sd110English English CST operator's manual SD110 Serial No. 5233258001- 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 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. Presentation 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. Operating techniques 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. Safety when servicing CAUTION Indicates a potentially hazardous situation which may result in machine damage. Service and maintenance 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 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 instructions ............................................ 33 Operating techniques ............................................ 84 Eco driving ......................................................................... 85 Signalling diagram ............................................................. 86 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 Safety when servicing ............................................ 88 ................................................................................................... 167 Hydraulic system ................................................................... 156 Axles .................................................................. 205 Service history ............. 165 Drum ........................................... 174 Greasing ..................................................................................... 144 Transmission ........................................... 184 Recommended lubricants .... 189 Service capacities and change intervals ................................... 197 Wheels ...................... 141 Electrical system ......................................... 198 Drum ................................................................................................... 188 Alphabetical index ................................ 131 Engine air cleaner ................................................ 124 Engine ....................................................................................................................................................................................................................................................................................................................... 204 Dimensions .......................................................................................................................... 125 Fuel system ............... 199 Specifications ... 116 General inspection of machine .................... 180 Lubrication and service chart ............................... 208 Specifications ....................................... 158 Brake system ...................................................................................................... 163 Steering system .... 195 Brake ......................Table of contents 4 Service and maintenance .............................................................................................................................. 133 Cooling system .......................................................................... 211 ............. 164 Wheels ...................................................................... 200 Machine weights ........................................ 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 Drum vibration Symbol Description Anti-wheel spin Drum vibration control Anti-drum spin High amplitude Manual vibration control Presentation 9 Symbol Description Low amplitude Symbol Description Auto vibration control Frequency (vibration) Vibration control Ignition switch Caution Tie-down points and tow points International symbols Symbol Description On/start Symbol Description 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 Hourmeter Symbol Description 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 Start switch Symbol Description 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 Symbol Description Slow speed Control lever – dual direction . Presentation Machine view 13 Machine view Directional terms The terms left and right. 1 Front 2 Rear 3 Left 4 Right 1 3 4 2 V11053 79 Machine view . when used in this manual. indicate the sides of the machine as seen from the operator seat facing the front of the machine. Presentation 14 Machine view Location of components 11 12 7 15 14 13 16 17 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 15 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 . where permitted limits have been determined and given according to international standards. EMC-directive CE-marking. Any person carrying out changes that affect the safety of the machine is also responsible for the same. Our machines have been tested particularly for electromagnetic interference. A machine or device which meets the requirements should be CEmarked. As proof that the requirements are met.Presentation 16 CE-marking.” 2004/108/EC. EU's EMC directive The electronic equipment of the machine may in some cases cause interference to other electronic equipment. the equipment must be CE-marked and tested on the machine with regard to electromagnetic interference. . If other electronic equipment is fitted to this machine. This EU declaration also covers attachments manufactured by Volvo Construction Equipment. The sound certificate includes both measured external values and guaranteed sound level. which should be kept safe and retained for at least 10 years. the machine meets the applicable “Essential Health and Safety Requirements. 2006/42/EC. when delivered. an EU Declaration of Conformity and a sound certificate regarding sound level in dB (A) are supplied with the machine. EMC-directive CE-marking If this machine is CE-marked. provides a general description of what demands can be made on the machine from a safety point of view. this means that. or suffer from external electromagnetic interference. The EU’s EMC-directive about “Electromagnetic Compatibility.” which are given in the EU Machinery Directive. The CE-marking of the machine and the declaration of conformity also cover the EMC-directive. The documentation is a valuable document. These declarations are issued by Volvo Construction Equipment for each individual machine. The document should always accompany the machine when it is sold. which may constitute safety risks. and in all telephone enquiries or correspondence the PIN must always be quoted. Bangalore. Phone: +91 80 2219 2500 Fax :+91 80 2839 4651 Name & Machine types SD110 Series of Single-Drum.Presentation Product plates 17 Product plates Machine identification Manufacturer Volvo India Private Limited. The product identification plate contains product identification number (PIN). the manufacturing code and machine serial number. Product identification plate . When ordering spare parts. Peenya Industrial area. India. This information should be recorded and kept in a convenient location for future reference. 7 & 8 . in the articulation area. The PIN contains important information about the machine including the model number. Serial number and product range The serial number effectivity for the SD110 Series of compactors covered in this manual is outlined below. Vibratory Soil Compactors. Phase 1. Compactor Series SD110 SD110 Effective with Serial Number Effective from S/N 52332 — 99999 Effective from S/N 58000 — 99999 Product identification plate The product identification plate is located on the front side of the rear frame.560058. 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. 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.Presentation 18 Product plates Engine. Reference numbers: ENGINE TYPE RATING KW/HP @ RPM RATING STD GOVERNING CLASS ENGINE No. Engine identification plate Table. Open the engine hood to access engine identification plate. . Contact your manufacturer’s local authorized dealer or distributor for additional information or assistance as required. If they have been lost or no longer are legible. The decals must be kept free from dirt so that they can be read and understood. understand and follow the information and warning decals which are positioned on the machine. . Refer to the Parts Catalogue for this machine which identifies the proper location and part number (order number) of all decals.Presentation Information and warning decals 19 Information and warning decals The operator should read. they must be replaced immediately. If this machine has a rollover protective structure (ROPS). seat belts must be worn to avoid serious injury or death from being thrown out. 3 Improper operation of this equipment can cause serious injury or death. 5 Rollover of this machine can cause serious injury or death. Read and understand the operator and safety instructions before operating and servicing. A rollover can occur. Never sit on railing around operator compartment. .Presentation 20 Information and warning decals International decals 1 Do not sit on rail. Do not operate this machine near or on an inclined surface. 2 Crush area. Can cause serious injury or death. Stop machine before performing maintenance. Do not operate with guards or shields removed. 4 Rotating fan and belt. Install articulation lock pin before servicing. Can cause serious injury. Always shut down the engine and allow to cool before removing the expansion tank pressure cap. Inhibitor contains alkali. Avoid contact with skin and eyes. . This engine is equipped with an electric heater starting aid. Steam or fluid escaping from the expansion tank can burn. 7 WARNING Use of ether may cause explosion or severe injury. Remove the expansion tank pressure cap slowly to relieve pressure. Injury can result when removing the expansion tank pressure cap. Avoid contact with steam or escaping fluid. Do not use ether.Presentation Information and warning decals 21 6 Radiator (expansion tank). Presentation 22 Information and warning decals Decals/Plates and reflectors V1100949 Location of Decals/Plates REF NO. DECAL 1 2 3 4 5 6 7 Checklist Warning: Rollover Warning: Do not sit on Rails Lube chart Warning: Misoperation Warning: Crushing hazard (each on both side) Warning: Runaway machine QUANTITY LOCATION 1 1 2 1 1 2 1 Cowling frame Steps on hydraulic tank Railings Hydraulic tank Console Machine side frame Console . Volvo recommends that the purchaser use the service program for the non-road engine. 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. Volvo recommends that the owner keep all records and receipts of such maintenance. including the recommended engine emission control maintenance.750 USD for each violation.Presentation USA federal clean air act 23 USA federal clean air act The Federal Clean Air Act Section 203. Customer Assistance Volvo Construction Equipment wishes to help assure that the Emission Control System Warranty is properly administered. These records or receipts should be transferred to each subsequent purchaser of the non-road engine. In order to document that the proper regular maintenance has been performed on the non-road engine. 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. The law prescribes a fine of up to $2. 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. 40 CFR 89.a (3) prohibits the removal of air pollution control devices or the modification of an EPAcertified non-road engine to a non certified configuration. . known as preventative maintenance. The Federal regulations implementing the Clean Air Act for nonroad engines. An example of a prohibited modifications is the recalibration of the fuel system so that the engine will exceed the certified horsepower or torque.1003(a)(3)(i). 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. 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. 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. the fuel's sulfur content should be as low as possible. Check for fuel leaks (with the engine running at high idle): Visually check unions and hose connections. the use of lighter distillate or higher cetane level fuel are recommended. 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. Check for leaks. Engine working conditions and ambient temperature influence the selection of the fuel with respect to cold handling properties and cetane levels. below 0 ºC (32 ºF).Presentation 24 USA federal clean air act Service performed by your local dealer Your local dealer is best suited to give you good. In this way you will assist your local dealer in reducing the time required to do service on your machine. He can tailor a maintenance program for your needs. The diesel fuels recommended for use shall meet ASTM designation: D 975 no. In cold weather conditions. For scheduled service or maintenance. Fuel system Fuel recommendations: The fuel used must be clean. 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. inspections. cetane level and sulfur content are most important when selecting fuel for optimum combustion and minimum wear.05 percent by weight. completely distilled. 2D (T-T) with a cetane level above 42 and sulfur content not exceeding 0. stable and noncorrosive. Distillation range. In order to avoid excessive sedimentation and to minimize the emissions of sulfur dioxide. adjustments. 1D (C-B) or no.). Check for cracks. it is essential that it receives regularly scheduled service. and maintenance. Check the condition of the fuel hoses for: Ageing Cracks Blisters Scuffing Check the condition of the fuel tank: Drain condensation water. Discuss your servicing and maintenance requirements with your local dealer. Check the mounting. (Final boiling point maximum 349 ºC (660 ºF) and cetane minimum 45. . .Presentation USA federal clean air act 25 Check the turbocharger: Visually check for leaks in the intake hoses and exhaust pipe of the turbocharger. 14 1 2 3 4 5 15 16 17 18 19 20 21 22 6 7 8 9 23 24 10 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 11 12 13 V1100601 1. Two speed switch It is a two position (HIGH/LOW) rocker switch. various indicators mounted on it. Hourmeter and mobile charger plug are mounted on the left side of the control console. ignition key switch. horn.Instrument panels 26 Instrument panels Instrument panels Control box which is mounted on control console has following control switches. A decal is placed on it to show HIGH and LOW position. All compaction work must . emergency stop switch. fuel level gauge. When it is positioned to LOW activates front lights to low beam. 2. beacon lamp starts flashing and revolving. Parking brake test switch It is a rocker momentary switch. when the parking brake switch is in ON position. when it is positioned to OFF. left side indicator lamps of the machine activates.Instrument panels 27 be done with the switch in the LOW position. that provides the operator with the means to manually engage the parking brake. Beacon lamp switch (option) It is two position (ON/OFF) rocker switch. NOTICE Machine will not start. Parking brake switch It is a rocker switch. 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. that provides the operator to test the working of parking brake. Turn light Indicator switch It is a three position (LEFT/OFF/RIGHT) rocker switch. . When the switch is positioned to ON . 3. When hazard switch is positioned to ON . right side indicator lamps of the machine activates and when moved to left. Hazard switch It is two position (ON/OFF) rocker switch. turn indicating lamps do not work as turn indicators. while the HIGH speed position is used for travelling. 9. 6. Front head lamps switch (high / low beam) It is a three position (HIGH/LOW/OFF) rocker switch. front lights are off. if the parking brake switch is in OFF position. When it is positioned to ON rear lights are on. 7. When moved to right. 4. 5. Rear working lights switch It is a two position (ON/OFF) switch. When it is positioned to HIGH activates front lights to high beam. NOTICE When hazard switch is on. rear lights are off. Red light is provided on the switch which illuminates. when it is positioned to OFF. . all turn indicating lamps flash simultaneously. fill the fuel. . 11.Instrument panels 28 10. when turned anti-clockwise to the PREHEAT position. Engine coolant indicator It glows when engine coolant temperature is high. when turned clockwise to the RUN position. 14. Emergency stop switch It connects and disconnects electrical power from vehicle circuits. Air filter clog indicator It glows when air filter is clogged. Turning the ignition key back to the STOP position. causing the machine to immediately shutdown and the parking brakes to get engaged. Engine preheat indicator It glows while preheating the engine. Operator has to wear the seat belt properly. with indication of “E” red colour. It is an analogue gauge. It indicates the fuel level in the fuel tank. Stop the machine immediately and check the coolant level. Ignition key switch Ignition key is inserted/removed at the STOP position. 16. 12. If the indicator shows fuel level in “E” red area. Ignition key switch energizes the electrical system to preheat the engine. When the ignition key is released the Ignition switch returns to the RUN position automatically. Seat belt indicator It blinks if operator does not wear the seat belt or seat belt is not put properly. This provides the operator with a means to shutdown the vehicle operation. 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 . When the button is pressed down. turns off the electrical system and stops the engine. When turned further clockwise to the START position the starter motor is engaged. . the main current is turned off. Horn push button Press the horn button to sound the horn and alert personnel to the approaching machine or when changing direction. 15. 13. Fuel level indicator WARNING Stop the engine before filling fuel. “1/2” mark and “F”. 17. This activity is for engine cold-start Ignition key switch energizes the electrical system. Left turn signal indicator It indicates LEFT turn light indicators are on. when alternator is not charging the battery. . 20. It does not work if battery cut-off switch is OFF. Hourmeter It is mounted on the left side of control console. It blinks when turn light indicator switch is pressed ‘RIGHT’ until it is pressed ‘OFF’. It is directly connected to the battery.Instrument panels 29 18. This is to facilitate mobile charging. 22. Right turn signal indicator It indicates RIGHT turn light indicators are on. 19. 23. It displays the engine run time in hours with a resolution of 0. Mobile charger plug It is mounted on the left side of control console. Battery no charge indicator It glows. 24.1 hour. Front lights high beam indicator It glows when front lights high beam switch is ON. 21. It blinks when turn light indicator switch is pressed ‘LEFT’ until it is pressed ‘OFF’. Engine oil low pressure indicator It indicates the engine oil pressure is low. It is connected to the engine governor thru a cable.Other controls 30 Controls Other controls Controls Travel control lever 1 2 1 Travel control lever. The control has three positions. and for no drum vibration mode. To propel the machine forward. vibration control lever to be operated in backward direction. The Propulsion (TRAVEL) Control lever is located at the right side of the operator’s seat. 2 Vibration control lever. It also functions as the control for hydrostatic braking. To have a varying drum vibration frequency with high amplitude. . 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). Move the control upward to obtain engine “HIGH RPM” and move the control downward to obtain engine “LOW RPM”. move the control slowly back to the Stop (S) position. gradually move the control to the Forward position. vibration control lever to be in neutral position. Stop (S). 1 Propulsion control lever. This also provides hydrostatic braking. move the control slowly back to the Stop (S) position. To propel the machine in reverse. similarly to have a varying drum vibration frequency with low amplitude. V1090832 Propulsion control lever. gradually move the control backward to the Reverse position. Forward (F) . vibration control lever to be operated in forward direction. Vibration control lever helps operator to select high or low amplitude and variable vibration frequency depending on the requirement. and Reverse (R) with variable speed ranges in either direction. To stop the travel of the machine. Throttle control The THROTTLE Control is located on the right side of the console in front of operator seat. This control varies machine direction and speed of travel. The Vibration (VPM) Control lever varies the vibrations per minute of the drum. To stop the travel of the machine. 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. Contact an authorised Volvo dealer workshop if the ROPS has been damaged or modified. Ensure the ROPS is correctly installed. The machine can tip over. The machine is provided with roll-over protective structure (ROPS). WARNING Structural damage caused by the machine rolling over or by unpermitted modification weakens the cab ROPS.Other controls ROPS 31 ROPS ROPS WARNING Risk of crushing. . This could result in serious injury. ROPS used in conjunction with a seat belt will lessen the possibility of death or serious injury in the event of a rollover. . Operator comfort. The machine is equipped with a suspension seat that features two adjustments. resistance to lowering. Operator's manual. can be adjusted by rotating the handle clockwise for more resistance and counterclockwise for less resistance to lowering.Other controls 32 Operator comfort Operator comfort Operator seat WARNING Adjusting the seat should always be done when the machine is stationary. locating the seat and then releasing the handle. Keep the manual in the storage compartment so that it is always at hand. storage Operator's manual storage is located in front of operators seat in the control console. The entire suspension seat assembly and attached control console can be positioned forward or reverse by positioning the handle outward. Operating instructions Safety rules when operating 33 Operating instructions Danger zone Safety rules when operating The danger zone of this machine is the immediate area or zone surrounding the machine. DO NOT repair. Therefore. or has been involved in a rollover. Trained and authorized personnel must first notify the operator of their presence and are permitted within the danger zone during machine operation. drill. machine accessories or extensions which would allow contact with the machine if the machine.The machine has been used correctly and has been maintained according to instructions in Service Manuals and the Operator's Manual. General The manufacturer cannot ensure for all possible circumstances that might lead up to a potential hazard. . required skills and necessary tools to properly perform their functions. the combination of warnings listed in this manual and those placed on the machine itself are not intended to be all inclusive. They should also have comprehensive training.No security seals have been broken by unauthorized persons. . DO NOT operate this machine if the sunshade assembly/ROPS or railing assembly got structurally damaged. machine accessories or extensions were to move.The lubricant recommendations in the manual have been followed.Only Volvo genuine spare parts/accessories or attachments that meet Volvo's requirements have been used. Operators and maintenance personnel must be alert to recognize and avoid potential hazards. shows cracks. observe the following rules. . . railing assembly or on the machine assembly unless authorized in writing by the manufacturer. Safety when handling the machine Volvo Construction Equipment is only responsible if: . is not properly secured as originally installed. modify.All modifications and repairs have been performed as prescribed by Volvo. weld on or add attachments to the sunshade assembly/ROPS.Prescribed service and prescribed inspections have been performed at the stipulated points in time. . WARNING For safety. All other persons are not permitted in the danger zone during machine operation. DO NOT operate the machine unless the seat belt conforming to SAE and/ or ASAE standards is fastened. . and may cause damage to the machine or other material property. 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. must be corrected immediately. 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. maintenance and repair of the machine should be stated clearly. The machine must be used in accordance with its designated use as described in the operating manual. . Use of the machine for purposes other than that mentioned (such as for towing other vehicles/equipment) is considered contrary to its designated use. its misuse may constitute a risk to life and limb of the user or of third parties. Define the machine operator’s responsibilities . Nevertheless. 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. The machine must only be operated by safety-conscious persons who are fully aware of the risks involved in operating the machine. The machine is designed exclusively for the compaction of soil. Never operate a machine for which there is no Operator's Manual available.the operator should have the authority to refuse instructions by third parties that are contrary to safety.also with regard to observing traffic regulations . Operating the machine within the limits of its designated use also involves compliance with the inspection and maintenance directives contained in the operating manual. The manufacturer/supplier cannot be held liable for any damage resulting from such use.Operating instructions 34 Safety rules when operating The machine is built in accordance with state-of-the-art standards and recognized safety rules. especially those affecting the safety of the machine. Individual responsibilities of the personnel responsible for operation. An untrained operator may cause serious injuries and fatalities. It is important that the operator reads and follows the instructions in the machine's Operator's Manual. The risk of such misuse lies entirely with the user. Learn to understand the warning plates. setup. Statutory minimum age limits must be observed. Work on and with the machine must be performed by qualified personnel only. symbols and operating instructions for the machine before you start operating. Any functional disorders. e. and parking brake is applied. This applies to the installation and adjustment of safety devices and valves as well as to welding work on load bearing elements. Manuals must always be available at the site where the machine is used. ALWAYS tie back or otherwise secure long hair. This is especially important for persons who work only occasionally on the machine. issuing and/or wearing of personal protective equipment. articulation lock bar/pin is in locked position. 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. Safety when operating on public roads Road signs. NEVER make any modifications to the machine which might affect safety without the manufacturer’s approval. which may be required when considering traffic speed and intensity or other local conditions. wear close-fitting garments and avoid wearing jewelry such as rings. BE SURE all safety instructions and warnings attached to the machine are complete and perfectly legible. must be used. brake. hair. hydraulic and steering systems must be performed by skilled personnel with special knowledge and training for such work. REPORT the malfunction to the proper authority/person. These compulsory regulations may also deal with the handling of hazardous substances. NEVER provide service or maintenance to the machine unless the drum and wheels are adequately chocked.Operating instructions Safety rules when operating 35 Work on the mainframes. or jewelry being caught up in the machinery. SUPPLEMENT operating instructions with detailed working instructions pertaining to the specific work location. STOP the machine immediately in the event of any malfunction. OBSERVE all safety instructions and warnings attached to the machine. . Reading the instructions after work has begun is too late. USE protective equipment wherever required by the circumstances or by law. OBSERVE AND INSTRUCT the user in all other generally applicable legal and mandatory regulations relevant to accident prevention and environmental protection. MAKE CERTAIN personnel are working in compliance with the operating instructions and are alert to risks and safety factors.g. Injury may result from clothing. and traffic regulations. traffic restricting arrangements and other safety devices. ALWAYS ADHERE to prescribed intervals or those specified in the operating instructions for routine checks and inspections. during set up or maintenance. Organizational measures STOW manuals in the manual pouch/box provided on the machine. Prior to starting. Always keep the minimum clearance from overhead power lines. See page No. The manufacturer and local authorized dealer or distributor cannot be held responsible for any damage resulting from such use. 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. The machine must be used in accordance with its designated use as described in this operation and maintenance manual. especially those affecting the safety of the machine. Contact supervisor or manufacturer’s local authorized dealer or distributor with any questions. Use of the machine for any other purpose. See page No. recognize. 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.55 for overhead power line minimum clearances and procedures when operating near overhead power lines. particularly the safety instructions. Operate the machine only when it is in good condition. All personnel must be alert to. Operating the machine near overhead power lines requires special precautions. is contrary to its designated use. Never guess about how to safely operate and maintain this equipment. 8 for an explanation of the intended use. operating or maintaining the machine. Make sure the machine is used only as intended by the manufacturer. and have the required skills and tools to do their jobs. read and understand this manual. Any functional disorders. such as for towing other vehicles or equipment. . The risk of such misuse lies entirely with the user.Operating instructions 36 Safety rules when operating Rotating warning beacon may be used: . Make sure the machine is operated and maintained only by safety-conscious persons who have been authorized.when working on or by the side of the roadway. properly trained.on vehicle during road maintenance work . must be corrected immediately.when the vehicle constitutes a hindrance or impedes other traffic . Always wear or use proper personal protective equipment while operating or maintaining the machine. and avoid potential hazards associated with performing their work. Electrocution hazard DANGER Risk of electrocution Working near or making contact with overhead power lines may lead to electrical flash-over and electrocution. to work on the electrical system or electrical components of the machine. bracelets and necklaces. Be sure that work on the machine chassis. such as during set up or maintenance. Allow only skilled electricians. and traffic regulations. Always tie back or otherwise secure long hair. Always be sure that persons who operate or work on the machine have read the operating instructions and especially. Statutory minimum age limits must be observed. including observing traffic regulations. Avoid wearing jewellery such as rings. Injury may result from clothing. . 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. hydraulic and steering systems is performed only by skilled personnel trained to perform such work. 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. Make certain personnel work in compliance with the operating instructions and are alert to risks and safety factors. or jewellery being caught in the machinery. Supplement operating instructions with detailed work instructions for specific work activities and locations. and wear close-fitting garments. setup. brake. Observe all safety instructions in this manual and on decals attached to the machine. or persons instructed by them. 