in the machine's Operator's Manual. An untrained operator may cause serious injuries and fatalities. Never operate a machine for which there is no Operator's Manual available. Learn to understand the warning plates, symbols and operating instructions for the machine before you start operating. WARNING Always read safety instructions and warnings before operating. Improper operation and maintenance is the most frequent cause of machinery faults and problems. In the event of a fault, it is recommended to read through this manual. If the cause of the problem or solution cannot be determined when following the troubleshooting chart below, contact the manufacturer’s local authorized dealer or distributor. Troubleshooting charts Engine will not start Symptom Starter does not rotate Possible cause Solution Emergency stop switch pushed down Check emergency stop switch/reset if required sensing parking brake is applied condition Parking brake release switch Turn ignition key on and off FSR lever not in stop position Move FSR lever to stop position Fuse FL1 and F1defective Check console fuses and replace Battery discharged Service must be performed by authorised and trained personnel Battery disconnect switch off Turn switch on Battery cable connections loose or disconnected Clean and tighten terminal connections Starter relay fault Ignition switch defective Service must be performed by authorised and trained personnel. Starter solenoid or starter defective Starter does rotate Empty fuel tank Fill, see page No. for specifications Defective wiring Service must be performed by authorised and trained personnel. 196 Operating instructions 74 Measures in case of machine failure Difficult starting and poor/irregular performance SYMPTOM POSSIBLE CAUSE SOLUTION Difficult starting and poor/irregular performance Low battery power Service must be performed by authorised and trained personnel Battery discharged Service must be performed by authorised and trained personnel or see page No.71 for boost starting Battery cable connections loose or disconnected Clean and tighten terminal connections, see page No. 147 Using too high a viscosity oil in low ambient temps Use appropriate oil grade for ambient temperature conditions, see page No.194 for engine oil specifications Fuel line blockage due to wax separation in winter Change fuel filters, and bleed fuel system, check for fuel line leaks and loose connections, see page . Always use winter grade fuel in winter, see page No.129 . Blocked air cleaner element Clean or replace element, see page No. 136 Incorrect valve clearance Service must be performed by authorised and trained personnel Defective fuel injectors Fuel pump failure Defective turbo charger Engine making excessive fumes SYMPTOM POSSIBLE CAUSE SOLUTION Engine making excessive fumes Engine oil level too high Drain engine oil to correct level, see page No. 194 for engine oil specifications Blocked air cleaner element Clean or replace element, see page No.136 Low compression due to the poor condition of the valves or incorrect clearance Service must be performed by authorised and trained personnel Engine overheats — stop engine immediately SYMPTOM POSSIBLE CAUSE SOLUTION Engine overheats — stop engine immediately Excessive dirt on cooling system Clean the cooling fins Engine coolant level too low Check coolant level, see page No. 141. Engine belt broken Service must be performed by authorised and trained personnel Engine oil level low Check oil level, see page No. 126 Thermostat defective Service must be performed by authorised and trained personnel Blocked cooling air flow Operating instructions Measures in case of machine failure 75 Low engine oil pressure — red warning light illuminates SYMPTOM POSSIBLE CAUSE SOLUTION Low engine oil pressure — red warning light illuminates Low engine oil level (low engine oil pressure warning light should illuminate) Add oil to correct level, see page No. 126 for details Lubrication system leak Stop engine and check for leaks and tighten any loose fittings on the system oil Fuses, check If a fault occurs with a component or function, replace the associated fuse with an exact replacement. See page No. 153 for details on fuse identification, ratings and associated circuits. Operating instructions 76 Retrieving and towing Retrieving and towing Retrieving and towing WARNING Always use classified cables, lifting straps, shackles and hooks with sufficient lifting capacity. WARNING Incorrect or faulty equipment or improper towing methods may cause accidents. Therefore, carefully follow the instructions given below. The following instructions are to be followed if it becomes necessary to tow the compactor. Attach to the compactor at the tie down and tow points only. Tie down and tow point locations are located on each side of the machine, see page No.81 for location of machine tie down and tow point locations. Towing a disabled machine NOTICE In the event of an engine problem or other malfunction, it may become necessary to tow your compactor. To tow the compactor requires disengaging the propulsion system and releasing the spring-applied brakes. WARNING If the engine cannot be started, the brake and steering functions will be severely limited. In such cases, towing should only be performed in an emergency situation by experienced and trained personnel and only for the shortest possible distance (see towing). If possible, transport the machine on a trailer. WARNING Incorrect or faulty equipment or improper towing methods may cause accidents. Therefore, carefully follow the instructions given below. Disengaging the propulsion system Make sure that the parking brake switch is in the “Applied” position. Operating instructions Retrieving and towing 77 Make sure that the drum and wheel chocks are in place. Propulsion pump Propulsion pump bypass function engagement Locate and gain access to the multifunction valve cartridges of the propulsion pump. Hold the pressure limiter housing with a 1-1/16" wrench and loosen the bypass actuator with a 1 1/4" wrench about 3 revolution in counter clockwise to open the bypass valve in propulsion pump. Do not rotate more than three revolutions, as additional rotation will generate external leakage. Open both the bypass valves to engage the bypass function. Move the propulsion control lever in the operator's compartment to the full “Forward” for towing the machine in forward direction. Move the propulsion control lever in the operator's compartment to the full “Reverse” for towing the machine in reverse direction. Release the parking brake in the axle. See page No.78 NOTICE Machine runaway condition could occur. Do not leave the machine with the brakes released after towing. Releasing the spring-applied brakes. NOTICE While towing observe that the machine wheels are free to rotate, if not check for release of parking brake. Make sure that the operator is seated in the operator's seat with seat belt put on, to control steering, when towing the compactor. NOTICE Steering of compactor is limited, as the hydraulic system do not receive power from engine. Check with the local regulations and laws, for the use of tow chains on highways. Make sure that the vehicle, which does the towing, is at least as heavy as the machine being towed. This will ensure sufficient braking capabilities, to be able to pull and stop both machines. Operating instructions 78 Retrieving and towing Remove the chocks and tow the machine for a short distance of 200 metersat a maximum speed of 2km/hr. NOTICE Machine runaway condition could occur. Do not leave the machine with the brakes released after towing. Chock the wheels and drum. To close the bypass valve in propulsion pump, tighten the bypass actuators in clockwise direction about 3 revolution. Tighten the bypass actuator to a torque value of 41 N•m (30 lbf•ft). Manual release of parking brake NOTICE For Drum drive option, follow the below procedure for releasing the parking brake. NOTICE Manual release of parking brake is only for towing purpose, before releasing the brake manually, read the towing instructions. Releasing Locate the pilot pressure line on the brake valve. Disconnect the pilot pressure line and connect to the external hand pump to brake valve pilot pressure port. CAUTION Plug hoses and connections immediately. Switch the parking brake to released condition. Increase the brake line pressure using hand pump to maximum pressure of 24 bar (350 psi) to release the brake. NOTICE Do not exceed the brake release pressure 24 bar (350 psi), excessive pressure can damage the seal Applying Applying the parking brake. Release the external hand pump pressure and disconnect. Connect the pilot line to brake valve. Clean for any oil spillage. Operating instructions Retrieving and towing 79 Manual release of parking brake WARNING Always block the wheels before mechanically releasing the parking brake to prevent the machine from rolling. WARNING All changes to the adjusting screws must take place with the engine turned off. The starter inhibitor will be out of operation when the engine is subsequently started. NOTICE There are 4 set of screws and nuts are provided on the axle (2 Nos. on front & 2 Nos. on rear side of the axle) to release the brake manually during towing or emergency. Manual release of axle brake Loosen the nuts of screws provided for the manual release on the axle. Move the nuts backwards by 8 mm. Axle pressure plate adjustment 1 Nut 2 Screw 3 Seal 4 Pressure plate 5 Bellevelle washers Tighten the screws (2) so as to fasten them onto the pressure plate. Using wrench tighten the screws in an alternate sequence, considering one side at a time, either left or right side of the axle, by 1/4 turn at a time to compress the bellevelle washers and disengage the braking units. NOTICE Tighten screws maximum by one turn. Axle brake release screw tightening Operating instructions 80 Retrieving and towing Parking brake adjustment after towing. Adjustment after manual release 1 Screw. 2 Nut. 3 Seal. 1 2 3 4 Remove screws complete, with nuts and seals. Replace the seals. Apply grease to the screws. Install all parts into the arm and tighten the screws in alternate sequence. Axle brake release screw adjustment 5 Adjust screws to obtain a gap of 34 mm (allowable tolerance +0.5 mm) in relation to the arm. 6 Lock the screw position with the nut. NOTICE Hold the screws into the position while locking the nuts to maintain the gap of 34 mm. 7 Make sure that the gap maintained between the axle arm and the screw head top is 34 mm. Axle brake release adjustment Actions after recovering and towing WARNING All changes to the adjusting screws must take place with the engine turned off. The starter inhibitor will be out of operation when the engine is subsequently started. To put back the machine to service To Re-engage the propulsion system, See page No.76 Parking brake adjustment after towing, See page No. 78 Check the parking using parking brake switch, See page No.Parking brake, checking of function Put back the machine in service. Operating instructions Transporting machine 81 Transporting machine Before driving machine on public roads, check with a supervisor for instructions and information with respect to local traffic regulations regarding construction machinery. Loading the machine under its own power 1 2 3 4 Choose level ground which will solidly support the vehicle. Clean the trailer surface and loading ramps. Before loading machine, block the wheels of the trailer. A signal person must assist the operator with any necessary warnings. 5 Approach the transporter loading ramps squarely to make sure machine does not drop off side of ramp. 6 Drive machine onto transporter. 7 Shut down the engine, apply parking brake and lock all lockable compartments. Securing the machine to the transporter 1 After loading the machine to the transporter, ensure that articulation lock pin is in the locked position. 2 Block the drum. 3 Tie-down machine using a chain and tensioning device or other appropriate equipment to the tie-down points. 4 The driver of the transport must be aware of its total weight, load on the axles, and the overall dimensions of the machine. Transporting the machine SECURING THE UNIT FOR TRANSPORT - When securing the unit for transport, use only the designated tie-down locations to fasten the unit to the transport vehicle. Decals on the unit indicate the locations to tie the unit down. Use only properly rated tiedowns and securing equipment. Place chocks at the front and rear of the unit while securing to the transport vehicle. If the transport vehicle will be stationary for an extended period of time without being moved, do not remove the chocks until transporting the unit. Operating instructions 82 Transporting machine V1100948 Lifting, Tie-down and wheel chocking locations USE only appropriate means of transport and lifting gear of adequate capacity. ENTRUST to experienced persons only the fastening of loads and the instructing of crane operators. The personnel giving the instructions must be within sight or sound of the operator. DO NOT attempt to load the machine on the transporters without knowledge and experience with the operation of the machine. ALWAYS use a ramp when loading the machine on the transporter. Be sure ramps are of adequate strength, low angle, and proper height and width. POSITION the machine on the transporter or hauling vehicle centred from side to side and apply the brake. USE proper chock blocks in front and rear of the wheels of the transporter when loading the machine. ENSURE the trailer is on level ground and approach the transporter loading ramps squarely to make sure the machine does not drop off the side of the ramp. KEEP the transporter deck clean of clay, oil, mud, frost and other material that can become slippery. USE proper chock blocks on the front of the drum and rear of the wheels once loaded onto the transporter. SHUT the engine OFF, apply the parking brake, and lock all lockable compartments. ENSURE the articulation lock bar/lock pin is secured in the locked position before transporting the machine. Operating instructions Transporting machine 83 TIE-DOWN the machine using chains and tensioning devices or other appropriate equipment to the tie-down points as marked on the machine. Ensure all transport devices, tie-down equipment and methods comply with all applicable transport regulations in the jurisdictions where the equipment is loaded/unloaded or in transit. KNOW the overall height, total weight, load on the axles and the overall dimensions of the of the machine and hauling vehicle. For dimensions and Machine weights, See page No. 206 and 204 . Observe height, width and weight regulations along the intended route to ensure safe passage of the equipment at all times, especially when encountering overhead objects, tunnels, bridges, intersections, and other obstacles along the intended route. Operating techniques 84 Operating techniques Operating techniques WARNING Machine operators must have sufficient skills and knowledge of the content in the Operator's Manual before operating the machine. It is important that the operator reads and follows the instructions in the machine's Operator's Manual. An untrained operator may cause serious injuries and fatalities. Never operate a machine for which there is no Operator's Manual available. Learn to understand the warning plates, symbols and operating instructions for the machine before you start operating. The speed of travel of a vibratory roller has a tremendous effect on the compaction results. As opposed to a static roller where speed of travel matters very little to the compaction process, a vibratory roller needs “dwell” time for each vibration to develop its potential. This means that travel speed is of the utmost importance if maximum consolidation is to be accomplished. Travel speeds of more than 4.83 km/hour (3mph) usually do not develop the compaction needed, in proportion to the increased travel speed. On the other hand it is very easy to achieve over-compaction with multiple passes over the same plot due to the efficiency of Compactors. NOTICE STATICS SHOW THAT OVER-COMPACTION MAY ACTUALLY REDUCE FINAL DENSITY DUE TO MACHINE BOUNCE WHICH TENDS TO BREAK DOWN THE ALREADY ACHIEVED DENSITY OVER-COMPACTION CAN ALSO LEAD TO EXCESSIVE WEAR ON YOUR UNIT IF IN DOUBT ABOUT THE PROPER COMPACTION TECHNIQUE, CONSULT YOUR VOLVO Authorized DISTRIBUTOR/DEALER. Watch for bystanders and never allow anyone to be near the machine while operating. Operating techniques Eco driving 85 Eco driving To utilise the system in the best way and at the lowest fuel consumption, the engine speed should be kept low when not compacting. Operating techniques 86 Signalling diagram Signalling diagram If the operator's visibility is restricted, e.g., due to a big load, use a signal man. The faster lifting, lowering, or movement that is required, the livelier the signal man's movements should be. If two or several operators use the same signal man, determine ahead of time how the lift is to be done and how signals shall be given to each operator. START Arms extended horizontally with palms facing forward STOP Right arm pointing up with palm facing forward END Hands held together at chest height RAISE Right arm pointing up with palm facing forward and hand moving slowly in a circle LOWER Right arm pointing down with palm facing forward and hand moving slowly in a circle VERTICAL DISTANCE Hands indicate relevant distance MOVE FORWARD Both arms bent with palms facing up and underarms moving slowly and repeatedly up towards the body MOVE BACK Both arms bent with palms facing down and underarms moving slowly and repeatedly down away from the body DANGER (EMERGENCY STOP) Both arms up with palms facing forward Operating techniques Signalling diagram OPERATE IN INDICATED DIRECTION Arm extended horizontally with palm facing down and small movements back and forth slowly to the right OPERATE IN INDICATED DIRECTION Arm extended horizontally with palm facing down and small movements back and forth slowly to the left 87 HORIZONTAL DISTANCE Hands indicate relevant distance Safety when servicing 88 Safety when servicing Safety concerns everybody! Always follow the instructions in the machine's operator's manual. Volvo designs and manufactures machines with a high level of safety as well as effectiveness. All this work may be wasted if anyone who is about to perform service on any of our machines does not read the safety instructions, or does not follow them, e.g., does not replace guards, climbs on slippery machine parts instead of using a ladder, uses the wrong tools for the job. In order to maintain safe and efficient function, always use genuine Volvo spare parts intended and adapted for the machine. If other spare parts than genuine Volvo are used then Volvo Construction Equipment cannot be held responsible for machine damage, and warranty claims will be denied. Machines seldom cause accidents, instead people often do. A safety-conscious person and a well-maintained machine make for a safe, effective and profitable combination. Those who do not follow the safety instructions and observe the warnings in this manual must make sure that their work method is safe. Otherwise, there is a great risk of accidents, perhaps even accidents that result in fatalities. WARNING WARNING SYMBOL This symbol is shown at various points throughout the manual. The appearance of it means "Warning, stay alert! Your safety may be involved!" Get to know the capacity and limits of your machine! Safety when servicing This section deals with the safety rules that must be followed when performing checks and service work. Volvo Construction Equipment rejects all responsibility if other tools, lifting devices, or work methods than those described in this publication are used. Other safety rules, information and warning texts are given in each section. NOTICE Lifting with a jack must only be carried out by trained personnel Safety when servicing 89 WARNING If work must be done on the machine before it has cooled down; beware of hot fluids and hot components that can cause severe burns. Before you begin any service work on the machine: Service work which is not carried out in the correct way is dangerous. All service work should be carried out by a qualified technician who is having sufficient knowledge of the machine, and trained to use the proper tools and equipment to carry out the service task in a correct way. WARNING During service, hearing protection and safety goggles must be used. NOTICE No work must be carried out on the machine until you have acquired the appropriate knowledge to do so. In any work concerning the operation, conversion or adjustment of the machine and its safety oriented devices or any work related to maintenance, inspection and repair, always observe the start up and shutdown procedures set out in the operating instructions and the information on maintenance work. ENSURE that the maintenance area is adequately secured. If the machine is completely shut down for maintenance and repair work, it must be placed in the service position, See page 92 and secured against inadvertent starting by: Locking the principal control elements and removing the ignition key Attaching a warning sign to the ignition or main switch CARRY OUT maintenance and repair work only if the machine is positioned on stable and level ground and has been secured against inadvertent movement and buckling. LIFTING THE UNIT - When raising the unit off the ground, apply the parking brake. Attach the lifting apparatus only to the unit’s designated lifting points using properly rated lifting straps, cables, or chains. Use spreader bars to ensure equal weight distribution during lifting as well as avoid contact with the unit. See page 99. USE CARE when attaching and securing lifting tackle to individual parts and large assemblies being moved for replacement purposes to avoid the risk of accidents. USE lifting gear that is in perfect condition and with adequate lifting capacity. NEVER work or stand under suspended loads. ALWAYS USE the correct tools and workshop equipment when performing