Dynapac CA270 Instruction Manual

Vibratory roller engine cummins 4bt 3.9 102c

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Operating & Maintenance

ICA270-IN2EN1.pdf

Vibratory roller

Cummins 4BT 3.9 102C

Serial number

10000153x0E000909 -

(Carraro rear axle)

Original instruction

Reservation for changes

Printed in India

CA270

Engine

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Page 1 Instructions manual Instructions manual Operating & Maintenance Operating & Maintenance ICA270-IN2EN1.pdf ICA270-IN2EN1.pdf Vibratory roller Vibratory roller CA270 CA270 Engine Engine Cummins 4BT 3.9 102C Cummins 4BT 3.9 102C Serial number Serial number 10000153x0E000909 - 10000153x0E000909 - (Carraro rear axle) (Carraro rear axle)
Page 3: Table Of Contents
Table of Contents Introduction ..........................1 The machine ....................1 Intended use ....................1 Warning symbols..................1 Safety information ..................1 General ....................... 2 Safety - General instructions....................3 Safety - when operating ......................5 Slopes ......................5 Driving near edges ..................6 Special instructions ........................
Page 4 Machine description ....................... 17 Identification ......................17 Product identification number on the frame ..........17 Machine plate.................... 17 Explanation of 17PIN serial number............18 Engine plates .................... 18 Decals........................19 Location - decals ..................19 Safety decals..................... 20 Info decals....................22 Instrument/Controls ....................
Page 5 Operator position..................35 View ......................35 Interlock..................... 36 Starting ........................36 Start of diesel motor .................. 36 Operating......................... 38 Operating the roller ................... 38 Vibration ........................39 Vibration On/Off ..................39 Vibration - Activation ................. 39 Braking ........................40 Normal braking..................40 Emergency braking ...................
Page 6 Unlocking the articulation ................46 Towing/Recovering....................46 Alternative 1 ....................46 Short distance towing with the engine running.......... 46 Alternative 2 ....................47 Towing short distances when the engine is inoperative......47 Rear axle brake..................47 Releasing the parking brake in the drum ..........48 Towing the roller..................
Page 7 Scrapers, Pad-drum .................. 62 Soften scrapers (Optional) ................ 63 Air circulation - Check ................63 Coolant level - Check ................64 Diesel engine Check oil level ..............65 Fuel tank - Filling..................65 Hydraulic reservoir - Check fluid level............66 Brakes - Check..................
Page 8 Fuel pre-filter - Replacement..............80 Maintenance - 1000h ......................81 Hydraulic fluid filter - Replacement ............81 Hydraulic fluid reservoir - Draining ............82 Fuel tank - Drainage.................. 83 Rear axle differential - Oil change............. 84 Rear axle transmission - Oil change ............85 Rear axle's planetary gears - Draining the oil ...........
Page 9: Introduction
Introduction Introduction The machine CA270 is one of Dynapac's medium-heavy soil compaction rollers. Intended use All types of base courses and subbase courses can be compacted deeper and the interchangeable drums, D to PD, and vice versa, facilitate even greater variety in the range of application.
Page 10: General
Introduction Read the entire manual before starting the Read the entire manual before starting the machine and before carrying out any machine and before carrying out any maintenance. maintenance. Replace immediately the instruction manuals if Replace immediately the instruction manuals if lost, damaged or unreadable.
Page 11: Safety - General Instructions
Safety - General instructions Safety - General instructions (Also read the safety manual) The operator must be familiar with the contents of the OPERATION section The operator must be familiar with the contents of the OPERATION section before starting the roller. before starting the roller.
Page 12 Changes are only to be made after written approval has been given safety. Changes are only to be made after written approval has been given by Dynapac. by Dynapac. 18. Avoid using the roller before the hydraulic fluid has reached its normal 18.
Page 13: Safety - When Operating
Safety - when operating Safety - when operating Prevent persons from entering or remaining in Prevent persons from entering or remaining in the danger area, i.e. a distance of at least 7 m the danger area, i.e. a distance of at least 7 m (23 ft) in all directions from operating machines.