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. All electrical work must be performed in accordance with electrical engineering guidelines and local regulations. hair. maintain and repair the machine. Be aware of personal safety hazards. the issuing and/or wearing of personal protective equipment. These compulsory regulations may also deal with the handling of hazardous substances. The operator should have the authority to refuse instructions by third parties that are contrary to safe practices.Operating instructions Safety rules when operating Selection and qualification of personnel 37 Make sure only qualified personnel work on and with the machine. Describe clearly the responsibilities of individuals who operate. Use personal protective equipment whenever required by work circumstances or by law. Define the machine operator responsibilities for safe machine operation. Do not wear radio or music headphones while operating the machine. Always adhere to prescribed intervals listed in the operating instructions and maintenance instructions for routine checks. safety shoes. if there are any questions about the operation or maintenance of this machine. broken. or missing parts. Never guess – always check! Remember. additions or conversions to the machine which might affect safety without the manufacturer’s approval in writing. Performing scheduled preventive maintenance consistently will extend the life of the machine. Ensure that routine maintenance and lubrication procedures are dutifully performed. Always use personal protective equipment. Replace any guards and shields removed. eye and ear protection. Stop the machine immediately in the event of any malfunction. while operating or maintaining the machine. mount them securely. Do not operate the machine while under the influence of drugs or alcohol. such as hard hats. Observe all fire fighting procedures. This applies to the installation and adjustment of safety devices and valves as well as to welding work on loadbearing components.Operating instructions 38 Safety rules when operating Be sure all safety Warning and instruction decals attached to the machine are complete and readable. Never perform service or maintenance on the machine in any manner other than that which is described in this manual. Never make any modifications. Repair or replace any malfunctioning. . 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. Contact supervisor. Refer to the preventive maintenance schedule located in maintenance instructions in this manual. Pre-start inspection Inspect the machine daily. Do not wear jewellery while operating the machine. failure to adhere to these safety instructions may result in serious injury or even death. Report the malfunction to the proper supervisory personnel. or any manufacturer’s authorized dealer or distributor. and clear all maintenance tools before starting the engine after maintenance. Mandatory safety measures Never clean. lubricate or service the machine when it is running. inspections and maintenance procedures. Always fill the fuel tank either outside or in an adequately ventilated room. Refer to the decal location drawing in the safety section of this operation and maintenance manual at safety related decals. Ensure that all necessary precautions are taken to ensure that the machine is used only when in a safe and reliable condition. gradeability. banks. This machine should only be brought into service where the machine is applicable to the situation and conditions of the construction site. Know the location of the emergency stop (E-Stop) switch. Never fill the fuel tank with the engine running. Know the capabilities and limitations of the machine with respect to speed. width of the driving lane. such as holes. Smoking is prohibited within 15 m (50 feet) of the machine while refuelling. and braking. soundproofing elements and exhausts. Check for any maintenance and repair warning tags placed on the machine. as well as the transporter dimensions and weight.Operating instructions Safety rules when operating 39 Verify that all safety warning and instruction decals are in place and readable. Always wipe up any spilled fuel. steering. while the machine is located near an open flame. water melt pits. . or curb and street boxes. underground culverts. This includes the height and width of the overall machine. Use caution when refuelling. Remove any dirt. emergency shut off equipment. Operate this machine only if all safety and protective devices originally provided by the manufacturer are in place and in good condition. Working within dangerous areas Check for dangerous conditions in the work area. Do not operate the machine until repairs have been made and the warning tags have been removed by authorized personnel. These instructions are as important as any other equipment on the machine. This includes the stability and condition of the ground. 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. Ensure that all safety and protective devices are in place and in good working order. Avoid any operation that might risk machine stability. Avoid any operation that might sacrifice safety. This includes removable safety devices. Safety instructions governing operation Avoid any operating mode or procedure that might sacrifice safety. manhole covers. or while operating personnel are smoking. Be aware of the dimensions of the machine. debris or foreign material from the operator platform to reduce the danger of slipping. See page No. Watch the indicators during start-up and shutdown procedures in accordance with the operating instructions. Check that accessories have been safely stowed away before setting the machine in motion. Ensure that the forwardstop-reverse (FSR) propulsion control lever is in the S (stop) position. Before starting the engine. Always secure the machine to prevent inadvertent movement and unauthorized use before leaving it. . Make sure no one is in danger or at risk before starting the machine or setting it in motion. Starting Always use hand rails and steps to get on and off the machine. Check the surrounding area for pedestrians. If the machine is not operating properly. Always wear the seat belt when operating the machine. ensure that the parking brake control is in the “applied” position. Always make sure the machine is in a condition that meets those regulations. Check the machine at least once each shift for damage and report damage to your supervisor. Read and follow all safety warning and instruction decals. Always keep a safe distance away from the edges of building pits and slopes. Always maintain a three-point contact when climbing onto or off of the machine as shown. 26 for parking brake control details. Check the surrounding area for pedestrians. or lifting it with a crane. Before attempting to start the engine. Make sure no one is in danger or at risk before starting the machine or setting it in motion. Make sure bridges are rated to hold the weight of this machine before crossing them. See operating instructions in this manual. shut down the machine immediately. underpasses. Check that braking. Observe all the valid traffic regulations when traveling on public roads. steering. Turn on the lighting system in conditions of poor visibility and after dark.Operating instructions 40 Safety rules when operating Make sure there is sufficient clearance when moving the machine through tunnels. and under power lines. 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. signalling and lighting systems are fully functional before moving the machine. Provide an observer when loading and unloading the machine from a truck or trailer. 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. Do not work in the vicinity of overhanging banks or on grades that could cause the machine to slide or roll over. flames and lighted smoking materials away from batteries. and know who has the responsibility for signalling. 4 Remove the booster cables in the reverse order of their connection as soon as the engine has started. Never change to a lower gear on a slope. Never climb on or off the machine while it is operating or moving. Never carry passengers. Look in all directions before changing your direction of travel. When using another machine to boost-start. 1 Connect the Positive (+) terminal of the booster battery to the Positive (+) terminal of the discharged battery. Close all sound baffles during operation. Know the area in which you are working. travelling. it must not touch the machine that is being started. Always wear eye protection when working on or near batteries. Never boost-start a frozen battery. This may result in uncontrolled machine movements. Familiarize yourself with work site obstructions and any other potential hazards in the area. Follow these procedures when boost-starting the machine. away from the battery. always change before . Operating Make sure no person or obstruction is in your line of travel before moving the machine. 3 Follow all recommended engine starting procedures. it will explode. 2 Connect the Negative (–) terminal of the booster battery to the best ground point on the machine.Operating instructions Safety rules when operating Start the engine only while at the operator console. Keep sparks. Use extreme caution and be observant when operating the machine in close quarters or in congested areas. or loading and unloading. Always remain seated with the seat belt on when operating the machine whether compacting. Avoid side hill travel. 41 Boost starting WARNING Never boost-start the machine by connecting directly to the starter motor. Always operate up and down slopes. Know the hand signals used (required) for particular machine operations and machine travel. Be aware that lead acid batteries generate explosive gases while charging. No riders. Maintenance Follow the start-up and shutdown procedures set forth in the operating instructions before performing any work on the machine. 92 . To stop the machine. Always retract the seat belt fully before leaving the operator station.Operating instructions 42 Safety rules when operating reaching it. Read and follow all safety warning and instruction decals. inspection and/or repair. Apply the parking brake. Refer to safety rules for starting. Ensure that the maintenance area is adequately secured as outlined below. Turn ignition switch to OFF. Exhaust fumes can kill. Always maintain a “three-point contact” when climbing on or off the machine. Never allow anyone to stand within the machine’s articulation area when the engine is running. Always be sure that all control switches are in the OFF position and that the engine is shut down before leaving the machine. if it is completely shut down for maintenance and repair work. Control engine speed with the throttle control. See page No. Position the throttle control to “idle rpm”. If this is not practical. Always mount and dismount the machine using walkways. Do not run the engine in a closed building for an extended length of time. steps and handrails provided. especially when parking in areas of heavy traffic. Always keep the FSR propulsion control lever in low speed range close to the S (stop) position when climbing or descending hills. Install the articulation lock pin. and lock all lockable compartments. Reduce the travel speed by moving the FSR propulsion control lever slowly toward the S (stop) position. and warning devices to warn others of the machine. Use proper flags. Always perform compacting operations at high engine speed. barriers. Secure the machine against inadvertent starting. slowly push the FSR propulsion control lever to the S (stop) position. conversion or adjustment of the machine and its safety oriented devices. Never jump from the operator platform to the ground. This includes the operation. park the machine at a right angle to the slope and block the drum and wheels. and any work related to maintenance. Stopping Always park the machine on solid level ground. Control the machine travel speed with the FSR propulsion control lever. Do not tow the machine except as explained in the operating instructions of this manual. Always use the correct tools and workshop equipment when performing maintenance on the machine. especially connections and threaded unions. 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. never use aggressive detergents. Never work or stand under suspended loads. Check de-energized parts for the presence of power. Clean the machine. and hydraulic fluid lines for leaks. Keep all platforms and standing surfaces free from mud. Check and inspect machine electrical equipment at regular intervals. lubricant. Clean the machine at the end of each workday while it is still warm. Repair or replace faulty parts immediately. or chains. chafe marks and damage after cleaning. Ground or short circuit any parts found to contain residual power. Perform maintenance and repair work only if the machine is positioned on stable and level ground and has been secured to prevent movement. Use spreader bars to ensure equal weight distribution during lifting as well as avoid contact with the machine. must be corrected immediately. Use lint free cleaning rags. snow and ice. Cover or tape all openings which – for safety and functional reasons – must be protected against water. NOTICE Lifting the machine must only be carried out by trained personnel.Operating instructions Safety rules when operating 43 for procedure to secure the machine for maintenance and repair work. Special care must be taken with electric motors and switch gear cabinets. Tighten any screwed connections that have been loosened during maintenance and repair. Remove all covers and tapes applied for that purpose after cleaning the machine. Examine all fuel. Faults. of any traces of oil. such as loose connections or scorched cables. apply the parking brake. Lifting the machine – When raising the machine off the ground. cables. steam or detergent penetration before cleaning the machine with water. Use lifting gear that is in proper operating condition and with adequate lifting capacity. dirt. fuel or preservatives before carrying out maintenance or repair. Insulate adjacent live parts and elements. . Attach the lifting apparatus only to the machine’s designated lifting points using properly rated lifting straps. Ensure during cleaning of the machine that temperature sensors do not come into contact with hot cleaning agents. loose connections. steam jet (high pressure cleaning) or detergents. See page No. Do not work on hydraulic lines while the engine is running and the system is under pressure. Inspect hydraulic hoses and screwed connections regularly. Do this immediately upon completion of the maintenance and repair activity. Disconnect the battery cables when working on the electrical system. Use a piece of cardboard to check for leaks. leakage. deformation. Remember that hot hydraulic fluid will cause serious burns. Faults. fitting separation. Do not work on any hydraulic hose or fitting until the pressure has been relieved correctly. Be sure the battery area is well ventilated (clear of fumes) should it be necessary to connect a jump battery or battery charger. Replace them if they show signs of chafing. Look for leaks and signs of damage.Operating instructions 44 Safety rules when operating Replace and check any safety devices removed during setup. cleaning. It is dangerous to operate the machine without these decals. blistering. or examining the machine with the engine running. the articulation lock pin is in the locked position. such as loose connections or scorched cables must be corrected immediately. Always wipe up any spilled fuel. 92. maintenance or repair activities. cracking. . Never use your hands to check for hydraulic leaks when inspecting an hydraulic system. Do not perform service or maintenance on the machine unless the drum and wheels are adequately blocked. Replace faulty parts immediately. open flames or smoking within 15 m (50 feet) of the machine while refuelling. Be sure the battery charger is turned off when making the connections if battery charging is required. Fumes from the battery can ignite by a spark and explode. and always wear gloves and eye protection while checking. Wait for hot hydraulic fluid to cool down before disconnecting hydraulic lines. whenever possible. and the parking brake is applied. Inspect hydraulic hose assemblies visually at regular intervals. Refer to the parts manual for the proper location and part number of all decals. brittleness. Avoid servicing. corrosion or other damages which may affect their function and strength. Never fill the fuel tank of the machine with the engine running. Do not alter the engine governor settings from those indicated in the engine manual and the engine option plate. The hydraulic fluid remains under pressure long after the engine has been stopped. Be sure the machine is adequately secured to prevent movement. Do not permit sparks. Always replace damaged or lost warning and instruction decals. Inspect and check the machine’s electrical equipment at regular intervals. Disconnect the battery cables when welding on the machine. Allow only qualified and authorized personnel to weld. Ensure the clamp on the earth cable (ground) has a good contact near the joint to be welded. The fittings. Use only genuine original equipment manufacturer’s replacement parts. qualified and authorized personnel. Follow the manufacturer’s instructions for the specific equipment involved. Wear appropriate personal protective equipment. Use only original fuses with the specified current rating. Get immediate treatment if hydraulic fluid has been injected under your skin. Follow established lockout. Make sure all welding work is carried out by fully trained. This will protect the warranty and ensure the safe operation and optimum performance of the machine. Remove dust and other flammable substances and make sure that the premises are adequately ventilated to avoid the risk of fire and explosion. Welding safely on the machine Proper welding procedures are necessary in order to avoid damage to the electronic controls and to the bearings. All work must be done in accordance with electrical engineering guidelines and local regulations. flame cut or perform any grinding work on the machine. flame cutting and grinding operations. Depressurize the hydraulic system sections to be serviced before servicing them. or instructed person working under the supervision and guidance of a skilled electrician. grease and other chemical substances. Lay and fit hydraulic lines properly. Clean the machine before starting welding. Switch off the machine immediately if trouble occurs in the electrical system. Remove electrical power to components of the machine before performing inspection. Allow only a skilled electrician. There may be a risk of explosion and fire. maintenance and repair work. . instructed. Be careful when handling hot fluid or parts to avoid burning or scalding. to work on the electrical system of the machine. Ensure that all consumable and replaced parts are disposed of in an environmentally safe manner and in accordance with local guidelines and regulations.Operating instructions Safety rules when operating 45 Remember that fluid penetration from a pin-hole leak can cause serious injury or death. Observe all product related safety regulations when handling oil. tagout procedures. All regulations and safety stipulations must be strictly adhered to as well as the generally recognized standards for performing welding work. lengths and quality of the hoses must comply with the technical requirements. Ensure that no connections are interchanged. ice. Place blocks at the front and rear of the machine while securing to the transport vehicle. . Entrust to experienced persons only the fastening of loads and the instructing of crane operators. Use only properly rated tiedowns and securing equipment. Use proper blocks in front and rear of the wheels of the transporter when loading the machine. lights. mud. and roading Securing the machine for transport – When securing the machine for transport. and proper height and width. Be sure that the transporter is on level ground when loading the machine. Approach the transporter loading ramps squarely to make sure the machine does not drop off the side of the ramp. Be sure ramps are of adequate strength. oil. use only the designated tie-down locations to fasten the to the transport vehicle. If the transport vehicle will be stationary for an extended period of time without being moved.Operating instructions 46 Safety rules when operating Ensure that the welding current does not flow through any bearings. Ensure the articulation lock pin is secured in the locked position before transporting the machine. Obey all traffic regulations and be sure that the proper clearance flags. Always use a ramp when loading the machine on the transporter. Ensure the transporter is on level ground. frost and other material that can become slippery. Do not attempt to load the machine on the transporters without knowledge and experience with the operation of the machine. low angle. towing. and warning signs. Transporting. Shut the engine down. Know the approximate stopping distance at any given speed. and at overhead objects be sure you can safely pass beneath them. including the “Slow Moving Vehicle” emblem. are properly displayed when moving the machine on public access roads. Refer to operating instructions of this manual for proper brake release procedures. apply the parking brake. Use proper blocks to secure the drum and rear wheels of the machine once it is loaded onto the transporter. and lock all lockable compartments. Use only appropriate means of transport and lifting gear of adequate capacity. Keep the transporter deck clean of clay. Know the overall height of the machine and transporter. The personnel giving the instructions must be within sight or sound of the operator. Decals on the machine indicate the locations to tie the machine down. Observe height and weight regulations. do not remove the blocks until transporting the machine. 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 Starting 49 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. 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. Do not smoke near batteries 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. Use of the machine for purposes other than that mentioned (such as for towing other vehicles/equipment) is considered contrary to its designated use. 1 Read and understand the Operator's manual. 4 The machine operator's must operate the machine in such a way that the risk of accidents is minimised both for the operator. 7 The machine operator must follow the rules and recommendations given in the operator's manual. Take part in the emergency plan for the working site or other instructions about measurements in case of accidents. symbols and operating instructions for the machine before you start operating. . seated in the operator's seat. 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. Only take necessary action so as to reduce the effect of damage. If possible leave the machine in position. may be in the cab when operating. Wait for further instructions from the site management. Never operate a machine for which there is no Operator's Manual available. It is important that the operator reads and follows the instructions in the machine's Operator's Manual. Learn to understand the warning plates. An untrained operator may cause serious injuries and fatalities. The VOLVO/ supplier cannot be held liable for any damage resulting from such use. The risk of such misuse lies entirely with the user. 2 NEVER make any modifications to the machine which might affect safety without the VOLVO’s approval. Operator duties WARNING Machine operators must have sufficient skills and knowledge of the content in the Operator's Manual before operating the machine. This applies to the installation and adjustment of safety devices and valves as well as to welding work on load bearing elements.Operating instructions Safety rules when operating Accidents 51 WARNING Only the operator. Accidents and also incidents should be reported to the site management immediately. Avoid action which may make an investigation more difficult. but also pay attention to any statutory and national regulations or specific requirements or risks that apply on the work site. 3 The machine is designed exclusively for the compaction of soil. especially personal injuries. All other personnel must keep at a safe distance from the machine. frayed or loose stitching is found. articulation lock bar/pin is in locked position. Inspect belt hardware and fabric. On sloping terrain. 4 ALWAYS wear or use the proper safety items required for your personal protection. 3 The machine must be operational. especially personal injuries. 15 ALWAYS KEEP at a safe distance from the edges of building pits and slopes. 14 MAKE SURE there is sufficient clearance when crossing underpasses. 12 NEVER provide service or maintenance to the machine unless the drum and wheels are adequately chocked. 13 ALWAYS SWITCH ON the lighting system in conditions of poor visibility and after dark. i. . or jewelry being caught up in the machinery. always adapt your travelling speed to the prevailing ground conditions. 9 OBSERVE all safety instructions and warnings attached to the machine. Replace if hardware is damaged or if strap is nicked. 9 The machine operator must be in charge of the working area of the machine. and parking brake is applied. 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. bridges and tunnels or when passing under overhead lines.. Machine operator safety 1 AVOID any operational mode or procedure that might sacrifice safety. REPORT the malfunction to the proper authority/person. wear closefitting garments and avoid wearing jewelry such as rings. 6 CHECK the seat belt regularly for wear or damage. 16 AVOID any operation that might be a risk to machine stability. 2 TAKE all necessary precautions to ensure that the machine is used only when in a safe and reliable condition. 3 Only take necessary action in order to reduce the effect of damage. 5 ALWAYS tie back or otherwise secure long hair. hair. 7 USE protective equipment wherever required by the circumstances or by law. 10 BE SURE all safety instructions and warnings attached to the machine are complete and perfectly legible.e fault which can cause accidents must be rectified. Prevent person from walking or standing near the machine while operating the machine . Accidents 1 Accidents and also incidents should be reported to the site management immediately. medicine or other drugs. Avoid action which may make an investigation more difficult. 8 OBSERVE all safety instructions and warnings attached to the machine.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. 17 NEVER CHANGE to a lower speed on a slope always change before reaching it. 11 STOP the machine immediately in the event of safety relevant malfunction or change in machine behavior during operation. Injury may result from clothing. 2 If possiable leave the machine in proper position. The following substances. lead acid batteries generate explosive gases. Handling hazardous materials The following information is provided to assist the machine owners and operators. skin contact and breathing fumes Avoid ingestion. 22 KEEP SPARKS. 20 AVOID personnel injury by making sure the compactor does not touch the other machine while it is being jump started.Operating instructions Safety rules when operating 53 18 ALWAYS SECURE the machine against inadvertent movement and unauthorized use before leaving the driver’s seat. are contained in or emitted by this machine and may be hazardous to health if exposed to or used incorrectly. 21 NEVER jump start a frozen battery. Do not touch controls or anything metals. skin contact and breathing fumes Avoid ingestion. skin contact and breathing fumes Avoid ingestion. While charging. skin contact and breathing fumes Avoid ingestion. do not enter or exit the machine. stay well away from the machine until the storms passes. 19 During electrical storms. 23 ALWAYS wear safety glasses when working on or near batteries. Further information may be obtained by contacting the local manufacturer’s authorized distributor. If you are off the machine. Substance Antifreeze Hydraulic oil Engine lubricating oil Preservative grease Rust preventive Engine fuel Battery electrolyte SAE gear oil Substance Engine exhaust fumes Engine exhaust fumes Electric motor dust (brushes/ insulation) Precaution Avoid ingestion. as it will explode. shown in below. remain seat with the machine stationary until the storm passes. skin contact and breathing fumes Avoid ingestion. lead acid batteries generate explosive gases. skin contact and breathing fumes Avoid ingestion. skin contact and breathing fumes Avoid ingestion. . flames and lighted smoking materials away from batteries. skin contact and breathing fumes Precaution Avoid breathing fumes Avoid buildup of fumes in confined spaces Avoid breathing during maintenance The following substances may be produced during the operation of this machine and may be hazardous to health. If you are in the machine. While charging. Batteries contain substances dangerous to your health and the environment. Remain in the machine while it is in contact with the power line. Suffocation hazard WARNING Exhaust fumes contain carbon monoxide. which is fatal when inhaled in a confined area. If this comes in contact with your skin rinse it off with soap and lots of water. 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. maintain a safe distance from overhead electric lines. Breathing exhaust fumes from internal combustion engines can lead to loss of consciousness. a colorless. Electrocution hazard WARNING Working near power lines may lead to electrical flash-over. odorless gas. stay in the operator seat until told that the power is off. Failure to obey this Warning could result in carbon monoxide poisoning and death. If work is to be carried out close to overhead lines. Never operate internal combustion engines in an enclosed area with poor ventilation. Warn personnel outside the machine not to touch it. carbon monoxide poisoning and suffocation. . drive the machine away from the danger zone. When operating 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. Do not dispose as general trash. Do not touch any metal surfaces in the cab. 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. Remember battery electrolyte is corrosive. Failure to obey this Warning could result in electrocution or death.Operating instructions 54 Safety rules when operating Battery disposal WARNING The battery electrolyte contains caustic sulphuric acid. keep this machine away from them. Avoid breathing exhaust fumes and be sure engine operation will not cause a concentration of toxic emissions. If contact cannot be broken. Dispose of batteries marked with the symbol shown below according to local and national regulations. Operating instructions Safety rules when operating Power lines.000 to 750.000 50.000 550.4 20 26 35 43 46 Know the location and voltage of all overhead power lines at the job site before operating the machine. Always keep the minimum clearance from overhead power lines. Operating the machine near overhead power lines requires special precautions. see the table below.000 500. Consider the long-span power line. Consider all overhead power lines to be 'live' with electric power. Keep the following in mind to ensure safety when operating: Operate the machine at slower than normal operation in the vicinity of power lines. Contact your local authority if there is any question whether the power lines are energised or their voltage.000 to 550. Pay attention when travelling over uneven ground that could cause the machine to lose balance.000 Minimum distance m 3 4 5 6 8 11 13 14 ft 10 13 16.000 69. Electrocution is possible if anyone touches both the machine and the ground. Always keep the minimum clearance from overhead power lines. minimum clearance 55 DANGER Risk of electrocution Working near or making contact with overhead power lines may lead to electrical flash-over and electrocution.000 to 500.000 250.000 to 250. Contact with overhead power lines may cause the power to trip out temporarily and power may be re-energised automatically without warning. Always be aware of the very serious risk if your machine comes in contact with high voltage. even those that are supposed to be without electric power.000 to 138.000 more than 750. Electrical flashovers may damage the machine and injure the operator at relatively great distances from the power line.000 138. which can sway and reduce the clearance.000 to 69. Remember that the voltage in the power line determines the safety distance. Always contact your local authority before starting work operations near overhead power lines. Minimum clearance from overhead power lines Voltage of overhead power lines Volt (V) up to 50. High voltage is lethal and may be powerful enough to destroy machine and attachments. . Prohibit persons from touching the machine or its load before it is confirmed to be safe. Failure to follow this instruction can result in electrocution or death! . If contact cannot be broken. Warn personnel outside the machine not to touch any part of the machine and to stay away. jump out as far as you can without touching any wires or the machine — keep upright and away. or drive the machine out of the overhead power lines if you can. 