maintenance on the machine. ALWAYS USE specially designed or otherwise safety oriented ladders and working platforms when doing overhead assembly work. Never use machine parts as a climbing aid. KEEP all handles, steps, handrails, platforms, landings and ladders free from mud, dirt, snow and ice. CLEAN the machine, especially connections and threaded unions, of any traces of oil, fuel or preservatives before carrying Safety when servicing 90 out maintenance/repair. NEVER use aggressive detergents. Use lint free cleaning rags. COVER OR TAPE all openings, for safety and functional reasons - must be protected against water, steam or detergent penetration before cleaning the machine with water, steam jet (high pressure cleaning) or detergents. Special care must be taken with electric equipments. ENSURE during cleaning of the machine that temperature sensors do not come into contact with hot cleaning agents. REMOVE all covers and tapes applied for that purpose after cleaning machine. EXAMINE all fuel, lubricant, and hydraulic fluid lines for leaks, loose connections, cut marks and damage after cleaning. REPAIR or REPLACE defective parts immediately. TIGHTEN any screwed connections that have been loosened during maintenance and repair. REPLACE any safety devices removed for setup, maintenance or repair purposes and checked immediately upon completion of the maintenance and repair work. ENSURE that all consumable and replaced parts are disposed safely and with minimum environmental impact. AVOID, whenever possible, servicing, cleaning, or examining the machine with the engine running. WARNING All forms of open fire and smoking should be avoided when filling the fuel tank. DON'T fill the fuel tank with the engine running, while near an open flame, or while smoking. ALWAYS wipe up any spilled fuel. DO NOT alter the engine governor settings from those indicated in the engine manual. ALWAYS replace damaged or lost decals. Refer to the parts manual for the proper location and part number for all decals. ENSURE the safe operation, optimum performance and safety of your warranty by using only genuine manufacturer’s replacement parts. SWITCH OFF battery disconnect switch and DISCONNECT the battery cables when working on the electrical system or when welding on the compactor. BE SURE the battery area is well ventilated (clear of fumes) should it be necessary to connect a jump battery. Fumes from the battery can ignite by a spark and explode. BE SURE the battery charger is “Off” when making the connections if battery charging is required. USE only original fuses with the specified current rating. Switch off the machine immediately if trouble occurs in the electrical system. WORK on the electrical system or equipment may only be carried out by a skilled electrician or by specially instructed personnel under the control and supervision of an electrician and in accordance with the applicable electrical engineering. CUT off the power supply to parts of the machine on which inspection, maintenance and repair work is to be carried out. CHECK the de-energized parts for the presence of power and ground or short circuit them in addition to insulating adjacent live parts and elements before starting work. Safety when servicing 91 INSPECT the electrical equipment of machines at regular intervals. Defects such as loose connections or scorched cables must be rectified immediately. DO NOT weld, flame cut or perform any grinding operations on the machine unless expressly authorized as there may be a risk of explosion and fire. CLEAN the machine and its surroundings from dust and other flammable substances and make sure that the premises are adequately ventilated (risk of explosion) before beginning welding, flame cutting and grinding operations. INSPECT hydraulic hoses at regular intervals and immediately replace if they show signs of chafing, cracking, brittleness, deformation, blistering, leakage, fitting separation, corrosion or other damage which may affect their function or strength. DO NOT work on hydraulic lines while the engine is running and the system is under pressure. The hydraulic fluid remains pressurized long after the engine has stopped. DO NOT work on any hydraulic hose or fitting until the pressure has been properly relieved. WAIT for fluid to cool down before disconnecting. Hot hydraulic fluid will cause severe burns. NEVER use your hands to check for leaks when inspecting an hydraulic system. Use a piece of cardboard and always wear gloves and safety glasses. GET immediate attention if fluid has been injected under your skin. Fluid penetration from a pin hole leak can cause severe injury or death. ENSURE hydraulic lines are laid and fitted properly. Ensure that no connections are interchanged. The fittings, lengths and quality of the hoses must comply with the technical requirements. OBSERVE the product related safety regulations when handling oil, grease and other chemical substances. Be careful when handling hot conscionable items. (risk of burning or scalding). Safety when handling oil and fuel When changing oil in the engine or hydraulic system, remember that the oil may be hot and can cause scalding or burn injuries. Engine and hydraulic oils, as well as diesel fuel, have a corrosive effect on mucous membranes (i.e. eyes, throat and on skin). Take special care to keep oils away from these sensitive body parts. Oils and fuels are hazardous to the environment. Take special care not to spill or discharge these fluids. Use approved containers and methods to handle and dispose of machine fluids. Use an authorized disposal and recycling company. Be aware of the risk of fire. Safety when servicing 92 Service position Service position Service position CAUTION Before starting any work, park the machine on a level surface and prepare it for service by putting it into service position according to Safety rules for service. NOTICE Refer to all applicable safety information, as well as the service & maintenance sections in the Operator's and Service Manual, before opening up the machine areas to conduct any maintenance or repairs to the machine. CAUTION Maintain greatest possible cleanliness. NOTICE It is important to maintain the greatest possible cleanliness in the work area and make sure that the machine is properly cleaned before carrying out service and maintenance procedures. The service technician must take the necessary precautions to prevent dirt and debris from entering sensitive areas of the machine, which could cause damage to expensive machine systems and components. For cleaning prior to repair, See page No. 116. Safety when servicing Service position 9 10 1 6 5 2 93 8 4 3 7 7 V1101141 Service position 1 Bring the propulsion control lever to STOP position. 2 Apply parking brake. 3 Bring the engine throttle lever to low rpm position. 4 Install the articulation lock pin. 5 Shut down engine, remove and retain the ignition key. 6 Attach warning tag to steering wheel. 7 Block the wheels and drum. 8 Allow hydraulic pressure to drop (as required). 9 Turn battery disconnect switch to OFF position. 10 Allow the engine to cool down. Service Position 1 Move the machine on a level and a stable surface. Bring the propulsion control lever to STOP position. 2 Apply the parking brake. NOTICE Indicator light on the parking brake switch glows. 3 Bring the engine throttle lever to low rpm position. 4 Place the articulation lock pin from the stowed to the articulation lock position. While seated on the operator seat, turn the steering wheel slowly until the articulation lock pin drops in place and is fully engaged with swivel frame. 5 Shut down the engine. Remove and retain the ignition key. Safety when servicing 94 Service position 6 Attach a warning tag to the steering wheel that the machine is out of service. NOTICE Follow all local regulations concerning lockout or tag-out procedures. WARNING Block the wheels to prevent accidental machine movement. 7 Block the wheels and drum with appropriate wedges or wheel chocks. 8 Allow hydraulic oil pressures to drop, before working on the hydraulic system. See page No. 174. NOTICE Hydraulic pumps and hoses will retain pressurized oil, when brake is being held in the released position. 9 Disconnect battery power by turning the battery disconnect switch to the OFF position or remove the ground terminals and cover exposed terminals before working on the machine's electrical system. See page No. 144. NOTICE Certain troubleshooting procedures and system tests will require that battery terminals remain connected. 10 Allow the engine to cool. WARNING If work must be done on the machine before it has cooled down; beware of hot fluids and hot components that can cause severe burns. NOTICE Changing of engine oil, Axle housing oil, Axle wheel end oil, Transmission oil, Drum eccentric oil, Drum carrier oil and Torque hub oil require the machine oil to be at operating temperature. Safety when servicing Before service, read 95 Before service, read Before service, read Prevent personal injuries Read the instructions in the Operator's Manual before starting to work on the machine. It is also important to read and follow the information and instructions on plates and decals. Do not wear loose-fitting clothes or jewellery that may get caught and cause injuries. Always use a hard hat, eye protection (safety glasses), gloves and protective work footwear when required by the job. Make sure that the ventilation is adequate if you are going to start the engine indoors. Do not stand in front of or behind the machine while the engine is running. Turn off the engine before removing any protective covers or opening any engine hoods. Accumulated pressure remains in the system even when the engine has been turned off. If a system is opened without first depressurizing it, high-pressure fluid may jet out. Use a piece of paper or cardboard when checking for leaks, never your hands. Make sure that stepping surfaces, handholds, and slip protected surfaces are free from oil, diesel fuel, dirt, and ice. Only step on parts of the machine that are provided with slip protection. It is important to use the right tools and the right equipment. Defective tools or equipment must be repaired or replaced. If service work has to be done under a raised attachment, it must first be secured. Engage the control lockout and apply the parking brake, if installed on the machine. Prevent machine damage Use equipment with sufficient lifting capacity if the machine or parts of it are to be lifted or supported. Volvo CE will not accept any responsibility if other lifting devices, tools, work methods, lubricants, and parts are used other than those described in this Operator's Manual. Make sure that no tools or other objects that may cause damage have been forgotten in or on the machine. Release the pressure in the hydraulic system before beginning service work. Machines used in environmentally contaminated or health hazardous areas must be equipped for such operations. As well, special safety rules apply for service work on such machines. Actions in connection with electric welding, See page NO. 146 Make sure that all protective plates, covers, and hoods on the machine are in place before starting the engine and operating the machine. Use the three-point contact while claiming the machine. Prevent environmental influence Be conscious of the environment when carrying out service and maintenance. Oil and other liquids dangerous to the environment Safety when servicing 96 Before service, read and released into the environment will cause damage. Oil degrades very slowly in water and sediment. One litre of oil can destroy millions of litres of drinking water. NOTICE In common for all points below is that all waste is to be handed over to a treatment and disposal firm approved by the authorities. When draining, oils and liquids must be collected in suitable vessels and steps taken to avoid spillage. vessels and steps taken to avoid spillage. Used filters must be drained of all liquid before they are passed on as waste. Used filters from machines which work in environments with asbestos or other dangerous dust, must be placed in the bag supplied with the new filter. Batteries contain substances dangerous to the environment and health. Used batteries must therefore be handled as waste dangerous to the environment. Consumables, e.g. used rags, gloves and bottles may also be contaminated with oils and liquids dangerous to the environment and must in that case be treated as waste dangerous to the environment. Safety when servicing Maintenance Before you begin any service work on the machine: Service work which is not carried out in the correct way is dangerous. All service work should be carried out by a qualified technician who is having sufficient knowledge of the machine, and trained to use the proper tools and equipment to carry out the service task in a correct way. WARNING During service, hearing protection and safety goggles must be used. NOTICE No work must be carried out on the machine until you have acquired the appropriate knowledge to do so. In any work concerning the operation, conversion or adjustment of the machine and its safety oriented devices or any work related to maintenance, inspection and repair, always observe the start up and shutdown procedures set out in the operating instructions and the information on maintenance work. ENSURE that the maintenance area is adequately secured. If the machine is completely shut down for maintenance and repair work, it must be placed in the service position, See page No. 92 and secured against inadvertent starting by: Locking the principal control elements and removing the ignition key Attaching a warning sign to the ignition or main switch Safety when servicing Before service, read 97 CARRY OUT maintenance and repair work only if the machine is positioned on stable and level ground and has been secured against inadvertent movement and buckling. LIFTING THE UNIT - When raising the unit off the ground, apply the parking brake. Attach the lifting apparatus only to the unit’s designated lifting points using properly rated lifting straps, cables, or chains. Use spreader bars to ensure equal weight distribution during lifting as well as avoid contact with the unit. For Safety, when lifting and supporting the machine, See page No. 99. USE CARE when attaching and securing lifting tackle to individual parts and large assemblies being moved for replacement purposes to avoid the risk of accidents. USE lifting gear that is in perfect condition and with adequate lifting capacity. NEVER work or stand under suspended loads. ALWAYS USE the correct tools and workshop equipment when performing maintenance on the machine. ALWAYS USE specially designed or otherwise safety oriented ladders and working platforms when doing overhead assembly work. Never use machine parts as a climbing aid. KEEP all handles, steps, handrails, platforms, landings and ladders free from mud, dirt, snow and ice. CLEAN the machine, especially connections and threaded unions, of any traces of oil, fuel or preservatives before carrying out maintenance/repair. NEVER use aggressive detergents. Use lint free cleaning rags. COVER OR TAPE all openings, for safety and functional reasons - must be protected against water, steam or detergent penetration before cleaning the machine with water, steam jet (high pressure cleaning) or detergents. Special care must be taken with electric equipments. ENSURE during cleaning of the machine that temperature sensors do not come into contact with hot cleaning agents. REMOVE all covers and tapes applied for that purpose after cleaning machine. EXAMINE all fuel, lubricant, and hydraulic fluid lines for leaks, loose connections, cut marks and damage after cleaning. REPAIR or REPLACE defective parts immediately. TIGHTEN any screwed connections that have been loosened during maintenance and repair. REPLACE any safety devices removed for setup, maintenance or repair purposes and checked immediately upon completion of the maintenance and repair work. ENSURE that all consumable and replaced parts are disposed safely and with minimum environmental impact. AVOID, whenever possible, servicing, cleaning, or examining the machine with the engine running. AVOID, whenever possible, servicing or providing maintenance to the compactor unless the drum and wheels are adequately chocked, the articulation lock bar/lock pin is in the locked position, and parking brake is applied. WARNING All forms of open fire and smoking should be avoided when filling the fuel tank. DON'T fill the fuel tank with the engine running, while near an open flame, or while smoking. ALWAYS wipe up any spilled fuel. Safety when servicing 98 Before service, read DO NOT alter the engine governor settings from those indicated in the engine manual. ALWAYS replace damaged or lost decals. Refer to the parts manual for the proper location and part number for all decals. ENSURE the safe operation, optimum performance and safety of your warranty by using only genuine manufacturer’s replacement parts. SWITCH OFF battery disconnect switch and DISCONNECT the battery cables when working on the electrical system or when welding on the compactor. BE SURE the battery area is well ventilated (clear of fumes) should it be necessary to connect a jump battery. Fumes from the battery can ignite by a spark and explode. BE SURE the battery charger is “Off” when making the connections if battery charging is required. USE only original fuses with the specified current rating. Switch off the machine immediately if trouble occurs in the electrical system. WORK on the electrical system or equipment may only be carried out by a skilled electrician or by specially instructed personnel under the control and supervision of an electrician and in accordance with the applicable electrical engineering. CUT off the power supply to parts of the machine on which inspection, maintenance and repair work is to be carried out. CHECK the de-energized parts for the presence of power and ground or short circuit them in addition to insulating adjacent live parts and elements before starting work. INSPECT the electrical equipment of machines at regular intervals. Defects such as loose connections or scorched cables must be rectified immediately. DO NOT weld, flame cut or perform any grinding operations on the machine unless expressly authorized as there may be a risk of explosion and fire. CLEAN the machine and its surroundings from dust and other flammable substances and make sure that the premises are adequately ventilated (risk of explosion) before beginning welding, flame cutting and grinding operations. INSPECT hydraulic hoses at regular intervals and immediately replace if they show signs of chafing, cracking, brittleness, deformation, blistering, leakage, fitting separation, corrosion or other damage which may affect their function or strength. DO NOT work on hydraulic lines while the engine is running and the system is under pressure. The hydraulic fluid remains pressurized long after the engine has stopped. DO NOT work on any hydraulic hose or fitting until the pressure has been properly relieved. WAIT for fluid to cool down before disconnecting. Hot hydraulic fluid will cause severe burns. NEVER use your hands to check for leaks when inspecting an hydraulic system. Use a piece of cardboard and always wear gloves and safety glasses. GET immediate attention if fluid has been injected under your skin. Fluid penetration from a pin hole leak can cause severe injury or death. ENSURE hydraulic lines are laid and fitted properly. Ensure that no connections are interchanged. The fittings, lengths and quality of the hoses must comply with the technical requirements. OBSERVE the product related safety regulations when handling oil, grease and other chemical substances. Safety when servicing Before service, read 99 Be careful when handling hot conscionable items. (risk of burning or scalding). Safety when lifting and supporting complete machine Place the machine in service position, see page No. 92 WARNING Only use lifting devices with adequate capacity. WARNING Do not work under a hanging or suspended load! Use only lifting devices with sufficient capacity to safely support the expected weight you are lifting. All lifting devices (straps, slings, chains, ratchet blocks, etc.) must comply with applicable regulations and certifications. We can accept no responsibility for the use of sub-standard equipment and work practices. If you use a jack, the floor or ground must be even and of sufficient strength to support the expected load. Use the lifting eyes or lifting points that are located on certain points of the machine. See page No. 81 WARNING Never work under/on machines without using recommended support equipment. Lifting and supporting rear axle. Use a suitable lifting device or jack with proper rated capacity for the job to raise the machine as required for wheel removal. NOTICE The machine must be lowered from the jack onto an appropriate stand before the wheel is removed. Do not use the jack to support the weight of the machine when removing the wheel. Secure the machine with a stand under the end of the axle on the side that the wheel is to be removed. Secure the machine under the frame if the axle is to be removed. Make sure it is positioned correctly and has safe ground support for the expected load. NOTICE Never position jacks or stands under the fuel tank or engine. Lift the front frame at appropriate lifting points. Place support stands under the frame, before removing the drum or when separating the machine to work on the articulation frame joint and pivot pins. Safety when servicing 100 Before service, read Front frame support, (drum installed) Support the front drum frame with appropriate stands on both sides of the frame when working on the drum components with the drum installed, (such as replacing shock mounts, or drum vibration or drive motors). When lifting the front drum frame use appropriated lifting device with proper rated capacity. Front frame support, (drum removed) Use a suitable lifting device with proper rated capacity to