Page 14: Driving Near Edges
Safety - when operating Driving near edges When driving near an edge, minimum 2/3 of the drum width must be on solid ground. Keep in mind that the machine's center of gravity Keep in mind that the machine's center of gravity moves outwards when steering.
Page 15: Special Instructions
Special instructions Special instructions Standard lubricants and other recommended oils and fluids Before leaving the factory, the systems and components are filled with the oils and fluids specified in the lubricant specification. These are suitable for ambient temperatures in the range -15°C to +40°C (5°F - 105°F).
Page 16: Roll Over Protective Structure (Rops), Rops Approved Cab
Special instructions Roll Over Protective Structure (ROPS), ROPS approved cab If the machine is fitted with a Roll Over If the machine is fitted with a Roll Over Protective Structure (ROPS, or ROPS approved Protective Structure (ROPS, or ROPS approved cab) never carry out any welding or drilling in cab) never carry out any welding or drilling in the structure or cab.
Page 17: Jump Starting
Special instructions Jump starting Do not connect the negative cable to the Do not connect the negative cable to the negative terminal on the dead battery. A spark negative terminal on the dead battery. A spark can ignite the oxy-hydrogen gas formed can ignite the oxy-hydrogen gas formed around the battery.
Page 18 Special instructions ICA270-IN2EN1.pdf 2012-11-05...
Page 19: Technical Specifications
Technical specifications Technical specifications Vibrations - Operator station (ISO 2631) The vibration levels are measured in accordance with the operational cycle described in The vibration levels are measured in accordance with the operational cycle described in EU directive 2000/14/EC on machines equipped for the EU market, with vibration switched EU directive 2000/14/EC on machines equipped for the EU market, with vibration switched on, on soft polymer material and with the operator’s seat in the transport position.
Page 20: Dimensions, Side View
Technical specifications Dimensions, side view Dimensions Dimensions Wheelbase, drum and wheel Wheelbase, drum and wheel 2879 2879 113,3 113,3 Length, standard equipped roller Length, standard equipped roller 5550 5550 218,5 218,5 Height, with Canopy (STD, D) Height, with Canopy (STD, D) 2977 2977 117,2...
Page 21: Dimensions, Top View
Technical specifications Dimensions, top view Dimensions Dimensions Width, standard equipped roller Width, standard equipped roller 2384 2384 93,9 93,9 Overhang, left frame side Overhang, left frame side Overhang, right frame side Overhang, right frame side Turn radius, external Turn radius, external 5400 5400 212,6...
Page 22: Working Capacity
Technical specifications Working capacity Compaction data Compaction data Static linear load (D) Static linear load (D) 33,8 kg/cm 33,8 kg/cm 189,3 pli 189,3 pli Amplitude, high (STD, D) Amplitude, high (STD, D) 1,7 mm 1,7 mm 0,066 in 0,066 in Amplitude, low (STD, D) Amplitude, low (STD, D) 0,8 mm...
Page 23: Hydraulic System
Technical specifications Hydraulic system Opening pressure Opening pressure Drive system Drive system 38,0 38,0 Supply system Supply system Vibration system Vibration system 42,5 42,5 Control systems Control systems 17,5 17,5 Brake release Brake release ROPS - bolts Bolt dimensions : Bolt dimensions : M24 (PN 4700904562) M24 (PN 4700904562)
Page 24: Tightening Torque
Technical specifications Tightening torque Tightening torque in Nm (lbf.ft) for oiled or dry bolts tightened with a torque wrench. Metric coarse screw thread, bright galvanized (fzb): STRENGTH CLASS: 8.8, Oiled 8.8, Oiled 8.8, Dry 8.8, Dry 10.9, Oiled 10.9, Oiled 10.9, Dry 10.9, Dry 12.9, Oiled...
Page 25: Machine Description
Machine description Machine description Identification Product identification number on the frame The machine PIN (product identification number) (1) is punched on the right edge of the front frame or the upper edge of the right frameside. Fig. Front frame 1. PIN Machine plate The machine type plate (1) is attached to the front left side of the frame, beside the steering joint.
Page 26: Explanation Of 17Pin Serial Number
Machine description Explanation of 17PIN serial number A= Manufacturer 00123 00123 V 0 A 123456 V 0 A 123456 B= Family/Model C D E F C D E F C= Check letter D= No coding E= Production unit F= Serial number Engine plates The engine plate (1) is affixed to the right side of the engine.
Page 27: Decals
Machine description Decals Location - decals 14, 4 Warning, Crush zone Warning, Crush zone 7. Product sign 7. Product sign 13. Handbook compartment 13. Handbook compartment Warning, Rotating engine Warning, Rotating engine 8. Diesel fuel 8. Diesel fuel 14. Tire pressure 14.