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. If you need to get out because of fire. Find out what actions need to be taken if a person has been exposed to an electrical flashover.Operating instructions 56 Safety rules when operating Keep all persons away from the machine whenever it is close to power lines. stay in the operator seat until told that the power is off. Stay in the operator seat and lower any raised parts in contact with the overhead power lines. The lubricant recommendations in the manual have been followed. Therefore.No security seals have been broken by unauthorized persons. Any functional disorders. Nevertheless. drill. 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. . modify. weld on or add attachments to the sunshade assembly/ROPS. the combination of warnings listed in this manual and those placed on the machine itself are not intended to be all inclusive. required skills and necessary tools to properly perform their functions. its misuse may constitute a risk to life and limb of the user or of third parties. Operators and maintenance personnel must be alert to recognize and avoid potential hazards. especially those affecting the safety of the machine.Only Volvo genuine spare parts/accessories or attachments that meet Volvo's requirements have been used. The machine is designed exclusively for the compaction of soil. The machine is built in accordance with state-of-the-art standards and recognized safety rules. General The manufacturer cannot ensure for all possible circumstances that might lead up to a potential hazard. They should also have comprehensive training. The machine must only be operated by safety-conscious persons who are fully aware of the risks involved in operating the machine. or has been involved in a rollover. and may cause damage to the machine or other material property.Prescribed service and prescribed inspections have been performed at the stipulated points in time. . WARNING For safety. is not properly secured as originally installed. observe the following rules. The machine must be used in accordance with its designated use as described in the operating manual. must be corrected immediately.The machine has been used correctly and has been maintained according to instructions in Service Manuals and the Operator's Manual. Use of the machine for purposes other than that mentioned (such . DO NOT repair. shows cracks.All modifications and repairs have been performed as prescribed by Volvo. DO NOT operate this machine if the sunshade assembly/ROPS or railing assembly got structurally damaged.Operating instructions Measures before operating 57 Measures before operating Safety when handling the machine Volvo Construction Equipment is only responsible if: . Never operate a machine for which there is no Operator's Manual available. . These compulsory regulations may also deal with the handling of hazardous substances. 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. 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. hydraulic and steering systems must be performed by skilled personnel with special knowledge and training for such work. 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. An untrained operator may cause serious injuries and fatalities. setup.the operator should have the authority to refuse instructions by third parties that are contrary to safety. Define the machine operator’s responsibilities . It is important that the operator reads and follows the instructions in the machine's Operator's Manual. symbols and operating instructions for the machine before you start operating. maintenance and repair of the machine should be stated clearly. Organizational measures STOW manuals in the manual pouch/box provided on the machine.also with regard to observing traffic regulations . Learn to understand the warning plates. Individual responsibilities of the personnel responsible for operation. 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. OBSERVE AND INSTRUCT the user in all other generally applicable legal and mandatory regulations relevant to accident prevention and environmental protection. Statutory minimum age limits must be observed. Work on and with the machine must be performed by qualified personnel only.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. brake. issuing and/or wearing of personal protective equipment. Manuals must always be available at the site where the machine is used. and traffic regulations. e. NEVER make any modifications to the machine which might affect safety without the manufacturer’s approval. . .Carry out daily service. . . Reading the instructions after work has begun is too late.Adjust the operator seat and fasten the seat belt. OBSERVE all safety instructions and warnings attached to the machine. and parking brake is applied.Clean the dust around engine. This applies to the installation and adjustment of safety devices and valves as well as to welding work on load bearing elements. In cold weather. which can cause damage. ALWAYS tie back or otherwise secure long hair.Adjust and clean the mirrors. during set up or maintenance.Check that there are no persons in the vicinity of the machine. . . hair. . . MAKE CERTAIN personnel are working in compliance with the operating instructions and are alert to risks and safety factors.Check that hoods and covers are closed.Operating instructions Measures before operating SUPPLEMENT operating instructions with detailed working instructions pertaining to the specific work location.Check that there is sufficient fuel in the fuel tank. This is especially important for persons who work only occasionally on the machine. BE SURE all safety instructions and warnings attached to the machine are complete and perfectly legible.Check the level of hydraulic fluid. . STOP the machine immediately in the event of any malfunction.Make sure fire extinguisher if equipped is fully charged.Check for cracks on frame. . 59 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. Injury may result from clothing. refill if required. or jewelry being caught up in the machinery. .Read the Operator's manual. NEVER provide service or maintenance to the machine unless the drum and wheels are adequately chocked. ALWAYS ADHERE to prescribed intervals or those specified in the operating instructions for routine checks and inspections. . observe the following rules. WARNING For safety.Check that the battery disconnected switch is switched on. battery and cooler.Inspect steps and handholds for damage or loose parts. loose parts or leaks.g. Make necessary repairs if needed. REPORT the malfunction to the proper authority/person. . USE protective equipment wherever required by the circumstances or by law. V1065709 . wear close-fitting garments and avoid wearing jewelry such as rings. articulation lock bar/pin is in locked position. make sure that the freezing point of the coolant is sufficiently low and that the lubricating oil is intended for winter use.Check that there are no faulty. . .Inspect the failure of gauges in the instrument panels. .Operating instructions 60 Measures before operating .Travel alarm should be on before operating the machine. .Inspect working and other lights for proper operation. Sound the horn and let other workers and bystanders know you are starting the machine. . CAUTION If the engine sounds or runs strangely or if strong vibrations arise. Do not touch control levers or switches during start. ENSURE that the propulsion (travel) control is in the “STOP” position and parking brake control is in the “Applied” position. Pull up on the Emergency Stop Switch Turn the key to run position. NOTICE Allow the engine to run at low or idle rpm for a few minutes before normal operation. the ignition switch must be turned to stop position immediately. Warm up the machine. Sound the horn before beginning operation. Wait 30 seconds before a new attempt. CAUTION Do not crank the starting motor for more than 15 seconds to avoid overheating the motor. 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. 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. Release the key when the engine has started. Never rise the engine during the warm up period. Turn the key to the starting position.Operating instructions Starting engine 61 Starting engine NOTICE BEFORE starting the engine. warming up Hydraulic system. this may result in malfunctions. 2 Start the engine and let it idle for five minutes. When the oil is cold it is viscous. 1 Apply the parking brake. . 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. the engine speed must not exceed 1200 rpm. Moving the machine a short distance (for example when loading onto or off a trailer) can be done without a complete warm up. If one or more of the machine functions are forced against the end-of-stroke position without having first warmed up the system. warming up CAUTION Do not rush the warming up of the oil. It is important that the oil in the hydraulic system is properly warmed up before operating the machine. as forced warming up may damage the machine. Apply the parking brake and leave the engine idling so that the oil in the engine. In such situations. 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. transmission. The hydraulic functions of the machine therefore operate slower than when the oil is warm.Operating instructions 62 Hydraulic system. hydraulic system and axles is warmed up and becomes sufficiently fluid to provide proper lubrication. These operations must be executed with great care. V1092791 Vibration lever Drum vibration frequency selection Material Natural Frequency TYPE OF SOIL Sand Sand Sand Sandy Gravel Clay (Pad Foot) Silt Silt Firm Loose Uniformly Graded Wet Dry NATURAL FREQUENCY 1900 vpm 1400 vpm 1300 vpm 1500–1700 vpm 1200 vpm 1500–1700 vpm 900–1300 vpm 32 Hz 23 Hz 22 Hz 25–28 Hz 20 Hz 25–28 Hz 15–22 Hz . Select low amplitude for final or thin layer of soil.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. by moving vibration lever to Low position. and when soil is loose and granular. Return the control to S or “STOP” for normal braking. 12 ALWAYS LOOK in all directions BEFORE changing your direction of travel. ALWAYS operate up and down slopes.. . 9 DO NOT work in the vicinity of overhanging banks or on grades that could cause the compactor to slide or roll over. this will release the Brake.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. 5 Push the Parking Brake Switch to Off position. EXHAUST FUMES CAN KILL. Familiarize yourself with work site obstructions and any other potential hazards in the area. 2 Remove and stow the Articulation Lock Pin in it’s stowed position. 7 KNOW the area in which you are working. 13 DO NOT attempt to control compactor travel speed with the throttle control. the greater the speed in that direction. When operating the compactor maintain the engine speed at full “Operating rpm. traveling. The further the control is moved from the S or “STOP” position. 3 Move the throttle Control lever to the low operating RPM. The compactor is to be on solid. 2 NEVER CLIMB up or climb down the compactor while it is in motion. The HIGH speed is to be used only for “roading” the compactor. 4 USE EXTREME CAUTION and be very observant when operating in close quarters or congested areas. PROPELLING THE MACHINE 1 Check the travel and work area for people and obstructions. 10 AVOID side hill travel. level ground and the Parking brake is to be in the applied position. 3 ALWAYS remain seated with the seat belt on when operating the compactor whether compacting. 5 NEVER carry passengers.” 14 DO NOT run the engine in a closed building for an extended length of time. ALWAYS keep the propulsion (travel) control lever in low speed range close to the “STOP” position when climbing or descending hills. 8 KNOW and USE the hand signals required for particular jobs and know who has the responsibility for signaling. 11 NEVER allow anyone to stand within the compactor’s articulation area when the engine is running. or loading/ unloading. 6 Move the Propulsion Control Lever to achieve the desired direction and safe speed of travel as determined by the conditions. 6 CLOSE all sound baffles during operation. 4 Position the Two-Speed Control Switch to LOW position. Operating instructions Operating 65 7 Once the compactor is in motion. 6 Turn the Ignition Switch to the OFF position. 4 Install the Articulation Lock Pin in it’s locked position. 8 Fill the diesel fuel tank with clean Diesel Fuel to prevent condensation in the tank. SHUTDOWN PROCEDURE 1 Move the Vibration Control lever to the stop position. Allow the engine to idle for a few minutes to avoid high internal heat rise and allow for heat dissipation. move the vibration control lever to the desired eccentric rotation direction and amplitude. NOTICE When the eccentrics are engaged/disengaged. 9 Lock all lockable compartments and remove the ignition key. 5 Position the throttle control lever to the ‘Idle RPM position. This is a normal condition and is caused by the eccentric weights changing position. . there is a noise clunk that will be heard. 2 Move the propulsion control lever to S or stop position. 3 Apply parking brake and make sure the parking brake indicator is glowing. or the direction of rotation is changed. 7 Choke the machine drum and wheels with suitable wedges. This will in turn release the brake pressure and the machine is free to move as directed. Once the switch is placed in the OFF position. Once the charge relief pressure is obtained. The parking brake is released when the engine is running and the park brake switch is moved to the OFF position. description The parking brake system on this machine consist of a spring applied brake located in the rear axle of the machine. This allows the charge pressure of the charge pump to flow into the brake release circuit.Operating instructions 66 Braking Braking Parking brake. electrical current is supplied to the brake-destroke valve and valve is actuated. The parking brake is released by hydraulic pressure supplied from the charge pump of the propulsion pump. . the oil supplied to the brake at the axle via a hydraulic hose will overcome the force of the brake spring. The parking brake is turned ON and OFF by means of a switch located on the instrumental panel. If this is not possible. ALWAYS move the propulsion control lever to “STOP” position . 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. 3 USE proper flags. . position the throttle control to “low /idle rpm”. turn ignition switch to OFF and lock all lockable compartments. barriers and warning devices.Operating instructions Stopping 67 Stopping Stopping 1 ALWAYS park the compactor on solid level ground. apply the parking brake. especially when parking in areas of heavy traffic. install the articulation lock pin. 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. If available. inspection and repair. NOTICE In any work concerning the operation.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. conversion or adjustment of the machine and its safety oriented devices or any work related to maintenance. Clean drum scrapers of accumulated material. lock all vandal protection devices on the machine. 4 Touch up the paint finish to avoid rusting. such as for the off-season. 13 Protect the tyres and all exposed rubber components against direct sunlight. 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. 1 Position the machine on level ground. NOTICE Follow all safety instructions for application and removal of the anti-rust agent provided by the agent manufacturer. 6 Apply the parking brake. 2 Apply the parking brake. 5 Position the machine on level ground. 12 Treat exposed parts with anti-rust agent which can be easily removed at a later date. Correct as required. 7 Place the battery disconnect switch in the OFF position. 1 Inspect machine for any damage or missing components. 5 Remove all valuable items from the machine which can be easily stolen. Prepare machine for use from storage. 2 Inspect machine for any damage or missing components. 9 Remove all valuable items from the machine which can be easily stolen. 1 Lubricate the machine. 3 Place all switches and controls in the OFF position. 11 Place the battery disconnect switch in the OFF position. 14 Plug exhaust pipe. Perform this maintenance before bringing the machine back into service following storage. 4 Shut down the engine and remove the key. Correct as required. 2 Fill the fuel tank and hydraulic tank to the maximum level. 3 Remove all tyres and rubber protective covers .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. 7 Place all switches and controls in the OFF position. 3 Wash the machine and allow it to dry. 8 Shut down the engine and remove the key. 6 Close and lock all doors and accessible areas. The sequence of the steps may change dependent on storage location. 10 Close and lock all doors and accessible areas. 5 6 7 8 9 Check all fluid levels and add as necessary. Check air cleaner elements condition. Check tyre pressure and correct if necessary. Correct as required Place the battery disconnect switch in the ON position. Check alternator belt tension and correct if necessary.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. . 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. Make sure that the battery disconnect switch is in OFF position. Check booster cables and clamps for damage. See page No. Make sure that the machines do not come into contact with one another. The booster battery must have the same voltage as the battery for the engine requiring the jump starting. 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” . Before connecting the booster cables Before connecting the booster cables. Make sure that the propulsion control lever is in STOP position. 1 Check that the booster battery or any other power source has the same voltage as the battery on the machine. Connection of the booster cables To start with the booster battery following steps must be followed. Make sure that the ignition switch is in OFF position. Make sure that the vibration control lever is in neutral position. WARNING Batteries may explode due to the current surge if a fully-charged battery is connected to a completely discharged or frozen battery. 2 Do not under any circumstances disconnect the cables from the batteries on the machine. Make sure that the parking brake is in applied position. Make sure that cables and clamps are tightly connected. WARNING Battery charging generates hydrogen gas. an open flame or a spark near the battery may cause a powerful explosion. Short-circuiting. Make sure ventilation is adequate when charging batteries. be sure to check the following: Booster cables and clamps must be appropriately dimensioned for the size of the battery. 147 to access the battery. in the battery compartment of the rear frame. . etc. NOTICE Make sure that the clamps are tightly connected with the battery terminals. which may be explosive. 4 Connect the negative (-) terminal of the booster battery to the grounding of the machine to be jump started. corrosion. Never smoke near batteries. Personal injuries may be sustained. 6 After the cables are connected. make sure that the positive (+) and negative (-) clamps do not touch. 8 Crank the engine of the machine to be jump started for a maximum of 30 seconds. Troubleshooting. Wait two minutes between starting attempts. wait 5 minutes before starting the machine.Operating instructions 72 Measures in case of machine failure NOTICE When connecting the cables. 7 Start the engine with the booster battery. then the positive clamp cable “A”. A BOOSTER BATTERY BATTERY OF THE MACHINE TO BE JUMP STARTED B MACHINE TO BE JUMP STARTED V1076862 Connection of booster cables 5 Turn the battery disconnect switch to ON position . see page Decal locations for checklist decal location. general Pre-start check Prior to attempting to start the engine refer to the checklist decal located in the operator area. Failure to follow directions listed on this checklist may prevent the operator from starting the engine. turn OFF the machine with booster battery. . 9 Once the engine has started. 10 Remove the negative clamp cable “B” first. then attempt to start the engine that needs to be jump started. Troubleshooting charts Engine will not start Symptom Starter does not rotate Possible cause Emergency stop switch pushed down sensing parking brake is applied condition FSR lever not in stop position Fuse FL1 and F1defective Battery discharged Battery disconnect switch off Battery cable connections loose or disconnected Starter relay fault Ignition switch defective Starter solenoid or starter defective Starter does rotate Empty fuel tank Defective wiring Fill. Learn to understand the warning plates. If the cause of the problem or solution cannot be determined when following the troubleshooting chart below. WARNING Always read safety instructions and warnings before operating. . it is recommended to read through this manual. for specifications Solution Check emergency stop switch/reset if required Parking brake release switch Turn ignition key on and off Move FSR lever to stop position Check console fuses and replace Service must be performed by authorised and trained personnel Turn switch on Clean and tighten terminal connections Service must be performed by authorised and trained personnel.Operating instructions Measures in case of machine failure WARNING 73 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. In the event of a fault. symbols and operating instructions for the machine before you start operating. see page No. contact the manufacturer’s local authorized dealer or distributor. 196 Service must be performed by authorised and trained personnel. Improper operation and maintenance is the most frequent cause of machinery faults and problems. see page No. see page No. see page No. check for fuel line leaks and loose connections. Always use winter grade fuel in winter. see page No. 194 for engine oil specifications Clean or replace element. 136 Service must be performed by authorised and trained personnel Battery cable connections loose or disconnected Using too high a viscosity oil in low ambient temps Fuel line blockage due to wax separation in winter Blocked air cleaner element Incorrect valve clearance Defective fuel injectors Fuel pump failure Defective turbo charger Engine making excessive fumes SYMPTOM Engine making excessive fumes POSSIBLE CAUSE Engine oil level too high SOLUTION Drain engine oil to correct level. see page . see page No. and bleed fuel system. see page No. Service must be performed by authorised and trained personnel Check oil level. 141.71 for boost starting Clean and tighten terminal connections.129 .136 Service must be performed by authorised and trained personnel Blocked air cleaner element Low compression due to the poor condition of the valves or incorrect clearance Engine overheats — stop engine immediately SYMPTOM Engine overheats — stop engine immediately POSSIBLE CAUSE Excessive dirt on cooling system Engine coolant level too low Engine belt broken Engine oil level low Thermostat defective Blocked cooling air flow SOLUTION Clean the cooling fins Check coolant level. see page No.Operating instructions 74 Measures in case of machine failure Difficult starting and poor/irregular performance SYMPTOM Difficult starting and poor/irregular performance POSSIBLE CAUSE Low battery power Battery discharged SOLUTION Service must be performed by authorised and trained personnel Service must be performed by authorised and trained personnel or see page No. 147 Use appropriate oil grade for ambient temperature conditions. see page No.194 for engine oil specifications Change fuel filters. 126 Service must be performed by authorised and trained personnel . Clean or replace element. see page No. check If a fault occurs with a component or function. .Operating instructions Measures in case of machine failure Low engine oil pressure — red warning light illuminates SYMPTOM Low engine oil pressure — red warning light illuminates POSSIBLE CAUSE Low engine oil level (low engine oil pressure warning light should illuminate) Lubrication system leak SOLUTION 75 Add oil to correct level. See page No. 126 for details Stop engine and check for leaks and tighten any loose fittings on the system oil Fuses. replace the associated fuse with an exact replacement. ratings and associated circuits. 153 for details on fuse identification. lifting straps. WARNING Incorrect or faulty equipment or improper towing methods may cause accidents. Tie down and tow point locations are located on each side of the machine. The following instructions are to be followed if it becomes necessary to tow the compactor. In such cases. Towing a disabled machine NOTICE In the event of an engine problem or other malfunction. it may become necessary to tow your compactor. transport the machine on a trailer. WARNING Incorrect or faulty equipment or improper towing methods may cause accidents. Therefore. the brake and steering functions will be severely limited.81 for location of machine tie down and tow point locations. Attach to the compactor at the tie down and tow points only. shackles and hooks with sufficient lifting capacity. To tow the compactor requires disengaging the propulsion system and releasing the spring-applied brakes. Disengaging the propulsion system Make sure that the parking brake switch is in the “Applied” position. towing should only be performed in an emergency situation by experienced and trained personnel and only for the shortest possible distance (see towing). see page No. . If possible. Therefore. WARNING If the engine cannot be started.Operating instructions 76 Retrieving and towing Retrieving and towing Retrieving and towing WARNING Always use classified cables. carefully follow the instructions given below. carefully follow the instructions given below. Open both the bypass valves to engage the bypass function. for the use of tow chains on highways. to control steering.Operating instructions Retrieving and towing Make sure that the drum and wheel chocks are in place. Make sure that the operator is seated in the operator's seat with seat belt put on. See page No. NOTICE Steering of compactor is limited. 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. Move the propulsion control lever in the operator's compartment to the full “Forward” for towing the machine in forward direction. This will ensure sufficient braking capabilities. . if not check for release of parking brake. Check with the local regulations and laws. is at least as heavy as the machine being towed. which does the towing. 77 Propulsion pump Propulsion pump bypass function engagement Locate and gain access to the multifunction valve cartridges of the propulsion pump. Make sure that the vehicle. to be able to pull and stop both machines.78 NOTICE Machine runaway condition could occur. as the hydraulic system do not receive power from engine. Move the propulsion control lever in the operator's compartment to the full “Reverse” for towing the machine in reverse direction. when towing the compactor. as additional rotation will generate external leakage. Do not leave the machine with the brakes released after towing. Do not rotate more than three revolutions. NOTICE While towing observe that the machine wheels are free to rotate. Releasing the spring-applied brakes. Release the parking brake in the axle. NOTICE Manual release of parking brake is only for towing purpose. Release the external hand pump pressure and disconnect. . follow the below procedure for releasing the parking brake. Chock the wheels and drum. To close the bypass valve in propulsion pump. Manual release of parking brake NOTICE For Drum drive option. NOTICE Machine runaway condition could occur. Clean for any oil spillage. Tighten the bypass actuator to a torque value of 41 N•m (30 lbf•ft). read the towing instructions. Disconnect the pilot pressure line and connect to the external hand pump to brake valve pilot pressure port. Releasing Locate the pilot pressure line on the brake valve. excessive pressure can damage the seal Applying Applying the parking brake. Do not leave the machine with the brakes released after towing. Switch the parking brake to released condition.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. before releasing the brake manually. CAUTION Plug hoses and connections immediately. tighten the bypass actuators in clockwise direction about 3 revolution. NOTICE Do not exceed the brake release pressure 24 bar (350 psi). Connect the pilot line to brake valve. Increase the brake line pressure using hand pump to maximum pressure of 24 bar (350 psi) to release the brake. The starter inhibitor will be out of operation when the engine is subsequently started. Manual release of axle brake Loosen the nuts of screws provided for the manual release on the axle. 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. NOTICE There are 4 set of screws and nuts are provided on the axle (2 Nos. Move the nuts backwards by 8 mm.Operating instructions Retrieving and towing Manual release of parking brake 79 WARNING Always block the wheels before mechanically releasing the parking brake to prevent the machine from rolling. on rear side of the axle) to release the brake manually during towing or emergency. either left or right side of the axle. considering one side at a time. Axle brake release screw tightening . NOTICE Tighten screws maximum by one turn. on front & 2 Nos. Using wrench tighten the screws in an alternate sequence. WARNING All changes to the adjusting screws must take place with the engine turned off. by 1/4 turn at a time to compress the bellevelle washers and disengage the braking units. 2 Nut. 78 Check the parking using parking brake switch.76 Parking brake adjustment after towing. checking of function Put back the machine in service. Apply grease to the screws. See page No. Install all parts into the arm and tighten the screws in alternate sequence.Parking brake. The starter inhibitor will be out of operation when the engine is subsequently started. Replace the seals. Axle brake release adjustment Actions after recovering and towing WARNING All changes to the adjusting screws must take place with the engine turned off. Axle brake release screw adjustment 5 Adjust screws to obtain a gap of 34 mm (allowable tolerance +0. To put back the machine to service To Re-engage the propulsion system. . 3 Seal.Operating instructions 80 Retrieving and towing Parking brake adjustment after towing.5 mm) in relation to the arm. 6 Lock the screw position with the nut. 7 Make sure that the gap maintained between the axle arm and the screw head top is 34 mm. 1 2 3 4 Remove screws complete. See page No. Adjustment after manual release 1 Screw. NOTICE Hold the screws into the position while locking the nuts to maintain the gap of 34 mm. with nuts and seals. See page No. Decals on the unit indicate the locations to tie the unit down. use only the designated tie-down locations to fasten the unit to the transport vehicle. Place chocks at the front and rear of the unit while securing to the transport vehicle. and the overall dimensions of the machine. do not remove the chocks until transporting the unit. 3 Tie-down machine using a chain and tensioning device or other appropriate equipment to the tie-down points. Transporting the machine SECURING THE UNIT FOR TRANSPORT . block the wheels of the trailer.Operating instructions Transporting machine 81 Transporting machine Before driving machine on public roads. Use only properly rated tiedowns and securing equipment. 6 Drive machine onto transporter. . Securing the machine to the transporter 1 After loading the machine to the transporter. 2 Block the drum. 4 The driver of the transport must be aware of its total weight. 7 Shut down the engine. A signal person must assist the operator with any necessary warnings. apply parking brake and lock all lockable compartments. If the transport vehicle will be stationary for an extended period of time without being moved. Clean the trailer surface and loading ramps. load on the axles. ensure that articulation lock pin is in the locked position. Loading the machine under its own power 1 2 3 4 Choose level ground which will solidly support the vehicle. Before loading machine.When securing the unit for transport. check with a supervisor for instructions and information with respect to local traffic regulations regarding construction machinery. 