support the front drum frame when the drum is removed from the machine, or when separating the machine, (i.e. for replacing articulation or oscillation pins). Some simple rules regarding tyre handling TYRE INFLATION - Check the unit tyre pressure when cold and inflate to the recommended pressure. Remove the wheel from the unit whenever pressure is below 80% of the recommended pressure. Place the tyre in a cage and inflate using a clip-on air check and remove tyre pressure gauge. Do not overinflate; otherwise the tyre may explode causing severe injury or death. Inflating Never stand to the side of the tyre while inflating. Use a selflocking outlet with a hose long enough to allow you to stand outside of the hazard zone during inflation, see the illustration. Make sure that the hazard zone is clear when the tyre is inflated. The machine must be unladen when checking tyre pressure. Tyres and rims suspected of being damaged should not be inflated with the wheel attached to the machine. Fitting of tyres and rims V1021831 Never stand to the side of the tyre while inflating Handling of tyres should be performed by authorised personnel only. The tyre should be deflated before removal from the machine. Never install a tyre on a rim that has not been recommended for that tyre. Use a lubricant recommended by the tyre manufacturer when fitting onto the rim. Repairing tyres and rims Never cut, weld nor heat the wheel parts in any manner. Exercise caution when using bead breakers and hydraulic jacks. Remain outside the hazard zone when removing foreign objects from the tyres. A bead breaker that releases can cause severe personal injury and may result in death. Safety when servicing Before service, read 101 Working in environmentally contaminated areas Machines that are used in environmentally contaminated and/or health-hazardous areas shall be specially equipped for operation in such an environment. Used engine air filters from machines working in environments with asbestos or other hazardous dust shall be put into tightsealing plastic bags that the new filters come in, then leave the used filters for destruction. Environmental handling for the future V1032979 The world stands before gigantic challenges on environmental matters where clean water, climate change, and use of chemicals are some of the most important issues. Volvo has an important function in meeting these challenges and contributing to a more ecologically sustainable development. Quality, safety and environment are Volvo core values and have for a long time been integral parts of our company and our products. Volvo Construction Equipment works with continuous improvement of the machines' environmental performance. An important factor to retain the machine's performance is the service offered by the workshops. This service manual contains recommendations, warning texts, etc. to facilitate your work for the environment. Safety when servicing 102 Preparations before service Preparations before service Articulation hinge The articulation lock is used to prevent accidental articulation of the machine. The articulation lock pin must be in the locked position prior to shipment and before performing any checks or service operations. Place the articulation lock pin in the stowed position for compaction operations. Safety when servicing Entering, leaving and climbing the machine 103 Entering, leaving and climbing the machine Entering, leaving and climbing the machine WARNING For safety, observe the following rules. Three point contact. Do not jump on/off a machine, especially never get on / off when the machine moves. Never grasp the control lever to get on / off. Use hand holds and steps when entering, leaving or climbing the machine. Use the three-point grip, that is two hands and one foot or two feet and one hand. Always face the machine. Always wipe mud and oil off all footboards, handrails and your footwear, rear view mirrors and lights. Clean your boots and wipe your hands before getting on the machine. Safety when servicing 104 Fire prevention Fire prevention WARNING Using the machine in environments with high risk of fire or explosion requires special training and equipment. There is always a risk of fire. Find out what kind of fire extinguisher is used on your working site and how to use it. If the machine is equipped with a fire extinguisher, it should be kept near the operator’s seat on the left side of the operator. Fire prevention measures Do not smoke or have an open flame near a machine when filling with fuel or when the fuel system is opened and in contact with the surrounding air. Diesel fuel oil is flammable and must not be used for cleaning. Use conventional car care products meant for cleaning or degreasing. Also bear in mind that certain solvents can cause skin rashes, damage to the paint finish and constitute fire hazard. Keep the place clean where the service is to be carried out. Oil and water can make the floor slippery and is also dangerous in connection with electrical equipment or electrically powered tools. Oily and greasy clothes are a serious fire hazard. Check daily that the machine and the equipment, for example underbelly plates are free from dust and oil. Besides reducing the risk of fire, it is also easier to detect faulty or loose components. NOTICE Take great care if a high-pressure wash is used for cleaning. Electrical components and electrical leads can be damaged even at a moderately high pressure and temperature. Protect electrical leads in an appropriate way. Take extra care when cleaning a machine working in a firesensitive environment, for example saw-mill and refuse dumps. The risk of spontaneous combustion can be further reduced by installing insulation of the silencer guard. It is important that the fire extinguisher is maintained in order to work when it is needed. Safety when servicing Fire prevention 105 Check that fuel lines, hydraulic and brake hoses and electrical cables have not been damaged by chafing or are not in danger of being damaged in that way because of incorrect installation or clamping. This applies particularly to unfused cables, which are red and marked R (B+) and routed: - between the batteries - between battery and starter motor - between alternator and starter motor Electrical cables must not lie directly against oil or fuel lines. Do not weld or grind on components which are filled with flammable liquids, for example tanks and hydraulic pipes. Exercise care with such work also in the proximity of such places. A fire extinguisher should be kept near to hand. Actions in case of fire If the circumstances permit and your own safety is not jeopardised, take the following steps at the slightest sign of fire: 1 Stop the machine, if the machine is in motion. 2 Move the propulsion control lever to stop position. 3 Turn the ignition key to stop position. 4 Exit the from the machine. 5 Call the fire brigade. 6 Turn off the battery disconnect switch. 7 Attempt to put out the fire, if possible. Otherwise, move away from the machine and out of the danger zone. Actions after fire When handling a machine which has been damaged by fire or been exposed to intense heat, the following protective measures must be followed: Use thick, protective gloves made of rubber and wear goggles. Never touch burnt components with your bare hands in order to avoid contact with melted polymer materials. First wash thoroughly with plenty of lime water (a solution consisting of calcium hydroxide, that is slaked lime in water). Handling heated fluoro-carbon rubber, see page No.109. Safety when servicing 106 Fire prevention Fire prevention measures General There may always be a risk of fire. Learn the correct type of fire extinguisher to use, how to use it, and where it is kept,if the machine is equipped. If the machine is provided with a hand-held fire extinguisher, it should meet local requirements. Any on-board fire extinguisher must be kept fully charged and in good working order at all times. 1017936 Fire extinguisher Do not smoke when refuelling or expose diesel fuel to open flames Any on-board fire fighting equipment should be considered as a complement to the operator's own fire fighting efforts. It is not a replacement. Never expose diesel fuel to open flame or smoking materials, especially when refuelling or the fuel system is open to the air. Never use diesel fuel as a cleaner, use an approved cleaning solvent. Certain solvents are usually flammable and can cause skin rashes or other conditions. Do not inhale solvent vapours. Never use engine starting aids, especially if the machine is equipped with an automatic preheating intake air system. Ensure the machine is properly equipped for working in dry or forested areas. Equipment such as a spark arrester may be required. At the first sign of a fire, take the following actions if the situation will safely permit: - Drive the machine away from the danger area. - Shut down the engine with the ignition key switch. - Leave the operator platform quickly and safely. - Turn the battery disconnect switch off. - Begin extinguishing the fire and call for assistance if required. Cleanliness Cleanliness is important to effective machine service. Contamination introduced to machine systems can shorten component service life and cause the machine to malfunction. Keep the service area clean. Oil or water on the floor can create a dangerous work environment, increasing the risk of falls and electrocution. Oily and greasy clothing and shop rags are a fire hazard. Safety when servicing Fire prevention 107 The machine should be inspected daily for the build-up of flammable debris. This will reduce the chance of a fire, and will make it easier to detect loose or leaking parts. CAUTION If a high-pressure washer is used when cleaning, work carefully since damage may be caused to electrical components and insulation of the electrical cabling even at relatively moderate water pressure and temperature. Protect electrical cabling in a suitable manner. Take special care to keep machines clean in applications such as coal mines where the risk of fire is greatest. In such applications, suitable equipment to reduce the risk of fire should be installed and maintained. Electrical system Inspect wiring for chafing, breakage, and any routing condition that could expose wiring to damage. This is especially important for positive electrical wires that could make contact with the frame (ground). Pay special attention to the cables between the batteries, from the batteries to the starter, and between the alternator and starter. When reconnecting wires, it is important to connect, route and secure them so they are protected from damage and wear. They must not be routed in contact with fuel or oil hoses. If any auxiliary electrical equipment is installed on the machine, wiring must be fused, connected and routed to avoid exposure to wear or damage. Fuel, hydraulic and brake systems Check to make sure fuel, hydraulic and brake hoses are not worn or damaged, and are routed to avoid rubbing. Welding and grinding work CAUTION A fire extinguisher should be easily accessible during all welding work. Move the machine to a clean, safe area before welding, grinding or using an oxy/acetylene torch on it. This type of work should only be done in a clean area and not in places that contain combustible liquids, such as fuel tanks, hydraulic pipes or similar. Work with extra care when welding, grinding or torch cutting near flammable objects. Welding on painted surfaces releases dangerous fumes, and results in a poor weld joint, that can result in failure and potential accidents. Always remove paint from areas to be welded. See also Check list after fire or heat exposure As a precaution, all o-rings and seals should be handled as if they were made of fluor rubber. See page No.112. Safety when servicing 108 Fire prevention WARNING Avoid splashing when washing a machine damaged by fire. For this reason, never use high-pressure washing equipment. Never touch burnt components or parts with your bare hands when there is a risk that you may be exposed to contact with burnt fluor rubber. See page No.112. Wear thick, protective neoprene gloves, goggles, and approved respirator. First, wash thoroughly with plenty of lime water (a solution or a suspension of calcium hydroxide, i.e. slaked lime). Seek medical attention if skin contact with burnt fluor rubber is suspected. The affected skin should be treated with Hydrofluoric Acid Burn Jelly or similar. Symptoms may not appear until several hours after contact with burnt fluor rubber. Wash with lime water, then discard protective gloves, rags and other items that may have contacted burnt fluor rubber. Safety when servicing Handling hazardous materials 109 Handling hazardous materials Heated paint WARNING Heating of painted surfaces, rubber or plastics parts may cause the formation of substances dangerous to health or environment. Take care when, for example, welding, grinding or gas cutting. Wear protective equipment. Heated paint gives off poisonous gases. Therefore, paint must be removed from an area with a radius of at least 10 cm (4 in) before carrying out welding, grinding or gas cutting. In addition to the health hazard, the weld will be of inferior quality and strength, which, in the future, may cause the weld to break. Methods and precautionary measures when removing paint Blasting - use respiratory protective equipment and protective goggles Paint remover or other chemicals - use a portable air extractor, respiratory protective equipment and protective gloves Grinding machine - use a portable air extractor, respiratory protective equipment and protective gloves and goggles Never burn painted parts after they have been discarded. They should be disposed of by a licensed disposal plant. Heated rubber and plastics Polymer materials can, when heated, form compounds which are dangerous to health and environment and must therefore never be burned when scrapped. If gas cutting or welding is to be carried out near such materials, the following safety instructions must be followed: - Protect the material from heat. - Use protective gloves, protective goggles and respiratory protective equipment. Safety when servicing 110 Handling hazardous materials Heated fluoro-carbon rubber WARNING Seals that can withstand high temperatures may be made of fluoro-carbon rubber. At very high temperatures fluoro-carbon rubber forms substances, which are very corrosive to skin and lungs. Wear protective equipment. When handling a machine which has been damaged by fire or been exposed to intense heat, the following measures should be taken: Use thick, rubber gloves and wear protective goggles. Discard gloves, rags and other items that have been in contact with heated fluoro-carbon rubber after first having washed these items in lime water (a solution of calcium hydroxide, that is slaked lime in water). The area around a part which has been very hot and which may be made of fluoro-carbon rubber should be decontaminated by thorough and ample washing with lime water. As a precaution, all seals (O-rings and other oil seals) should be handled as if they were made of fluoro-carbon rubber. The hydrofluoric acid may remain on the machine parts for several years after a fire. If swelling, redness or a stinging feeling appears and one suspects that the cause may be contact with heated fluorocarbon rubber, contact a medical doctor immediately. Several hours may pass, however, before any symptoms appear and there is no immediate warning. The acid cannot be rinsed or washed off from the skin. Treat instead with Hydrofluoric Acid Burn Jelly or similar before contacting a medical doctor. Batteries WARNING Handling batteries may lead to that electrolyte comes into contact with eyes, skin or clothes. Wear protective equipment. Electrolyte splashes in eyes must be rinsed off with water immediately. Electrolyte on skin must be washed off with soap and water immediately. Seek medical advice. Batteries develop explosive gases. Therefore, do not smoke and avoid naked flames and sparks when working in the vinicity of batteries. Make sure that metal objects such as tools, rings and wrist watches do not come into contact with the battery terminals. Ensure that the caps are always mounted on the battery terminals. Do not tilt batteries as otherwise the battery acid may escape. Discharged batteries must never be connected to fully charged batteries. Danger of explosion. Keep the battery surface clean and dry. Immediately wash any leaked battery acid with soda dissolved in water. Batteries contain materials that are damaging to health and the environment. The batteries must therefore be disposed of in accordance with the applicable national regulations. Safety when servicing Handling hazardous materials 111 When dismantling a battery, the mass cable must be disconnected first and, for installation, the last to be connected in order to prevent the formation of sparks. Used batteries must be disposed of in accordance with the applicable national regulations. Disconnect the batteries from the machine before loading them from an external source. For the charging of batteries, see page 150. For starting using auxiliary batteries, see page Starting with booster battery. Environmentally safe handling Always choose an environmentally friendly alternative where one is available, e.g., biodegradable oils. Always follow national and local environmental regulations. All waste shall be brought to a waste handling company, approved by the authorities. Oils and fluids Oils and fluids, e.g., coolant, that are not reused shall be collected in tight-sealing containers and left for destruction. Filters Oil and fuel filters shall be drained and put into sealed containers before they are left for destruction. Batteries WARNING Risk of serious corrosive injuries! Batteries contain environmentally hazardous substances and corrosive acid. Shall be left for recycling. Corrosive acid V1033092 Chemicals Chemicals, paints, glue, cleaning agents, etc. shall be left for recycling and destruction. Rubber and plastics Rubber materials and plastics may not be burned. Shall be left for recycling. Tyres shall be handled according to special rules. Safety when servicing 112 Handling hazardous materials Electronics Electrical and electronic waste, e.g., circuit boards and bulbs, shall be left for recycling. Waste handling Contribute to careful use of natural resources by following the steps below when handling waste. If possible, deposit the waste for recycling. REUSE of products is the best from an environmental aspect. MATERIAL RECYCLING for use in new products is a good environmental alternative. ENERGY RECOVERY by burning combustible materials is a good alternative when recycling is not possible. DESTRUCTION is used for hazardous waste. Destruction is performed in special facilities. DEPOSITION is the worst from an environmental aspect and should be avoided as much as possible. STORAGE is a temporary measure until a suitable recycling method has been developed. Health hazards with paint, plastics and rubber Work on painted surfaces Never weld or cut with a torch on painted surfaces. All paint decomposes, when heated and generates a vast number of different substances, that may be irritating and, in case of repeated exposure, be very hazardous to health. The following safety actions shall be followed: Remove the paint by sandblasting at least 10 cm (4 in) around the welding or cutting point (use breathing mask). If the paint cannot be removed by sandblasting, then remove the paint in another way, e.g., with paint solvent/remover. NOTICE When using paint remover/solvent, use air extraction, breathing protection and protective work gloves. Grinding machines with high-speed grinding discs also heat the paint and may only be used if there is an air extractor on the grinder. Use breathing protection as well. Safety when servicing Handling hazardous materials 113 Rubber and plastics WARNING When heated, rubber and plastics can give off substances that are hazardous to personal health and the environment. The following safety instructions shall be followed: Do not weld or cut with a torch near polymer materials (plastics and rubber) without first protecting them from the heat. Never burn polymer materials when scrapping them. Be careful when handling machines that have been exposed to fire or other intense heat. See page No.107. Always use gloves, protective safety glasses and breathing protection. Fluor rubber WARNING Risk of serious corrosive injuries! WARNING When hydrogen fluoride rubber is heated, there is a risk of hydrogen fluoride gas build-up already at approx. 