Page 28: Safety Decals
Machine description Safety decals Always make sure that all safety decals are completely legible, and remove dirt or order new decals if they have become illegible. Use the part number specified on each decal. 4700903422 Warning - Crush zone, articulation/drum. Maintain a safe distance from the crush zone.
Page 29 Machine description 4700904165 Warning - Toxic gas (option, ACC) Read the instruction manual. 4700903590 -Emergency exit 2012-11-05 ICA270-IN2EN1.pdf...
Page 30: Info Decals
Machine description Info decals Coolant Coolant Diesel fuel Diesel fuel Lifting point Lifting point Hoisting plate Hoisting plate Handbook compartment Handbook compartment Master switch Master switch Hydraulic fluid Hydraulic fluid Tire pressure Tire pressure Securing point Securing point Hydraulic fluid level Hydraulic fluid level Noise power level Noise power level...
Page 31: Instrument/Controls
Machine description Instrument/Controls Locations - Instruments and controls Fig. Instruments and control panel Driving lights, Low beam Driving lights, Low beam Control panel Control panel Driving lights, High beam Driving lights, High beam Parking brake On/Off Parking brake On/Off Hazard flashers Hazard flashers Transport mode/Traction control (Optionr) Transport mode/Traction control (Optionr)
Page 32: Locations - Control Panel And Controls
Machine description Locations - Control panel and controls Fig. Control panel Fig. Operator's station Fig. Operator position Starter switch Starter switch Low fuel level Low fuel level Emergency stop Emergency stop Oil pressure, diesel engine Oil pressure, diesel engine Vibration ON/OFF Vibration ON/OFF Parking brake Parking brake...
Page 33: Function Description
Machine description Function description Designation Designation Symbol Symbol Function Function Starter switch Starter switch Positions 1-2: Shut off position, key can be Positions 1-2: Shut off position, key can be removed. removed. Position 3a: All instruments and electric controls Position 3a: All instruments and electric controls are supplied with power.
Page 34 Machine description Designation Designation Symbol Symbol Function Function Hazard beacon, switch Hazard beacon, switch Where depressed, the hazard beacon is on Where depressed, the hazard beacon is on (Optional) (Optional) Direction indicators, Direction indicators, When depressed to the left, the left direction When depressed to the left, the left direction switch (Optional) switch (Optional)
Page 35: Controls In The Cab
Machine description Controls in the cab Fig. Cab roof, front Fig. Cab roof, rear 1. Front wiper 4. Hammer for emergency escape 2. Rear wiper (Optional) 3. Front and rear windshield washers Fig. Cab right side. Heater (Option) Fig. Cab, rear 5 .Control, temperature 9.
Page 36: Function Description Of Instruments And Controls In The Cab
Machine description Function description of instruments and controls in the cab Designation Designation Symbol Symbol Function Function Front wiper, switch Front wiper, switch Press to operate the front screen wiper. Press to operate the front screen wiper. Rear wiper, switch (Optional) Rear wiper, switch (Optional) Press to operate the rear screen wiper.
Page 37: Electrical System
Machine description Electrical system Main fuses The main fuse (1) is placed by the battery disconnector (4). The fuse is of the flat pin type. The fuel solenoid relay (2) and the starter relay (3) are also fitted here. Main fuse 40A (Orange) Fig.
Page 38: Relays
Machine description Relays Direction indicators Direction indicators Stop lights Stop lights Working lights Working lights Fig. Control column 1. Flasher relay 2. Stop light relay 3. Working lights relay 4. Fuse boxes ICA270-IN2EN1.pdf 2012-11-05...
Page 39: Fuses
Machine description Fuses The figure shows the position of the fuses. The table below gives fuse amperage and function. All fuses are flat pin fuses. The machine is equipped with a 12V electrical system and an AC alternator. Fig. Fuses boxes. Fuses in boxes F1 Fuses in boxes F1 Emergency stop, ECU, reversing alarm,...
Page 40: Fuses And Relay In Cab Heater Box (Optional)
Machine description Fuses and relay in cab heater box (Optional) To access the fuses (x2) in the heater box, release the plug (1) The relay in the heater box is accessed by releasing the screws (2) and (3) on the top of the cover, and the screws (3) on the front of the cover, after which the cover (4) can be lifted off the heater box.
Page 41: Operation
Operation Operation Before starting Master switch - Switching on Remember to carry out daily maintenance. Refer to the maintenance instructions. The master switch is located in the engine compartment. Open the engine cover and set the key (1) to the ON position. The entire roller is now supplied with power.