5 Approach the transporter loading ramps squarely to make sure machine does not drop off side of ramp. ALWAYS use a ramp when loading the machine on the transporter. USE proper chock blocks in front and rear of the wheels of the transporter when loading the machine. and proper height and width. ENSURE the articulation lock bar/lock pin is secured in the locked position before transporting the machine. DO NOT attempt to load the machine on the transporters without knowledge and experience with the operation of the machine. Tie-down and wheel chocking locations USE only appropriate means of transport and lifting gear of adequate capacity. oil. KEEP the transporter deck clean of clay. . mud. low angle. frost and other material that can become slippery. apply the parking brake. USE proper chock blocks on the front of the drum and rear of the wheels once loaded onto the transporter. The personnel giving the instructions must be within sight or sound of the operator.Operating instructions 82 Transporting machine V1100948 Lifting. 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. POSITION the machine on the transporter or hauling vehicle centred from side to side and apply the brake. ENTRUST to experienced persons only the fastening of loads and the instructing of crane operators. and lock all lockable compartments. Be sure ramps are of adequate strength. SHUT the engine OFF. intersections. total weight. and other obstacles along the intended route. tie-down equipment and methods comply with all applicable transport regulations in the jurisdictions where the equipment is loaded/unloaded or in transit. tunnels. especially when encountering overhead objects. KNOW the overall height. Ensure all transport devices. See page No. load on the axles and the overall dimensions of the of the machine and hauling vehicle. For dimensions and Machine weights. Observe height. bridges.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. 206 and 204 . width and weight regulations along the intended route to ensure safe passage of the equipment at all times. . As opposed to a static roller where speed of travel matters very little to the compaction process. Learn to understand the warning plates. Never operate a machine for which there is no Operator's Manual available. 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. An untrained operator may cause serious injuries and fatalities. . The speed of travel of a vibratory roller has a tremendous effect on the compaction results. symbols and operating instructions for the machine before you start operating. 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. a vibratory roller needs “dwell” time for each vibration to develop its potential.83 km/hour (3mph) usually do not develop the compaction needed. Watch for bystanders and never allow anyone to be near the machine while operating. It is important that the operator reads and follows the instructions in the machine's Operator's Manual. in proportion to the increased travel speed. Travel speeds of more than 4.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. This means that travel speed is of the utmost importance if maximum consolidation is to be accomplished. the engine speed should be kept low when not compacting.Operating techniques Eco driving 85 Eco driving To utilise the system in the best way and at the lowest fuel consumption. . . If two or several operators use the same signal man. or movement that is required. due to a big load. lowering. use a signal man. the livelier the signal man's movements should be. The faster lifting.g. e. 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 86 Signalling diagram Signalling diagram If the operator's visibility is restricted. determine ahead of time how the lift is to be done and how signals shall be given to each operator. Operating techniques Signalling diagram 87 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 HORIZONTAL DISTANCE Hands indicate relevant distance . information and warning texts are given in each section.Safety when servicing 88 Safety when servicing Safety concerns everybody! Always follow the instructions in the machine's operator's manual. Those who do not follow the safety instructions and observe the warnings in this manual must make sure that their work method is safe. and warranty claims will be denied. or work methods than those described in this publication are used. Otherwise. WARNING WARNING SYMBOL This symbol is shown at various points throughout the manual. A safety-conscious person and a well-maintained machine make for a safe. 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. Machines seldom cause accidents. Volvo Construction Equipment rejects all responsibility if other tools. e..g. Volvo designs and manufactures machines with a high level of safety as well as effectiveness. does not replace guards. climbs on slippery machine parts instead of using a ladder. NOTICE Lifting with a jack must only be carried out by trained personnel . 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. instead people often do. Other safety rules. there is a great risk of accidents. If other spare parts than genuine Volvo are used then Volvo Construction Equipment cannot be held responsible for machine damage. uses the wrong tools for the job. always use genuine Volvo spare parts intended and adapted for the machine. lifting devices. perhaps even accidents that result in fatalities. or does not follow them. In order to maintain safe and efficient function. effective and profitable combination. 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. hearing protection and safety goggles must be used. and trained to use the proper tools and equipment to carry out the service task in a correct way. platforms. Before you begin any service work on the machine: Service work which is not carried out in the correct way is dangerous. Use spreader bars to ensure equal weight distribution during lifting as well as avoid contact with the unit. USE lifting gear that is in perfect condition and with adequate lifting capacity.When raising the unit off the ground. ALWAYS USE specially designed or otherwise safety oriented ladders and working platforms when doing overhead assembly work. dirt. CLEAN 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. apply the parking brake. Attach the lifting apparatus only to the unit’s designated lifting points using properly rated lifting straps. it must be placed in the service position. especially connections and threaded unions. or chains. WARNING During service. conversion or adjustment of the machine and its safety oriented devices or any work related to maintenance. NEVER work or stand under suspended loads. All service work should be carried out by a qualified technician who is having sufficient knowledge of the machine. cables.Safety when servicing 89 WARNING If work must be done on the machine before it has cooled down. always observe the start up and shutdown procedures set out in the operating instructions and the information on maintenance work. NOTICE No work must be carried out on the machine until you have acquired the appropriate knowledge to do so. landings and ladders free from mud. In any work concerning the operation. ALWAYS USE the correct tools and workshop equipment when performing maintenance on the machine. LIFTING THE UNIT . steps. handrails. beware of hot fluids and hot components that can cause severe burns. fuel or preservatives before carrying . inspection and repair. Never use machine parts as a climbing aid. snow and ice. ENSURE that the maintenance area is adequately secured. If the machine is completely shut down for maintenance and repair work. of any traces of oil. KEEP all handles. See page 99. ENSURE the safe operation. CUT off the power supply to parts of the machine on which inspection.must be protected against water. Switch off the machine immediately if trouble occurs in the electrical system. and hydraulic fluid lines for leaks. loose connections. AVOID. REPAIR or REPLACE defective parts immediately. steam or detergent penetration before cleaning the machine with water. Use lint free cleaning rags. ALWAYS replace damaged or lost decals. EXAMINE all fuel. DON'T fill the fuel tank with the engine running. steam jet (high pressure cleaning) or detergents. for safety and functional reasons . SWITCH OFF battery disconnect switch and DISCONNECT the battery cables when working on the electrical system or when welding on the compactor. Refer to the parts manual for the proper location and part number for all decals. WARNING All forms of open fire and smoking should be avoided when filling the fuel tank. ENSURE during cleaning of the machine that temperature sensors do not come into contact with hot cleaning agents. ENSURE that all consumable and replaced parts are disposed safely and with minimum environmental impact. . COVER OR TAPE all openings. lubricant. BE SURE the battery area is well ventilated (clear of fumes) should it be necessary to connect a jump battery. while near an open flame. maintenance or repair purposes and checked immediately upon completion of the maintenance and repair work. BE SURE the battery charger is “Off” when making the connections if battery charging is required. Fumes from the battery can ignite by a spark and explode. cleaning. REPLACE any safety devices removed for setup. optimum performance and safety of your warranty by using only genuine manufacturer’s replacement parts. or while smoking. DO NOT alter the engine governor settings from those indicated in the engine manual. USE only original fuses with the specified current rating.Safety when servicing 90 out maintenance/repair. 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. 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. TIGHTEN any screwed connections that have been loosened during maintenance and repair. NEVER use aggressive detergents. servicing. REMOVE all covers and tapes applied for that purpose after cleaning machine. maintenance and repair work is to be carried out. or examining the machine with the engine running. ALWAYS wipe up any spilled fuel. whenever possible. cut marks and damage after cleaning. Special care must be taken with electric equipments. lengths and quality of the hoses must comply with the technical requirements. WAIT for fluid to cool down before disconnecting. as well as diesel fuel. INSPECT hydraulic hoses at regular intervals and immediately replace if they show signs of chafing. flame cut or perform any grinding operations on the machine unless expressly authorized as there may be a risk of explosion and fire. blistering. DO NOT work on any hydraulic hose or fitting until the pressure has been properly relieved. Use approved containers and methods to handle and dispose of machine fluids. Defects such as loose connections or scorched cables must be rectified immediately. brittleness. fitting separation. Ensure that no connections are interchanged.e. Oils and fuels are hazardous to the environment. 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. Use an authorized disposal and recycling company. Be aware of the risk of fire. throat and on skin). . Take special care to keep oils away from these sensitive body parts. Use a piece of cardboard and always wear gloves and safety glasses. Hot hydraulic fluid will cause severe burns. cracking. OBSERVE the product related safety regulations when handling oil. eyes. Be careful when handling hot conscionable items. The hydraulic fluid remains pressurized long after the engine has stopped. have a corrosive effect on mucous membranes (i.Safety when servicing 91 INSPECT the electrical equipment of machines at regular intervals. Fluid penetration from a pin hole leak can cause severe injury or death. grease and other chemical substances. Safety when handling oil and fuel When changing oil in the engine or hydraulic system. leakage. deformation. flame cutting and grinding operations. NEVER use your hands to check for leaks when inspecting an hydraulic system. DO NOT weld. 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. Engine and hydraulic oils. The fittings. Take special care not to spill or discharge these fluids. (risk of burning or scalding). GET immediate attention if fluid has been injected under your skin. remember that the oil may be hot and can cause scalding or burn injuries. ENSURE hydraulic lines are laid and fitted properly. as well as the service & maintenance sections in the Operator's and Service Manual.Safety when servicing 92 Service position Service position Service position CAUTION Before starting any work. before opening up the machine areas to conduct any maintenance or repairs to the machine. The service technician must take the necessary precautions to prevent dirt and debris from entering sensitive areas of the machine. 116. 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. CAUTION Maintain greatest possible cleanliness. . See page No. For cleaning prior to repair. which could cause damage to expensive machine systems and components. 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. 2 Apply parking brake. 8 Allow hydraulic pressure to drop (as required). 4 Place the articulation lock pin from the stowed to the articulation lock position. turn the steering wheel slowly until the articulation lock pin drops in place and is fully engaged with swivel frame. remove and retain the ignition key. 5 Shut down engine. NOTICE Indicator light on the parking brake switch glows. 10 Allow the engine to cool down. 9 Turn battery disconnect switch to OFF position. 3 Bring the engine throttle lever to low rpm position. Bring the propulsion control lever to STOP position. 5 Shut down the engine. 4 Install the articulation lock pin. 7 Block the wheels and drum.Safety when servicing Service position 9 10 1 6 5 2 8 93 4 7 Service position 1 Bring the propulsion control lever to STOP position. 3 Bring the engine throttle lever to low rpm position. . Remove and retain the ignition key. 6 Attach warning tag to steering wheel. While seated on the operator seat. 2 Apply the parking brake. 3 7 V1101141 Service Position 1 Move the machine on a level and a stable surface. WARNING Block the wheels to prevent accidental machine movement. before working on the hydraulic system. Axle wheel end oil.Safety when servicing 94 Service position 6 Attach a warning tag to the steering wheel that the machine is out of service. NOTICE Certain troubleshooting procedures and system tests will require that battery terminals remain connected. 7 Block the wheels and drum with appropriate wedges or wheel chocks. beware of hot fluids and hot components that can cause severe burns. 144. 174. Transmission oil. NOTICE Follow all local regulations concerning lockout or tag-out procedures. . See page No. 8 Allow hydraulic oil pressures to drop. Drum eccentric oil. Axle housing oil. NOTICE Changing of engine oil. when brake is being held in the released position. See page No. Drum carrier oil and Torque hub oil require the machine oil to be at operating temperature. NOTICE Hydraulic pumps and hoses will retain pressurized oil. 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. 10 Allow the engine to cool. WARNING If work must be done on the machine before it has cooled down. and hoods on the machine are in place before starting the engine and operating the machine. If a system is opened without first depressurizing it. Volvo CE will not accept any responsibility if other lifting devices. Turn off the engine before removing any protective covers or opening any engine hoods. dirt. Machines used in environmentally contaminated or health hazardous areas must be equipped for such operations. and ice. Oil and other liquids dangerous to the environment . Defective tools or equipment must be repaired or replaced. diesel fuel. Always use a hard hat. Do not wear loose-fitting clothes or jewellery that may get caught and cause injuries. Make sure that no tools or other objects that may cause damage have been forgotten in or on the machine. See page NO. Accumulated pressure remains in the system even when the engine has been turned off. Make sure that the ventilation is adequate if you are going to start the engine indoors. read Before service. It is important to use the right tools and the right equipment.Safety when servicing Before service. and slip protected surfaces are free from oil. As well. If service work has to be done under a raised attachment. read Prevent personal injuries Read the instructions in the Operator's Manual before starting to work on the machine. covers. eye protection (safety glasses). Use a piece of paper or cardboard when checking for leaks. Prevent environmental influence Be conscious of the environment when carrying out service and maintenance. Do not stand in front of or behind the machine while the engine is running. and parts are used other than those described in this Operator's Manual. it must first be secured. high-pressure fluid may jet out. read 95 Before service. 146 Make sure that all protective plates. handholds. special safety rules apply for service work on such machines. Engage the control lockout and apply the parking brake. tools. Prevent machine damage Use equipment with sufficient lifting capacity if the machine or parts of it are to be lifted or supported. if installed on the machine. Actions in connection with electric welding. never your hands. Release the pressure in the hydraulic system before beginning service work. Only step on parts of the machine that are provided with slip protection. gloves and protective work footwear when required by the job. work methods. lubricants. It is also important to read and follow the information and instructions on plates and decals. Make sure that stepping surfaces. Use the three-point contact while claiming the machine. Consumables. NOTICE No work must be carried out on the machine until you have acquired the appropriate knowledge to do so. vessels and steps taken to avoid spillage. All service work should be carried out by a qualified technician who is having sufficient knowledge of the machine. must be placed in the bag supplied with the new filter. 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. When draining. conversion or adjustment of the machine and its safety oriented devices or any work related to maintenance. inspection and repair. it must be placed in the service position. Used filters from machines which work in environments with asbestos or other dangerous dust. ENSURE that the maintenance area is adequately secured. read and released into the environment will cause damage. Oil degrades very slowly in water and sediment. Used batteries must therefore be handled as waste dangerous to the environment. WARNING During service. See page No. and trained to use the proper tools and equipment to carry out the service task in a correct way. always observe the start up and shutdown procedures set out in the operating instructions and the information on maintenance work. 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 . One litre of oil can destroy millions of litres of drinking water. If the machine is completely shut down for maintenance and repair work. 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. Used filters must be drained of all liquid before they are passed on as waste. hearing protection and safety goggles must be used.g. oils and liquids must be collected in suitable vessels and steps taken to avoid spillage. 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. used rags. Batteries contain substances dangerous to the environment and health.Safety when servicing 96 Before service. In any work concerning the operation. e. or examining the machine with the engine running. Special care must be taken with electric equipments. REPLACE any safety devices removed for setup. servicing or providing maintenance to the compactor unless the drum and wheels are adequately chocked. platforms. cleaning. steam jet (high pressure cleaning) or detergents.Safety when servicing Before service. NEVER use aggressive detergents. fuel or preservatives before carrying out maintenance/repair. or chains. ALWAYS wipe up any spilled fuel. landings and ladders free from mud. steps. . 99. USE lifting gear that is in perfect condition and with adequate lifting capacity. AVOID. or while smoking. 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. and parking brake is applied. REMOVE all covers and tapes applied for that purpose after cleaning machine. while near an open flame. ALWAYS USE specially designed or otherwise safety oriented ladders and working platforms when doing overhead assembly work. ENSURE during cleaning of the machine that temperature sensors do not come into contact with hot cleaning agents. snow and ice. See page No. handrails. ALWAYS USE the correct tools and workshop equipment when performing maintenance on the machine. ENSURE that all consumable and replaced parts are disposed safely and with minimum environmental impact. the articulation lock bar/lock pin is in the locked position. Use spreader bars to ensure equal weight distribution during lifting as well as avoid contact with the unit. AVOID. cut marks and damage after cleaning. Use lint free cleaning rags. WARNING All forms of open fire and smoking should be avoided when filling the fuel tank. For Safety. dirt. whenever possible. NEVER work or stand under suspended loads. KEEP all handles. lubricant. whenever possible. maintenance or repair purposes and checked immediately upon completion of the maintenance and repair work. loose connections.When raising the unit off the ground. cables. CLEAN the machine. of any traces of oil. and hydraulic fluid lines for leaks. Never use machine parts as a climbing aid. REPAIR or REPLACE defective parts immediately. servicing. apply the parking brake. especially connections and threaded unions. COVER OR TAPE all openings. when lifting and supporting the machine. EXAMINE all fuel. Attach the lifting apparatus only to the unit’s designated lifting points using properly rated lifting straps. LIFTING THE UNIT .must be protected against water. for safety and functional reasons . DON'T fill the fuel tank with the engine running. 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. TIGHTEN any screwed connections that have been loosened during maintenance and repair. steam or detergent penetration before cleaning the machine with water. CUT off the power supply to parts of the machine on which inspection. 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. optimum performance and safety of your warranty by using only genuine manufacturer’s replacement parts. OBSERVE the product related safety regulations when handling oil. DO NOT work on any hydraulic hose or fitting until the pressure has been properly relieved. 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. USE only original fuses with the specified current rating. maintenance and repair work is to be carried out. DO NOT work on hydraulic lines while the engine is running and the system is under pressure. 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. GET immediate attention if fluid has been injected under your skin. cracking. The fittings. Switch off the machine immediately if trouble occurs in the electrical system. Fumes from the battery can ignite by a spark and explode. ENSURE the safe operation. ENSURE hydraulic lines are laid and fitted properly. Fluid penetration from a pin hole leak can cause severe injury or death. Use a piece of cardboard and always wear gloves and safety glasses. SWITCH OFF battery disconnect switch and DISCONNECT the battery cables when working on the electrical system or when welding on the compactor.Safety when servicing 98 Before service. BE SURE the battery area is well ventilated (clear of fumes) should it be necessary to connect a jump battery. . deformation. brittleness. leakage. Hot hydraulic fluid will cause severe burns. 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. INSPECT the electrical equipment of machines at regular intervals. Defects such as loose connections or scorched cables must be rectified immediately. blistering. fitting separation. WAIT for fluid to cool down before disconnecting. lengths and quality of the hoses must comply with the technical requirements. ALWAYS replace damaged or lost decals. INSPECT hydraulic hoses at regular intervals and immediately replace if they show signs of chafing. Ensure that no connections are interchanged. The hydraulic fluid remains pressurized long after the engine has stopped. BE SURE the battery charger is “Off” when making the connections if battery charging is required. corrosion or other damage which may affect their function or strength. NEVER use your hands to check for leaks when inspecting an hydraulic system. read DO NOT alter the engine governor settings from those indicated in the engine manual. grease and other chemical substances. Refer to the parts manual for the proper location and part number for all decals. NOTICE The machine must be lowered from the jack onto an appropriate stand before the wheel is removed. Use a suitable lifting device or jack with proper rated capacity for the job to raise the machine as required for wheel removal. . Place support stands under the frame. See page No. All lifting devices (straps. chains. Lift the front frame at appropriate lifting points. 81 WARNING Never work under/on machines without using recommended support equipment. Do not use the jack to support the weight of the machine when removing the wheel. the floor or ground must be even and of sufficient strength to support the expected load. Lifting and supporting rear axle. read Be careful when handling hot conscionable items. We can accept no responsibility for the use of sub-standard equipment and work practices. NOTICE Never position jacks or stands under the fuel tank or engine.Safety when servicing Before service. before removing the drum or when separating the machine to work on the articulation frame joint and pivot pins. Secure the machine with a stand under the end of the axle on the side that the wheel is to be removed. (risk of burning or scalding). Secure the machine under the frame if the axle is to be removed. see page No. 92 WARNING Only use lifting devices with adequate capacity. Use the lifting eyes or lifting points that are located on certain points of the machine. 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. If you use a jack. etc. ratchet blocks.) must comply with applicable regulations and certifications. 99 Safety when lifting and supporting complete machine Place the machine in service position. slings. Make sure it is positioned correctly and has safe ground support for the expected load. 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 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. V1021831 Never stand to the side of the tyre while inflating 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 Working in environmentally contaminated areas 101 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 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. V1032979 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. 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. Three point contact. damage to the paint finish and constitute fire hazard. Also bear in mind that certain solvents can cause skin rashes. for example underbelly plates are free from dust and oil. NOTICE Take great care if a high-pressure wash is used for cleaning. Besides reducing the risk of fire. for example saw-mill and refuse dumps. Oily and greasy clothes are a serious fire hazard. It is important that the fire extinguisher is maintained in order to work when it is needed.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. . 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. The risk of spontaneous combustion can be further reduced by installing insulation of the silencer guard. Take extra care when cleaning a machine working in a firesensitive environment. There is always a risk of fire. Diesel fuel oil is flammable and must not be used for cleaning. it is also easier to detect faulty or loose components. Check daily that the machine and the equipment. If the machine is equipped with a fire extinguisher. Keep the place clean where the service is to be carried out. it should be kept near the operator’s seat on the left side of the operator. Use conventional car care products meant for cleaning or degreasing. Find out what kind of fire extinguisher is used on your working site and how to use it. Oil and water can make the floor slippery and is also dangerous in connection with electrical equipment or electrically powered tools. Electrical components and electrical leads can be damaged even at a moderately high pressure and temperature. Protect electrical leads in an appropriate way. 6 Turn off the battery disconnect switch. First wash thoroughly with plenty of lime water (a solution consisting of calcium hydroxide.between alternator and starter motor Electrical cables must not lie directly against oil or fuel lines.Safety when servicing Fire prevention 105 Check that fuel lines. see page No. the following protective measures must be followed: Use thick.between the batteries . 7 Attempt to put out the fire. Never touch burnt components with your bare hands in order to avoid contact with melted polymer materials. Actions after fire When handling a machine which has been damaged by fire or been exposed to intense heat. A fire extinguisher should be kept near to hand. for example tanks and hydraulic pipes.between battery and starter motor . move away from the machine and out of the danger zone. if the machine is in motion. Otherwise. that is slaked lime in water). take the following steps at the slightest sign of fire: 1 Stop the machine. which are red and marked R (B+) and routed: . protective gloves made of rubber and wear goggles. 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. 4 Exit the from the machine. Handling heated fluoro-carbon rubber. Do not weld or grind on components which are filled with flammable liquids. Actions in case of fire If the circumstances permit and your own safety is not jeopardised. 5 Call the fire brigade. Exercise care with such work also in the proximity of such places.109. 2 Move the propulsion control lever to stop position. . if possible. This applies particularly to unfused cables. 3 Turn the ignition key to stop position. . increasing the risk of falls and electrocution. especially if the machine is equipped with an automatic preheating intake air system.Leave the operator platform quickly and safely. Oil or water on the floor can create a dangerous work environment.Drive the machine away from the danger area. 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. . Learn the correct type of fire extinguisher to use. Contamination introduced to machine systems can shorten component service life and cause the machine to malfunction. Equipment such as a spark arrester may be required. Cleanliness Cleanliness is important to effective machine service. it should meet local requirements.if the machine is equipped.Safety when servicing 106 Fire prevention Fire prevention measures General There may always be a risk of fire.Turn the battery disconnect switch off. If the machine is provided with a hand-held fire extinguisher. . how to use it. take the following actions if the situation will safely permit: . . use an approved cleaning solvent. Ensure the machine is properly equipped for working in dry or forested areas. . Certain solvents are usually flammable and can cause skin rashes or other conditions. Never expose diesel fuel to open flame or smoking materials.Begin extinguishing the fire and call for assistance if required. Do not inhale solvent vapours. and where it is kept. Any on-board fire extinguisher must be kept fully charged and in good working order at all times. Never use engine starting aids. Oily and greasy clothing and shop rags are a fire hazard. Keep the service area clean. Never use diesel fuel as a cleaner.Shut down the engine with the ignition key switch. At the first sign of a fire. especially when refuelling or the fuel system is open to the air. safe area before welding. hydraulic and brake hoses are not worn or damaged. See page No. work carefully since damage may be caused to electrical components and insulation of the electrical cabling even at relatively moderate water pressure and temperature. This will reduce the chance of a fire. hydraulic and brake systems Check to make sure fuel. suitable equipment to reduce the risk of fire should be installed and maintained. . that can result in failure and potential accidents. connected and routed to avoid exposure to wear or damage. such as fuel tanks. and any routing condition that could expose wiring to damage. Fuel. CAUTION If a high-pressure washer is used when cleaning. Always remove paint from areas to be welded. and will make it easier to detect loose or leaking parts. Welding and grinding work CAUTION A fire extinguisher should be easily accessible during all welding work. grinding or using an oxy/acetylene torch on it. This is especially important for positive electrical wires that could make contact with the frame (ground). from the batteries to the starter. See also Check list after fire or heat exposure As a precaution.112. Move the machine to a clean. it is important to connect. Take special care to keep machines clean in applications such as coal mines where the risk of fire is greatest. They must not be routed in contact with fuel or oil hoses. and results in a poor weld joint. Protect electrical cabling in a suitable manner. wiring must be fused. and are routed to avoid rubbing. Electrical system Inspect wiring for chafing.Safety when servicing Fire prevention 107 The machine should be inspected daily for the build-up of flammable debris. Work with extra care when welding. grinding or torch cutting near flammable objects. breakage. If any auxiliary electrical equipment is installed on the machine. and between the alternator and starter. Pay special attention to the cables between the batteries. In such applications. all o-rings and seals should be handled as if they were made of fluor rubber. Welding on painted surfaces releases dangerous fumes. route and secure them so they are protected from damage and wear. When reconnecting wires. This type of work should only be done in a clean area and not in places that contain combustible liquids. hydraulic pipes or similar. Symptoms may not appear until several hours after contact with burnt fluor rubber. See page No. For this reason. i. 