320 °C (610 °F). When inhaled, the gas is extremely corrosive to respiratory tracts. Certain seals designed to withstand high operating temperatures (e.g., in engines, transmissions, axles, brakes, hydraulic motors and pumps) may be made of fluor rubber which, when heated to high temperatures, generate hydrogen fluoride and hydrofluoric acid. Hydrofluoric acid is highly acidic and corrosive. It cannot be rinsed or washed off the skin and causes very severe burn and corrosive injuries that take a very long time to heal. As a rule, injured tissue must be removed surgically. Hydrofluoric acid may remain on machine parts for a very long time (several years) after a fire. NOTICE In case of contact with hydrofluoric acid, it may take several hours before any symptoms appear. If swelling, redness or burning sensations appear and contact with heated fluor rubber is suspected to be the cause, seek immediate medical attention. If a machine or a component for a machine has been exposed to fire or other intense heat it shall be handled by specially trained personnel. For all handling of machines after a fire, use heavy-duty gloves made of neoprene rubber and effective safety goggles. Safety when servicing 114 Handling hazardous materials WARNING Burning of painted parts, plastic or rubber parts constitutes a health hazard. See page 111 for environmentally safe handling. Decontamination The area around a heated part that is suspected to be made of fluor rubber shall be decontaminated by thorough and ample washing with lime water ( a solution or suspension of calcium hydroxide, that is, slaked lime) in water. After completing the decontamination work, wash the gloves in the lime water and then discard them. If the machine has been exposed to a fire or other intense heat, the safety actions in the following checklist shall be followed unconditionally at all times, See page 107. Asbestos information The components in Volvo CE's machines are free from asbestos, that is why it is important to use genuine Volvo spare parts. Safety when handling oil and fuel When changing oil in the engine or hydraulic system, remember that the oil may be hot and can cause scalding or burn injuries. Engine and hydraulic oils, as well as diesel fuel, have a corrosive effect on mucous membranes (i.e. eyes, throat and on skin). Take special care to keep oils away from these sensitive body parts. Oils and fuels are hazardous to the environment. Take special care not to spill or discharge these fluids. Use approved containers and methods to handle and dispose of machine fluids. Use an authorized disposal and recycling company. See page No.101 for environmental handling for the future. Be aware of the risk of fire. Safety when servicing Handling line, tubes and hoses 115 Handling line, tubes and hoses WARNING If oil or fuel leaks from high pressure hoses or loose screws is found, stop operations immediately and contact an authorized Volvo dealer workshop. Do not bend high pressure lines. Do not strike high pressure lines. Do not install any lines that are bent or damaged. Check lines, tubes and hoses carefully. Do not reuse hose, tube and fittings. Do not use your bare hand to check for leaks. Tighten all connections. Consult your Volvo CE dealer for the recommended tightening torque. If any of the following conditions are found, replace the parts. Consult your Volvo CE dealer. End fittings are damaged or leaking. Outer coverings are chafed or cut. Strengthening wires are exposed. Outer coverings are ballooning. Flexible part of the hoses are kinked. End fittings are displaced. Foreign material is embedded in the coverings. CAUTION Make sure that all clamps, guards and heat shields are correctly installed. This contributes to preventing vibrations, chafing against other parts and excessively strong generation of heat. Service and maintenance 116 Service and maintenance Service history After each completed service at a workshop authorised by Volvo CE, the service history should be filled in, see page 208. Service history is a valuable document, which can be referred to when for example selling the machine. Cleaning prior to repair The machine should be cleaned regularly with conventional car care products in order to eliminate the risk of damage to the paint finish and other surfaces on the machine. Cleaning the machine prior to conducting repairs is especially important in order to reduce the risk of contaminants from entering sensitive areas of the machine. Dust, dirt and other debris entering into the fuel, lubrication, cooling and hydraulic systems can cause premature wear, corrosion, blockages and overheating, which will damage expensive machine components and cause machine systems to fail. CAUTION Avoid using strong cleaning agents or chemicals in order to minimise the risk of damage to the paint finish. NOTICE Daily clean the areas on the machine where dust, chips and similar may collect in order to minimize the risk of fire. See page 117. Daily cleaning will be required if material is adhering to the drum, or has become jammed between the drum and its scraper. Recommendations for cleaning the machine 1 Park the machine in a place intended for cleaning. 2 Remove any material jammed between the drum and its scraper. 3 Open the air filter access cover and clean the air cleaner evacuator valve and inspect the rubber for cracks. (Replace as required). 4 Install protective covers, barriers or safety cap plugs to protect sensitive components and machine areas from water entry. NOTICE 5 6 7 8 9 Protect all electrical components, control panels and leads in an appropriate way to prevent entry of water or steam when using high pressure cleaning methods. Follow the instructions supplied with the car care product. The water temperature must not exceed 60 °C (140 °F). If high-pressure wash is used, keep a distance of at least 20– 30 cm (8–12 in) between nozzle and machine surface. Excessive pressure and too short a distance may cause damage. Use a soft sponge. Clean the whole machine with water only. Service and maintenance 117 After cleaning: 1 Remove all protective materials (covers, barriers, tape, plastic wrap or safety cap plugs etc.) added for protection against water entry. 2 Always lubricate the machine immediately after washing, especially in the areas that water or contaminants may have entered. These areas include the vertical and horizontal swivel pins and bushings and cylinder pins if the fittings are not plugged with a pipe plug. NOTICE Plugs indicate a maintenance free bearing. 3 After washing, run the engine until it is warm. This will help to dry out engine components and electrical connections. 4 Perform the daily or as required maintenance checks. 5 Touch-up the paint finish when required. Cleaning of engine compartment Machines operating in dusty environment require daily attention and cleaning of the engine compartment and surrounding areas. Cleaning tips Checking and cleaning should preferably be carried out at the end of the working shift, or prior to startup if the machine has been parked for an extended period of time. The machine should be parked in a place intended for cleaning, away from bystanders and other equipment. Place the machine in the service position, see page No.92 (Shut down Engine and switch OFF battery disconnect). Use personal protective equipment such as protective goggles, gloves and respirator. Begin with the highest areas and end with the lowest on top of the fuel tank and areas near the fuel tank. Remove exterior dirt and debris first, then open all covers and hoods to access interior areas for cleaning. Loose material is removed with compressed air. After cleaning, check and rectify any leaks or maintenance issues. Close all covers and hoods, and place the machine back in service. Precaution when working on the electrical system Before working on the electrical system of the machine, carefully read and follow all instructions in the safety section of this service manual. Do not attempt to repair, test or adjust the electrical system unless you are a qualified service electrician. Before carrying out any work involving testing or removal and fitting of components in the electrical system, place the machine in the service position. See page No. 92 and turn the battery disconnect switch to the OFF position. Use only test instruments with light-emitting diode (LED) displays to trace electrical faults. Do not use test equipment Service and maintenance 118 that uses light bulbs. The voltage characteristics of light bulbs can destroy sensitive and expensive electronic components. When installing a two-way radio, mobile telephone and similar equipment, follow the manufacturer's installation instructions in order to eliminate interference with the function of the electronic system and components on the machine. Before any tests are carried out on the alternator, the batteries and electrical leads must be checked for insulation faults, poor contacts or corrosion. Check the alternator belts. Correct any visible faults before beginning electrical checks. During all tests of alternating current equipment, secure connections must be used. One loose lead may damage the alternator. Never disconnect the main lead of the alternator or the lead to it’s field winding while the engine is running. Damage may result. If the current output terminal of the alternator is connected to the mainframes while the engine is running, alternator damage will result. Use only charged batteries to test the electrical system. Before working with the batteries See page No.144. Test the battery acid for specific gravity using a hydrometer. When installing or replacing a battery, make sure that correct polarity is followed. Always disconnect the negative (ground) cable first and reconnect it last. If a booster battery is required for starting the engine, follow the instructions in the Operator’s Manual and See page No.Starting with booster battery. Before welding on the machine or attachments connected to the machine, See page No.146. Cleaning machine CAUTION If a high-pressure washer is used when cleaning, work carefully since damage may be caused to electrical components and insulation of the electrical cabling even at relatively moderate water pressure and temperature. Protect electrical cabling in a suitable manner. Clean the machine regularly with conventional car care products. Avoid using strong cleaning agents or chemicals to minimize the risk of damage to the paint finish and other surfaces on the machine. Clean the machine prior to conducting repairs to reduce the risk of contaminants from entering sensitive areas of the machine. Dust, dirt and other debris entering into the fuel, lubrication, cooling and hydraulic systems can cause premature wear, corrosion, blockages and overheating. This will result in damage Service and maintenance 119 to expensive machine components and cause machine systems to fail. NOTICE Clean the areas daily on the machine where dust, chips and similar may collect in order to minimize the risk of fire. NOTICE Keep all exterior and interior window surfaces clean to ensure proper visibility. Clean any dirt and debris from the seals and sealing surfaces periodically to ensure proper performance. Measures before cleaning the machine 1 Remove any material jammed between the drum and the drum scraper. 2 Check that the air cleaner evacuator check valve on the air cleaner is clean and that rubber is not cracked. Replace as required. Recommendations for cleaning the machine: 1 2 3 4 Place the machine in a place intended for cleaning. Follow the instructions supplied with the car care product. The water temperature must not exceed 60 °C (140 °F). If a high pressure washer is used, keep a distance of at least 20–30 cm (8–12 in) between the nozzle and the machine surface. Excessive pressure and too short a distance may cause damage. Protect electrical leads in an appropriate way. 5 Use a soft sponge. 6 Finish by rinsing the whole machine with water only. Measures after cleaning the machine 1 Remove all material added for protection from water entry during machine washdown. 2 Always lubricate the machine after washing. Grease fittings immediately. Do not grease optional self-lubricating bearings. 3 Check for defects in the air cleaner ducts and correct as required. 4 Check air intake for accumulation of debris that could restrict air flow and clear. 5 Check air cleaner mounting hardware for security and correct as required. 6 Check all hoses for cracks, chafing, or deterioration and replace at the first sign of probable failure. 7 Touch up the paint finish when required. Touch-up painting Clean the machine. Check for faults to the paint finish that may expose bare metal. Carefully repair any faults to the paint finish. Service and maintenance 120 Periodic maintenance NOTICE The following list provides references and links to periodic or “as required” maintenance procedures not covered at the specific hourly intervals listed in the service programme and described in this section of the service manual. For further information on these procedures, See service and maintenance section in this manual or follow the links provided to the appropriate maintenance procedure for the items listed below. As required maintenance 1 Check the air cleaner connections and ducts for leaks. 2 Check/clean the air cleaner primary filter as required when the clog indicator in the shows red or more frequently in extremely dusty conditions. See page No.. 133. 3 Replace the air cleaner primary filter element for every 500 hours, or if damaged or heavily soiled beyond cleaning. See page No. 136. 4 Replace air cleaner secondary (safety) filter element after three primary filter element changes, or if air cleaner elements are damaged or heavily soiled. See page No. 138. NOTICE 5 6 7 8 9 10 Change interval maximum is reached when records indicated that the primary element has been replaced 3 times or 1 year duration has passed since the last replacement. Clean and wash the machine. See page No. 116. Clean the engine compartment See page No. 117. Torque any loose bolted connections. See page No. 202 and 201 . Check the battery disconnect switch. See page No. 145. Inspect the drum shock mounts. See page No.169. Place the machine back in service. Maintenance service, general To prevent minor irregularities from developing into serious conditions, several other services or checks are recommended for the same intervals as the periodic lubrication. The purpose of these services or checks is to ensure the uninterrupted and safe operation of the unit by revealing the need for adjustment caused by normal machine operation and wear. NOTICE Prior to starting any work on the machine, observe the following Warnings and Cautions: Service and maintenance 121 WARNING Always read the booklet Safety before proceeding. WARNING Any person who does not follow the safety instructions and who ignores warnings in this manual must make absolutely sure that their work method is safe. Otherwise, there is a great risk of serious accidents and injuries, perhaps even fatalities. CAUTION Before starting any work, park the machine on a level surface and prepare it for service by putting it into service position according to Safety rules for service. CAUTION Read the environment section in the "Safety" booklet CAUTION Do the work in an environmentally safe manner. Observe the following operational procedures. Do not speed the engine when it is cold. Always chock the wheels when parking the machine. Do not grease the machine while the engine is running. Always perform safety checks prior to starting/using the machine Always operate the machine at full engine speed when compacting or traveling the machine. Never operate the machine across slopes. On machines equipped with a Rollover Protection Structure (ROPS), wear seat belt at all times. Before starting the engine, always check that the propulsion control is in the STOP position and the parking brake is ON . Always sound the horn before moving the machine to alert personnel, and allow sufficient time before putting the machine into motion. Always use protective clothing such as gloves, goggles and safety helmet when performing service maintenance. Service and maintenance 122 Maintenance service, daily Place the machine in service position. See page No. 92. Check the engine oil level. See page No. 126. Drain the water from the water separator. See page No. 131. Check engine coolant level and add if necessary. See page No. 141. Clean the radiator and cooler fins. See page No. 142. Switch on battery disconnect-switch and turn ignition key switch to the ‘ON’ position and check workings of electrical basic components. See page No. 145 Check the air cleaner clog indicator in control console for air filters clogging. Also check the air cleaner system. See page No. 133. Test parking brake using the parking brake test switch. See page No. 163 . Check fuel level on the fuel level gauge. Add if necessary. Check for leakages, physical damage to any machine components. Check condition of the drum and clean it if necessary. See page No. 167. Place the machine back in service. Maintenance service, every 50 hours 1 Place the machine in service position. See page No. 92 . 2 Perform daily maintenance service. See page No. 122. 3 Check the battery electrolytes, cables and terminals. See page No. 151 . 4 Check for air cleaner system integrity. See page No. 133 5 Check the tyre pressure. See page No. 165. 6 Check the wheel nuts torque. See page No. 165. 7 Check the hydraulic oil level. See page No. 175. 8 Check the torque hub oil level. See page No. 167 . 9 Check the drum eccentric oil level. See page No. 168. 10 Lubricate the swivel pins with grease. See page No. 180. 11 Lubricate the steering cylinder pins with grease. See page No 180. 12 Lubricate Shift linkage. See page No. 182 . 13 Clean carrier breather. See page No. 169. 14 Place the machine back in service. Maintenance service, every 100 hours Place the machine in service position. See page No. 92. Perform daily and 50 hours maintenance service. See page No 122 and 122. Check axle housing oil level. See page No. 158 . Check transmission oil level. See page No. 158 and 156. Check wheel end/axle hubs oil level. See page No. 158. Place the machine back in service. Maintenance service, every 250 hours Place the machine in service position. See page No. 92 . Perform the daily, 50 hours and 100 hours maintenance service. 122, 122 and 122 Clean the axle breather. See page No. 161. Service and maintenance 123 Change the engine oil. See page No. 126. NOTICE After engine oil is changed, do not start the engine until the engine oil filter is replaced. Change the engine oil filter. See page No. 128. Change the fuel filters. See page No. 129 Change the water separator. See page No. 131. Change the hydraulic oil filters. See page No. 175. Place the machine back in service. Maintenance service, every 500 hours Place the machine in service position. See page No. 92. Perform the daily, 50 hours, 100 hours and 250 hours maintenance service. See page No. 122, 122, 122 and 122 Check the tension in fan and alternator belt. See page No. 130. Change the engine air cleaner primary element. See page No. 136. Torque the articulation vertical nuts. See page No. 201. Torque the horizontal swivel nut. See page No. 201. Check torque of the axle mounting bolts. See page No. 201. Change the axle transmission oil. See page No. 156. Change the axle housing oil. See page No. 160. Change the axle wheel end/axle hubs oil. See page No. 158. Change drum torque hub oil. See page No. 170. Change the drum carrier oil. See page No. 169. Change the drum eccentric oil. See page No. 172. Test run the machine. Check for the changed oil levels. Place the machine back in service. Maintenance service, every 1000 hours Place the machine in service position. See page No. 92. Perform the daily, 50 hours, 100 hours , 250 hours and 500 hours maintenance service. See page No. 122, 122, 122, 122 and 123 Clean the suction strainers and replace if necessary. See page No. 178. Change the hydraulic oil. See page No. 176. Place the machine back in service. Service and maintenance 124 General inspection of machine General inspection of machine Lap type seat belt, checking and maintenance Ensure that the mounting hardware is tight. Check the seat belt regularly for wear or damage. Inspect the belt hardware and fabric. Replace the seat belt if the hardware is damaged or if the strap is nicked, frayed or loose sticking is found. Seat belt assemblies should be replaced every 3 years regardless of appearance. Seat belt strength degrades over time and use due to exposure to weather, ultraviolet (UV) and abrasives (dirt). Service and maintenance Engine 125 Engine Engine hood, opening and closing To open the engine hood CAUTION Risk of engine hood falling down. Do not operate the machine with a completely or partly open engine hood. Pull down the latches on both sides of the machine to release the hood. WARNING Risk of crushing injuries NOTICE Never reach into the engine compartment or work under a partly raised engine hood supported only by the tension springs. Hold the engine hood at the cutout provided at rear end and raise it completely upward. 1 2 3 Latches Engine hood Cutout To Close the engine hood NOTICE Make sure there are no persons under the engine hood and all tools and equipments are removed from the engine compartment before lowering the engine hood. Pull down the engine hood with help of retractor strap till it sits on the frame. Service and maintenance 126 Engine Hold the engine hood at the cutout and slowly push down until the hood is lowered to the fully closed position. Pull up the latches on both sides of the machine to draw the hood down and press them forward to close the latches and secure the hood. Retractor strap Engine oil level, check CAUTION Always handle oils and other environmentally hazardous fluids in an environmentally safe manner. WARNING Hot liquids and machine parts can cause burns. Allow the machine to cool before beginning any work. Place the machine in service position. See page No.92. Open the engine hood. Remove the dipstick, wipe it with a lint-free dry cloth and insert it back. Remove the dipstick again, check the engine oil level and insert the dipstick back. NOTICE Dipstick The engine oil level must be maintained between the marks on the dipstick. Never overfill the oil level or let it drop below the minimum level. Fill the engine oil if necessary. See page No. for filling instruction in 126. Close the engine hood. Place the machine back in service. Service and maintenance Engine 127 Engine Oil Change CAUTION Always handle oils and other environmentally hazardous fluids in an environmentally safe manner. WARNING Be careful when changing oil since hot oil may cause severe burns to unprotected skin. Draining Place the machine in service position. See page No. 92. Warm up the engine to the normal operating temperature. WARNING Never work under/on machines without using recommended support equipment. Remove the plug. Drain plug Attach a (hose connection) to the drain valve and drain the engine oil in a suitable container. For engine oil quantity See page No . 