Page 42: Driver Seat (Option)- Adjustment
Operation Driver seat (Option)- Adjustment Adjust the operator’s seat so that the position is comfortable and so that the controls are within easy reach. The seat can be adjusted as follows. - Length adjustment (1) - Weight adjustment (2) Fig. Driver seat - Back support angle (3) 1.
Page 43: Operator Position
Operation Operator position If a ROPS (2) (Roll Over Protective Structure) or a cab is fitted to the roller, always wear the seat belt (1) provided and wear a protective helmet. Replace the seat belt (1) if it shows signs of Replace the seat belt (1) if it shows signs of wear or has been subjected to high levels of wear or has been subjected to high levels of...
Page 44: Interlock
Operation Interlock The roller is equipped with Interlock. The engine switches off 4 seconds after the operator rises from the seat. The engine stops whether the forward/reverse lever is in the neutral or the drive position. The engine does not stop if the parking brake is activated.
Page 45 Operation Check while warming the engine that the warning lamps for the oil pressure (24) and charging (28) go out. The warning lamp (25) should remain on. When starting and driving a machine that is cold, When starting and driving a machine that is cold, remember that the hydraulic fluid is also cold and remember that the hydraulic fluid is also cold and that braking distances can be longer than normal...
Page 46: Operating
Operation Operating Operating the roller Under no circumstances is the machine to be Under no circumstances is the machine to be operated from the ground. The operator must be operated from the ground. The operator must be seated inside the machine during all operation. seated inside the machine during all operation.
Page 47: Vibration
Operation Vibration Vibration On/Off Activation/deactivation of the vibration is selected with the switch (20). The operator must activate the vibration via the switch (4) on the underside of the forward/reverse handle. See illustration below. Fig. Instrument panel 20. Vibration switch. Vibration - Activation Never activate vibration when the roller is Never activate vibration when the roller is...
Page 48: Braking
Operation Braking Normal braking Press the switch (4) to switch off the vibration. Move the forward/reverse lever (6) to the neutral position to stop the roller. Turn the engine speed control (33) forward to idling position. Set the parkering brake switch (31) in the On position. Always use the parking brake (31) when the Always use the parking brake (31) when the machine is stationary on a sloping surface.
Page 49: Switching Off
Operation Switching off Check instruments and warning lamps to see if any faults are indicated. Switch off all lights and other electrical functions. Turn the starter switch (1) to the left to switched off position 1. At the end of the shift, lower the instrument cover (22) and lock it.
Page 50: Chocking The Drums
Operation Chocking the drums Never disembark from the machine when the is Never disembark from the machine when the is engine running, unless the reserve/parking brake engine running, unless the reserve/parking brake knob is depressed. knob is depressed. Make sure that the roller is parked in a safe place Make sure that the roller is parked in a safe place with respect to other road users.
Page 51: Long-Term Parking
Long-term parking Long-term parking The following instructions should be followed The following instructions should be followed when long term parking (more than one month). when long term parking (more than one month). These measures apply when parking for a period of up to 6 months.
Page 52: Steering Cylinder, Hinges, Etc
Long-term parking Steering cylinder, hinges, etc. Lubricate the articulation bearing with grease (see under the heading "Every 50 hours of operation"). Grease the steering cylinder piston with conservation grease. Grease the hinges on the doors to the engine compartment and the cab. Grease both ends of the forward/reverse control (bright parts) (see under the heading 'Every 500 hours of operation').
Page 53: Miscellaneous
Miscellaneous Miscellaneous Lifting Locking the articulation Articulation must be locked to prevent inadvertent Articulation must be locked to prevent inadvertent turning before lifting the roller. turning before lifting the roller. Turn the steering wheel to the straight ahead position. Push in the emergency/parking brake knob. Pull out the lowermost locking pin (2), which has a a wire attached.
Page 54: Unlocking The Articulation