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. rags and other items that may have contacted burnt fluor rubber. never use high-pressure washing equipment.Safety when servicing 108 Fire prevention WARNING Avoid splashing when washing a machine damaged by fire. protective neoprene gloves. slaked lime). goggles. 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. then discard protective gloves.112. and approved respirator. First.e. Wash with lime water. . wash thoroughly with plenty of lime water (a solution or a suspension of calcium hydroxide. Wear thick. Heated paint gives off poisonous gases. grinding or gas cutting. welding. protective goggles and respiratory protective equipment. which. . when heated. Wear protective equipment.Safety when servicing Handling hazardous materials 109 Handling hazardous materials Heated paint WARNING Heating of painted surfaces. . Methods and precautionary measures when removing paint Blasting . form compounds which are dangerous to health and environment and must therefore never be burned when scrapped. respiratory protective equipment and protective gloves Grinding machine .use a portable air extractor.use a portable air extractor. rubber or plastics parts may cause the formation of substances dangerous to health or environment. paint must be removed from an area with a radius of at least 10 cm (4 in) before carrying out welding. Heated rubber and plastics Polymer materials can. in the future. for example. Therefore.Protect the material from heat. may cause the weld to break.Use protective gloves. They should be disposed of by a licensed disposal plant. In addition to the health hazard. If gas cutting or welding is to be carried out near such materials.use respiratory protective equipment and protective goggles Paint remover or other chemicals . grinding or gas cutting. respiratory protective equipment and protective gloves and goggles Never burn painted parts after they have been discarded. the weld will be of inferior quality and strength. the following safety instructions must be followed: . Take care when. . that is slaked lime in water). Wear protective equipment. Keep the battery surface clean and dry. As a precaution. redness or a stinging feeling appears and one suspects that the cause may be contact with heated fluorocarbon rubber. Several hours may pass. Wear protective equipment. Make sure that metal objects such as tools. do not smoke and avoid naked flames and sparks when working in the vinicity of batteries. When handling a machine which has been damaged by fire or been exposed to intense heat. rings and wrist watches do not come into contact with the battery terminals. all seals (O-rings and other oil seals) should be handled as if they were made of fluoro-carbon rubber. Batteries contain materials that are damaging to health and the environment. Do not tilt batteries as otherwise the battery acid may escape. Discard gloves. Treat instead with Hydrofluoric Acid Burn Jelly or similar before contacting a medical doctor. Danger of explosion. The acid cannot be rinsed or washed off from the skin. Batteries develop explosive gases. skin or clothes. Therefore. before any symptoms appear and there is no immediate warning. Batteries WARNING Handling batteries may lead to that electrolyte comes into contact with eyes.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. The hydrofluoric acid may remain on the machine parts for several years after a fire. 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. Discharged batteries must never be connected to fully charged batteries. rubber gloves and wear protective goggles. Electrolyte on skin must be washed off with soap and water immediately. If swelling. which are very corrosive to skin and lungs. Electrolyte splashes in eyes must be rinsed off with water immediately. Immediately wash any leaked battery acid with soda dissolved in water. however. Seek medical advice. 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. Ensure that the caps are always mounted on the battery terminals. contact a medical doctor immediately. At very high temperatures fluoro-carbon rubber forms substances. The batteries must therefore be disposed of in accordance with the applicable national regulations. the following measures should be taken: Use thick. g. glue. see page 150. biodegradable oils. Batteries WARNING Risk of serious corrosive injuries! Batteries contain environmentally hazardous substances and corrosive acid. Rubber and plastics Rubber materials and plastics may not be burned. that are not reused shall be collected in tight-sealing containers and left for destruction. shall be left for recycling and destruction. etc. approved by the authorities. Corrosive acid V1033092 Chemicals Chemicals. Environmentally safe handling Always choose an environmentally friendly alternative where one is available. cleaning agents.Safety when servicing Handling hazardous materials 111 When dismantling a battery. for installation. coolant.g. paints. Always follow national and local environmental regulations.. the last to be connected in order to prevent the formation of sparks.. e. Disconnect the batteries from the machine before loading them from an external source. For starting using auxiliary batteries. Shall be left for recycling. Filters Oil and fuel filters shall be drained and put into sealed containers before they are left for destruction. All waste shall be brought to a waste handling company. Tyres shall be handled according to special rules. Oils and fluids Oils and fluids. the mass cable must be disconnected first and. . see page Starting with booster battery. For the charging of batteries. Used batteries must be disposed of in accordance with the applicable national regulations. e. Shall be left for recycling. shall be left for recycling. All paint decomposes.. DEPOSITION is the worst from an environmental aspect and should be avoided as much as possible. REUSE of products is the best from an environmental aspect. 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. plastics and rubber Work on painted surfaces Never weld or cut with a torch on painted surfaces. in case of repeated exposure. Use breathing protection as well.g. breathing protection and protective work gloves. circuit boards and bulbs. If the paint cannot be removed by sandblasting. STORAGE is a temporary measure until a suitable recycling method has been developed. MATERIAL RECYCLING for use in new products is a good environmental alternative. e. be very hazardous to health. ENERGY RECOVERY by burning combustible materials is a good alternative when recycling is not possible. DESTRUCTION is used for hazardous waste. 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). then remove the paint in another way. . use air extraction. with paint solvent/remover. when heated and generates a vast number of different substances. that may be irritating and.Safety when servicing 112 Handling hazardous materials Electronics Electrical and electronic waste. Destruction is performed in special facilities. NOTICE When using paint remover/solvent. Health hazards with paint. Waste handling Contribute to careful use of natural resources by following the steps below when handling waste. e.. If possible.g. deposit the waste for recycling. . there is a risk of hydrogen fluoride gas build-up already at approx. . Be careful when handling machines that have been exposed to fire or other intense heat. 320 °C (610 °F).g. use heavy-duty gloves made of neoprene rubber and effective safety goggles. If swelling. See page No. 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. redness or burning sensations appear and contact with heated fluor rubber is suspected to be the cause. when heated to high temperatures. For all handling of machines after a fire. protective safety glasses and breathing protection. rubber and plastics can give off substances that are hazardous to personal health and the environment. 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. Never burn polymer materials when scrapping them. When inhaled. seek immediate medical attention. hydraulic motors and pumps) may be made of fluor rubber which. generate hydrogen fluoride and hydrofluoric acid. it may take several hours before any symptoms appear. Always use gloves. brakes. in engines. the gas is extremely corrosive to respiratory tracts. Hydrofluoric acid may remain on machine parts for a very long time (several years) after a fire. Hydrofluoric acid is highly acidic and corrosive. Fluor rubber WARNING Risk of serious corrosive injuries! WARNING When hydrogen fluoride rubber is heated.107.Safety when servicing Handling hazardous materials Rubber and plastics 113 WARNING When heated. NOTICE In case of contact with hydrofluoric acid. injured tissue must be removed surgically. Certain seals designed to withstand high operating temperatures (e. 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. transmissions. axles. As a rule. Use approved containers and methods to handle and dispose of machine fluids. Oils and fuels are hazardous to the environment. Be aware of the risk of fire. Take special care not to spill or discharge these fluids.101 for environmental handling for the future. as well as diesel fuel. See page No.e. 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 why it is important to use genuine Volvo spare parts. eyes. Use an authorized disposal and recycling company. slaked lime) in water. plastic or rubber parts constitutes a health hazard. throat and on skin). See page 107.Safety when servicing 114 Handling hazardous materials WARNING Burning of painted parts. After completing the decontamination work. remember that the oil may be hot and can cause scalding or burn injuries. have a corrosive effect on mucous membranes (i. If the machine has been exposed to a fire or other intense heat. Safety when handling oil and fuel When changing oil in the engine or hydraulic system. . See page 111 for environmentally safe handling. Engine and hydraulic oils. wash the gloves in the lime water and then discard them. that is. Asbestos information The components in Volvo CE's machines are free from asbestos. the safety actions in the following checklist shall be followed unconditionally at all times. Take special care to keep oils away from these sensitive body parts. guards and heat shields are correctly installed. Do not use your bare hand to check for leaks. tube and fittings. replace the parts. This contributes to preventing vibrations. Do not strike high pressure lines. If any of the following conditions are found. . Flexible part of the hoses are kinked. Do not install any lines that are bent or damaged. Consult your Volvo CE dealer. chafing against other parts and excessively strong generation of heat. tubes and hoses 115 Handling line. stop operations immediately and contact an authorized Volvo dealer workshop. Consult your Volvo CE dealer for the recommended tightening torque. tubes and hoses WARNING If oil or fuel leaks from high pressure hoses or loose screws is found. tubes and hoses carefully. Strengthening wires are exposed. Outer coverings are chafed or cut. End fittings are damaged or leaking. Tighten all connections. Do not reuse hose. Foreign material is embedded in the coverings. End fittings are displaced. CAUTION Make sure that all clamps.Safety when servicing Handling line. Outer coverings are ballooning. Check lines. Do not bend high pressure lines. Service history is a valuable document. lubrication.Service and maintenance 116 Service and maintenance Service history After each completed service at a workshop authorised by Volvo CE. blockages and overheating. or has become jammed between the drum and its scraper. If high-pressure wash is used. control panels and leads in an appropriate way to prevent entry of water or steam when using high pressure cleaning methods. 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. Use a soft sponge. 8 9 . Dust. Recommendations for cleaning the machine 1 Park the machine in a place intended for cleaning. The water temperature must not exceed 60 °C (140 °F). 2 Remove any material jammed between the drum and its scraper. dirt and other debris entering into the fuel. 4 Install protective covers. which will damage expensive machine components and cause machine systems to fail. Clean the whole machine with water only. CAUTION Avoid using strong cleaning agents or chemicals in order to minimise the risk of damage to the paint finish. See page 117. cooling and hydraulic systems can cause premature wear. Daily cleaning will be required if material is adhering to the drum. 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. which can be referred to when for example selling the machine. chips and similar may collect in order to minimize the risk of fire. 3 Open the air filter access cover and clean the air cleaner evacuator valve and inspect the rubber for cracks. see page 208. Follow the instructions supplied with the car care product. keep a distance of at least 20– 30 cm (8–12 in) between nozzle and machine surface. corrosion. the service history should be filled in. NOTICE Daily clean the areas on the machine where dust. barriers or safety cap plugs to protect sensitive components and machine areas from water entry. Excessive pressure and too short a distance may cause damage. (Replace as required). NOTICE 5 6 7 Protect all electrical components. See page No. Close all covers and hoods. Place the machine in the service position.Service and maintenance 117 After cleaning: 1 Remove all protective materials (covers. After cleaning. Use personal protective equipment such as protective goggles. The machine should be parked in a place intended for cleaning. Remove exterior dirt and debris first. especially in the areas that water or contaminants may have entered. Cleaning tips Checking and cleaning should preferably be carried out at the end of the working shift. 3 After washing. see page No. tape. Loose material is removed with compressed air. barriers. then open all covers and hoods to access interior areas for cleaning. 5 Touch-up the paint finish when required. run the engine until it is warm. Use only test instruments with light-emitting diode (LED) displays to trace electrical faults. away from bystanders and other equipment. 4 Perform the daily or as required maintenance checks.92 (Shut down Engine and switch OFF battery disconnect). Do not attempt to repair. 2 Always lubricate the machine immediately after washing. check and rectify any leaks or maintenance issues. plastic wrap or safety cap plugs etc. Precaution when working on the electrical system Before working on the electrical system of the machine. Do not use test equipment . Before carrying out any work involving testing or removal and fitting of components in the electrical system. gloves and respirator. carefully read and follow all instructions in the safety section of this service manual. These areas include the vertical and horizontal swivel pins and bushings and cylinder pins if the fittings are not plugged with a pipe plug.) added for protection against water entry. Cleaning of engine compartment Machines operating in dusty environment require daily attention and cleaning of the engine compartment and surrounding areas. 92 and turn the battery disconnect switch to the OFF position. test or adjust the electrical system unless you are a qualified service electrician. This will help to dry out engine components and electrical connections. and place the machine back in service. Begin with the highest areas and end with the lowest on top of the fuel tank and areas near the fuel tank. place the machine in the service position. NOTICE Plugs indicate a maintenance free bearing. or prior to startup if the machine has been parked for an extended period of time. During all tests of alternating current equipment. Before working with the batteries See page No. Test the battery acid for specific gravity using a hydrometer. make sure that correct polarity is followed. When installing or replacing a battery. work carefully since damage may be caused to electrical components and insulation of the electrical cabling even at relatively moderate water pressure and temperature. corrosion. Dust. Correct any visible faults before beginning electrical checks. Before any tests are carried out on the alternator. secure connections must be used. Avoid using strong cleaning agents or chemicals to minimize the risk of damage to the paint finish and other surfaces on the machine. lubrication. dirt and other debris entering into the fuel. Clean the machine prior to conducting repairs to reduce the risk of contaminants from entering sensitive areas of the machine. cooling and hydraulic systems can cause premature wear.Starting with booster battery.146. Before welding on the machine or attachments connected to the machine. See page No. follow the instructions in the Operator’s Manual and See page No. When installing a two-way radio. poor contacts or corrosion. blockages and overheating. Never disconnect the main lead of the alternator or the lead to it’s field winding while the engine is running. The voltage characteristics of light bulbs can destroy sensitive and expensive electronic components. Clean the machine regularly with conventional car care products. Use only charged batteries to test the electrical system. alternator damage will result. mobile telephone and similar equipment. If a booster battery is required for starting the engine. One loose lead may damage the alternator. If the current output terminal of the alternator is connected to the mainframes while the engine is running.Service and maintenance 118 that uses light bulbs. follow the manufacturer's installation instructions in order to eliminate interference with the function of the electronic system and components on the machine. Cleaning machine CAUTION If a high-pressure washer is used when cleaning. This will result in damage . Always disconnect the negative (ground) cable first and reconnect it last. the batteries and electrical leads must be checked for insulation faults. Protect electrical cabling in a suitable manner.144. Damage may result. Check the alternator belts. Recommendations for cleaning the machine: 1 2 3 4 Place the machine in a place intended for cleaning. Do not grease optional self-lubricating bearings. or deterioration and replace at the first sign of probable failure. Clean any dirt and debris from the seals and sealing surfaces periodically to ensure proper performance. 6 Finish by rinsing the whole machine with water only. 7 Touch up the paint finish when required. Excessive pressure and too short a distance may cause damage. 5 Check air cleaner mounting hardware for security and correct as required. Carefully repair any faults to the paint finish. NOTICE Clean the areas daily on the machine where dust. 3 Check for defects in the air cleaner ducts and correct as required. chafing. 2 Always lubricate the machine after washing.Service and maintenance 119 to expensive machine components and cause machine systems to fail. NOTICE Keep all exterior and interior window surfaces clean to ensure proper visibility. 5 Use a soft sponge. Touch-up painting Clean the machine. keep a distance of at least 20–30 cm (8–12 in) between the nozzle and the machine surface. 4 Check air intake for accumulation of debris that could restrict air flow and clear. 6 Check all hoses for cracks. chips and similar may collect in order to minimize the risk of fire. Grease fittings immediately. Check for faults to the paint finish that may expose bare metal. 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. . Protect electrical leads in an appropriate way. Measures after cleaning the machine 1 Remove all material added for protection from water entry during machine washdown. Follow the instructions supplied with the car care product. If a high pressure washer is used. The water temperature must not exceed 60 °C (140 °F). Replace as required. 136. 138. See service and maintenance section in this manual or follow the links provided to the appropriate maintenance procedure for the items listed below. 4 Replace air cleaner secondary (safety) filter element after three primary filter element changes. See page No. 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. As required maintenance 1 Check the air cleaner connections and ducts for leaks. Torque any loose bolted connections. 145. 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. Maintenance service. observe the following Warnings and Cautions: . Clean and wash the machine. See page No. Clean the engine compartment See page No. general To prevent minor irregularities from developing into serious conditions. 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. 117. NOTICE Prior to starting any work on the machine. Place the machine back in service. several other services or checks are recommended for the same intervals as the periodic lubrication.169. 133. or if air cleaner elements are damaged or heavily soiled. See page No. Check the battery disconnect switch. 116.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. See page No. See page No. See page No. See page No.. or if damaged or heavily soiled beyond cleaning. 202 and 201 . For further information on these procedures. Inspect the drum shock mounts. 3 Replace the air cleaner primary filter element for every 500 hours. Always use protective clothing such as gloves.Service and maintenance 121 WARNING Always read the booklet Safety before proceeding. On machines equipped with a Rollover Protection Structure (ROPS). Observe the following operational procedures. 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. park the machine on a level surface and prepare it for service by putting it into service position according to Safety rules for service. there is a great risk of serious accidents and injuries. CAUTION Before starting any work. Always chock the wheels when parking the machine. Do not speed the engine when it is cold. Never operate the machine across slopes. perhaps even fatalities. wear seat belt at all times. Always sound the horn before moving the machine to alert personnel. and allow sufficient time before putting the machine into motion. . Always perform safety checks prior to starting/using the machine Always operate the machine at full engine speed when compacting or traveling the machine. goggles and safety helmet when performing service maintenance. Otherwise. Before starting the engine. always check that the propulsion control is in the STOP position and the parking brake is ON . CAUTION Read the environment section in the "Safety" booklet CAUTION Do the work in an environmentally safe manner. Do not grease the machine while the engine is running. 158. 12 Lubricate Shift linkage. 3 Check the battery electrolytes. every 50 hours 1 Place the machine in service position. 167 . See page No. 175. 92 . 168. 163 . See page No. See page No. every 100 hours Place the machine in service position. See page No. See page No. See page No. 131. 122. Maintenance service. See page No 180. See page No. See page No. 4 Check for air cleaner system integrity. See page No. every 250 hours Place the machine in service position. See page No. 145 Check the air cleaner clog indicator in control console for air filters clogging. 142. Check condition of the drum and clean it if necessary. 151 . 14 Place the machine back in service. Perform daily and 50 hours maintenance service. Maintenance service. Switch on battery disconnect-switch and turn ignition key switch to the ‘ON’ position and check workings of electrical basic components. See page No. 180. Check the engine oil level. 13 Clean carrier breather. 133. 122. See page No. Perform the daily. See page No.Service and maintenance 122 Maintenance service. See page No. Drain the water from the water separator. 92. 11 Lubricate the steering cylinder pins with grease. See page No. See page No. See page No. physical damage to any machine components. Clean the radiator and cooler fins. 126. 7 Check the hydraulic oil level. See page No. 165. Place the machine back in service. Check fuel level on the fuel level gauge. 169. Check for leakages. 158 . Check engine coolant level and add if necessary. Also check the air cleaner system. 2 Perform daily maintenance service. See page No. 10 Lubricate the swivel pins with grease. 9 Check the drum eccentric oil level. Check transmission oil level. 161. See page No. 122 and 122 Clean the axle breather. daily Place the machine in service position. Add if necessary. Test parking brake using the parking brake test switch. 165. See page No. 92. cables and terminals. Check axle housing oil level. Maintenance service. 182 . 6 Check the wheel nuts torque. 167. See page No 122 and 122. . See page No. See page No. 8 Check the torque hub oil level. See page No. Place the machine back in service. 50 hours and 100 hours maintenance service. See page No. 133 5 Check the tyre pressure. Check wheel end/axle hubs oil level. 92 . See page No. 158 and 156. 141. See page No. 170. 201. See page No. every 1000 hours Place the machine in service position. 128. See page No. 201. See page No. See page No. Change the engine air cleaner primary element. 175. every 500 hours Place the machine in service position. Torque the horizontal swivel nut. See page No. 100 hours and 250 hours maintenance service. 50 hours. See page No. Change the hydraulic oil filters. 92. 130. Change the drum eccentric oil. Place the machine back in service. 160. 176. 100 hours . See page No. See page No. 122 and 122 Check the tension in fan and alternator belt. See page No. 158. Test run the machine. 122. See page No. See page No. See page No. 126. 122. 122. See page No. NOTICE After engine oil is changed. See page No. Check for the changed oil levels. Torque the articulation vertical nuts. 122 and 123 Clean the suction strainers and replace if necessary. Place the machine back in service. See page No. Change the axle wheel end/axle hubs oil. Check torque of the axle mounting bolts. 136. do not start the engine until the engine oil filter is replaced. Change the hydraulic oil. 129 Change the water separator. See page No. 178. Perform the daily. 156. See page No. See page No.Service and maintenance 123 Change the engine oil. Change the engine oil filter. Change the axle housing oil. 122. Perform the daily. Change the drum carrier oil. Change the axle transmission oil. 50 hours. Place the machine back in service. Maintenance service. 92. See page No. 122. 201. See page No. 172. See page No. Maintenance service. Change the fuel filters. See page No. 250 hours and 500 hours maintenance service. Change drum torque hub oil. . 131. 169. Check the seat belt regularly for wear or damage. Seat belt strength degrades over time and use due to exposure to weather. frayed or loose sticking is found. Replace the seat belt if the hardware is damaged or if the strap is nicked. . Seat belt assemblies should be replaced every 3 years regardless of appearance. ultraviolet (UV) and abrasives (dirt). Inspect the belt hardware and fabric. checking and maintenance Ensure that the mounting hardware is tight.Service and maintenance 124 General inspection of machine General inspection of machine Lap type seat belt. 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. opening and closing To open the engine hood CAUTION Risk of engine hood falling down. Pull down the latches on both sides of the machine to release the hood. 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.Service and maintenance Engine 125 Engine Engine hood. Do not operate the machine with a completely or partly open engine hood. Hold the engine hood at the cutout provided at rear end and raise it completely upward. . Pull down the engine hood with help of retractor strap till it sits on the frame. for filling instruction in 126. Close the engine hood. See page No. Place the machine back in service. wipe it with a lint-free dry cloth and insert it back.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. See page No. Place the machine in service position. Allow the machine to cool before beginning any work. Fill the engine oil if necessary. WARNING Hot liquids and machine parts can cause burns. check CAUTION Always handle oils and other environmentally hazardous fluids in an environmentally safe manner. Remove the dipstick again. 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. . NOTICE Dipstick The engine oil level must be maintained between the marks on the dipstick. Open the engine hood.92. Retractor strap Engine oil level. Remove the dipstick. Never overfill the oil level or let it drop below the minimum level. check the engine oil level and insert the dipstick back. Close the engine oil filler cap. NOTICE Engine oil filler cap Allow sufficient time for engine oil to settle down in the sump. 194. Remove the hose and plug the drain valve. 92. Draining Place the machine in service position. WARNING Be careful when changing oil since hot oil may cause severe burns to unprotected skin. Check for the leakage. Open the engine oil filler cap and fill the engine oil. For engine oil quantity See page No . 196.Service and maintenance Engine Engine Oil Change 127 CAUTION Always handle oils and other environmentally hazardous fluids in an environmentally safe manner. if any. Drain plug Attach a (hose connection) to the drain valve and drain the engine oil in a suitable container. For oil specification See page No. Warm up the engine to the normal operating temperature. Never overfill the oil level or let it drop below the minimum level. Open the engine hood. Remove the plug. NOTICE The engine oil level must be maintained between the marks on the dipstick. Run the engine at idle rpm for 2 min. WARNING Never work under/on machines without using recommended support equipment. See page No. For engine hood opening See page No. Clean the spillage. Check the engine oil level and fill if necessary. 125 . . oils and liquids in an environmentally safe way. Disconnect the engine oil pressure switch connection for easy access. Apply a thin film of oil to the engine oil filter seal. Fill oil if necessary. Engine oil filter. Place the machine back in service. Check for the leakage. 126 . Run the engine at idle rpm for 2 min. Check the engine oil level. See page No. For engine oil specification See page No. See page No. 126. 125. Allow the machine to cool before beginning any work. 1 2 Engine oil pressure switch Engine oil filter NOTICE Allow sufficient time for engine oil to settle down in sump before checking the engine oil level. For engine hood opening See page No. Place the machine in service position. Filling Place the machine back in service. Clean the engine oil filter head sealing surface. Clean the spillage if any. . replacing CAUTION Take care of filters. 125. For engine hood closing See page No. For filling instructions. 92. 