196. Remove the hose and plug the drain valve. Open the engine hood. For engine hood opening See page No. 125 . Open the engine oil filler cap and fill the engine oil. For oil specification See page No. 194. NOTICE The engine oil level must be maintained between the marks on the dipstick. Never overfill the oil level or let it drop below the minimum level. Close the engine oil filler cap. Clean the spillage, if any. Run the engine at idle rpm for 2 min. Check for the leakage. Check the engine oil level and fill if necessary. NOTICE Engine oil filler cap Allow sufficient time for engine oil to settle down in the sump. Service and maintenance 128 Engine Close the engine hood. For engine hood closing See page No. 125. Filling Place the machine back in service. Engine oil filter, replacing CAUTION Take care of filters, oils and liquids in an environmentally safe way. WARNING Hot liquids and machine parts can cause burns. Allow the machine to cool before beginning any work. Place the machine in service position. See page No. 92. Open the engine hood. For engine hood opening See page No. 125. Place a suitable container to collect the oil while removing the engine oil filter. Disconnect the engine oil pressure switch connection for easy access. Remove the engine oil filter using . Clean the engine oil filter head sealing surface. Apply a thin film of oil to the engine oil filter seal. Fill the engine oil filter with clean engine oil. For engine oil specification See page No. 194. Screw the engine oil filter until its seal touches the sealing surface and tighten further half turn by hand. NOTICE Do not over tighten the filter. 1 2 Engine oil pressure switch Engine oil filter Connect the engine oil pressure switch connection. Clean the spillage if any. Run the engine at idle rpm for 2 min. Check for the leakage. Check the engine oil level. See page No. 126 . Fill oil if necessary. For filling instructions, See page No. 126. NOTICE Allow sufficient time for engine oil to settle down in sump before checking the engine oil level. Close the engine hood. For engine hood closing See page No. 125. Place the machine back in service. Fuel system, bleeding Manual Air Bleeding CAUTION Do the work in an environmentally safe manner. Service and maintenance Engine 129 Use a suitable container, or a plastic hose and absorbent materials to collect and clean up any fuel that escapes during the bleeding procedure. Place the machine in service position. See page 92. Open the engine hood. Loosen the air vent screws of the fuel filters. Air vent screws Prime the fuel system with the plunger provided on water separator until the fuel flows without air bubbles through the fuel filters. Tighten the air vent screws of fuel filters. Pump the fuel some more with plunger pressing for 3–4 times. Start the engine and run it at idle rpm for around 5 minutes. NOTICE Make sure that the system it completely free from air. Plunger on water separator Shut down the engine. Clean the spillage if any. Place the machine back in service. Fuel filter, replacing CAUTION Take care of filters, oils and liquids in an environmentally safe way. WARNING Hot liquids and machine parts can cause burns. Allow the machine to cool before beginning any work. CAUTION Maintain greatest possible cleanliness when working on the fuel system. Place the machine in service position. See page 92. Open the engine hood. Place a suitable container to collect the fuel while removing the filters. Service and maintenance 130 Engine Remove the filters using oil filter wrench. Clean the filter head sealing surfaces. Apply a thin film of oil on to the each filter seal. Screw the filter until its seal touches the sealing surface and tighten further half turn by hand. NOTICE Do not over tighten the filter. Screw the second filter until its seal touches the sealing surface and tighten further half turn by hand. NOTICE Fuel filters location 1 Fuel filters 2 Air vent screws Do not over tighten the filter. Loosen the air vent screws and prime the fuel system. Tighten the air vent screws. Clean the spillage if any. Run the engine at idle rpm for 5 min. Check for the leakage. Close the engine hood. Place the machine back in service. Alternator belt, checking 1 Place the machine in service position. See page No.92 2 Open Engine hood of the machine. See page No.125 3 Check and make sure that the belt is properly aligned on the pulleys. 4 Inspect the drive belt for damage. Transverse (across the belt width) cracks & Longitudinal (direction of the belt length) cracks are not acceptable and the belt must be replaced. 5 Inspect for worn-out areas and if found or a piece of the belt is missing the belt must be replaced. Refer to engine manual for fan belt and alternator belt replacing. 6 Place the machine back in service. Belt 1 Transverse cracks 2 Longitudinal cracks Service and maintenance Fuel system 131 Fuel system Water separator, drain CAUTION Always handle oils and other environmentally hazardous fluids in an environmentally safe manner. Place the machine in service position. See page 92. Open the engine hood. Connect a suitable hose to water separator drain port. Place a suitable container to collect the water. Loosen the drain valve and pump the fuel until water gets drained out. Close the drain valve. Remove the hose. Clean the spillage if any. Close the engine hood. Place the machine back in service. Water separator Water separator, changing CAUTION Take care of filters, oils and liquids in an environmentally safe way. WARNING Hot liquids and machine parts can cause burns. Allow the machine to cool before beginning any work. CAUTION Maintain greatest possible cleanliness when working on the fuel system. Place the machine in service position. See page 92. Open the engine hood. Drain the water from the separator. See page 131. Place a suitable container to collect fuel while removing the fuel water separator. Service and maintenance 132 Fuel system Remove the water separator with the help of oil filter wrench. Clean the water separator head sealing surface. Apply a thin film of oil on the water separator seal. Screw the water separator until its seal touches the sealing surface and tighten further half turn by hand. NOTICE Fuel water separator Do not over tighten the water separator. Loosen the air vent screw and prime the fuel system. Tighten the air vent screw. Clean the spillage if any. Run the engine at idle rpm for 5 min. Check for the leakage. Close the engine hood. Place the machine back in service. Service and maintenance Engine air cleaner 133 Engine air cleaner Engine, air cleaner maintenance Maintenance of the air cleaner is due when the clog indicator glows in the control box. This indicates that the air cleaner is plugged and requires attention. CAUTION The air filter maintenance intervals depend on the amount of dust in the air and can therefore not be determined precisely. Under extremely dusty conditions daily cleaning may be required. The air cleaner is a dry type with two filter elements. A primary filter element, which is replaceable or can be cleaned, and a secondary (safety) filter element that should only be replaced and do not be cleaned. The secondary (safety) filter element should be replaced after every third primary filter element change. See page No. 133 for primary filter cleaning. See page No. 136 for Air cleaner primary filter replacement. See page No. 138 for Air cleaner secondary filter replacement. Air cleaner system, checking Place machine in the service position. See page No. 92 . Open the engine hood. For engine hood opening. See page No 125. Check the connections between air cleaner and the engine, make sure all clamps are tight and secure. Check the air cleaner hoses for cracks, bulges or other damage. Check air cleaner clog indicator on the control box. If air cleaner is clogged, clean the air cleaner primary filter. See page No. 133 . Close the engine hood. For engine hood closing. See page No. 125. Place back the machine in service. Air cleaner primary filter, cleaning Maintenance of the air cleaner is due only when the air cleaner clog indicator glows or every 500 hours, whichever is early. Clog Service and maintenance 134 Engine air cleaner indicator indicates that the air cleaner is clogged and requires attention. CAUTION The air filter maintenance intervals depend on the amount of dust in the air and can therefore not be determined precisely. Under extremely dusty conditions daily cleaning may be required. NOTICE The air cleaner is a dry type with two filters. Air cleaner primary filter, that is replaceable or can be cleaned, and air cleaner secondary filter that should only be replaced and never cleaned. The air cleaner secondary filter element should be replaced after every third air cleaner primary filter element change. CAUTION Do not, under any circumstances, run the engine without a filter or with a damaged one. Always have a spare filter at hand and keep it well protected from dirt. CAUTION Do the work in an environmentally safe manner. Place machine in the service position. See page 92 . Remove the mounting screws of operator seat platform, tilt open the operator seat platform and secure it with a stopper rod. 1 2 3 4 Mounting screw Operator seat platform Knob Air cleaner access cover Remove the air cleaner access cover by removing knobs. CAUTION Remove any dust from the air cleaner cover by squeezing the rubber ejector valve, located at the bottom of the cover. This job should be carried out regularly, based on experience. Service and maintenance Engine air cleaner 135 Squeeze the rubber ejector valve, then release. This will dump dust and dirt from the rubber ejector valve. Repeat if needed. 1 2 3 Rubber ejector valve Lock Air cleaner end cap Pull the lock, rotate the air cleaner end cap in counter clockwise direction and remove it. Carefully remove the air cleaner primary filter by pulling it straight out of the air cleaner housing. 1 2 Air cleaner housing Air cleaner primary filter Carefully clean the air cleaner housing.Check air cleaner primary filter for any damage. Replace it, if damaged. See page 136. CAUTION The secondary filter must be replaced, never cleaned. Never remove it unless it is to be replaced. Service and maintenance 136 Engine air cleaner Remove air cleaner secondary filter, if damaged. Replace it. See page Engine air cleaner secondary filter, replacing. WARNING Compressed air. Never direct to bare skin. Use protective equipment. Clean air cleaner primary filter with compressed air. Air cleaner secondary filter NOTICE Air cleaner primary filter should be cleaned from inside to outside. Compressed air should not exceed 5 bar (72.51 psi). Carefully install the cleaned air cleaner primary filter by pushing it straight into the air cleaner housing over the air cleaner secondary filter. NOTICE Make sure the air cleaner primary filter is properly seated. Air cleaner primary filter cleaning Check the evacuator valve so that it is not inverted, damaged or plugged. Install the air cleaner end cap, rotate in clockwise direction and push the lock. Install the air cleaner access cover. Place back the operator seat platform and secure with mounting screws. Place the machine back in service. Air cleaner primary filter, change CAUTION Do the work in an environmentally safe manner. CAUTION Do not, under any circumstances, run the engine without a filter or with a damaged one. Always have a spare filter at hand and keep it well protected from dirt. Place the machine in service position. See page 92. Service and maintenance Engine air cleaner 137 Remove the mounting screws of operator seat platform, tilt open the operator seat platform and secure it with a stopper rod. Remove the air cleaner access cover by removing knobs. 1 2 3 4 Mounting screw Operator seat platform Knob Air cleaner access cover CAUTION Remove any dust from the air cleaner cover by squeezing the rubber ejector valve, located at the bottom of the cover. This job should be carried out regularly, based on experience. Squeeze the rubber ejector valve, then release. This will dump dust and dirt from the rubber ejector valve. Repeat if needed. 1 2 3 Rubber ejector valve Lock Air cleaner end cap Pull the lock, rotate the air cleaner end cap in counter clockwise direction and remove it. Carefully remove the air cleaner primary filter by pulling it straight out of the air cleaner housing. Remove air cleaner secondary filter, If damaged. Replace it , See page Engine air cleaner secondary filter, replacing. CAUTION The secondary filter must be replaced, never cleaned. Never remove it unless it is to be replaced. Carefully install the new air cleaner primary filter by pushing it straight into the air cleaner housing over the air cleaner secondary filter. 1 2 Air cleaner housing Air cleaner primary filter NOTICE Make sure primary filter is properly seated. Service and maintenance 138 Engine air cleaner Make sure the rubber ejector valve is not inverted, damaged or plugged. Install the air cleaner end cap, rotate it clockwise direction and push the lock. Install the air cleaner access cover. Place back the operator seat platform and secure with mounting screws. Place the machine back in service. Air cleaner secondary filter, replacing CAUTION Do the work in an environmentally safe manner. CAUTION The secondary filter must be replaced, never cleaned. Never remove it unless it is to be replaced. Place machine in the service position. See page 92. Remove the mounting screws of operator seat platform, tilt open the operator seat platform and secure it with a stopper rod. 1 2 3 4 Mounting screws Operator seat platform Knob Air cleaner access cover Remove the air cleaner access cover by removing knobs. CAUTION Remove any dust from the air cleaner cover by squeezing the rubber ejector valve, located at the bottom of the cover. This job should be carried out regularly, based on experience. Squeeze the rubber ejector valve, then release. This will dump dust and dirt from the rubber ejector valve. Repeat if needed. Service and maintenance Engine air cleaner 139 Pull the lock, rotate the air cleaner end cap in counter clockwise direction and remove it. 1 2 3 Rubber ejector valve Lock Air cleaner end cap Remove the air cleaner primary filter. See page 136 . 1 2 Air cleaner housing Air cleaner primary filter Carefully clean the inside of the air cleaner housing. Remove the air cleaner secondary filter out of the air cleaner housing. Carefully install a new air cleaner secondary filter by pushing it straight into the air cleaner housing. NOTICE Make sure the air cleaner secondary filter is properly seated. Carefully install the cleaned or new air cleaner primary filter by pushing it straight into the air cleaner housing over the air cleaner secondary filter. NOTICE Air cleaner secondary filter Make sure the air cleaner primary filter is properly seated. Make sure the rubber ejector valve is not inverted, damaged or plugged. Install the air cleaner end cap, rotate in clockwise direction and push the lock. Install the air cleaner access cover. Service and maintenance 140 Engine air cleaner Place back the operator seat platform and secure with mounting screws. Place the machine back in service. Service and maintenance Cooling system 141 Cooling system Coolant level, check 1 Place the machine in service position. See page 92. 2 Open the engine hood. For engine hood opening. See page 125. 3 Check the coolant level. NOTICE The coolant level must be between center and top of the coolant level gauge. 4 Fill the coolant if necessary. See page 141. 5 Close the engine hood. For engine hood closing. See page 125 6 Place the machine back in service. Coolant level gauge Coolant, changing CAUTION Always handle oils and other environmentally hazardous fluids in an environmentally safe manner. WARNING Hot oil and hot engine coolant can cause severe burns! Draining 1 Place machine in the service position. See page 92. 2 Open the engine hood. For engine hood opening. See page 125 3 Locate the coolant drain plug below the frame and place a suitable container to collect the coolant. For quantity see page 196 Coolant drain plug Service and maintenance 142 Cooling system WARNING Before removing the radiator cap, stop the engine and let it cool down sufficiently. When removing it, turn it slowly to release the pressure. 4 Open the coolant filling cap. 5 Remove the coolant drain plug and drain the coolant in the container. 6 Plug the drain port. 1 2 Coolant filling cap Coolant level gauge Filling CAUTION Do not mix different coolants or corrosion protection as this may result in engine damages. 1 Fill the radiator with coolant till top of the coolant level gauge. For specification and quantity, See page 194 and 196. 2 Close the coolant filling cap. 3 Clean the spillage if any. 4 Start the engine and let it warm up at idle rpm to the normal operating temperature. 5 Check the coolant level and fill coolant if necessary. NOTICE Engine should be at the ambient temperature before checking the coolant level. 6 Close the engine hood. For engine hood closing. See page 125. 7 Place the machine back in service. Radiator and coolers, cleaning WARNING Hot liquids and machine parts can cause burns. Allow the machine to cool before beginning any work. Place the machine in service position. see page No.92. Open the engine hood. For engine hood opening, see page No. 125. Service and maintenance Cooling system 143 WARNING Use safety glasses. Check the sign of clogging of exposed cooling fins on the radiator and cooler. Remove any loose debris from the radiator and cooling fins. If clogging is dried on dirt use a suitable brush to remove from cooling fins. if dry dust is present, use compressed air. CAUTION When using compressed air, keep the nozzle at a distance from the fins to prevent damage. Damaged fins may cause leakage or overheating. In case of severe clogging (due to fluid leaks) apply a commercial cleaning detergent. Let it soak in, then wash it off with water spray and dry with compressed air. CAUTION Take care not to damage the cooling fins of the radiator core. NOTICE When using compressed air, water jets or steam cleaning methods, ensure that appropriate protective clothing is worn to protect eyes and exposed parts of the body. Close the engine hood. For engine hood closing, see page No. 125 Place the machine back in service. Service and maintenance 144 Electrical system Electrical system Special instructions for working on the electrical system Do not attempt to repair, test or adjust the electrical system unless you are a qualified electrician. Use only fully charged and otherwise satisfactory batteries to test the electrical system. The battery disconnect switch should be switched to OFF position when testing the battery acid for specific gravity using a hydrometer. When installing or replacing a battery, make sure that the correct polarity is followed. Always disconnect the negative (ground) cable first and reconnect it last. Before any tests are carried out on the alternator, the batteries and electrical leads must be checked for insulation faults, poor contacts or corrosion. Check the alternator belts. Correct any visible faults before beginning electrical checks. During all tests of alternating current equipment, secure connections must be used. One loose connection lead may damage the alternator. Do not disconnect the main lead of the alternator or the lead to it's field winding while the engine is running. Damage may result. If the current output terminal of the alternator is connected to the mainframes while the engine is running, alternator damage will result. Before removing or fitting components in the electrical system switch OFF the battery disconnect switch. Before welding on the compactor machine Refer to electric welding . Safety when working with batteries WARNING Risk of serious corrosive injuries! L64558A Battery charging Batteries contain sulphuric acid which is very corrosive to the human body and parts of the machine. In addition, batteries give off hydrogen gas when they are loaded (supplying electricity) or being charged. Together with the oxygen in the air, hydrogen gas forms a very explosive mixture. This combination, corrosive acid and explosive gas, means a high risk of accidents during all work with batteries used in vehicles. Therefore, it is very important that you take great care and follow the rules below when you are working with batteries. Service and maintenance Electrical system 145 Follow these instructions when charging batteries: Batteries give off explosive gases. Never smoke near batteries. Begin by disconnecting the ground lead when removing a battery. In order to reduce the risk of sparks that can cause fire, always connect the ground lead last when fitting a battery. Never tilt a battery to any great extent in any direction. Battery electrolyte may leak out. Do not connect a discharged battery in series with a fully charged battery. The current surge can cause the batteries to explode. Do not smoke near batteries! Do not allow metal objects (such as tools, rings, wristwatches) to come in contact with battery terminals. Risk of fire and personal injury. Always cover the top of the battery with a rag or other nonconducting material when you work close to the batteries. Always refit the terminal caps on the batteries. Batteries contain substances hazardous to health and the environment. Therefore, discarded batteries be handled according to governing local/national regulations. See page 111. Explosion hazard When a battery is being charged, a potentially explosive mixture of oxygen and hydrogen gas is formed. A short circuit, open flame or spark near the battery can cause a powerful explosion. Always turn off the main power to the battery charger before disconnecting the charging clamps. Ventilate the area well, especially if the battery is being charged in a confined space. Electrical components, basic check 1 2 3 4 5 6 7 8 9 10 Place the machine in service position. See page 92. Switch on the battery cutoff switch. Switch on the ignition key. Check the workings of the following electrical components. Indicating signals on the control panel Hazard indicating signal Front head lamp, low beam and high beam Rear working lamps Front and rear indicating lamps Parking lamps Horn Reverse alarm Start the engine. Check for the hour meter working. Check for the emergency stop switch working. Shut down the engine if it is running after emergency stop switch check. Switch off the battery cutoff switch. Place the machine back in service. Service and maintenance 146 Electrical system Battery disconnect switch (main switch), check The battery disconnect switch provides a means to disconnect the machine electrical system for added security, when the machine is not in use. Battery disconnect switch is connected between the negative battery cable and machine ground. It is located at the rear side of the machine. To access battery disconnect switch rear hood to be opened. If the machine is to be left unattended, turn the battery disconnect switch to the '“OFF” position. Place the machine in service position. Refer to 92. Open the rear hood of the machine . NOTICE Rear hood will fall back if it is not lifted to the full extent. Battery disconnect switch Open the battery box cover. Periodically check the condition of the cables and wiring harness to the battery disconnect switch. Inspect the cables and connections for cracks, corrosion or exposed and damaged wires. Make sure that the cable connections are tight. Replace damaged cables as required. Check the function of the battery disconnect switch and verify that all power to the machine is “OFF” when the battery disconnect switch is in the “OFF” position. NOTICE Do not bypass the battery disconnect switch. Replace the battery disconnect switch if it is not working properly. CAUTION Do not turn off the battery disconnect switch when the engine is running. The electrical system may be damaged. CAUTION Turn off the electric power with the battery disconnect switch before starting any work. Also remove the fuse for respective component. Close the battery box cover. Secure the rear hood back in place. Place the machine back in service. Electric welding If the service procedure includes welding, disconnect the following items: 1 Battery ground connection and battery disconnect switch with battery disconnect switch turned off. 2 Connectors for all electronic control units. 