Miscellaneous Unlocking the articulation Remember to unlock the articulation before Remember to unlock the articulation before operating. operating. Fold the locking arm (1) back and secure it in the locking lug (4) with the locking stud (3). Insert the lowermost locking pin (2) fitted with a wire, to secure the locking stud (3).
Page 55: Alternative 2
Miscellaneous Alternative 2 Towing short distances when the engine is inoperative First release both towing valves as per alternative 1. Chock the drums to prevent the roller from moving Chock the drums to prevent the roller from moving when the brakes are mechanically disengaged. when the brakes are mechanically disengaged.
Page 56: Releasing The Parking Brake In The Drum
Miscellaneous Releasing the parking brake in the drum Fig. Drum motor Remove and dispose of the rubber plug from the Remove and dispose of the rubber plug from the brake protector. brake protector. Loosen the metallic plug. Loosen the metallic plug. Use a screw fitted with a nut and washer.
Page 57: Towing The Roller
Miscellaneous Towing the roller When towing/recovering, the roller must be braked When towing/recovering, the roller must be braked by the towing vehicle. A towing bar must be used by the towing vehicle. A towing bar must be used as the roller has no brakes. as the roller has no brakes.
Page 58: Re-Activating The Rear Axle Brake
Miscellaneous Re-activating the rear axle brake Chock the drum and wheels to prevent the roller Chock the drum and wheels to prevent the roller from moving when the brakes are mechanically from moving when the brakes are mechanically disengaged. disengaged. Apply pressure (13 bar) into the parking brake ports (4).
Page 59: Operating Instructions - Summary
Operating instructions - Summary Operating instructions - Summary Follow the SAFETY INSTRUCTIONS specified in the Safety Manual. Follow the SAFETY INSTRUCTIONS specified in the Safety Manual. Make sure that all instructions in the MAINTENANCE section are followed. Make sure that all instructions in the MAINTENANCE section are followed. Turn the master switch to the ON position.
Page 60 Operating instructions - Summary ICA270-IN2EN1.pdf 2012-11-05...
Page 61: Preventive Maintenance
Preventive maintenance Preventive maintenance Complete maintenance is necessary for the machine to function satisfactorily and at the lowest possible cost. The Maintenance section includes the periodic maintenance that must be carried out on the machine. The recommended maintenance intervals assume that the machine is used in a normal environment and working conditions.
Page 62 Preventive maintenance ICA270-IN2EN1.pdf 2012-11-05...
Page 63: Maintenance - Lubricants And Symbols
DRUM OIL DRUM OIL Air temperature -15°C - +40°C Air temperature -15°C - +40°C Mobil SHC 629 Mobil SHC 629 Dynapac Drum Oil 1000, Dynapac Drum Oil 1000, (5°F-104°F) (5°F-104°F) P/N 4812156456 (5 liters) P/N 4812156456 (5 liters) GREASE...
Page 64: Maintenance Symbols
Maintenance - Lubricants and symbols DYNAPAC/AtlasCopco DYNAPAC/AtlasCopco FUEL FUEL See engine manual. See engine manual. TRANSMISSION OIL TRANSMISSION OIL Shell Spirax S4 TXM, Shell Spirax S4 TXM, API GL-4 or equivalent API GL-4 or equivalent COOLANT COOLANT Anti-freeze protection down to...
Page 65: Maintenance - Maintenance Schedule
Maintenance - Maintenance schedule Maintenance - Maintenance schedule Service and maintenance points Fig. Service and maintenance points 1. Cooler grille 1. Cooler grille Scrapers Scrapers Draining, fuel tank Draining, fuel tank 2. Fuel filter, fuel prefilter 2. Fuel filter, fuel prefilter Drum oil, level plug Drum oil, level plug Diesel engine suspension, x4...
Page 66: Every 10 Hours Of Operation (Daily)
Maintenance - Maintenance schedule Remove all dirt before filling, when checking Remove all dirt before filling, when checking oils and fuel and when lubricating using oil or oils and fuel and when lubricating using oil or grease. grease. The manufacturer’s instructions found in the The manufacturer’s instructions found in the engine manual also apply.
Page 67: Every 50 Hours Of Operation (Weekly)
Maintenance - Maintenance schedule Every 50 hours of operation (Weekly) Refer to the contents to find the page number of the sections referred to! Pos. in fig Pos. in fig Action Action Comment Comment Check that hoses and couplings are not leaking Check that hoses and couplings are not leaking Inspect/clean the filter element in the air cleaner Inspect/clean the filter element in the air cleaner...
Page 68: Every 500 Hours Of Operation (Every Three Months)
Maintenance - Maintenance schedule Every 500 hours of operation (Every three months) Refer to the contents to find the page number of the sections referred to ! Pos. in fig Pos. in fig Action Action Comment Comment Replace the fuel filter Replace the fuel filter Refer to the engine manual Refer to the engine manual...