125. Connect the engine oil pressure switch connection. Fill the engine oil filter with clean engine oil. Remove the engine oil filter using . Close the engine hood. See page No. WARNING Hot liquids and machine parts can cause burns. Fuel system. Screw the engine oil filter until its seal touches the sealing surface and tighten further half turn by hand. bleeding Manual Air Bleeding CAUTION Do the work in an environmentally safe manner.Service and maintenance 128 Engine Close the engine hood. For engine hood closing See page No. Open the engine hood. Place a suitable container to collect the oil while removing the engine oil filter. NOTICE Do not over tighten the filter. 194. oils and liquids in an environmentally safe way. Open the engine hood. or a plastic hose and absorbent materials to collect and clean up any fuel that escapes during the bleeding procedure. replacing CAUTION Take care of filters. Shut down the engine. Plunger on water separator Fuel filter. Clean the spillage if any. Allow the machine to cool before beginning any work. Tighten the air vent screws of fuel filters. Start the engine and run it at idle rpm for around 5 minutes. WARNING Hot liquids and machine parts can cause burns. . See page 92. Place the machine back in service. CAUTION Maintain greatest possible cleanliness when working on the fuel system. Loosen the air vent screws of the fuel filters. Pump the fuel some more with plunger pressing for 3–4 times. NOTICE Make sure that the system it completely free from air. Place a suitable container to collect the fuel while removing the filters. Place the machine in service position. Open the engine hood. 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. Place the machine in service position.Service and maintenance Engine 129 Use a suitable container. See page 92. 5 Inspect for worn-out areas and if found or a piece of the belt is missing the belt must be replaced. NOTICE Do not over tighten the filter. Apply a thin film of oil on to the each filter seal. Place the machine back in service. Fuel filters location 1 Fuel filters 2 Air vent screws Alternator belt. checking 1 Place the machine in service position.92 2 Open Engine hood of the machine. See page No. Run the engine at idle rpm for 5 min. Screw the second filter until its seal touches the sealing surface and tighten further half turn by hand. Check for the leakage. Clean the filter head sealing surfaces. Screw the filter until its seal touches the sealing surface and tighten further half turn by hand. 6 Place the machine back in service. Refer to engine manual for fan belt and alternator belt replacing. Loosen the air vent screws and prime the fuel system. Tighten the air vent screws. NOTICE Do not over tighten the filter. Close the engine hood. Belt 1 Transverse cracks 2 Longitudinal cracks .Service and maintenance 130 Engine Remove the filters using oil filter wrench. Clean the spillage if any. See page No. 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.125 3 Check and make sure that the belt is properly aligned on the pulleys. Place the machine in service position. WARNING Hot liquids and machine parts can cause burns. Drain the water from the separator. Allow the machine to cool before beginning any work. Clean the spillage if any. Open the engine hood. See page 92. . Water separator Water separator. Open the engine hood. changing CAUTION Take care of filters. oils and liquids in an environmentally safe way. Place the machine back in service. Place the machine in service position. Remove the hose. Connect a suitable hose to water separator drain port. drain CAUTION Always handle oils and other environmentally hazardous fluids in an environmentally safe manner. See page 92. CAUTION Maintain greatest possible cleanliness when working on the fuel system. Close the engine hood. See page 131.Service and maintenance Fuel system 131 Fuel system Water separator. Loosen the drain valve and pump the fuel until water gets drained out. Place a suitable container to collect the water. Place a suitable container to collect fuel while removing the fuel water separator. Close the drain valve. Place the machine back in service. Clean the water separator head sealing surface. Tighten the air vent screw. Clean the spillage if any. Screw the water separator until its seal touches the sealing surface and tighten further half turn by hand. NOTICE Do not over tighten the water separator. Loosen the air vent screw and prime the fuel system. Check for the leakage. Close the engine hood.Service and maintenance 132 Fuel system Remove the water separator with the help of oil filter wrench. Apply a thin film of oil on the water separator seal. Fuel water separator . Run the engine at idle rpm for 5 min. Open the engine hood. Place back the machine in service. Clog . The secondary (safety) filter element should be replaced after every third primary filter element change. Under extremely dusty conditions daily cleaning may be required. clean the air cleaner primary filter. which is replaceable or can be cleaned. 133 for primary filter cleaning. See page No. 138 for Air cleaner secondary filter replacement. If air cleaner is clogged. For engine hood opening. See page No. checking Place machine in the service position. See page No. 133 . and a secondary (safety) filter element that should only be replaced and do not be cleaned. The air cleaner is a dry type with two filter elements. whichever is early. bulges or other damage. Air cleaner primary filter. Check air cleaner clog indicator on the control box. A primary filter element. Check the connections between air cleaner and the engine. 92 . CAUTION The air filter maintenance intervals depend on the amount of dust in the air and can therefore not be determined precisely. See page No. make sure all clamps are tight and secure. 125. For engine hood closing. See page No. See page No 125. Close the engine hood. air cleaner maintenance Maintenance of the air cleaner is due when the clog indicator glows in the control box.Service and maintenance Engine air cleaner 133 Engine air cleaner Engine. See page No. Air cleaner system. This indicates that the air cleaner is plugged and requires attention. 136 for Air cleaner primary filter replacement. cleaning Maintenance of the air cleaner is due only when the air cleaner clog indicator glows or every 500 hours. Check the air cleaner hoses for cracks. tilt open the operator seat platform and secure it with a stopper rod. CAUTION The air filter maintenance intervals depend on the amount of dust in the air and can therefore not be determined precisely. See page 92 . Always have a spare filter at hand and keep it well protected from dirt. Under extremely dusty conditions daily cleaning may be required. that is replaceable or can be cleaned. based on experience. The air cleaner secondary filter element should be replaced after every third air cleaner primary filter element change.Service and maintenance 134 Engine air cleaner indicator indicates that the air cleaner is clogged and requires attention. under any circumstances. NOTICE The air cleaner is a dry type with two filters. CAUTION Do not. and air cleaner secondary filter that should only be replaced and never cleaned. This job should be carried out regularly. run the engine without a filter or with a damaged one. . located at the bottom of the cover. Remove the mounting screws of operator seat platform. Air cleaner primary filter. CAUTION Do the work in an environmentally safe manner. CAUTION Remove any dust from the air cleaner cover by squeezing the rubber ejector valve. 1 2 3 4 Mounting screw Operator seat platform Knob Air cleaner access cover Remove the air cleaner access cover by removing knobs. Place machine in the service position. 1 2 Air cleaner housing Air cleaner primary filter Carefully clean the air cleaner housing. CAUTION The secondary filter must be replaced. Replace it.Check air cleaner primary filter for any damage. Carefully remove the air cleaner primary filter by pulling it straight out of the air cleaner housing. . then release. if damaged. Never remove it unless it is to be replaced. 1 2 3 Rubber ejector valve Lock Air cleaner end cap Pull the lock.Service and maintenance Engine air cleaner 135 Squeeze the rubber ejector valve. rotate the air cleaner end cap in counter clockwise direction and remove it. See page 136. never cleaned. This will dump dust and dirt from the rubber ejector valve. Repeat if needed. Install the air cleaner access cover. See page Engine air cleaner secondary filter. Carefully install the cleaned air cleaner primary filter by pushing it straight into the air cleaner housing over the air cleaner secondary filter.Service and maintenance 136 Engine air cleaner Remove air cleaner secondary filter.51 psi). . Air cleaner secondary filter NOTICE Air cleaner primary filter should be cleaned from inside to outside. Use protective equipment. replacing. Place the machine in service position. run the engine without a filter or with a damaged one. under any circumstances. Place back the operator seat platform and secure with mounting screws. rotate in clockwise direction and push the lock. Air cleaner primary filter cleaning Air cleaner primary filter. Clean air cleaner primary filter with compressed air. change CAUTION Do the work in an environmentally safe manner. Always have a spare filter at hand and keep it well protected from dirt. NOTICE Make sure the air cleaner primary filter is properly seated. Replace it. See page 92. damaged or plugged. if damaged. CAUTION Do not. Place the machine back in service. Compressed air should not exceed 5 bar (72. Never direct to bare skin. Check the evacuator valve so that it is not inverted. Install the air cleaner end cap. WARNING Compressed air. Remove air cleaner secondary filter. Repeat if needed. Carefully install the new air cleaner primary filter by pushing it straight into the air cleaner housing over the air cleaner secondary filter.Service and maintenance Engine air cleaner 137 Remove the mounting screws of operator seat platform. Squeeze the rubber ejector valve. replacing. 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. tilt open the operator seat platform and secure it with a stopper rod. . never cleaned. Carefully remove the air cleaner primary filter by pulling it straight out of the air cleaner housing. Remove the air cleaner access cover by removing knobs. then release. based on experience. See page Engine air cleaner secondary filter. located at the bottom of the cover. If damaged. 1 2 3 Rubber ejector valve Lock Air cleaner end cap Pull the lock. Never remove it unless it is to be replaced. This will dump dust and dirt from the rubber ejector valve. 1 2 Air cleaner housing Air cleaner primary filter NOTICE Make sure primary filter is properly seated. rotate the air cleaner end cap in counter clockwise direction and remove it. CAUTION The secondary filter must be replaced. This job should be carried out regularly. Replace it . damaged or plugged. Install the air cleaner access cover. tilt open the operator seat platform and secure it with a stopper rod. CAUTION The secondary filter must be replaced. This will dump dust and dirt from the rubber ejector valve. rotate it clockwise direction and push the lock. Install the air cleaner end cap. never cleaned. replacing CAUTION Do the work in an environmentally safe manner. Repeat if needed. This job should be carried out regularly. Remove the mounting screws of operator seat platform. Never remove it unless it is to be replaced. then release. Air cleaner secondary filter. . See page 92. Place the machine back in service. located at the bottom of the cover.Service and maintenance 138 Engine air cleaner Make sure the rubber ejector valve is not inverted. 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. Place back the operator seat platform and secure with mounting screws. Squeeze the rubber ejector valve. Place machine in the service position. based on experience. Make sure the rubber ejector valve is not inverted. 1 2 3 Rubber ejector valve Lock Air cleaner end cap Remove the air cleaner primary filter. Remove the air cleaner secondary filter out of the air cleaner housing.Service and maintenance Engine air cleaner 139 Pull the lock. rotate the air cleaner end cap in counter clockwise direction and remove it. NOTICE Make sure the air cleaner secondary filter is properly seated. See page 136 . 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. Carefully install a new air cleaner secondary filter by pushing it straight into the air cleaner housing. Install the air cleaner access cover. rotate in clockwise direction and push the lock. NOTICE Air cleaner secondary filter Make sure the air cleaner primary filter is properly seated. Install the air cleaner end cap. . damaged or plugged. 1 2 Air cleaner housing Air cleaner primary filter Carefully clean the inside of the air cleaner housing. Service and maintenance 140 Engine air cleaner Place back the operator seat platform and secure with mounting screws. Place the machine back in service. . For engine hood opening. For quantity see page Coolant drain plug . NOTICE The coolant level must be between center and top of the coolant level gauge. For engine hood opening. For engine hood closing. See page 3 Locate the coolant drain plug below the frame and place a suitable container to collect the coolant. See page 141.Service and maintenance Cooling system 141 Cooling system Coolant level. See page 92. 5 Close the engine hood. See page 125. check 1 Place the machine in service position. 4 Fill the coolant if necessary. 3 Check the coolant level. See page 6 Place the machine back in service. See page 92. Coolant level gauge 125 Coolant. 2 Open the engine hood. WARNING Hot oil and hot engine coolant can cause severe burns! Draining 125 196 1 Place machine in the service position. changing CAUTION Always handle oils and other environmentally hazardous fluids in an environmentally safe manner. 2 Open the engine hood. 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. For engine hood closing. 4 Open the coolant filling cap. stop the engine and let it cool down sufficiently. turn it slowly to release the pressure. See page 194 and 196. NOTICE Engine should be at the ambient temperature before checking the coolant level. see page No. For specification and quantity. 6 Plug the drain port. see page No. See page 125. 1 Fill the radiator with coolant till top of the coolant level gauge.92. 6 Close the engine hood. 3 Clean the spillage if any. cleaning WARNING Hot liquids and machine parts can cause burns. 2 Close the coolant filling cap. When removing it.Service and maintenance 142 Cooling system WARNING Before removing the radiator cap. . Radiator and coolers. 125. 4 Start the engine and let it warm up at idle rpm to the normal operating temperature. Place the machine in service position. For engine hood opening. Open the engine hood. 5 Remove the coolant drain plug and drain the coolant in the container. 7 Place the machine back in service. Allow the machine to cool before beginning any work. 5 Check the coolant level and fill coolant if necessary. keep the nozzle at a distance from the fins to prevent damage. In case of severe clogging (due to fluid leaks) apply a commercial cleaning detergent.Service and maintenance Cooling system WARNING Use safety glasses. water jets or steam cleaning methods. CAUTION When using compressed air. For engine hood closing. Close the engine hood. Remove any loose debris from the radiator and cooling fins. use compressed air. Let it soak in. Damaged fins may cause leakage or overheating. if dry dust is present. If clogging is dried on dirt use a suitable brush to remove from cooling fins. 143 Check the sign of clogging of exposed cooling fins on the radiator and cooler. CAUTION Take care not to damage the cooling fins of the radiator core. see page No. NOTICE When using compressed air. . 125 Place the machine back in service. then wash it off with water spray and dry with compressed air. ensure that appropriate protective clothing is worn to protect eyes and exposed parts of the body. secure connections must be used. Before any tests are carried out on the alternator. If the current output terminal of the alternator is connected to the mainframes while the engine is running. make sure that the correct polarity is followed. When installing or replacing a battery. This combination. Safety when working with batteries WARNING Risk of serious corrosive injuries! Batteries contain sulphuric acid which is very corrosive to the human body and parts of the machine. Correct any visible faults before beginning electrical checks.Service and maintenance 144 Electrical system Electrical system Special instructions for working on the electrical system Do not attempt to repair. L64558A Battery charging . alternator damage will result. Before welding on the compactor machine Refer to electric welding . Together with the oxygen in the air. poor contacts or corrosion. In addition. Damage may result. During all tests of alternating current equipment. Always disconnect the negative (ground) cable first and reconnect it last. means a high risk of accidents during all work with batteries used in vehicles. the batteries and electrical leads must be checked for insulation faults. Before removing or fitting components in the electrical system switch OFF the battery disconnect switch. Do not disconnect the main lead of the alternator or the lead to it's field winding while the engine is running. One loose connection lead may damage the alternator. Check the alternator belts. it is very important that you take great care and follow the rules below when you are working with batteries. Therefore. hydrogen gas forms a very explosive mixture. corrosive acid and explosive gas. batteries give off hydrogen gas when they are loaded (supplying electricity) or being charged. The battery disconnect switch should be switched to OFF position when testing the battery acid for specific gravity using a hydrometer. 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. Battery electrolyte may leak out. always connect the ground lead last when fitting a battery. Always turn off the main power to the battery charger before disconnecting the charging clamps. The current surge can cause the batteries to explode. rings. Ventilate the area well. Check for the hour meter working. Begin by disconnecting the ground lead when removing a battery. Switch off the battery cutoff switch. a potentially explosive mixture of oxygen and hydrogen gas is formed. open flame or spark near the battery can cause a powerful explosion. In order to reduce the risk of sparks that can cause fire. Never smoke near batteries. Indicating signals on the control panel Hazard indicating signal Front head lamp. Electrical components. See page 92. Therefore. Never tilt a battery to any great extent in any direction. 5 6 7 8 9 10 . Switch on the battery cutoff switch. Always cover the top of the battery with a rag or other nonconducting material when you work close to the batteries. especially if the battery is being charged in a confined space. Check for the emergency stop switch working. Shut down the engine if it is running after emergency stop switch check. Batteries contain substances hazardous to health and the environment. discarded batteries be handled according to governing local/national regulations. Switch on the ignition key. Place the machine back in service. Do not allow metal objects (such as tools. basic check 1 2 3 4 Place the machine in service position. low beam and high beam Rear working lamps Front and rear indicating lamps Parking lamps Horn Reverse alarm Start the engine. A short circuit. Do not smoke near batteries! Explosion hazard When a battery is being charged. See page 111. Risk of fire and personal injury. Do not connect a discharged battery in series with a fully charged battery. Always refit the terminal caps on the batteries.Service and maintenance Electrical system Follow these instructions when charging batteries: 145 Batteries give off explosive gases. wristwatches) to come in contact with battery terminals. Check the workings of the following electrical components. If the machine is to be left unattended. Refer to 92. disconnect the following items: 1 Battery ground connection and battery disconnect switch with battery disconnect switch turned off. corrosion or exposed and damaged wires. The electrical system may be damaged. Secure the rear hood back in place. Replace the battery disconnect switch if it is not working properly. check The battery disconnect switch provides a means to disconnect the machine electrical system for added security. Close the battery box cover. Open the rear hood of the machine . 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. when the machine is not in use. Replace damaged cables as required. Close the battery box cover. turn the battery disconnect switch to the '“OFF” position. Place the machine back in service. Electric welding If the service procedure includes welding. 2 Connectors for all electronic control units. CAUTION Do not turn off the battery disconnect switch when the engine is running. 3 Connect the welding unit ground cable as close as possible to the work area. It is located at the rear side of the machine. NOTICE Do not bypass the battery disconnect switch. Also remove the fuse for respective component. Battery disconnect switch Open the battery box cover. NOTICE Rear hood will fall back if it is not lifted to the full extent. After completing your welding procedures. Battery disconnect switch is connected between the negative battery cable and machine ground. Inspect the cables and connections for cracks. Periodically check the condition of the cables and wiring harness to the battery disconnect switch.Service and maintenance 146 Electrical system Battery disconnect switch (main switch). Place the machine in service position. CAUTION Turn off the electric power with the battery disconnect switch before starting any work. Make sure that the cable connections are tight. To access battery disconnect switch rear hood to be opened. connect the above items in the . If needed charge the batteries . Make sure ventilation is adequate when charging batteries. The battery is mounted to the rear main frame. V 108862 0 Battery Location . an open flame or a spark near the battery may cause a powerful explosion. which may be explosive. Short-circuiting. Battery disconnect switch provides a means to disconnect the machine electrical system for added security when the machine is not in use. Make sure that the battery disconnect switch is connected last. Battery description The electrical system uses one 12 V battery.105 and 109. See page No. It is located at the rear side of the machine. WARNING Battery charging generates hydrogen gas. See page 150. Never smoke near batteries. The battery should be in good condition when troubleshooting the electrical system.Service and maintenance Electrical system 147 reverse order. . Begin by disconnecting the ground lead when removing a battery. means a high risk of accidents during all work with batteries used in vehicles. it is very important that you take great care and follow the rules below when you are working with batteries. Always turn off the charging current before disconnecting the charging clamps. batteries give off hydrogen gas when they are loaded (supplying electricity) or being charged. Risk of fire and personal injury. open flame or spark near the battery can cause a powerful explosion. Ventilate well. rings. Therefore. The current surge can cause the batteries to explode. hydrogen gas forms a very explosive mixture. Batteries contain substances hazardous to health and the environment. Do not allow metal objects (such as tools.Service and maintenance 148 Electrical system Safety when working with batteries WARNING Risk of serious corrosive injuries! Batteries contain sulphuric acid which is very corrosive to the human body and parts of the machine. an explosive mixture of oxygen and hydrogen is formed. Never smoke near batteries. Therefore. A short circuit. In addition. corrosive acid and explosive gas. Do not connect a discharged battery in series with a fully charged battery. Together with the oxygen in the air. L64558A Battery charging Follow these instructions when charging batteries: Batteries give off explosive gases. wristwatches) to come in contact with battery terminals. Always refit the terminal caps on the batteries. discarded batteries be handled according to governing local/national regulations. In order to reduce the risk of sparks that can cause fire. See 191. Battery electrolyte may leak out. This combination. Never tilt a battery to any great extent in any direction. always connect the ground lead last when fitting a battery. Do not smoke near batteries! Environmentally safe handling Charging batteries Explosion hazard When a battery is being charged. Always cover the top of the battery with a rag or other nonconducting material when you work close to the batteries. especially if the battery is charged in a confined space. Corrosive acid V1033092 Battery. Avoid spilling oil or grease onto the top of the battery. 3 Get the fan belt. distilled or deionized water. alternator and regulator setting checked regularly.Service and maintenance Electrical system WARNING Risk of serious corrosive injuries! 149 Corrosive sulphuric acid The battery electrolyte contains corrosive sulphuric acid. Maintenance free batteries will usually not require topping up. wash with a solution of sodium bicarbonate and water.20 Volts. Low maintenance batteries require the addition of deionized water only once or twice per year depending on conditions. Use distilled or deionized water and never over fill. rinse immediately with plenty of water and seek immediate medical attention. this may also affect a maintenance free battery. Electrolyte spilled on bare skin must be removed immediately. Do not add acid. 5 In case of any drop in electrolyte level. 2 Petroleum jelly should be applied to cable clamps and terminals. 4 Alternator charging voltage setting across battery terminals must be maintained at 12. maintenance 1 Top of the battery must be kept clean and dry. To remove dirt or moisture. A battery needing to be topped up continuously with deionized water is a sure sign that the machine electrical system requires careful checking. Avoid overcharging Overcharging produces rapid deterioration and corrosion which shortens battery life. Do not apply grease. Wash with soap and plenty of water. . Battery Care Keep batteries topped up Maintaining a sufficient electrolyte level ensures the electrolyte is neither too high or too low. If electrolyte gets into your eyes or any other sensitive body part. Check electrical connections Make sure that the battery terminals and cable connections are clean and tight. electrical wiring.00±0. The application of a thin layer of petroleum jelly can help reduce corrosion. Keep batteries clean and dry Dirt on a battery's surface leads to discharge and corrosion. Batteries contain hydrogen gas and air in a volatile mixture which is easily ignited. clothing or any other material which may become damaged. it is only half charged after 3 months. To prevent damage due to freezing.Service and maintenance 150 Electrical system Precautions To avoid short circuit. skin. . A fully charged battery. recharge batteries when the open circuit voltage drops to 12. will result in reduced performance and service life. Battery lifting Battery is heavy . metallic objects should not be placed on top of the battery. Do not add acid to cells and keep acid away from eyes. If contamination occurs. use large amount of water to neutralize and flush acid away. NOTICE It is recommended to return the old battery to the authorized battery manufacturer / dealer / smelter during purchase of a new battery. dry place in an upright position. To help reduce this discharge. Allowing batteries to stand for an extended period of time without recharging them. To preserve optimum battery performance and life. the electrolyte can freeze if it is stored below -7°C (+20°F). If a battery becomes severely discharged.make sure correct lifting procedures are used when moving battery.4 volts. there is a spontaneous electrical discharge that increases with storage temperature. stored at a temperature of -20°C (-4°F) loses insignificant charge during a 3 month period. Battery storage When a battery is at rest. always store batteries in a cool. If the same battery is stored at +30°C (86°F). Keep flames or sparks away from the battery at all times Battery contain sulphuric acid. do not allow batteries to become discharged or to be stored below -7°C (+20°F). Electrolyte spilled on bare skin should be removed immediately. CAUTION Always turn off the current to the battery charger before disconnecting the charging clamps. A short-circuit. Hydrogen gas is flammable and may be explosive. Therefore. as an extremely cold battery will not accept a normal charge.Service and maintenance Electrical system Battery. before starting. Never smoke near batteries. until the temperature rises. WARNING The battery electrolyte contains corrosive sulphuric acid. Battery charging Batteries must only be charged using a battery charger. charging 151 WARNING During battery charging. rinse immediately with plenty of water and seek immediate medical attention. that is. and make sure that they are adequately tightened. Wash the affected area with soap and plenty of water. make sure that the battery must be at least halfcharged. when the battery is at rest. and free from corrosion and dirt. allow it to come to room temperature. If the battery is extremely cold. . Check the battery terminal connections. open flame or spark near the battery can cause a powerful explosion. CAUTION Always disconnect the electric power to the battery charger before the charging clamps are removed. ventilate well. If electrolyte gets into your eyes or any other sensitive body part. hydrogen gas is formed. Check the battery voltage. See page No. b If the indicator turn white. rinse immediately with plenty of water and seek immediate medical attention. 125. checking electrolyte WARNING Corrosive sulphuric acid The battery electrolyte includes corrosive sulphuric acid. Battery access cover NOTICE Use a suitable washer to open and to close the service plugs. c If the indicator turns red. open the service plugs. For engine hood opening See page No. If electrolyte gets into your eyes or any other sensitive body part. a If the indicator is green. battery is OK. Close the engine hood. Remove the battery access cover. Place the machine in service position.Service and maintenance 152 Electrical system Battery. See page No. Check the electrolyte level indicator on the batteries. Wash with soap and plenty of water. battery need to be charged. add distilled water to maximum level and close the service plugs or call the service person. Electrolyte spilled on bare skin must be removed immediately. Open the engine hood. Place the machine back in service. For engine hood closing. Battery electrolyte level indicator . Install the battery access cover. 125. 92. FL2 15 Fuse. fuses 153 13 14 15 2 3 1 4 5 6 7 8 9 10 11 12 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. FL3 .Service and maintenance Electrical system Component location. Brake dump. Two speed solenoid. . Tachometer. Hourmeter. rear light switch. Component list. Park brake test.155. Brake lights relay. Brake-latching relay Circuit. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Relays Power relay Front light low beam relay Alarm relay Brake latching relay Brake light relay Hazard relay Reverse light relay Flasher relay Position light relay Rear light relay Front light high beam relay Seat timer relay Starter relay Glow plug relay Location Control box Control box Control box Control box Control box Control box Control box Control box Control box Control box Control box Control box Battery compartment Battery compartment For relay locations. See page No. See page No. Horn.Service and maintenance 154 Electrical system Component list.153. Relays SI NO. Fuses SI NO. 1 Fuse F1 Ampere rating 40 A Circuit protected Power relay.5 A 15 A 10 A 60 A 60 A 100 A For fuse locations. Engine oil pressure gauge. position light switch Mobile charger Front high beam lights Rear lights Reverse lights Flasher Beacon light Cluster and air filter Audible alarm Position light Low beam front lights Fuel solenoid Main fuse Glow plug Battery charging circuit 2 3 4 5 6 7 8 9 10 11 12 13 14 15 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 FL1 FL2 FL3 10 A 15 A 15 A 10 A 10 A 10 A 10 A 10 A 7. Pump-Destroke circuit. V-belt switch. Seat switch. Fuel gauge. Park brake. Engine oil temperature gauge. relays 13 155 14 7 8 2 1 11 3 4 5 6 9 10 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 .Service and maintenance Electrical system Component location. See page No. checking oil level Place the machine in service position. Fix back the transmission oil fill/level plug. Check the transmission oil level. beware of hot fluids and hot components that can cause severe burns. oil level must be at bottom edge of the transmission oil fill/level hole.Service and maintenance 156 Transmission Transmission Transmission. Transfer gearbox case 1 Oil fill/level plug 2 Oil drain plug . add oil through transmission oil level/fill hole. required. See page No. Allow axle transfer case to cool. Clean around the transmission oil fill/level plug. 92. Remove the transmission oil fill/level plug. 194. Clean and apply thread sealant to transmission oil fill/level plug. WARNING If work must be done on the machine before it has cooled down. Place the machine back in service. Clean for the oil spillage. Fill the transmission oil case with transmission oil through the transmission oil fill/level hole. Make sure that the transmission oil level is at correct level. See page No. changing oil 157 NOTICE Oil must be at normal operating temperature when draining Run the machine until the transmission oil reaches operating temperature. 