3 Connect the welding unit ground cable as close as possible to the work area. Close the battery box cover. After completing your welding procedures, connect the above items in the Service and maintenance Electrical system 147 reverse order. Make sure that the battery disconnect switch is connected last. WARNING Battery charging generates hydrogen gas, which may be explosive. Short-circuiting, an open flame or a spark near the battery may cause a powerful explosion. Make sure ventilation is adequate when charging batteries. Never smoke near batteries. See page No.105 and 109. Battery description The electrical system uses one 12 V battery. The battery is mounted to the rear main frame. It is located at the rear side of the machine. Battery disconnect switch provides a means to disconnect the machine electrical system for added security when the machine is not in use. The battery should be in good condition when troubleshooting the electrical system. If needed charge the batteries , See page 150. V 108862 0 Battery Location Service and maintenance 148 Electrical system Safety when working with batteries WARNING Risk of serious corrosive injuries! L64558A Battery charging Batteries contain sulphuric acid which is very corrosive to the human body and parts of the machine. In addition, batteries give off hydrogen gas when they are loaded (supplying electricity) or being charged. Together with the oxygen in the air, hydrogen gas forms a very explosive mixture. This combination, corrosive acid and explosive gas, means a high risk of accidents during all work with batteries used in vehicles. Therefore, it is very important that you take great care and follow the rules below when you are working with batteries. Follow these instructions when charging batteries: Batteries give off explosive gases. Never smoke near batteries. Begin by disconnecting the ground lead when removing a battery. In order to reduce the risk of sparks that can cause fire, always connect the ground lead last when fitting a battery. Never tilt a battery to any great extent in any direction. Battery electrolyte may leak out. Do not smoke near batteries! Do not connect a discharged battery in series with a fully charged battery. The current surge can cause the batteries to explode. Do not allow metal objects (such as tools, rings, wristwatches) to come in contact with battery terminals. Risk of fire and personal injury. Always cover the top of the battery with a rag or other nonconducting material when you work close to the batteries. Always refit the terminal caps on the batteries. Batteries contain substances hazardous to health and the environment. Therefore, discarded batteries be handled according to governing local/national regulations. See 191, Environmentally safe handling Charging batteries Explosion hazard When a battery is being charged, an explosive mixture of oxygen and hydrogen is formed. A short circuit, open flame or spark near the battery can cause a powerful explosion. Always turn off the charging current before disconnecting the charging clamps. Ventilate well, especially if the battery is charged in a confined space. Service and maintenance Electrical system 149 WARNING Risk of serious corrosive injuries! Corrosive sulphuric acid The battery electrolyte contains corrosive sulphuric acid. Electrolyte spilled on bare skin must be removed immediately. Wash with soap and plenty of water. If electrolyte gets into your eyes or any other sensitive body part, rinse immediately with plenty of water and seek immediate medical attention. Corrosive acid V1033092 Battery, maintenance 1 Top of the battery must be kept clean and dry. 2 Petroleum jelly should be applied to cable clamps and terminals. Do not apply grease. 3 Get the fan belt, electrical wiring, alternator and regulator setting checked regularly. 4 Alternator charging voltage setting across battery terminals must be maintained at 12.00±0.20 Volts. 5 In case of any drop in electrolyte level, distilled or deionized water. Do not add acid. Battery Care Keep batteries topped up Maintaining a sufficient electrolyte level ensures the electrolyte is neither too high or too low. Use distilled or deionized water and never over fill. Maintenance free batteries will usually not require topping up. Low maintenance batteries require the addition of deionized water only once or twice per year depending on conditions. Check electrical connections Make sure that the battery terminals and cable connections are clean and tight. The application of a thin layer of petroleum jelly can help reduce corrosion. Avoid overcharging Overcharging produces rapid deterioration and corrosion which shortens battery life. A battery needing to be topped up continuously with deionized water is a sure sign that the machine electrical system requires careful checking, this may also affect a maintenance free battery. Keep batteries clean and dry Dirt on a battery's surface leads to discharge and corrosion. Avoid spilling oil or grease onto the top of the battery. To remove dirt or moisture, wash with a solution of sodium bicarbonate and water. Service and maintenance 150 Electrical system Precautions To avoid short circuit, metallic objects should not be placed on top of the battery. Batteries contain hydrogen gas and air in a volatile mixture which is easily ignited. Keep flames or sparks away from the battery at all times Battery contain sulphuric acid. Do not add acid to cells and keep acid away from eyes, skin, clothing or any other material which may become damaged. If contamination occurs, use large amount of water to neutralize and flush acid away. Battery lifting Battery is heavy - make sure correct lifting procedures are used when moving battery. NOTICE It is recommended to return the old battery to the authorized battery manufacturer / dealer / smelter during purchase of a new battery. Battery storage When a battery is at rest, there is a spontaneous electrical discharge that increases with storage temperature. A fully charged battery, stored at a temperature of -20°C (-4°F) loses insignificant charge during a 3 month period. If the same battery is stored at +30°C (86°F), it is only half charged after 3 months. To help reduce this discharge, always store batteries in a cool, dry place in an upright position. If a battery becomes severely discharged, the electrolyte can freeze if it is stored below -7°C (+20°F). To prevent damage due to freezing, do not allow batteries to become discharged or to be stored below -7°C (+20°F). Allowing batteries to stand for an extended period of time without recharging them, will result in reduced performance and service life. To preserve optimum battery performance and life, recharge batteries when the open circuit voltage drops to 12.4 volts. Service and maintenance Electrical system 151 Battery, charging WARNING During battery charging, hydrogen gas is formed. Hydrogen gas is flammable and may be explosive. A short-circuit, open flame or spark near the battery can cause a powerful explosion. Therefore, ventilate well. Never smoke near batteries. WARNING The battery electrolyte contains corrosive sulphuric acid. Electrolyte spilled on bare skin should be removed immediately. Wash the affected area with soap and plenty of water. If electrolyte gets into your eyes or any other sensitive body part, rinse immediately with plenty of water and seek immediate medical attention. Battery charging Batteries must only be charged using a battery charger. Check the battery terminal connections, and make sure that they are adequately tightened, and free from corrosion and dirt. Check the battery voltage, when the battery is at rest, that is, before starting, make sure that the battery must be at least halfcharged. If the battery is extremely cold, allow it to come to room temperature, as an extremely cold battery will not accept a normal charge, until the temperature rises. CAUTION Always disconnect the electric power to the battery charger before the charging clamps are removed. CAUTION Always turn off the current to the battery charger before disconnecting the charging clamps. Service and maintenance 152 Electrical system Battery, checking electrolyte WARNING Corrosive sulphuric acid The battery electrolyte includes corrosive sulphuric acid. Electrolyte spilled on bare skin must be removed immediately. Wash with soap and plenty of water. If electrolyte gets into your eyes or any other sensitive body part, rinse immediately with plenty of water and seek immediate medical attention. Place the machine in service position. See page No. 92. Open the engine hood. For engine hood opening See page No. 125. Remove the battery access cover. Check the electrolyte level indicator on the batteries. a If the indicator is green, battery is OK. b If the indicator turn white, battery need to be charged. c If the indicator turns red, open the service plugs, add distilled water to maximum level and close the service plugs or call the service person. Battery access cover NOTICE Use a suitable washer to open and to close the service plugs. Install the battery access cover. Close the engine hood. For engine hood closing. See page No. 125. Place the machine back in service. Battery electrolyte level indicator Service and maintenance Electrical system 153 Component location, fuses 13 14 15 2 3 4 5 6 7 8 9 10 11 12 1 V110079 5 Fuses 1 Fuse F1 2 Fuse F2 3 Fuse F3 4 Fuse F4 5 Fuse F5 6 Fuse F6 7 Fuse F7 8 Fuse F8 9 Fuse F9 10 Fuse F10 11 Fuse F11 12 Fuse F12 13 Fuse, FL1 14 Fuse, FL2 15 Fuse, FL3 Service and maintenance 154 Electrical system Component list, Fuses SI NO. Fuse Ampere rating Circuit protected 1 F1 40 A Power relay, Park brake, Park brake test, Brake dump, Brake lights relay, Pump-Destroke circuit, Brake-latching relay Circuit, Horn, V-belt switch, Tachometer, Engine oil pressure gauge, Engine oil temperature gauge, Hourmeter, Two speed solenoid, Seat switch, Fuel gauge, rear light switch, position light switch 2 F2 10 A Mobile charger 3 F3 15 A Front high beam lights 4 F4 15 A Rear lights 5 F5 10 A Reverse lights 6 F6 10 A Flasher 7 F7 10 A Beacon light 8 F8 10 A Cluster and air filter 9 F9 10 A Audible alarm 10 F10 7.5 A Position light 11 F11 15 A Low beam front lights 12 F12 10 A Fuel solenoid 13 FL1 60 A Main fuse 14 FL2 60 A Glow plug 15 FL3 100 A Battery charging circuit For fuse locations, See page No.153. Component list, Relays SI NO. Relays Location 1 Power relay Control box 2 Front light low beam relay Control box 3 Alarm relay Control box 4 Brake latching relay Control box 5 Brake light relay Control box 6 Hazard relay Control box 7 Reverse light relay Control box 8 Flasher relay Control box 9 Position light relay Control box 10 Rear light relay Control box 11 Front light high beam relay Control box 12 Seat timer relay Control box 13 Starter relay Battery compartment 14 Glow plug relay Battery compartment For relay locations, See page No.155. Service and maintenance Electrical system Component location, relays 13 14 7 8 2 3 4 5 6 1 9 10 11 12 V1100735 Relays 1 Power relay 2 Low beam relay 3 Alarm relay 4 Brake latch relay 5 Brake lights relay 6 Hazard relay 7 Reverse light relay 8 Flasher relay 9 Position light relay 10 Rear light relay 11 High beam relay 12 Seat switch timer relay 13 Starter relay 14 Glow plug relay 155 Service and maintenance 156 Transmission Transmission Transmission, checking oil level Place the machine in service position. See page No. 92. Allow axle transfer case to cool. WARNING If work must be done on the machine before it has cooled down; beware of hot fluids and hot components that can cause severe burns. Clean around the transmission oil fill/level plug. Remove the transmission oil fill/level plug. Check the transmission oil level, oil level must be at bottom edge of the transmission oil fill/level hole. Clean and apply thread sealant to transmission oil fill/level plug. required, add oil through transmission oil level/fill hole. See page No. 194. Fix back the transmission oil fill/level plug. Clean for the oil spillage. Place the machine back in service. Transfer gearbox case 1 Oil fill/level plug 2 Oil drain plug Service and maintenance Transmission 157 Transmission, changing oil NOTICE Oil must be at normal operating temperature when draining Run the machine until the transmission oil reaches operating temperature. Place the machine in service position. See page No. 92. Place a suitable container below the transmission oil case. Remove the transmission oil fill/level plug. WARNING Work carefully when changing oil as hot oil can cause severe burns to unprotected skin. Remove transmission oil drain plug and drain the transmission oil. Clean and apply thread sealant to transmission oil drain plug. Place back the transmission oil drain plug. Fill the transmission oil case with transmission oil through the transmission oil fill/level hole, until the oil level is at the bottom edge of the oil fill/level port. See page No. 194 and 196. Clean and apply thread sealant to transmission oil fill/level plug. Test run the machine. Check the transmission oil level. See page No. 156 . Clean for the oil spillage. Make sure that the transmission oil level is at correct level. Place the machine back in service. Transmission oil case 1 Transmission oil fill/level plug 2 Transmission oil drain plug CAUTION Always handle oils and other environmentally hazardous fluids in an environmentally safe manner. Service and maintenance 158 Axles Axles Axles, checking oil level Place the machine in service position. See page No. 92. WARNING If work must be done on the machine before it has cooled down; beware of hot fluids and hot components that can cause severe burns. Allow the axle housing to cool. Locate and clean around both the oil level plugs. Remove any one of the axle housing oil level plug. Check the axle housing oil level, it must be at the bottom edge of the axle housing oil level port. Add axle housing oil through the oil fill hole if required. See page No. 194 . Clean the axle housing oil level plug and apply thread sealant to it. Fix back the oil level plug and tighten it. Clean around the oil level plugs for oil spillage. Place the machine back in service. Oil level plugs of the axle Axle hubs, checking oil level Park the machine service position. See page No. 92. NOTICE Make sure that the rear wheel is positioned with the axle wheel end hub oil fill/level plug in the 9 o'clock position before shutting down the engine. Axle wheel end hub oil fill/level hole Allow axle wheel end hub oil to cool. Place a suitable container bellow the axle wheel end hub oil fill/ level plug. Clean around the axle wheel end hub oil fill/level plug. Remove the axle wheel end hub oil fill/level plug. Check and make sure that the oil level is at bottom edge of the axle wheel end hub oil fill/level port. See page No. 158 Clean the axle wheel end hub oil fill/level plug. Fix back and tighten the axle wheel end hub oil fill/level plug Clean up for the oil spillage. Similarly check the oil level of other side of the axle. Place the machine back in service. Service and maintenance Axles 159 Axle hubs, changing oil WARNING Work carefully when changing oil as hot oil can cause severe burns to unprotected skin. Run the machine till the axle wheel end hub oil reaches operating temperature. NOTICE Make sure that the wheel is positioned with the axle wheel end hub oil fill/level plug in the 6 o'clock position before securing the machine in service position. Place the machine in service position. See page 92. Clean around the axle wheel end hub oil fill/level plug. Place a suitable container under the axle wheel end hub oil fill/ level plug. Axle wheel end hub oil fill/level plug at 6 o'clock position Remove the axle wheel end hub oil fill/level plug and drain the oil. Axle wheel end hub oil, draining Service and maintenance 160 Axles Position the wheel end hub oil fill/level hole to the 9 o'clock position. Fill the axle wheel end hub through oil fill/level hole, until oil level is at the bottom edge of the fill/level port. See page 196 and 158. Clean the axle wheel end hub oil fill/level plug. Place back the axle wheel end hub oil fill/level plug. Clean for any spilled oil. Repeat the procedure for the other side of the axle wheel end hub. Test run the machine. Check the wheel end hub oil level. See page 158. Place the machine back in service. Axle wheel end hub oil fill/level plug at 9 o'clock position Rear axle, changing oil Axle housing oil changing WARNING Work carefully when changing oil as hot oil can cause severe burns to unprotected skin. Start the machine and run until the axle housing oil reaches operating temperature. NOTICE Axle housing oil must be at normal operating temperature when draining. Place the machine in service position. See page No. 92. Locate and clean around the three axle housing oil drain plugs. Axle housing drain plugs Place a suitable container under the axle housing drain plugs. Service and maintenance Axles 161 Remove the axle housing drain plugs and drain the axle housing oil. CAUTION Always handle oils and other environmentally hazardous fluids in an environmentally safe manner. Clean the axle housing drain plugs and apply thread sealant. Fix back the axle housing drain plugs. Clean around the axle housing drain plugs for oil spillage. Locate and clean around the axle housing oil fill plug. AXLE HOUSING OIL FILL PLUG V1076328 Axle housing oil fill plug Remove the axle housing fill plug. Fill the oil through the fill hole, until oil level is at the bottom edge of the check port. See page No. 194 and 158. Clean and apply thread sealant to axle housing fill plug. Fix back the axle housing fill plug. Test run the machine. Check the axle housing oil level. See page No. 158 . Clean up for any oil spillage. Place the machine back in service. Axle breather, cleaning Place the machine in service position. See page No. 92. Allow the axle to cool. Service and maintenance 162 Axles Locate and clean the area around the two axle breathers. Axle breathers Remove the axle breathers. Protect the breather ports to avoid contaminants entering the axle. Fix back the axle breathers. Clean the breathers with solvent and allow it to dry. Place the machine back in service. Axle breather installation Service and maintenance Brake system 163 Brake system Parking brake performance The parking brake test switch must be used to verify the parking brake functioning. Start the machine and position it in an area clear of personnel and obstructions. Park brake test 1 Park brake test switch 2 Park brake switch Press the parking brake switch. Press and hold the parking brake test switch and move the propulsion control lever FORWARD or REVERSE. The machine should NOT move. If the machine does move, shut down engine and have the fault corrected before continuing operation. Move the propulsion control lever to STOP position. Release the parking brake test switch. Shut down the engine. Propulsion control lever Service and maintenance 164 Steering system Steering system Steering cylinder pins, greasing Place the machine in service position. See page 92. ■ Clean steering cylinders pin grease fittings. CAUTION Wipe off grease nipples and grease gun before greasing, so that dirt and sand are not introduced through the grease nipples into the bearings. ■ Apply the recommended grease to each fitting until the grease exits from the sealing surface. See page 194 . ■ Place the machine back in service. Cap end cover side Rod eye end side Service and maintenance Wheels 165 Wheels Tyres, wear and air pressure, checking Before checking tyre pressures or inflating, See page No. 100. WARNING Inflating a tyre may cause it to explode. This may lead to accidents. Use a self-attaching air chuck with a hose long enough to enable you, when inflating, to stand by the tyre tread, but as far away as possible. Park the machine on level ground with the wheel rotated so that the tyre inflation valve is located at the 12 o'clock position. Remove the tyre inflation valve cap. Check the tyre pressure, when tyres are cold, using an appropriate pressure gauge. Make sure that the normal operating pressure is not above 1.1 bar (16 psi), See page 198 for size and pressure of tyre. After checking the tyre pressure, place the valve caps to prevent dirt, moisture and foreign material from damaging the valve core After checking the tyre pressure, place the valve caps to prevent dirt, moisture and foreign material from damaging the valve core. Check the wheel rim for excessive rust, cracks, missing or loose wheel bolts, or other damage which could cause premature tyre wear or failure Check the wheel rim for excessive rust, cracks, missing or loose wheel bolts, or other damage which could cause premature tyre wear or failure NOTICE Placing water in tyres is an economical means of adding weight to the wheels . The addition of calcium chloride is recommended to prevent the water from freezing. If a tyre with ballast is replaced, the replacement tyre must also contain ballast. Report tyre and wheel rim defects to a qualified person who is equipped and trained to perform tyre repair service. Tyre inflation valve Wheel nuts, check torque Place the machine in service position, See page No.92. Torque the wheel nuts evenly in clockwise and diagonal pattern. For torque value See page No.201 and 202. Service and maintenance 166 Wheels NOTICE If new or replacement wheel or wheel nuts have been installed they may require more frequent checks until they are properly seated. Place the machine back in service. V1098837 Wheel nuts Service and maintenance Drum 167 Drum Drum, checking Place the machine in service position. See page No.92. Perform a visual inspection of the drum assembly. Remove all adhering materials on the drum. Place the machine back in service. Drum carrier, checking oil level ■ Place the machine in service position. See page 92. ■ Allow the carrier to cool . ■ Clean the area around the oil level check plug located on the lower side of the carrier. NOTICE The drain plug is located at the 6 o'clock position on the bottom of the carrier and should not be removed except for draining the carrier oil. ■ Remove the oil level check plug and check the oil level in the carrier. Oil should be level with the bottom edge of the level check plug hole. Drum carrier plug location. 