Page 69: Maintenance, 10H
Maintenance, 10h Maintenance, 10h Park the roller on a level surface. Park the roller on a level surface. When checking and making adjustments, the When checking and making adjustments, the engine should be switched off and the engine should be switched off and the emergency/parking brake should be applied, if emergency/parking brake should be applied, if not otherwise specified.
Page 70: Steel Scrapers (Optional)
Maintenance, 10h Steel scrapers (Optional) If necessary, adjust distance to the drum as follows: Undo the screws (2) on the scraper attachment. Then adjust the scraper blade (1) to 20 mm from the drum. Tighten the screws (2). Repeat the procedure for the other scraper blades (x4). Fig.
Page 71: Soften Scrapers (Optional)
Maintenance, 10h Soften scrapers (Optional) Loosen the screws (2). Then, adjust the scraper blade (1) so that it lightly touches the drum. Tighten the screws (2). Fig. Scrapers 1. Scraper blade 2. Screws Air circulation - Check Ensure that the diesel engine has free circulation of cooling air through the vents in the hood.
Page 72: Coolant Level - Check
Maintenance, 10h Coolant level - Check Cooling liquid holder is placed up beside the hydraulic oil tank and is seen easiest from the right side of the roller. The filler cap (2) is accessible from the top of the engine hood. Check the coolant level with the engine stopped and cold.
Page 73: Diesel Engine Check Oil Level
Maintenance, 10h Diesel engine Check oil level Take care not to touch any hot parts of the engine Take care not to touch any hot parts of the engine or the radiator when removing the dipstick. Risk or the radiator when removing the dipstick. Risk for burns.
Page 74: Hydraulic Reservoir - Check Fluid Level
Maintenance, 10h Hydraulic reservoir - Check fluid level The sight glass is located on the right-hand side of the roller behind the operator's seat. Place the roller on a flat surface and check the fluid level in the sight glass (1). If the level is too low, top up with the type of hydraulic fluid specified in the lubricant specification.
Page 75 Maintenance, 10h Brakes - Check Check operation of the brakes as follows: Check operation of the brakes as follows: Checking the parking brake Drive the roller slowly forward. Hold the steering wheel firmly and brace yourself for a sudden stop. Push in the parking brake switch (1).
Page 76 Maintenance, 10h ICA270-IN2EN1.pdf 2012-11-05...
Page 77: Maintenance - 50H
Maintenance - 50h Maintenance - 50h Park the roller on a level surface. Park the roller on a level surface. When checking and making adjustments, the When checking and making adjustments, the engine should be switched off and the engine should be switched off and the emergency/parking brake should be applied, if emergency/parking brake should be applied, if not otherwise specified.
Page 78: Backup Filter - Change
Maintenance - 50h Backup filter - Change Change the backup filter with a new filter after every third replacement of the main filter. To change the backup filter (1), pull the old filter out of its holder, insert a new filter and reassemble the air cleaner in the reverse order.
Page 79: Articulation - Lubrication
Maintenance - 50h Articulation - Lubrication Do not allow anyone to remain in the vicinity of the Do not allow anyone to remain in the vicinity of the steering joint when the engine is running. Risk of steering joint when the engine is running. Risk of being crushed when the steering is operated.
Page 80: Tires - Air Pressure - Wheel Nuts - Tightening
Maintenance - 50h Tires - Air pressure - Wheel nuts - Tightening Check the tire pressures using a pressure gauge. If the tires are filled with fluid, the air valve (1) must be in the "12 o'clock" position during pumping. Recommended pressure: See Technical Specifications.
Page 81: Maintenance - 250H
Maintenance - 250h Maintenance - 250h Park the roller on a level surface. Park the roller on a level surface. When checking and making adjustments, the When checking and making adjustments, the engine should be switched off and the engine should be switched off and the emergency/parking brake should be applied, if emergency/parking brake should be applied, if not otherwise specified.
Page 82: Rear Axle Transmission Box - Check Oil Level
Maintenance - 250h Rear axle transmission box - Check oil level Never work under the roller when the engine is Never work under the roller when the engine is running. Park on a level surface. Block the wheels running. Park on a level surface. Block the wheels securely.
Page 83: Drum - Checking The Oil Level