92. Clean for the oil spillage. . Place the machine in service position. 194 and 196. WARNING Work carefully when changing oil as hot oil can cause severe burns to unprotected skin. Clean and apply thread sealant to transmission oil fill/level plug. Place the machine back in service. Check the transmission oil level. See page No. until the oil level is at the bottom edge of the oil fill/level port. 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. See page No. Test run the machine.Service and maintenance Transmission Transmission. 156 . Place a suitable container below the transmission oil case. Remove transmission oil drain plug and drain the transmission oil. Remove the transmission oil fill/level plug. Clean and apply thread sealant to transmission oil drain plug. Place back the transmission oil drain plug. Add axle housing oil through the oil fill hole if required. checking oil level Place the machine in service position. it must be at the bottom edge of the axle housing oil level port. Fix back the oil level plug and tighten it. Allow the axle housing to cool. Place the machine back in service. 158 Clean the axle wheel end hub oil fill/level plug.Service and maintenance 158 Axles Axles Axles. checking oil level Park the machine service position. See page No. Axle wheel end hub oil fill/level hole . Check the axle housing oil level. See page No. Oil level plugs of the axle Axle hubs. Fix back and tighten the axle wheel end hub oil fill/level plug Clean up for the oil spillage. Locate and clean around both the oil level plugs. beware of hot fluids and hot components that can cause severe burns. See page No. Allow axle wheel end hub oil to cool. See page No. Check and make sure that the oil level is at bottom edge of the axle wheel end hub oil fill/level port. Clean around the axle wheel end hub oil fill/level plug. WARNING If work must be done on the machine before it has cooled down. 92. 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. Place a suitable container bellow the axle wheel end hub oil fill/ level plug. Clean the axle housing oil level plug and apply thread sealant to it. 194 . Clean around the oil level plugs for oil spillage. Place the machine back in service. Similarly check the oil level of other side of the axle. Remove the axle wheel end hub oil fill/level plug. Remove any one of the axle housing oil level plug. changing oil 159 WARNING Work carefully when changing oil as hot oil can cause severe burns to unprotected skin. draining . Place the machine in service position. Run the machine till the axle wheel end hub oil reaches operating temperature. Place a suitable container under the axle wheel end hub oil fill/ level plug.Service and maintenance Axles Axle hubs. See page 92. Axle wheel end hub oil. 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. Clean around the axle wheel end hub oil fill/level plug. 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. changing oil Axle housing oil changing WARNING Work carefully when changing oil as hot oil can cause severe burns to unprotected skin. See page No. Axle housing drain plugs Place a suitable container under the axle housing drain plugs. Check the wheel end hub oil level. Place back the axle wheel end hub oil fill/level plug. Axle wheel end hub oil fill/level plug at 9 o'clock position Rear axle. Clean the axle wheel end hub oil fill/level plug. Clean for any spilled oil. until oil level is at the bottom edge of the fill/level port. See page 196 and 158. See page 158. . Repeat the procedure for the other side of the axle wheel end hub. Start the machine and run until the axle housing oil reaches operating temperature. 92. Fill the axle wheel end hub through oil fill/level hole.Service and maintenance 160 Axles Position the wheel end hub oil fill/level hole to the 9 o'clock position. Locate and clean around the three axle housing oil drain plugs. Test run the machine. Place the machine in service position. NOTICE Axle housing oil must be at normal operating temperature when draining. Place the machine back in service. Clean around the axle housing drain plugs for oil spillage. 194 and 158. until oil level is at the bottom edge of the check port.Service and maintenance Axles Remove the axle housing drain plugs and drain the axle housing oil. See page No. Test run the machine. AXLE HOUSING OIL FILL PLUG V1076328 Axle housing oil fill plug Remove the axle housing fill plug. 158 . 161 CAUTION Always handle oils and other environmentally hazardous fluids in an environmentally safe manner. Axle breather. Fill the oil through the fill hole. Locate and clean around the axle housing oil fill plug. See page No. Fix back the axle housing fill plug. Clean up for any oil spillage. Clean and apply thread sealant to axle housing fill plug. Fix back the axle housing drain plugs. See page No. Clean the axle housing drain plugs and apply thread sealant. 92. . cleaning Place the machine in service position. Allow the axle to cool. Place the machine back in service. Check the axle housing oil level. Axle breathers Remove the axle breathers. Place the machine back in service. Protect the breather ports to avoid contaminants entering the axle. Clean the breathers with solvent and allow it to dry.Service and maintenance 162 Axles Locate and clean the area around the two axle breathers. Fix back the axle breathers. Axle breather installation . If the machine does move. Propulsion control lever . Shut down the engine. Move the propulsion control lever to STOP position. Start the machine and position it in an area clear of personnel and obstructions. Release the parking brake test switch. Press and hold the parking brake test switch and move the propulsion control lever FORWARD or REVERSE. Park brake test 1 Park brake test switch 2 Park brake switch Press the parking brake switch. The machine should NOT move.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. shut down engine and have the fault corrected before continuing operation. greasing Place the machine in service position. ■ Apply the recommended grease to each fitting until the grease exits from the sealing surface. CAUTION Wipe off grease nipples and grease gun before greasing. ■ Place the machine back in service. See page 194 . See page 92. Cap end cover side Rod eye end side .Service and maintenance 164 Steering system Steering system Steering cylinder pins. ■ Clean steering cylinders pin grease fittings. so that dirt and sand are not introduced through the grease nipples into the bearings. See page No. This may lead to accidents. moisture and foreign material from damaging the valve core After checking the tyre pressure. Torque the wheel nuts evenly in clockwise and diagonal pattern. Check the tyre pressure. or other damage which could cause premature tyre wear or failure Check the wheel rim for excessive rust. . Use a self-attaching air chuck with a hose long enough to enable you. WARNING Inflating a tyre may cause it to explode. moisture and foreign material from damaging the valve core. If a tyre with ballast is replaced. Park the machine on level ground with the wheel rotated so that the tyre inflation valve is located at the 12 o'clock position. missing or loose wheel bolts. Make sure that the normal operating pressure is not above 1. when inflating.201 and 202. cracks. place the valve caps to prevent dirt. 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 . check torque Place the machine in service position. but as far away as possible. After checking the tyre pressure.92. wear and air pressure. when tyres are cold. place the valve caps to prevent dirt. The addition of calcium chloride is recommended to prevent the water from freezing. For torque value See page No. Report tyre and wheel rim defects to a qualified person who is equipped and trained to perform tyre repair service.1 bar (16 psi). See page No. cracks. Remove the tyre inflation valve cap. using an appropriate pressure gauge. Tyre inflation valve Wheel nuts. Check the wheel rim for excessive rust. checking Before checking tyre pressures or inflating. to stand by the tyre tread. missing or loose wheel bolts. the replacement tyre must also contain ballast.Service and maintenance Wheels 165 Wheels Tyres. See page 198 for size and pressure of tyre. 100. V1098837 Wheel nuts . Place the machine back in service.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. 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. Oil should be level with the bottom edge of the level check plug hole. ■ Allow the carrier to cool . ■ Clean up any excess oil. one is oil level plug and other is oil fill plug. Drum carrier plug location.Service and maintenance Drum 167 Drum Drum. Drum carrier breather Drum drive (torque hub). See page 92. Remove all adhering materials on the drum. ■ Remove the oil level check plug and check the oil level in the carrier. ■ Fix back and tighten the carrier oil level check plug. 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. ■ Place the machine back in service. Drum carrier. Place the machine back in service. ■ Clean the area around the oil level check plug located on the lower side of the carrier. Perform a visual inspection of the drum assembly. checking oil level NOTICE There are two plugs on the torque hub. checking oil level ■ Place the machine in service position.92. ■ Make sure that the breather is clean and tightened. See page No. . checking Place the machine in service position. oil fill plug will be in 12 o' clock position. Clean for any oil spillage. See page No. Reposition the oil level plug to 12 o'clock position. Close the oil level port with oil level plug. Reposition the oil level plug to 3 o'clock position. Clean the oil level plug with solvent and apply thread sealant. Fix back the oil level plug and tighten it. Clean the oil fill plug with solvent and apply thread sealant to it. NOTICE When the oil level plug is in 3 o' clock position. Remove the oil level plug. Fix back the oil fill plug and tighten it. Clean the area around the oil level check plug. Add fresh oil through fill hole until the oil is level with the bottom edge of the oil level check port. See page 92. Loosen the oil level plug. Remove the oil level check plug and check that the oil level is filled to the bottom edge of the oil level check port. checking oil level ■ Place the machine in service position. with the oil level plug in 12 o'clock position. 1 2 Drum Index Eccentric fill plug (at 12 o'clock) . remove the oil fill plug which will be at 12 o'clock position. Place the machine back in service. If the oil level has dropped below the oil level check port. 92 . Oil level fill plug Drum eccentric.Service and maintenance 168 Drum Place the machine in service position. with the drum index at the 12 o’clock position. For specification see page no 194 . ■ If oil is to be added. ■ 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. Clean the breather with solvent and allow it to dry. Drum carrier breather . Torque all screws and nuts to specification as necessary. Drum shock mounts checking Carrier breather. Check the condition of the drum shock mounts periodically for loosening or signs of deterioration. See page No. Replace shock mounts (one at a time) that have torn or excessively cracked rubber.92. 194. cleaning Clean the area around the carrier breather located on top of the carrier.Service and maintenance Drum NOTICE 169 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. For specification See page no.201. remove the fill plug and add oil . Fix back the breather and tighten. Remove the breather. Cover the breather port to prevent contaminants from entering the system. NOTICE Oil level must be at the centre of the sight gauge. ■ Check the oil level is to the centre of the sight gauge. See page No. Place the machine back in service. checking Place the machine in service position. changing oil NOTICE Oil must be at normal operating temperature when draining. Drum carrier breather plug Place a suitable container below the drain plug. Remove the level check plug. Run the machine until the drum carrier assembly reaches operating temperature. See page 92. 2 Drum carrier oil drain plug . Add oil until oil runs out of the level check plug mounting hole.Service and maintenance 170 Drum Drum carrier. Carrier oil level check plug 1 Drum carrier oil level check plug. Remove the fill / breather plug on carrier assembly. Place the machine back in service. Remove the drain plug and drain the oil. Fix back the fill / breather plug. Place the machine in the service position. Clean the fill/breather plug with solvent. CAUTION Always handle oils and other environmentally hazardous fluids in an environmentally safe manner. WARNING Work carefully when changing oil as hot oil can cause severe burns to unprotected skin. Clean and fix back the drain plug and tighten. Fix back the level check 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. ■ Reposition the oil level plug to 3 o'clock position. changing oil 171 CAUTION Always handle oils and other environmentally hazardous fluids in an environmentally safe manner. NOTICE There are two plugs on the torque hub.Service and maintenance Drum Drum drive (torque hub). See page No. NOTICE When the oil level plug is in 3 o'clock position. oil fill plug will be in 12 o'clock position. Oil level plug at 12 o'clock position ■ Loosen the oil level plug. Loosening of oil level plug . one is oil level plug and other is oil fill plug. 92. ■ Place the machine service position with oil level plug in 12 o'clock position. ■ Remove the oil level plug. ■ Reposition the oil level plug to 6 o'clock position. ■ Fix back the oil fill plug and tighten it. NOTICE Oil must be at normal operating temperature when draining. ■ Clean the oil fill plug and apply thread sealant to it. ■ Reposition the oil level plug to 12 o'clock position. Removing of oil fill plug ■ Close the oil level port with oil level plug. ■ Remove the oil level plug at the 6 o’clock position and allow the oil to drain. ■ Fix back the oil level plug and tighten it. till the oil level must be at bottom edge of the oil level port. . WARNING Work carefully when changing oil as hot oil can cause severe burns to unprotected skin. ■ Place a suitable container under the torque hub.Service and maintenance 172 Drum ■ Remove the oil fill plug which will be at 12 o'clock position. ■ Place the machine back in service. ■ Fill the oil through the fill port which will be at 12 o'clock position. ■ Clean up any oil spillage. ■ Make sure that the torque hub oil is at correct level. ■ Test run the machine and check for any leaks. ■ Clean the oil level plug with solvent and apply thread sealant. changing oil WARNING Work carefully when changing oil as hot oil can cause severe burns to unprotected skin. Oil level plug at 12 o'clock position Drum eccentric. ■ Reposition the oil level plug to 3 o'clock position. CAUTION Always handle oils and other environmentally hazardous fluids in an environmentally safe manner. Test run the machine and check for any leaks. ■ Fill the drum eccentric with fresh eccentric oil through the fill hole. ■ Place the machine on level ground in service 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. ■ Clean up any oil spillage. ■ Place suitable container to collect the oil drain. level-read position. 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. . ■Place the machine back in service.Service and maintenance Drum 173 ■ Run the machine so that the eccentric oil reaches operating temperature. This will also bottom-out the drain plug in the 6 o'clock position and the level indicator gauge in the 4 o'clock. ■ Make sure that the eccentric oil is at correct level. with the drum index (angle mounted on the inside of the drum) at the 12 o’clock position. ■ Remove the fill plug and the drain plug and drain the oil. ■ Clean and place back the drain plug. CAUTION Always handle oils and other environmentally hazardous fluids in an environmentally safe manner. Follow these basic precautions: Never adjust a pressure relief valve or other pressure-limiting device to a higher pressure than specified. CAUTION Always handle oils and other environmentally hazardous fluids in an environmentally safe manner. The system must be properly maintained to avoid the potential for accidents and injury. Use a piece of cardboard. WARNING Risk of personal injury! Wear safety glasses and use protective gloves. lock valves and similar hydraulic components are designed to retain pressure or oil flow. or before the residual pressure has been released. there will still be residual pressure at various point is the hydraulic system. resulting in serious personal injuries. Use extreme care when working with accumulators. Never use your hands to check for oil leaks. Pressure accumulators have a pressurized gas charge as well as residual hydraulic pressure. Check valves. Never tighten leaky fittings with the engine running. Release pressure by completely moving the hydraulic control levers back and forth several times.) hole in the cylinder to eliminate the risk of explosion. leaks or damage before it bursts. wear. WARNING If the pressure is not released before opening the system. fitting or component without first relieving residual pressure. Releasing hydraulic pressure When you shut down the engine. Replace any hydraulic hose immediately that shows signs of swelling. It is important that each person who comes in contact with the machine be alert to any faults. Fine jets have high penetrating capacity on bare skin. Never discard a hydraulic accumulator without first carefully drilling a 3 mm (1/8 in. oil under high pressure will jet out. The hoses become "slack" when the hydraulic pressure is released.Service and maintenance 174 Hydraulic system Hydraulic system Safety when working on hydraulic systems The hydraulic system operates at high oil pressures. WARNING Leaking high-pressure hydraulic hoses may cause severe injuries. Never disconnect any hydraulic hose. . Greatest possible cleanliness should be maintained during all handling of hydraulic components and hydraulic oil. See page No. ■ Check the hydraulic oil level by looking at the sight gauges of the hydraulic tank. 1 V1092471 Hydraulic oil tank. If required add fresh clean hydraulic oil through the oil fill plug. 92.Service and maintenance Hydraulic system 175 Carefully loosen the hydraulic hose. 1 High level indicator sight gauge 2 Low level indicator sight gauge Hydraulic oil filter. Secure operator seat platform with the seat stopper rod. ■ Park the machine on a level surface. checking oil level CAUTION It is very important to keep the hydraulic system free from any impurities. residual pressure can still be trapped in the hydraulic system. 176. as these can cause abnormal wear and may lead to expensive downtime. 2 NOTICE Oil must be filled when oil level drops down to minimum level in the low level indicator sight gauge. changing Place machine in service position. Hydraulic system. Tilt open the operator seat platform to access the two hydraulic filters. Hydraulic oil filters . See page No. Similarly replace other hydraulic filter. To check foaming. Therefore. wipe areas in question clean before any work is carried out. Make sure that there is no foaming in the hydraulic tank. See page No. open the hydraulic tank filler cap check the hydraulic oil condition with the torch. Remove the hydraulic oil filter by turning it counterclockwise using a filter wrench NOTICE Discard the filters in accordance with local environmental guidelines. Hydraulic oil tank. until the O-ring just touches the sealing surface. CAUTION Always handle oils and other environmentally hazardous fluids in an environmentally safe manner. Start the engine and check for leaks. Clean the hydraulic oil filters and filter heads before removing them from the machine in an effort to prevent contamination of the hydraulic system. Run the machine until the hydraulic oil reaches operating temperature. 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. Foaming in hydraulic oil can lead to hydraulic system failure. Fill new hydraulic oil filter with fresh hydraulic oil and screw the filter to filter head. tighten further half by hand. . Lubricate new O-ring with thin film of fresh hydraulic oil and replace it to new hydraulic oil filter. as it is possible to distort the threads or damage the filter element seals. is an indication of air leakage. 92.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 . Reconnect the disconnected hose. Place the operator seat back in position. Place the suitable container to collect the hydraulic oil spillage. Place machine in service position. Hose to be disconnected NOTICE Do not overtighten the hydraulic oil filters. Clean for the oil spillage. Clean the filter head and make sure that there is no gasket material or other debris remaining on the filter head. NOTICE Foaming in hydraulic tank. into the hydraulic system. Place the machine back in service.Service and maintenance Hydraulic system WARNING 177 Work carefully when changing oil as hot oil can cause severe burns to unprotected skin. See page No. Clean and apply thread sealant to the drain plug. Fuel. 175. Start the engine and check all hydraulic connections for any leaks. Hydraulic tank. Remove the breather filler cap and fill hydraulic tank with clean hydraulic oil. lubricant and filling capacities for capacity of the container. See page No. Check the hydraulic oil level. Hydraulic oil tank fill plug Cleaning of hydraulic tank. See page No. Hydraulic oil tank drain plug Remove the drain plug and drain the hydraulic oil. Draining of hydraulic oil Place a suitable container below the hydraulic tank drain port located at the bottom of the tank. Filling of hydraulic oil Clean the hydraulic tank. Fuel. lubricant and filling capacities. Fix back the drain plug. See page No. 177. Dispose the used hydraulic oil in accordance with local environmental guidelines. . Fix back the breather filler cap and clean for oil spillage. cleaning Start the engine and run the machine until the hydraulic oil reaches operating temperature. Clean around heads of hexagonal head screws of the hydraulic tank lid. Drain the hydraulic oil. Clean inside the hydraulic tank by using clean and lint free cloth.92. Remove hydraulic tank lid by removing the screws. 176. Run the machine until the hydraulic oil reaches operating temperature. Fill the hydraulic oil to hydraulic tank. . 175. Reinstall hydraulic tank lid with the screws and tighten. See page No . Greatest possible cleanliness should be maintained during all handling of hydraulic components and hydraulic oil. Refer Filling of hydraulic tank in page No. See page No. Place machine in the service position. Check the hydraulic oil level. cleaning CAUTION It is very important to keep the hydraulic system free from any impurities. Check gasket for damage and if found damage replace it. Draining of hydraulic oil in page 176. See page No. Apply thin film of grease on both side of the gasket and replace the gasket. Place the machine back in service. Remove the tank cover gasket and clean the tank cover gasket area on the hydraulic tank. 92. See page No. as these can cause abnormal wear and may lead to expensive downtime. Gasket installation Hydraulic oil suction strainer.Service and maintenance 178 Hydraulic system Place machine in service position. Remove the two strainers with adapter from the hydraulic oil tank. Strainer with adapter 1 Adapter 2 Strainer . 176. See Draining of hydraulic oil in page No. using a stiff fiber brush to remove imbedded impurities and allow the suction strainer to air dry. Clean the strainers with solvent. Fill the hydraulic tank with clean hydraulic oil. 176. Hydraulic tank hoses to disconnect NOTICE Follow below 2 steps when replacing the strainers. Apply hydraulic sealant and install the cleaned/new strainers with adapter to hydraulic tank. See page No. replace strainers. Remove the plugs and reconnect the disconnected hoses to hydraulic tank. NOTICE If embedded materials cannot be removed . Disconnect the propulsion pump and vibration pump suction hoses on the tank side and plug the disconnected hoses immediately. Remove the adapter from the old strainer. Start the engine and check hydraulic connections for leaks. Clean the hydraulic tank. 177.Service and maintenance Hydraulic system 179 Drain the hydraulic oil tank. Apply hydraulic sealant to removed adapter and install it to the new strainer. Refer to Filling of hydraulic oil in page No. Shut down the engine. CAUTION Wipe off grease nipples and grease gun before greasing.Service and maintenance 180 Greasing Greasing Swivel joint (horizontal and vertical) pins. Clean the vertical and horizontal swivel pin grease fittings. Horizontal swivel pin grease fittings Vertical swivel pin grease fittings . See page No. 194 for the proper type of grease. Apply the recommended grease to each fitting until the grease exits from the sealing surface. so that dirt and sand are not introduced through the grease nipples into the bearings. Place the machine back in service. greasing Start the engine and articulate the machine fully to the left. 1 Wipe off grease nipples and grease gun to avoid dirt and sand entering the bearing. . V1090184 V1090184 Manual greasing. 3 Operate all the cylinders to their end positions without any load on the equipment. . The grease in the space inside the outer seal collects dirt and prevents dirt and also water from penetrating into the bearing. water and abrasive material may enter the bearings. greasing 181 The service life of bushings and pivot pins can be extended considerably.Replace old grease which may contain dirt. if the machine is greased regularly and in a correct way.Add grease to the bearing to reduce friction between pin and bushing. the compactor unit should be greased every 10 hours or daily.Service and maintenance Greasing Bearings. clean grease is forced out through the outer seals. digging unit Grease the points shown below every 50 hours or weekly. NOTICE Under severe operating conditions where mud. the compactor unit should be greased every 10 hours or daily. During the first 100 hours. The greasing of bearings has two main purposes: . 2 Fill with grease until new. Service and maintenance 182 Greasing Lubrication points. (number of nipples in brackets) 1 Steering cylinder both side NOTICE Under severe operating conditions where mud. Shift linkage. 194 . Locate the shift linkage for engine throttle and lubricate with 2 drops of engine oil. 92. 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. grease every 10 hours or daily. See page No. 2 Remove the mounting screws of operator seat platform. lubricating CAUTION Always handle oils and other environmentally hazardous fluids in an environmentally safe manner. . Fill with grease until new. 1 Place the machine in service position. For engine oil specification See page No. water and abrasive material may enter the bearings. clean grease is forced out through the outer seals. Wipe off grease nipples and grease gun to avoid that dirt and sand not are entering the greasing system. Place back the operator seat platform and secure with mounting screws. 194. Place the machine back in service. 194. For engine oil specification See page No. 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. Install the cowling cover. Shift linkage for vibration pump .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. Service and maintenance 184 Lubrication and service chart Lubrication and service chart . Service and maintenance Lubrication and service chart Lubrication and service chart 185 V1102328 Lubrication chart . 141. 182 See page No. 158 AR See page No. A S A CL SAE 85W-90 LS API GL5 S. A SAE 85W-90 LS API GL5 S.A MPG-EP2 grease MPG-EP2 grease Compressed air Volvo super hydraulic oil ISO VG 46 G G S. 167 See page No. Change coolant at 6000 hrs/ 4 yrs. A S. Check indicator Primary filter element clean / change when clog indicates Secondary filter element change @ every 3rd change of primary filter element. 169 AR See page No. 133 See page No. Clean fins. no.126. 175 475 Nm (350 lbf ft) See page No. A S. Drain collected water. 15W-40 Service required S. 165 FTLH See page No. See page No.142 AR See page No. Periodic Lubrication Schedule Service interval 10 Hours ordDaily 3 4 5 Water separator drain Fuel tank Engine coolant Diesel fuel Volvo VCS coolant D S. 180 1. A 6 50 Hours or weekly 7 8 9 10 11 12 13 14 15 16 17 100 Hours 18 or monthly 19 20 Engine cooling system Battery Torque hub oil Swivel and cylinder pins Center swivel Tyre pressure Hydraulic oil Wheel nuts Eccentric oil Air cleaning system integrity Shift linkage Carrier breather Axle housing oil Transmission oil Wheel end oil Engine oil MOBIL SHC 630 Distilled water S S. 151 FTLH See page No. A SAE 85W-90 LS API GL5 S. 1 2 Description Engine oil Air cleaner Recommended lubricant VDS-3. 165 FTLH See page No. A S. A SAE 85W-90 LS API GL5 S. See page No. CL-4. 164 See page No. 168 See page No.1 bar (16 psi) See page No. See page No.131 285 litre ( 75 US gal) See page No.Service and maintenance 186 Lubrication and service chart Ref. 158 Table. A . See page No. 156 FTLH See page No. T S. A S Comments Fill to dipstick full mark. 83 US gal) maximum See page No. 130 180 l (47 US gal) See page No. 126 See page No. F C S D. 201 FTLH See page No. 161 See page No. CL-4.8 l (0. 156 1. 160 1. F SAE 85W-90 LS API GL5 D. 175 187 See page No. F S. 178 SAE 85W-90 LS API GL5 D.136 See page No.5 US gal) maximum See page No. 128 See page No. 15W-40 See parts manual Service required D. no. T D.Service and maintenance Lubrication and service chart Service interval 250 hours or quarterly Ref. 128 and 131 500 Hours 26 or semiannually 27 28 29 30 31 32 33 34 35 36 1000 Hours or annually Service functions 37 38 S.158 624 Nm (460 lbf ft) See page No.T SAE 85W-90 LS API GL5 D. 21 22 23 24 25 Description Engine oil Engine oil filter Axle housing breather Hydraulic filters See parts manual Engine fuel filters See parts manual and water separator Articulating vertical nuts Eccentric oil Axle housing oil Transmission oil Wheel end oil Axle mounting bolts Horizontal swivel nut Torque hub oil Carrier oil Air filter primary element Poly V-belt Hydraulic oil change Suction strainer ISO VG 46 MOBIL SHC 630 Recommended lubricant VDS-3. F MOBIL SHC 630 D. 176 See page No.9 litre (0. F SAE 85W-90 LS API GL5 D. F CL S – Check C – Change FTLH – Fill to level hole/ mark T — Torque A – Add G – Grease D – Drain F – Fill CL – Clean AR – As required . 172 11 litre (2.53 US gal) See page No. 201 41 litre (10. 201 1491 Nm (1100 lbf ft) See page No. F 678 Nm (500 lbf lt) See page No.47 US gal) maximum See page No . 170 2 l (0. F C CL C C Comments See page No. 169 See page No.9 US gal) maximum See page No. T S. .Specifications 188 Specifications Specifications. general This section of the manual contains technical specifications for the SD110 Series of Vibratory Soil Compactors. See page No. 17. For general information regarding Machine identification. For general Machine dimensions. 