1 Oil level check plug 2 Oil drain plug ■ If it is necessary to add oil to the carrier between oil changes, remove the breather/filler plug located at the 12 o'clock position on top of the carrier and add oil until oil runs out of the level check plug hole. ■ Fix back and tighten the carrier oil level check plug. ■ Make sure that the breather is clean and tightened. ■ Clean up any excess oil. ■ Place the machine back in service. Drum carrier breather Drum drive (torque hub), checking oil level NOTICE There are two plugs on the torque hub, one is oil level plug and other is oil fill plug. Service and maintenance 168 Drum Place the machine in service position, with the oil level plug in 12 o'clock position. See page No. 92 . Clean the area around the oil level check plug. Loosen the oil level plug. Reposition the oil level plug to 3 o'clock position. Remove the oil level check plug and check that the oil level is filled to the bottom edge of the oil level check port. NOTICE When the oil level plug is in 3 o' clock position, oil fill plug will be in 12 o' clock position. Oil level fill plug If the oil level has dropped below the oil level check port, remove the oil fill plug which will be at 12 o'clock position. Add fresh oil through fill hole until the oil is level with the bottom edge of the oil level check port. For specification see page no 194 . Close the oil level port with oil level plug. Clean the oil fill plug with solvent and apply thread sealant to it. Fix back the oil fill plug and tighten it. Reposition the oil level plug to 12 o'clock position. Remove the oil level plug. Clean the oil level plug with solvent and apply thread sealant. Fix back the oil level plug and tighten it. Clean for any oil spillage. Place the machine back in service. Drum eccentric, checking oil level ■ Place the machine in service position, with the drum index at the 12 o’clock position. See page 92. 1 2 Drum Index Eccentric fill plug (at 12 o'clock) Service and maintenance Drum 169 NOTICE This will also place the drain plug in the 6 o'clock position and the oil level sight gauge in the 4 o'clock position. ■ Check the oil level is to the centre of the sight gauge. NOTICE Oil level must be at the centre of the sight gauge. ■ If oil is to be added, remove the fill plug and add oil . For specification See page no. 194. ■ Place the machine back in service. Position of drum for checking eccentric oil level 1 Eccentric fill plug (at 12 o'clock) 2 Eccentric drain plug (at 6 o'clock) 3 Eccentric oil level sight gauge (at 4 o'clock) Drum shock mounts, checking Place the machine in service position. See page No.92. Check the condition of the drum shock mounts periodically for loosening or signs of deterioration. Replace shock mounts (one at a time) that have torn or excessively cracked rubber. Torque all screws and nuts to specification as necessary. See page No.201. Place the machine back in service. Drum shock mounts checking Carrier breather, cleaning Clean the area around the carrier breather located on top of the carrier. Remove the breather. Cover the breather port to prevent contaminants from entering the system. Clean the breather with solvent and allow it to dry. Fix back the breather and tighten. Drum carrier breather Service and maintenance 170 Drum Drum carrier, changing oil NOTICE Oil must be at normal operating temperature when draining. WARNING Work carefully when changing oil as hot oil can cause severe burns to unprotected skin. CAUTION Always handle oils and other environmentally hazardous fluids in an environmentally safe manner. Run the machine until the drum carrier assembly reaches operating temperature. Place the machine in the service position. See page 92. Remove the fill / breather plug on carrier assembly. Drum carrier breather plug Place a suitable container below the drain plug. Remove the drain plug and drain the oil. Clean and fix back the drain plug and tighten. Remove the level check plug. Add oil until oil runs out of the level check plug mounting hole. Fix back the level check plug. Clean the fill/breather plug with solvent. Fix back the fill / breather plug. Test run the machine and check for any leaks. Clean up for any oil spillage . Make sure that the drum carrier oil is at correct level. Place the machine back in service. Carrier oil level check plug 1 Drum carrier oil level check plug. 2 Drum carrier oil drain plug Service and maintenance Drum 171 Drum drive (torque hub), changing oil CAUTION Always handle oils and other environmentally hazardous fluids in an environmentally safe manner. NOTICE There are two plugs on the torque hub, one is oil level plug and other is oil fill plug. ■ Place the machine service position with oil level plug in 12 o'clock position. See page No. 92. Oil level plug at 12 o'clock position ■ Loosen the oil level plug. ■ Reposition the oil level plug to 3 o'clock position. NOTICE When the oil level plug is in 3 o'clock position, oil fill plug will be in 12 o'clock position. Loosening of oil level plug Service and maintenance 172 Drum ■ Remove the oil fill plug which will be at 12 o'clock position. ■ Reposition the oil level plug to 6 o'clock position. ■ Place a suitable container under the torque hub. WARNING Work carefully when changing oil as hot oil can cause severe burns to unprotected skin. ■ Remove the oil level plug at the 6 o’clock position and allow the oil to drain. ■ Reposition the oil level plug to 3 o'clock position. ■ Fill the oil through the fill port which will be at 12 o'clock position, till the oil level must be at bottom edge of the oil level port. Removing of oil fill plug ■ Close the oil level port with oil level plug. ■ Clean the oil fill plug and apply thread sealant to it. ■ Fix back the oil fill plug and tighten it. ■ Reposition the oil level plug to 12 o'clock position. ■ Remove the oil level plug. ■ Clean the oil level plug with solvent and apply thread sealant. ■ Fix back the oil level plug and tighten it. ■ Test run the machine and check for any leaks. ■ Clean up any oil spillage. ■ Make sure that the torque hub oil is at correct level. ■ Place the machine back in service. Oil level plug at 12 o'clock position Drum eccentric, changing oil WARNING Work carefully when changing oil as hot oil can cause severe burns to unprotected skin. NOTICE Oil must be at normal operating temperature when draining. CAUTION Always handle oils and other environmentally hazardous fluids in an environmentally safe manner. Service and maintenance Drum 173 ■ Run the machine so that the eccentric oil reaches operating temperature. ■ Place the machine on level ground in service position , with the drum index (angle mounted on the inside of the drum) at the 12 o’clock position. 1 2 Drum Index Eccentric fill plug (at 12 o'clock) NOTICE This positioning will place the eccentric fill plug in the 12 o'clock position. This will also bottom-out the drain plug in the 6 o'clock position and the level indicator gauge in the 4 o'clock, level-read position. ■ Place suitable container to collect the oil drain. ■ Remove the fill plug and the drain plug and drain the oil. CAUTION Always handle oils and other environmentally hazardous fluids in an environmentally safe manner. ■ Clean and place back the drain plug. ■ Fill the drum eccentric with fresh eccentric oil through the fill hole. 1 2 3 Eccentric fill plug (at 12 o'clock) Eccentric drain plug (at 6 o'clock) Eccentric oil level sight gauge (at 4 o'clock) ■ Clean and fix back the fill plug. Test run the machine and check for any leaks. ■ Clean up any oil spillage. ■ Make sure that the eccentric oil is at correct level. ■Place the machine back in service. Service and maintenance 174 Hydraulic system Hydraulic system Safety when working on hydraulic systems The hydraulic system operates at high oil pressures. The system must be properly maintained to avoid the potential for accidents and injury. It is important that each person who comes in contact with the machine be alert to any faults. WARNING Risk of personal injury! Wear safety glasses and use protective gloves. Follow these basic precautions: Never adjust a pressure relief valve or other pressure-limiting device to a higher pressure than specified. Replace any hydraulic hose immediately that shows signs of swelling, wear, leaks or damage before it bursts. Never discard a hydraulic accumulator without first carefully drilling a 3 mm (1/8 in.) hole in the cylinder to eliminate the risk of explosion. Releasing hydraulic pressure When you shut down the engine, there will still be residual pressure at various point is the hydraulic system. Never disconnect any hydraulic hose, fitting or component without first relieving residual pressure. WARNING If the pressure is not released before opening the system, oil under high pressure will jet out, resulting in serious personal injuries. WARNING Leaking high-pressure hydraulic hoses may cause severe injuries. Fine jets have high penetrating capacity on bare skin. Never use your hands to check for oil leaks. Use a piece of cardboard. Never tighten leaky fittings with the engine running, or before the residual pressure has been released. Pressure accumulators have a pressurized gas charge as well as residual hydraulic pressure. Use extreme care when working with accumulators. Check valves, lock valves and similar hydraulic components are designed to retain pressure or oil flow. CAUTION Always handle oils and other environmentally hazardous fluids in an environmentally safe manner. Release pressure by completely moving the hydraulic control levers back and forth several times. The hoses become "slack" when the hydraulic pressure is released. Service and maintenance Hydraulic system 175 Carefully loosen the hydraulic hose, residual pressure can still be trapped in the hydraulic system. Hydraulic system, checking oil level CAUTION It is very important to keep the hydraulic system free from any impurities, as these can cause abnormal wear and may lead to expensive downtime. Greatest possible cleanliness should be maintained during all handling of hydraulic components and hydraulic oil. ■ Park the machine on a level surface. ■ Check the hydraulic oil level by looking at the sight gauges of the hydraulic tank. 2 NOTICE Oil must be filled when oil level drops down to minimum level in the low level indicator sight gauge. If required add fresh clean hydraulic oil through the oil fill plug. See page No. 176. 1 V1092471 Hydraulic oil tank. 1 High level indicator sight gauge 2 Low level indicator sight gauge Hydraulic oil filter, changing Place machine in service position. See page No. 92. Tilt open the operator seat platform to access the two hydraulic filters. Secure operator seat platform with the seat stopper rod. Hydraulic oil filters Service and maintenance 176 Hydraulic system Disconnect the hydraulic oil filter hose towards filter side (to access to the vibration charge filter) and plug it immediately . Clean the hydraulic oil filters and filter heads before removing them from the machine in an effort to prevent contamination of the hydraulic system. Place the suitable container to collect the hydraulic oil spillage. Remove the hydraulic oil filter by turning it counterclockwise using a filter wrench NOTICE Hose to be disconnected Discard the filters in accordance with local environmental guidelines. Clean the filter head and make sure that there is no gasket material or other debris remaining on the filter head. Lubricate new O-ring with thin film of fresh hydraulic oil and replace it to new hydraulic oil filter. Fill new hydraulic oil filter with fresh hydraulic oil and screw the filter to filter head, until the O-ring just touches the sealing surface, tighten further half by hand. NOTICE Do not overtighten the hydraulic oil filters, as it is possible to distort the threads or damage the filter element seals. Similarly replace other hydraulic filter. Reconnect the disconnected hose. Clean for the oil spillage. Place the operator seat back in position. Start the engine and check for leaks. Make sure that there is no foaming in the hydraulic tank. NOTICE Foaming in hydraulic tank, is an indication of air leakage, into the hydraulic system. To check foaming, open the hydraulic tank filler cap check the hydraulic oil condition with the torch. Foaming in hydraulic oil can lead to hydraulic system failure. Hydraulic oil tank, changing oil CAUTION Any work on the hydraulic system requires great demands on cleanliness. Even very small particles can cause damage or clog up the system. Therefore, wipe areas in question clean before any work is carried out. CAUTION Always handle oils and other environmentally hazardous fluids in an environmentally safe manner. Run the machine until the hydraulic oil reaches operating temperature. Place machine in service position. See page No. 92. Service and maintenance Hydraulic system 177 WARNING Work carefully when changing oil as hot oil can cause severe burns to unprotected skin. Draining of hydraulic oil Place a suitable container below the hydraulic tank drain port located at the bottom of the tank. See page No. Fuel, lubricant and filling capacities for capacity of the container. Hydraulic oil tank drain plug Remove the drain plug and drain the hydraulic oil. Dispose the used hydraulic oil in accordance with local environmental guidelines. Clean and apply thread sealant to the drain plug. Fix back the drain plug. Hydraulic oil tank fill plug Cleaning of hydraulic tank. Clean the hydraulic tank. See page No. 177. Filling of hydraulic oil Remove the breather filler cap and fill hydraulic tank with clean hydraulic oil. See page No. Fuel, lubricant and filling capacities. Fix back the breather filler cap and clean for oil spillage. Start the engine and check all hydraulic connections for any leaks. Check the hydraulic oil level. See page No. 175. Place the machine back in service. Hydraulic tank, cleaning Start the engine and run the machine until the hydraulic oil reaches operating temperature. Service and maintenance 178 Hydraulic system Place machine in service position. See page No. 92. Drain the hydraulic oil. See page No. Draining of hydraulic oil in page 176. Clean around heads of hexagonal head screws of the hydraulic tank lid. Remove hydraulic tank lid by removing the screws. Remove the tank cover gasket and clean the tank cover gasket area on the hydraulic tank. Clean inside the hydraulic tank by using clean and lint free cloth. Check gasket for damage and if found damage replace it. Apply thin film of grease on both side of the gasket and replace the gasket. Reinstall hydraulic tank lid with the screws and tighten. Fill the hydraulic oil to hydraulic tank. Refer Filling of hydraulic tank in page No. 176. Check the hydraulic oil level, See page No. 175. Place the machine back in service. Gasket installation Hydraulic oil suction strainer, cleaning CAUTION It is very important to keep the hydraulic system free from any impurities, as these can cause abnormal wear and may lead to expensive downtime. Greatest possible cleanliness should be maintained during all handling of hydraulic components and hydraulic oil. Run the machine until the hydraulic oil reaches operating temperature. Place machine in the service position. See page No .92. Service and maintenance Hydraulic system 179 Drain the hydraulic oil tank. See Draining of hydraulic oil in page No. 176. Disconnect the propulsion pump and vibration pump suction hoses on the tank side and plug the disconnected hoses immediately. Remove the two strainers with adapter from the hydraulic oil tank. Clean the strainers with solvent, using a stiff fiber brush to remove imbedded impurities and allow the suction strainer to air dry. NOTICE If embedded materials cannot be removed , replace strainers. Hydraulic tank hoses to disconnect NOTICE Follow below 2 steps when replacing the strainers. Remove the adapter from the old strainer. Apply hydraulic sealant to removed adapter and install it to the new strainer. Apply hydraulic sealant and install the cleaned/new strainers with adapter to hydraulic tank. Remove the plugs and reconnect the disconnected hoses to hydraulic tank. Clean the hydraulic tank. See page No. 177. Fill the hydraulic tank with clean hydraulic oil. Refer to Filling of hydraulic oil in page No. 176. Start the engine and check hydraulic connections for leaks. Strainer with adapter 1 Adapter 2 Strainer Service and maintenance 180 Greasing Greasing Swivel joint (horizontal and vertical) pins, greasing Start the engine and articulate the machine fully to the left. Shut down the engine. CAUTION Wipe off grease nipples and grease gun before greasing, so that dirt and sand are not introduced through the grease nipples into the bearings. Clean the vertical and horizontal swivel pin grease fittings. Apply the recommended grease to each fitting until the grease exits from the sealing surface. See page No. 194 for the proper type of grease. Place the machine back in service. Horizontal swivel pin grease fittings Vertical swivel pin grease fittings Service and maintenance Greasing 181 Bearings, greasing The service life of bushings and pivot pins can be extended considerably, if the machine is greased regularly and in a correct way. The greasing of bearings has two main purposes: - Add grease to the bearing to reduce friction between pin and bushing. - Replace old grease which may contain dirt. The grease in the space inside the outer seal collects dirt and prevents dirt and also water from penetrating into the bearing. V1090184 V1090184 Manual greasing, digging unit Grease the points shown below every 50 hours or weekly. During the first 100 hours, the compactor unit should be greased every 10 hours or daily. NOTICE Under severe operating conditions where mud, water and abrasive material may enter the bearings, the compactor unit should be greased every 10 hours or daily. 1 Wipe off grease nipples and grease gun to avoid dirt and sand entering the bearing. 2 Fill with grease until new, clean grease is forced out through the outer seals. 3 Operate all the cylinders to their end positions without any load on the equipment. Service and maintenance 182 Greasing Lubrication points, (number of nipples in brackets) 1 Steering cylinder both side NOTICE Under severe operating conditions where mud, water and abrasive material may enter the bearings, grease every 10 hours or daily. Wipe off grease nipples and grease gun to avoid that dirt and sand not are entering the greasing system. Fill with grease until new, clean grease is forced out through the outer seals. Shift linkage, lubricating CAUTION Always handle oils and other environmentally hazardous fluids in an environmentally safe manner. 1 Place the machine in service position. See page No. 92. 2 Remove the mounting screws of operator seat platform, tilt open the operator seat platform and secure it with a stopper rod. 1 2 3 Mounting screw Operator seat platform Cowling cover Remove the cowling cover. Locate the shift linkage for engine throttle and lubricate with 2 drops of engine oil. For engine oil specification See page No. 194 . Service and maintenance Greasing 183 Shift linkage for engine throttle 1 Locate the shift linkage for propulsion pump and lubricate with 2 drops of engine oil. For engine oil specification See page No. 194. Shift linkage for propulsion pump Locate the shift linkage for vibration pump and lubricate with 2 drops of engine oil. For engine oil specification See page No. 194. Install the cowling cover. Place back the operator seat platform and secure with mounting screws. Place the machine back in service. Shift linkage for vibration pump Service and maintenance 184 Lubrication and service chart Lubrication and service chart Service and maintenance Lubrication and service chart 185 Lubrication and service chart V1102328 Lubrication chart Service and maintenance 186 Lubrication and service chart Table. Periodic Lubrication Schedule Service interval Ref. no. Description Recommended lubricant Service required Comments 10 Hours ordDaily 1 Engine oil VDS-3, CL-4, 15W-40 S, A Fill to dipstick full mark. See page No.126. 2 Air cleaner S Check indicator Primary filter element clean / change when clog indicates Secondary filter element change @ every 3rd change of primary filter element. 3 Water separator drain D Drain collected water. See page No.131 4 Fuel tank Diesel fuel S, A 285 litre ( 75 US gal) 5 Engine coolant Volvo VCS coolant S, A See page No. Change coolant at 6000 hrs/ 4 yrs. See page No. 141. 6 Engine cooling system S Clean fins. See page No.142 7 Battery Distilled water S, A AR See page No. 151 8 Torque hub oil SAE 85W-90 LS API GL5 S,A FTLH See page No. 167 9 Swivel and cylinder pins MPG-EP2 grease G See page No. 164 10 Center swivel MPG-EP2 grease G See page No. 180 11 Tyre pressure Compressed air S, A 1.1 bar (16 psi) See page No. 165 12 Hydraulic oil Volvo super hydraulic oil ISO VG 46 S, A FTLH See page No. 175 13 Wheel nuts S, T 475 Nm (350 lbf ft) See page No. 165 14 Eccentric oil S, A FTLH See page No. 168 15 Air cleaning system integrity S See page No. 133 16 Shift linkage A See page No. 182 17 Carrier breather CL See page No. 169 100 Hours 18 or monthly Axle housing oil SAE 85W-90 LS API GL5 S, A AR See page No. 158 19 Transmission oil SAE 85W-90 LS API GL5 S, A AR See page No. 156 20 Wheel end oil SAE 85W-90 LS API GL5 S, A FTLH See page No. 158 50 Hours or weekly MOBIL SHC 630 Engine oil Service and maintenance Lubrication and service chart 187 Service interval Ref. no. Description Recommended lubricant Service required Comments 250 hours or quarterly 21 Engine oil VDS-3, CL-4, 15W-40 D, F See page No. 126 22 Engine oil filter See parts manual C See page No. 128 23 Axle housing breather CL See page No. 161 24 Hydraulic filters See parts manual C See page No. 175 25 Engine fuel filters See parts manual and water separator C See page No. 128 and 131 Articulating vertical nuts S, T 678 Nm (500 lbf lt) See page No. 201 D, F 41 litre (10.83 US gal) maximum See page No. 172 500 Hours 26 or semiannually 27 Eccentric oil MOBIL SHC 630 28 Axle housing oil SAE 85W-90 LS API GL5 D, F 11 litre (2.9 US gal) maximum See page No. 160 29 Transmission oil SAE 85W-90 LS API GL5 D, F 1.9 litre (0.5 US gal) maximum See page No. 156 30 Wheel end oil SAE 85W-90 LS API GL5 D, F 1.8 l (0.47 US gal) maximum See page No .158 31 Axle mounting bolts S, T 624 Nm (460 lbf ft) See page No. 201 32 Horizontal swivel nut S,T 1491 Nm (1100 lbf ft) See page No. 201 33 Torque hub oil SAE 85W-90 LS API GL5 D, F FTLH See page No. 170 34 Carrier oil MOBIL SHC 630 D, F 2 l (0.53 US gal) See page No. 169 35 Air filter primary element C See page No.136 36 Poly V-belt S See page No. 130 1000 Hours or annually 37 Hydraulic oil change D, F 180 l (47 US gal) See page No. 176 38 Suction strainer CL See page No. 178 Service functions S – Check C – Change FTLH – Fill to level hole/ mark T — Torque ISO VG 46 A – Add G – Grease D – Drain F – Fill CL – Clean AR – As required Specifications 188 Specifications Specifications, general This section of the manual contains technical specifications for the SD110 Series of Vibratory Soil Compactors. For general information regarding Machine identification, See page No. 17. For general Machine dimensions, See page No. 206. Specifications Recommended lubricants 189 Recommended lubricants General information Lubrication is an essential part of preventive maintenance, affecting to a great extent the useful life of the unit. Periodic lubrication of the moving parts reduces to a minimum the possibility of mechanical failures. For maximum machine life and performance, use only genuine manufacturer-approved lubricants. See 185 and Recommended lubricants. Different lubricants are needed and some components require more frequent lubrication than others. It is important that the specific instructions regarding types of lubricants and the frequency of their application be followed. The lubrication and service chart shows those items requiring regular service and the interval at which they should be performed. To obtain the maximum long-life results from the machine, a regular service program should be followed as recommended in this manual. The suggested intervals are based on average operating conditions. In extremely severe, dusty or wet operating conditions, more frequent lubrication may be necessary. All oil levels are to be checked with the machine parked on a level surface and while the oil is cold, unless otherwise specified. On plug-type check points, the oil levels are to be at the bottom edge of the check port. All grease fittings are SAE standard, unless otherwise indicated. Grease non-sealed fittings until grease is seen extruding from the fitting. Grease fittings that are worn and will not hold the grease gun, or those that have a stuck check ball, must be replaced. Over-lubrication on non-sealed fittings will not harm the fittings or components. But, under lubrication will definitely lead to a shorter component life. Unless otherwise indicated, items not equipped with grease fittings (linkages, pins, levers, etc.) should be lubricated with oil once a week. Motor oil, applied sparingly, will provide the necessary lubrication and help prevent the formation of rust. An anti-seize compound may be used if rust has not formed. Otherwise, the component must be cleaned first. Thoroughly wash all fittings, caps, plugs, etc. with nonflammable, non-toxic cleaning solution before servicing to prevent dirt from entering while performing the service. Lubricants must be at operating temperature before draining. During regular lubrication service, visually check the entire unit to ensure that capscrews, nuts and pins are properly secured. Spot check several capscrews and nuts for proper torque. If any are found loose, a more thorough investigation must be made. Stop the machine if any function does not operate or operates incorrectly. Report the problem to your supervisor or site management. Do not continue operations until the problem is corrected. If necessary, contact authorized distributor for results. Specifications 190 Recommended lubricants Fuel Viscosity (ASTM-D-445) 1.3 to 5.8 centistokes per second at 40 °C (104 °F) Cetane number (ASTM-D-613) 40 minimum at temperatures above 0 °C (32 °F) 45 minimum at temperatures below 0 °C (32 °F) Sulfur content (ASTM-D-129 or 1552) Not to exceed 0.05% by weight Water and sediment (ASTM-D-1796) Not to exceed 0.1% by volume Carbon residue (Ramsbottom, ASTM D-524 or Conradson, ASTM-D-189) Not to exceed 0.25% by weight on 10% volume residue Flash point (ASTM-D-93) At least 52 °C (125 °F) or legal temperature if higher than 52 °C (125 °F) Density (ASTM-D-287) –1 °C to 6 °C (30 °F to 42 °F) API gravity at 16 °C (60 °F) (0.816 to 0.876 Sp. Gr.) Cloud point (ASTM-D-97) 6 °C (10 °F) below lowest ambient temperature at which the fuel is expected to operate Active sulfur Copper strip corrosion not to exceed No. 2 rating after 3 hours at 49 °C (122 °F) Ash (ASTM-D-482) Not to exceed 0.02% by weight Distillation (ASTM-D-86) The distillation curve must be smooth and continuous. At least 90% of the fuel must evaporate at less than 360 °C (680 °F). All of the fuel must evaporate at 385 °C (725 °F) Specifications Recommended lubricants 191 Coolant Only use Volvo Coolant VCS when topping up or changing coolant. To avoid damage to engine and cooling system, different coolants or corrosion protection must not be mixed. When using concentrated Volvo Coolant VCS and clean water, the mixture should contain 40–60% concentrated coolant and 60–40% clean water. The amount of concentrated coolant must never be less than 40% of the total mixture, see table below. Freeze protection down to Mixed-in amount of concentrated coolant -25 °C (-13 °F) 40 % -35 °C (-31 °F) 50% -46 °C (-51 °F) 60% The concentrated coolant must not be mixed with water that contains a high degree of lime (hard water), salt or metals. The clean water for the cooling system must also meet the following requirements: Description Value Total number of solid particles < 340 ppm Total hardness < 9.5° dH Chloride < 40 ppm Sulphate < 100 ppm pH value 5.5-9 Silica < 20 mg SiO2/litre Iron < 0.10 mg Fe/litre Manganese < 0.05 mg Mn/litre Electrical conductivity < 500 µS/cm Organic material, COD-Mn < 15 mg/litre If there is any doubt about the water quality use ready-mixed Volvo Coolant VCS, which contains 40% concentrated coolant. Do not mix with any other ready-mixed coolants since this may result in engine damage. Specifications Recommended lubricants 192 Hydraulic oil Only use Volvo genuine hydraulic oil approved by Volvo Construction Equipment must be used. Do not mix different brands of hydraulic oil as this can lead to damage in the hydraulic system. For the hydraulic oil specification, see page No.194 . Ambient temperature °C °F -40 -40 -30 -22 -20 -4 -10 +14 (B) Oil grade 0 +32 +10 +50 +20 +68 (A) (B) +30 +86 +40 +104 +50 +122 +60 +140 (C) (A) (C) (B) (A) (A) : Ambient temperature recommended for general use of hydraulic system and components. (B) : Ambient temperature guide for machine operation from a hydraulic oil viewpoint only, it does not guarantee the completion machine for other conditions like engine starting performance. In this range a warming-up period is needed to obtain proper performance. (C) : Ambient temperature range to operate machine under special conditions, not a recommendation for general use conditions. Additional recommendation for severe cold areas A field solution for severe cold condition of ambient temperature between -40°C and +20°C. - Type : Anti-wear type hydraulic oil Viscosity characteristic Viscosity index : More than 130 Kinematic Viscosity : Less than 5,000cSt at -40°C, More than 5.6cSt at +90°C NOTICE This value is approximately equivalent to ISO Viscosity grade #22. NOTICE It is minimum theoretical recommendation without the guarantee of machine condition. Lubricant Extreme Pressure Multipurpose Lubricant Extreme pressure (EP) multipurpose gear lubricant is compounded to achieve high load carrying capacity and meet the requirements of either API-GL-5 or MIL-L-2105C. Unless otherwise specified, SAE-90 viscosity oil may be used for yearround service. Low temperature usage is restricted as indicated in the table below. EP Multipurpose Lubricant SAE Viscosity No. Min. Ambient Temp. 75W –40 °C (–40 °F) 80W –26 °C (–15 °F) 85W –12 °C (+10 °F) 90 –7 °C (+20 °F) Specifications Recommended lubricants 193 EP Multipurpose Lubricant SAE Viscosity No. Min. Ambient Temp. 140 +5 °C (+40 °F) 250 +10 °C (+50 °F) Extreme Pressure Multipurpose Grease Extreme pressure multipurpose grease is a lithium soap base grease with a high load carrying capacity. The properties listed in table below are recommended. EP Multipurpose Grease Timken OK Load 18 kg (40 lb) minimum Dropping Point 177 °C (350 °F) minimum Oil Viscosity 75 SUS minimum at 99 °C (210 °F) Water Resistance Excellent Under normal operating conditions, the following consistency grades are recommended: NLGI No. 0 ambient temp. below –18 °C (0 °F) NLGI No. 1 or No. 2 for ambient temp. –18–38 °C (0–100 °F) NLGI No. 2 or No. 3 for ambient temp. over 38 °C (100 °F) Bearing and Gear Lubricant Bearing and gear lubricant provides better thermal and oxidation stability than conventional mineral oils. The lubricant has naturally high viscosity indexes compared to mineral oils, providing lower viscosity at lower temperatures and higher viscosity at higher temperatures. See table below. Bearing and Gear Lubricant Lubricant Viscosity ISO Viscosity Grade 220 API Gravity 31.9 Viscosity Index 152 Viscosity: cSt at 40 °C cSt at 100 °C 216 25.2 Specifications 194 Recommended lubricants Recommended lubricants, specifications The quality of the hydraulic oil and engine oil is important to the satisfactory performance of any hydraulic system and engine. The hydraulic oil serves as the power transmission medium, system coolant, and lubricant. Selection of the proper oil is essential to ensure proper system performance and life. For the specifications and requirements of hydraulic oil and engine oil used in this machine should meet specification mentioned in the below table . Recommended Lubricants, specification Engine oil VDS-3, CL-4, 15W-40 Hydraulic oil ISO VG 46 Drum Eccentric oil Drum Carrier oil Mobil SHC 630 Drum Drive oil Axle Housing oil Axle Brake oil SAE 85W-90 LS Engine Coolant VCS Coolant Grease fittings, pins, seals MPG–EP2 Grease NOTICE For additional information and specifications regarding lubrication, filling capacities and maintenance, See page No. 196 as well as the 185. Specifications Service capacities and change intervals 195 Service capacities and change intervals Environmentally safe handling Handling Fluids and Oil, Fuel Filters 1 When draining fluids, ensure that adequate sealable containers are available and that every care is taken to prevent spillage. 2 Always ensure waste fluids are disposed of in an environmentally safe manner. 3 Always ensure that used filters are stored in secure containers and disposed of in an environmentally safe manner. Lubricant recommendation GENERAL INFORMATION Lubrication is an essential part of preventive maintenance, affecting to a great extent the useful life of the unit. Periodic lubrication of the moving parts reduces to a minimum the possibility of mechanical failures. For maximum machine life and performance, we recommend the use of genuine authorized brand lubricants. See page 185. Different lubricants are needed and some components in the unit require more frequent lubricant than others. Therefore, it is important that the instructions regarding types of lubricant and frequency of the application be explicitly followed. See page 185 for lubrication and service chart. It shows those items requiring regular service and the interval at which they should be performed. A regular service program should be geared to the items listed under each interval. These intervals are based on average operating conditions. In the event of extremely severe, dusty or wet operating conditions, more frequent lubrication than specified may be necessary. All oil levels are to be checked with the machine parked on a level surface and while the oil is cold, unless otherwise specified. On plug-type check points, the oil levels are to be at the bottom edge of the check port. All grease fittings are SAE STANDARD, unless otherwise indicated. Grease non-sealed fittings until grease is seen extruding from the fitting. Over-lubrication on non-sealed fittings will not harm the fittings or components, but under lubrication will definitely lead to a shorter life. Unless otherwise indicated, items not equipped with grease fittings (linkages, pins, levers, etc.) should be lubricated with oil once a week. Motor oil, applied sparingly, will provide the necessary lubrication and help prevent the formation of rust. An Specifications 196 Service capacities and change intervals anti-seize compound may be used if rust has not formed. Otherwise, the component must be cleaned first. Grease fittings must be replaced when they are worn to the point that they fail to hold the grease gun, or when they have a stuck check ball. Lubrication and service schedules To prevent minor irregularities from developing into serious conditions, the following other services or checks are recommended for the same intervals as the periodic lubrication: 1 Thoroughly wash all fittings, caps, plugs, etc. with nonflammable, non-toxic cleaning solution before servicing to prevent dirt from entering while performing the service. 2 Lubricants must be at operating temperature when draining. 3 During regular lubrication service, visually check the entire unit to ensure that capscrews, nuts and pins are properly secured. 4 Spot check several capscrews and nuts for proper torque. If any are found loose, a more thorough investigation must be made. 5 If a defect is detected which requires special maintenance service, stop the machine operation until the defect has been corrected. If necessary, contact the local authorized distributor for assistance. 6 Periodic lubrication requirements and explanation of lubrication and service symbols are listed in the 185. These requirements include lubricant checks and greasing designated areas of the machine. Fuel, lubricant and filling capacities Filling capacities Fuel tank 285 L (75 US gal) Hydraulic oil tank 180 L (47.5 US gal) Transmission oil 1.9 L (0.5 US gal) Engine oil 15.5 L (4.09 US gal) Axle housing oil 1.1 L (0.29 US gal) Drum eccentric oil 41 L (10.83 US gal) Drum Carrier oil 2 L (0.52 US gal) Wheel end oil 1.8 L (0.47 US gal) Radiator Coolant 22 L (5.81 US gal) Specifications Brake Brake Brakes, specifications Table. Brakes Description Specification Service brakes, Type of system. Hydrostatic through the propulsion system. Secondary/Parking brake. Spring-applied, hydraulic released. Location of secondary/parking brakes. Axle, multiple wet disc. Secondary/parking brake release pressure. 15 bar (217 psi). 197 Specifications 198 Wheels Wheels Tyre sizes and pressures specifications Tyre sizes and pressures Tyre size 23.1-26 R3, 8PR Tyre pressure 1.1 Bar (16 psi) Tyre ballast With 3/4th of water Specifications Drum 199 Drum Drum, specifications Table. Vibration Description Specifications Single vibrating drum 2134 mm (84 in.) wide x 1450 mm (59 in.) dia. x 25 mm (1 in.) thick shell Maximum amplitude Minimum amplitude Dynamic force @ frequency SD110 25,401 kgs (56,000 lbs) @ 1,817 vpm (30 Hz.) , (Variable) SD110 16,783 kgs (37,000 lbs) @ 1,817 vpm (30 Hz.) , (Variable) Dynamic force applied SD110 294 kN (66,000 lbs.) SD110 209 kN (47,000 lbs.) Nominal amplitude - eccentric SD110 1.92 mm (0.076 in.) SD110 1.29 mm (0.051 in.) Eccentric moment SD110 6,878 kg/mm (597 lb-in.) SD110 4,609 kg/mm (400 lb-in.) Specifications 200 Specifications Specifications Specifications Specifications 201 Critical mounting torques Use the following recommended torque chart for bolts and nuts of SAE Grade 5 or better quality. If other torques are required, they will be indicated in the text. Table. SAE TORQUE CHART Function of fastener Size Torque N•m lbf ft Axle To Rear Frame M20 x 240 730 540 Frame joint – Articulation vertical pin Nuts M48 678 500 Frame joint – Articulation oscillation (horizontal pin) M72 nut 1491 1100 Engine mounting bracket front M16 229 169 Mount propulsion cable mounting bracket M8 26 19 Steering column to steering valve. M10 61 45 Operator platform assembly to main frame M12 107 79 Assembly carrier plate with shock mounting plate M16 373 275 Assembly shock mount with shock mounting plate M12 x 35 of carrier assembly 149 110 Assembly torque hub and drive plate 3/4 “–16UNF 569 420 Assembly motor mounting bracket and torque hub 5/8 “–11UNC 100 74 Assembly bearing housing with drum M16 x 90 373 275 Assembly shock mount with drum M12 x 30 149 110 Assembly shock mount with drive assembly M16 149 110 Assembly vibration motor with carrier assembly M12 x 35 107 79 Assembly of cover with bearing housing M8 x 20 28 21 Tyre mounting assembly on axle M22 523 386 Electrical system, specification Electrical system Battery 12 Volt, DC, Negative ground Alternator 12 Volt Starter 12 Volt, 4 kw Frame link/articulation, specifications Articulation / Oscillation link Articulation angle ± 40° Oscillation angle ± 17° Gradeability (Theoretical) – Dependant on traction Specifications 202 Specifications Tightening torque, specifications SAE Torque charts Use the following recommended torque charts for bolts and nuts of SAE Grade 5 or better quality. If other torques are required, they will be indicated in the text. 8.8 Metric coarse and fine threads Thread N•m lbf ft M6 10 7.4 M8 24 18 M10 48 35 M12 85 63 M14 140 103 M16 220 160 M20 430 320 M24 740 550 10.9 Metric coarse and fine threads Thread N•m lbf ft M6 12 9 M8 30 22 M10 60 44 M12 105 78 M14 175 130 M16 275 204 M20 540 400 M24 805 549 UNC threads Coarse thread Torque N•m Fine thread. Torque lbf ft. N•m lbf ft 1/4 – 20 12 9 1/4 – 28 15 11 5/16 – 18 26 19 5/16 – 24 28 21 3/8 – 16 50 37 3/8 – 24 57 42 7/16 – 14 80 59 7/16 – 20 89 66 1/2 – 13 122 90 1/2 – 20 136 100 9/16 – 12 176 130 9/16 – 18 197 145 5/8 – 11 244 180 5/8 – 18 278 205 3/4 – 10 434 320 3/4 – 16 481 355 7/8 – 9 698 515 7/8 – 14 773 570 1–8 1051 775 1 – 12 1146 845 1 1/8 – 7 1492 1100 1 1/8 – 12 1668 1230 Specifications Specifications Coarse thread Torque N•m Fine thread. 203 Torque lbf ft. N•m lbf ft 1 1/4 – 7 2088 1540 1 1/4 – 12 2319 1710 1 3/8 – 6 2739 2020 1 3/8 – 12 3119 2300 1 1/2 – 6 3648 2690 1 1/2 – 12 4095 3020 NOTICE Torque values used in this table are based on plated, yellow zinc, dicromate bolts. NOTICE Use high strength thread locking compound on all bolts larger than 5/16 inch. NOTICE Use medium strength “thread locking compound” on bolts 5/16 inch and smaller to fill all gaps between the engaged bolt and nut threads. NOTICE All thread fasteners will have thread locking compound applied, except the following: 1 2 3 4 5 Wheel bolts/nuts Nylon insert nuts Whizlock bolts and nuts Fasteners less than 1/4-inch diameter If specifically instructed not to apply thread locking compound Specifications 204 Machine weights Machine weights Machine weights Valid for serial numbers Model version Serial number start SD110 Bangalore 58001 Table. Weights Description Weight Operating weight 11190 kg (24674 lb) Static weight at tyres 5078 kg (11197 lb) Static weight at drum 6112 kg (13477 lb) Shipping 10941 kg (24125 lb) Machine weights Table. Weights Description Weight Operating weight 11125 kg (24526 lb) Static weight at tires 5025 kg (11078 lb) Static weight at drum 6100 kg (13448 lb) Shipping 10876 kg (23977 lb) Serial number stop Bangalore 99999 Specifications Dimensions Dimensions 205 Specifications Dimensions 206 Machine dimensions The figure below provides a dimensional outline of the SD110 Tier 3 machine, the values of which are defined in the dimensions table. A B D C W G V U E1 E F I J K S S T U1 R H L M O N Q P V1100931 Machine dimension Machine dimensions Letter Description mm Inches A Front width 2310 90.94 B Drum width 2134 84 C Track 625 24.61 D Machine width @ Tire 2100 82.67 E Height, ROPS 3090 121.65 E1 Height