206. See page No. On plug-type check points. visually check the entire unit to ensure that capscrews. Unless otherwise indicated. Grease fittings that are worn and will not hold the grease gun. If necessary. the oil levels are to be at the bottom edge of the check port. etc. levers. Lubricants must be at operating temperature before draining. caps. Do not continue operations until the problem is corrected. All oil levels are to be checked with the machine parked on a level surface and while the oil is cold. must be replaced. An anti-seize compound may be used if rust has not formed. Otherwise. under lubrication will definitely lead to a shorter component life. Thoroughly wash all fittings. All grease fittings are SAE standard. plugs. use only genuine manufacturer-approved lubricants. non-toxic cleaning solution before servicing to prevent dirt from entering while performing the service.) should be lubricated with oil once a week. unless otherwise specified. with nonflammable. To obtain the maximum long-life results from the machine. Different lubricants are needed and some components require more frequent lubrication than others. Motor oil. See 185 and Recommended lubricants. pins. or those that have a stuck check ball. Stop the machine if any function does not operate or operates incorrectly.Specifications Recommended lubricants 189 Recommended lubricants General information Lubrication is an essential part of preventive maintenance. The lubrication and service chart shows those items requiring regular service and the interval at which they should be performed. For maximum machine life and performance. Spot check several capscrews and nuts for proper torque. a more thorough investigation must be made. more frequent lubrication may be necessary. Report the problem to your supervisor or site management. Periodic lubrication of the moving parts reduces to a minimum the possibility of mechanical failures. contact authorized distributor for results. etc. If any are found loose. Over-lubrication on non-sealed fittings will not harm the fittings or components. will provide the necessary lubrication and help prevent the formation of rust. the component must be cleaned first. Grease non-sealed fittings until grease is seen extruding from the fitting. items not equipped with grease fittings (linkages. a regular service program should be followed as recommended in this manual. nuts and pins are properly secured. dusty or wet operating conditions. . affecting to a great extent the useful life of the unit. applied sparingly. The suggested intervals are based on average operating conditions. In extremely severe. During regular lubrication service. unless otherwise indicated. But. It is important that the specific instructions regarding types of lubricants and the frequency of their application be followed. 8 centistokes per second at 40 °C (104 °F) 40 minimum at temperatures above 0 °C (32 °F) 45 minimum at temperatures below 0 °C (32 °F) Not to exceed 0. At least 90% of the fuel must evaporate at less than 360 °C (680 °F).3 to 5. Gr.Specifications 190 Recommended lubricants Fuel Viscosity (ASTM-D-445) Cetane number (ASTM-D-613) Sulfur content (ASTM-D-129 or 1552) Water and sediment (ASTM-D-1796) Carbon residue (Ramsbottom.05% by weight Not to exceed 0.) 6 °C (10 °F) below lowest ambient temperature at which the fuel is expected to operate Copper strip corrosion not to exceed No. 2 rating after 3 hours at 49 °C (122 °F) Not to exceed 0.816 to 0.876 Sp. ASTM-D-189) Flash point (ASTM-D-93) Density (ASTM-D-287) Cloud point (ASTM-D-97) Active sulfur Ash (ASTM-D-482) Distillation (ASTM-D-86) 1.25% by weight on 10% volume residue At least 52 °C (125 °F) or legal temperature if higher than 52 °C (125 °F) –1 °C to 6 °C (30 °F to 42 °F) API gravity at 16 °C (60 °F) (0. ASTM D-524 or Conradson. All of the fuel must evaporate at 385 °C (725 °F) .02% by weight The distillation curve must be smooth and continuous.1% by volume Not to exceed 0. COD-Mn Value < 340 ppm < 9. salt or metals. .10 mg Fe/litre < 0. Do not mix with any other ready-mixed coolants since this may result in engine damage. The amount of concentrated coolant must never be less than 40% of the total mixture. the mixture should contain 40–60% concentrated coolant and 60–40% clean water. To avoid damage to engine and cooling system. When using concentrated Volvo Coolant VCS and clean water. The clean water for the cooling system must also meet the following requirements: Description Total number of solid particles Total hardness Chloride Sulphate pH value Silica Iron Manganese Electrical conductivity Organic material. see table below. different coolants or corrosion protection must not be mixed. Freeze protection down to -25 °C (-13 °F) -35 °C (-31 °F) -46 °C (-51 °F) Mixed-in amount of concentrated coolant 40 % 50% 60% The concentrated coolant must not be mixed with water that contains a high degree of lime (hard water).5-9 < 20 mg SiO2/litre < 0. which contains 40% concentrated coolant.Specifications Recommended lubricants Coolant 191 Only use Volvo Coolant VCS when topping up or changing coolant.05 mg Mn/litre < 500 µS/cm < 15 mg/litre If there is any doubt about the water quality use ready-mixed Volvo Coolant VCS.5° dH < 40 ppm < 100 ppm 5. NOTICE It is minimum theoretical recommendation without the guarantee of machine condition. Type : Anti-wear type hydraulic oil Viscosity characteristic Viscosity index : More than 130 Kinematic Viscosity : Less than 5. Unless otherwise specified. 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. SAE-90 viscosity oil may be used for yearround service. –40 °C (–40 °F) –26 °C (–15 °F) –12 °C (+10 °F) –7 °C (+20 °F) . it does not guarantee the completion machine for other conditions like engine starting performance. EP Multipurpose Lubricant SAE Viscosity No.6cSt at +90°C NOTICE This value is approximately equivalent to ISO Viscosity grade #22.000cSt at -40°C. For the hydraulic oil specification.Specifications 192 Recommended lubricants Hydraulic oil Only use Volvo genuine hydraulic oil approved by Volvo Construction Equipment must be used. Ambient Temp. Do not mix different brands of hydraulic oil as this can lead to damage in the hydraulic system. Additional recommendation for severe cold areas A field solution for severe cold condition of ambient temperature between -40°C and +20°C. In this range a warming-up period is needed to obtain proper performance. More than 5. Low temperature usage is restricted as indicated in the table below. Ambient temperature °C °F -40 -40 -30 -22 (B) Oil grade (B) (B) -20 -4 -10 +14 0 +32 (A) (A) (A) +10 +50 +20 +68 (C) (C) +30 +86 +40 +104 +50 +122 +60 +140 (A) : Ambient temperature recommended for general use of hydraulic system and components.194 . 75W 80W 85W 90 Min. not a recommendation for general use conditions. (B) : Ambient temperature guide for machine operation from a hydraulic oil viewpoint only. see page No. (C) : Ambient temperature range to operate machine under special conditions. See table below. 140 250 Min. +5 °C (+40 °F) +10 °C (+50 °F) 193 Extreme Pressure Multipurpose Grease Extreme pressure multipurpose grease is a lithium soap base grease with a high load carrying capacity. The lubricant has naturally high viscosity indexes compared to mineral oils. Bearing and Gear Lubricant Lubricant ISO Viscosity Grade API Gravity Viscosity Index Viscosity: cSt at 40 °C cSt at 100 °C Viscosity 220 31. EP Multipurpose Grease Timken OK Load Dropping Point Oil Viscosity Water Resistance 18 kg (40 lb) minimum 177 °C (350 °F) minimum 75 SUS minimum at 99 °C (210 °F) Excellent Under normal operating conditions. over 38 °C (100 °F) Bearing and Gear Lubricant Bearing and gear lubricant provides better thermal and oxidation stability than conventional mineral oils. 0 ambient temp. 2 or No. the following consistency grades are recommended: NLGI No. 3 for ambient temp.9 152 216 25. providing lower viscosity at lower temperatures and higher viscosity at higher temperatures. 1 or No.2 .Specifications Recommended lubricants EP Multipurpose Lubricant SAE Viscosity No. –18–38 °C (0–100 °F) NLGI No. Ambient Temp. The properties listed in table below are recommended. below –18 °C (0 °F) NLGI No. 2 for ambient temp. 196 as well as the 185. system coolant. pins. . See page No. 15W-40 ISO VG 46 Mobil SHC 630 SAE 85W-90 LS VCS Coolant MPG–EP2 Grease NOTICE For additional information and specifications regarding lubrication. and lubricant. specification Engine oil Hydraulic oil Drum Eccentric oil Drum Carrier oil Drum Drive oil Axle Housing oil Axle Brake oil Engine Coolant Grease fittings. Selection of the proper oil is essential to ensure proper system performance and life. filling capacities and maintenance. CL-4. specifications The quality of the hydraulic oil and engine oil is important to the satisfactory performance of any hydraulic system and engine.Specifications 194 Recommended lubricants Recommended lubricants. 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. seals VDS-3. The hydraulic oil serves as the power transmission medium. levers. pins. we recommend the use of genuine authorized brand lubricants. 2 Always ensure waste fluids are disposed of in an environmentally safe manner. more frequent lubrication than specified may be necessary. applied sparingly. A regular service program should be geared to the items listed under each interval. An .Specifications Service capacities and change intervals 195 Service capacities and change intervals Environmentally safe handling Handling Fluids and Oil. unless otherwise indicated.) should be lubricated with oil once a week. These intervals are based on average operating conditions. Different lubricants are needed and some components in the unit require more frequent lubricant than others. See page 185 for lubrication and service chart. All grease fittings are SAE STANDARD. but under lubrication will definitely lead to a shorter life. It shows those items requiring regular service and the interval at which they should be performed. it is important that the instructions regarding types of lubricant and frequency of the application be explicitly followed. In the event of extremely severe. items not equipped with grease fittings (linkages. will provide the necessary lubrication and help prevent the formation of rust. All oil levels are to be checked with the machine parked on a level surface and while the oil is cold. For maximum machine life and performance. Therefore. Over-lubrication on non-sealed fittings will not harm the fittings or components. 3 Always ensure that used filters are stored in secure containers and disposed of in an environmentally safe manner. affecting to a great extent the useful life of the unit. Lubricant recommendation GENERAL INFORMATION Lubrication is an essential part of preventive maintenance. Grease non-sealed fittings until grease is seen extruding from the fitting. Unless otherwise indicated. the oil levels are to be at the bottom edge of the check port. ensure that adequate sealable containers are available and that every care is taken to prevent spillage. etc. Motor oil. On plug-type check points. Fuel Filters 1 When draining fluids. Periodic lubrication of the moving parts reduces to a minimum the possibility of mechanical failures. dusty or wet operating conditions. See page 185. unless otherwise specified. visually check the entire unit to ensure that capscrews.09 US gal) 1. 5 If a defect is detected which requires special maintenance service. etc.1 L (0. If any are found loose. lubricant and filling capacities Filling capacities Fuel tank Hydraulic oil tank Transmission oil Engine oil Axle housing oil Drum eccentric oil Drum Carrier oil Wheel end oil Radiator Coolant 285 L (75 US gal) 180 L (47.29 US gal) 41 L (10. the following other services or checks are recommended for the same intervals as the periodic lubrication: 1 Thoroughly wash all fittings.Specifications 196 Service capacities and change intervals anti-seize compound may be used if rust has not formed. the component must be cleaned first. Otherwise. Lubrication and service schedules To prevent minor irregularities from developing into serious conditions. caps. stop the machine operation until the defect has been corrected.83 US gal) 2 L (0. contact the local authorized distributor for assistance.5 US gal) 15. or when they have a stuck check ball. 2 Lubricants must be at operating temperature when draining.81 US gal) . 3 During regular lubrication service.9 L (0. Fuel.47 US gal) 22 L (5. Grease fittings must be replaced when they are worn to the point that they fail to hold the grease gun.5 L (4. 4 Spot check several capscrews and nuts for proper torque. 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.52 US gal) 1.8 L (0. plugs. nuts and pins are properly secured. a more thorough investigation must be made.5 US gal) 1. If necessary. non-toxic cleaning solution before servicing to prevent dirt from entering while performing the service. with nonflammable. Specifications Brake 197 Brake Brakes. Axle. Secondary/Parking brake. Brakes Description Service brakes. specifications Table. multiple wet disc. Secondary/parking brake release pressure. Type of system. . Specification Hydrostatic through the propulsion system. Location of secondary/parking brakes. 15 bar (217 psi). Spring-applied. hydraulic released. Specifications 198 Wheels Wheels Tyre sizes and pressures specifications Tyre sizes and pressures Tyre size Tyre pressure Tyre ballast 23.1-26 R3.1 Bar (16 psi) With 3/4th of water . 8PR 1. specifications Table.29 mm (0.) dia.783 kgs (37.) .) Minimum amplitude SD110 16.) wide x 1450 mm (59 in.) SD110 1.92 mm (0.817 vpm (30 Hz. (Variable) SD110 209 kN (47. (Variable) SD110 294 kN (66.Specifications Drum 199 Drum Drum.401 kgs (56. Vibration Description Single vibrating drum Dynamic force @ frequency Specifications 2134 mm (84 in.609 kg/mm (400 lb-in.000 lbs) @ 1. x 25 mm (1 in.000 lbs.076 in.) SD110 4.eccentric Eccentric moment .) SD110 6.000 lbs) @ 1.) SD110 1.) Dynamic force applied Nominal amplitude .) thick shell Maximum amplitude SD110 25.) .051 in.878 kg/mm (597 lb-in.000 lbs.817 vpm (30 Hz. Specifications 200 Specifications Specifications . SAE TORQUE CHART Function of fastener Axle To Rear Frame Frame joint – Articulation vertical pin Nuts Size M20 x 240 M48 Torque N•m 730 678 1491 229 26 61 107 373 149 569 100 373 149 149 107 28 523 lbf ft 540 500 1100 169 19 45 79 275 110 420 74 275 110 110 79 21 386 Frame joint – Articulation oscillation (horizontal pin) M72 nut Engine mounting bracket front Mount propulsion cable mounting bracket Steering column to steering valve. DC. Negative ground 12 Volt 12 Volt. 4 kw Frame link/articulation. specification Electrical system Battery Alternator Starter 12 Volt. specifications Articulation / Oscillation link Articulation angle Oscillation angle Gradeability (Theoretical) – Dependant on traction ± 40° ± 17° . they will be indicated in the text. Table. Operator platform assembly to main frame Assembly carrier plate with shock mounting plate M16 M8 M10 M12 M16 Assembly shock mount with shock mounting plate M12 x 35 of carrier assembly Assembly torque hub and drive plate Assembly bearing housing with drum Assembly shock mount with drum Assembly shock mount with drive assembly Assembly vibration motor with carrier assembly Assembly of cover with bearing housing Tyre mounting assembly on axle 3/4 “–16UNF M16 x 90 M12 x 30 M16 M12 x 35 M8 x 20 M22 Assembly motor mounting bracket and torque hub 5/8 “–11UNC Electrical system.Specifications Specifications Critical mounting torques 201 Use the following recommended torque chart for bolts and nuts of SAE Grade 5 or better quality. If other torques are required. 9 Metric coarse and fine threads Thread M6 M8 M10 M12 M14 M16 M20 M24 N•m 12 30 60 105 175 275 540 805 lbf ft 9 22 44 78 130 204 400 549 UNC threads Coarse thread N•m 1/4 – 20 5/16 – 18 3/8 – 16 7/16 – 14 1/2 – 13 9/16 – 12 5/8 – 11 3/4 – 10 7/8 – 9 1–8 1 1/8 – 7 12 26 50 80 122 176 244 434 698 1051 1492 9 19 37 59 90 130 180 320 515 775 1100 Torque lbf ft. 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.8 Metric coarse and fine threads Thread M6 M8 M10 M12 M14 M16 M20 M24 N•m 10 24 48 85 140 220 430 740 lbf ft 7. 1/4 – 28 5/16 – 24 3/8 – 24 7/16 – 20 1/2 – 20 9/16 – 18 5/8 – 18 3/4 – 16 7/8 – 14 1 – 12 1 1/8 – 12 15 28 57 89 136 197 278 481 773 1146 1668 Fine thread.4 18 35 63 103 160 320 550 10.Specifications 202 Specifications Tightening torque. N•m 11 21 42 66 100 145 205 355 570 845 1230 Torque lbf ft . 8. they will be indicated in the text. yellow zinc. NOTICE All thread fasteners will have thread locking compound applied. 1540 2020 2690 1 1/4 – 12 1 3/8 – 12 1 1/2 – 12 2319 3119 4095 Fine thread. dicromate bolts. N•m 1710 2300 3020 Torque lbf ft 203 NOTICE Torque values used in this table are based on plated. NOTICE Use high strength thread locking compound on all bolts larger than 5/16 inch.Specifications Specifications Coarse thread N•m 1 1/4 – 7 1 3/8 – 6 1 1/2 – 6 2088 2739 3648 Torque lbf ft. 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. 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 Serial number stop Bangalore 99999 Table. Weights Description Operating weight Static weight at tyres Static weight at drum Shipping Weight 11190 kg (24674 lb) 5078 kg (11197 lb) 6112 kg (13477 lb) 10941 kg (24125 lb) Machine weights Table. Weights Description Operating weight Static weight at tires Static weight at drum Shipping Weight 11125 kg (24526 lb) 5025 kg (11078 lb) 6100 kg (13448 lb) 10876 kg (23977 lb) . Specifications Dimensions 205 Dimensions . 61 82. ROPS Height<Beacon lamp mm 2310 2134 625 2100 3090 3305 Inches 90.Specifications 206 Dimensions Machine dimensions The figure below provides a dimensional outline of the SD110 Tier 3 machine.67 121.12 . A B D C W G V U E F I J K S H L M O P N Q S T U1 R E1 V1100931 Machine dimension Machine dimensions Letter A B C D E E1 Description Front width Drum width Track Machine width @ Tire Height.65 130.94 84 24. the values of which are defined in the dimensions table. Specifications Dimensions Machine dimensions Letter F G H I J K L M N O P Q R S T U U1 V W Y Z Description Steering wheel height Side clearance Drum thickness Deck Height Curb Clearance Angle K Front hub to bumper Articulation to front Hub Articulation to rear Hub Wheel/Drum base Length overall Rear hub to bumper Rolling radius (Tire) Angle S Ground clearance Drum diameter Tyre diameter Turning radius (Inner drum edge) Turning radius (Outer drum edge ) Articulation angle Oscillation angle mm 2330 91 25 1420 515 36° 995 1348 1991 3342 5640 1253 705 19° 495 1500 1560 3652 5960 ±40° ±17° Inches 91.75 19° 19.17 53.39 131.98 55.05 61.7 234.27 36° 39.9 20.42 143.4 49.58 0.73 3.33 27.67 78.64 ±40° ±17° 207 .57 222.48 59. Specifications 208 Service history Service history Service 100 hours Date Hours Type of service Warranty Inspection Signature and stamp Service 500 hours Date Hours Type of service Service and maintenance Signature and stamp Service 1000 hours Date Hours Type of service Warranty Inspection Service and maintenance Signature and stamp Service 1500 hours Date Hours Type of service Service and maintenance Signature and stamp Service 2000 hours Date Hours Type of service Service and maintenance Signature and stamp Service 2500 hours Date Hours Type of service Service and maintenance Signature and stamp Service 3000 hours Date Hours Type of service Service and maintenance Signature and stamp Service 3500 hours Date Hours Type of service Service and maintenance Signature and stamp Service 4000 hours Date Hours Type of service Service and maintenance Signature and stamp . Specifications Service history Service 4500 hours Date Hours Type of service Service and maintenance Signature and stamp 209 Service 5000 hours Date Hours Type of service Service and maintenance Signature and stamp Service 5500 hours Date Hours Type of service Service and maintenance Signature and stamp Service 6000 hours Date Hours Type of service Service and maintenance Signature and stamp Service 6500 hours Date Hours Type of service Service and maintenance Signature and stamp Service 7000 hours Date Hours Type of service Service and maintenance Signature and stamp Service 7500 hours Date Hours Type of service Service and maintenance Signature and stamp Service 8000 hours Date Hours Type of service Service and maintenance Signature and stamp Service 8500 hours Date Hours Type of service Service and maintenance Signature and stamp Service 9000 hours Date Hours Type of service Service and maintenance Signature and stamp . Specifications 210 Service history Type of service Hours Service and maintenance Signature and stamp Service 9500 hours Date Service 10000 hours Date Hours Type of service Service and maintenance Signature and stamp . .................................................................. complete machine .......... checking oil level .................................................................................................. 174 Hydraulic system.............................................................................................................. charging ........... 169 CE-marking.............................. 201 Danger zone ......................................... 62 Hydraulic tank.............. checking ................ 199 Drum carrier.......................................................................... 158 Axles..... 189 General inspection of machine ................................. 145 Electrical system............ 102 Axle breather.. 158 Batteries ........... checking oil level ........................... checking electrolyte ........................ 85 Electric welding ........................... 158 Axles ................... 159 Axle hubs................ 133 Alternator belt............... 150 Battery........... 133 Air cleaner secondary filter... changing oil .................... cleaning ...... 33 Decals/Plates and reflectors ...... check ... 129 Fuel system ........ 51 Actions after recovering and towing . checking oil level .............................. lubricant and filling capacities ....................................................................... 167 Drum drive (torque hub)............................. relays .. air cleaner maintenance .... 16 Check list after fire or heat exposure ...... 8 Air cleaner primary filter........................................ bleeding .................................. 192 Hydraulic oil filter......... 117 Cleaning prior to repair ............................ 196 Fuses........................... specifications .................. replacing ............... 141 Coolant............................................ 136 Air cleaner primary filter....................................................... 118 Cleaning of engine compartment .. Fuses ......... 17 Machine specific symbols ... 191 Coolant level.................... 125 Engine air cleaner ..................... 9 Lap type seat belt...... 204 Maintenance service... check .............................Alphabetical index 211 Accidents .......................................... 197 Brake system ..................... 167............. checking ........... cleaning ....... 8 Environmentally safe handling ...................... cleaning .............................................. Relays .... 130 Articulation hinge . 141 Cooling system ......... 116 Component list........ 201 Fuel ............................ 154 Component list............................. 167 Drum....................... checking oil level ......................... 103 Environmental handling for the future .......... 18 Entering............................................................................................... 154 Component location.............................................. checking oil level ................ 172 Drum eccentric.............. 151 Battery........................................................ leaving and climbing the machine ......................................... identification ...................... 175 Hydraulic oil suction strainer............................. replacing ................................... 127 Engine oil filter........ 146 Electrical components..... 178 Hydraulic oil tank..... 131 Fuel system............... cleaning . 146 Battery storage ............................ fuses ... checking .................... 138 Air cleaner system...................................................................... 171 Drum drive (torque hub)......................................................................................................... 133 Engine hood................ change ........... tubes and hoses ................. basic check ........................... opening and closing .. 107 Cleaning machine .................... replacing .. 147 Battery disconnect switch (main switch)... 195 Lubrication and service chart ............................................................................................ 205 Drum ... 167 Drum eccentric.................................................. 196 Machine dimensions ...... 176 Hydraulic system .......................................................................... changing oil ... specifications ...... 128 Engine oil level............... 141 Critical mounting torques ...................... changing oil ..................... 168 Drum shock mounts...... 126 Engine.......... 75 General information ...... read ....... 145 Fire prevention ............................................... checking ................. checking and maintenance .................................................................................................................................................................. check ......... 20 International symbols ...................................... 170 Drum carrier.............................. changing ........................................................................................ 53................................................ 106 Frame link/articulation.......... 30 Coolant ............... 16 Explosion hazard ... 13 Machine weights ............................................. 104 Fire prevention measures ......................................... 185 Lubrication and service schedules ....................... 184.... 153 Component location.................. 199 Alphabetical index Eco driving ....... 124 Location of components ............ 125 Engine Oil Change ...... 22 Description. 195 EU's EMC directive ....... 201 Engine ......... 133 Engine......................... 14 Lubricant ............................................ 180 Handling hazardous materials ............................................................. 128 Fuel............. cleaning .............................................................................. 124 Greasing ................. specification .. 80 Additional Icons ............................................................................. 110 Battery description ... 109 Handling line......................... daily .......... 175 Hydraulic system........................... 115 Health hazards with paint........................ check . 66 Carrier breather....... greasing ....... 95 Brake ............ 192 Lubricant recommendation . 8 International decals ............................. checking oil level ......... 190 Fuel filter................................. warming up .................... changing ................................. 163 Brakes.... 181 Before service........................ 19 Intended use ........................... 206 Machine identification .. 161 Axle hubs........................................ 177 Information and warning decals ............. 101 Environmental requirements ............ 149 Bearings................. 169 Drum.............................. plastics and rubber ...... 155 Controls ............................... 111.................................. changing oil ................. 197 Braking . EMC-directive ................................... maintenance ............. 152 Battery............................. 5 Dimensions ...................... 8 Machine view .............................................................................. 122 ............. changing oil ...... specifications ..... 112 Hydraulic oil ............. ............... 73 Troubleshooting............................................ 189 Recommended lubricants...... 160 Recommended lubricants .... 69 Swivel joint (horizontal and vertical) pins............................... 100 Special instructions for working on the electrical system ....................... 208 Service position ........................ 198 Tyres..... every 50 hours ................................. storage .......................... 119 Towing a disabled machine .............................................................. changing .......... 120 Power lines...................... 99 Safety when operating on public roads .................................... 142 Rear axle............... 64 Operator comfort ....... 30 Tightening torque.............................................. 112 Water separator........ 67 Storage ...................................................... check torque ..................... 92 Shift linkage............ 30 Troubleshooting charts ...... 188 Starting engine ............. 180 Throttle control ................ drain .................................. 71 Operating ................... 76 Transmission .................. checking ........................................ changing oil ....................... general ..... changing oil ............................ wear and air pressure. component locations ............................................ description ..... 32 Operator's manual.......... general ............................................. 114 Safety when handling the machine ...................... 71 Steering cylinder pins................................... 123 Maintenance service............. 57 Safety when lifting and supporting complete machine ............................... 61 Starting with booster batteries ......... 174 Safety when working with batteries .... 182 Signalling diagram ................. 86 Some simple rules regarding tyre handling ................ 123 Maintenance service....... 131 Water separator.... greasing ................... 72 Tyre sizes and pressures specifications ............... 66 Periodic maintenance ..... every 500 hours .......... 88 Safety rules when operating .................................................. 194 Retrieving and towing ....................... 156 Transporting machine ... 165 USA federal clean air act ......................... cleaning ....................................................... 78.......... 23 Vibration ....... general ................. 51 Operator seat . greasing ..................... lubricating ....................................................... 116........ 156 Transmission............................... 122 Maintenance service............................................................ 122 Maintenance service..... 36 Safety when handling oil and fuel ............................................ 47 Safety concerns everybody! ..................................... 102 Product plates .......... specifications ...................................... 81 Travel control lever ................... 55 Precaution when working on the electrical system ... 117 Preparations before service ............................................................................................................................. 33........ 91................... 122 Maintenance service. 202 Touch-up painting .................. 32 Operator's protective structure......... 31 Safe operation of the machine ....................... 68 Measures before operating ......... 81 Transporting the machine ...... 144 Specifications............ 79 Measures after operating ..............................................212 Alphabetical index Maintenance service.......................... 131 Wheel nuts........................... 164 Stopping ................................... 63 Waste handling ....... 148 Service capacities and change intervals ...... every 250 hours ........................................... 195 Service history ............................................... 165 Wheels ...................... 157 Transmission.......... 163 Parking brake.... 120 Manual release of parking brake ................... 15 Parking ........... 17 Radiator and coolers...................................... 76 ROPS .................................. 165.......................... 57 Measures in case of machine failure ........................ every 100 hours ........................................................... 32 Operator duties ...................................... 33........................................... specifications ..................... 35 Safety when working on hydraulic systems ....................... 144....... every 1000 hours ....................... 101 ................ 69 Parking brake performance ........ minimum clearance .................. checking oil level ........... 164 Steering system ........................................................................................................................................................... 198 Working in environmentally contaminated areas ....................................