Maintenance - 250h Drum - Checking the oil level Place the roller on a level surface so that the filler plug (1) and the drum's number plate (2) are visible on the right side of the drum. The oil level should now reach the sight glass (3). If necessary, remove the filler plug (1) and fill to halfway up the sight glass.
Page 84: Bolted Joints - Checking Tightening Torque
Maintenance - 250h Bolted joints - Checking tightening torque Steering pump to diesel engine (1) 55 Nm, lightly oiled Rear axle suspension (2) 330 Nm (243 lbf.ft), oiled. Engine suspension (3). Check that all the M12 bolts (x20) are tightened, 70 Nm, and lightly oiled. Wheel nuts (4).
Page 85: Diesel Engine - Oil And Filter Change
Maintenance - 250h Diesel engine - Oil and Filter change Take great care when draining warm fluid and oil. Take great care when draining warm fluid and oil. Wear protective gloves and goggles. Wear protective gloves and goggles. The oil drain plug (1) is most easily accessible from the bottom of the engine and is located attached to a hose on the rear axle..
Page 86: Battery Cell
Maintenance - 250h Battery cell Take off the cell caps (1) and make sure that electrolyte (2) is about 10 mm (0.4 in) above the plates (3). Check the level of all cells. Top off with distilled water to the right level if the level is low. 10 mm If the ambient temperature is below freezing, run the engine for a while before topping off with distilled...
Page 87: Maintenance - 500H
Maintenance - 500h Maintenance - 500h Park the roller on a level surface. Park the roller on a level surface. When checking and making adjustments, the When checking and making adjustments, the engine should be switched off and the engine should be switched off and the emergency/parking brake should be applied, if emergency/parking brake should be applied, if not otherwise specified.
Page 88: Fuel Pre-Filter - Replacement
Maintenance - 500h Fuel pre-filter - Replacement Ensure good ventilation (air extraction) if the Ensure good ventilation (air extraction) if the diesel engine is run indoors. Risk of carbon diesel engine is run indoors. Risk of carbon monoxide poisoning. monoxide poisoning. Loosen the hose clamps (2) and remove the pre-filter (1).
Page 89: Maintenance - 1000H
Maintenance - 1000h Maintenance - 1000h Park the roller on a level surface. Park the roller on a level surface. When checking and making adjustments, the When checking and making adjustments, the engine should be switched off and the engine should be switched off and the emergency/parking brake should be applied, if emergency/parking brake should be applied, if not otherwise specified.
Page 90: Hydraulic Fluid Reservoir - Draining
Maintenance - 1000h Apply a thin coat of fresh hydraulic fluid to the seal on the new filter. Screw tight the filter by hand. First tighten the filter until its seal is in contact with First tighten the filter until its seal is in contact with the filter attachment.
Page 91: Fuel Tank - Drainage
Maintenance - 1000h Fuel tank - Drainage Water and sediment in the fuel tank are removed via the drainage plug (1) in the bottom of the fuel tank. Be very careful during draining. Do not drop the Be very careful during draining. Do not drop the plug or else all the fuel will flow out.
Page 92: Rear Axle Differential - Oil Change
Maintenance - 1000h Rear axle differential - Oil change Never work under the roller when the engine is Never work under the roller when the engine is running. Park on a level surface. Block the wheels running. Park on a level surface. Block the wheels securely.
Page 93: Rear Axle Transmission - Oil Change
Maintenance - 1000h Rear axle transmission - Oil change Before draining the oil, use the breather (7) to release possible internal pressure. Wipe clean and remove one of the two level/filler plugs (5) and the drain plug (6) and drain the oil into a suitable receptacle.
Page 94: Rear Axle's Planetary Gears - Oil Change - Oil Filling
Maintenance - 1000h Rear axle's planetary gears - Oil change - Oil filling Set the roller so that the plug (4) in the planetary gear is at "3 o' clock". Wipe clean and remove the plug (4). Fill with oil to the lower edge of the level hole. Use transmission oil.
Page 95: Maintenance - 2000H
Maintenance - 2000h Maintenance - 2000h Park the roller on a level surface. Park the roller on a level surface. When checking and making adjustments, the When checking and making adjustments, the engine should be switched off and the engine should be switched off and the emergency/parking brake should be applied, if emergency/parking brake should be applied, if not otherwise specified.
Page 96: Drum - Oil Change
Maintenance - 2000h Drum - Oil change Place the roller on a level surface so that the drain plug (1) is straight down. Position a container that holds 15 liters under the plug. Save the oil and dispose of it in an approved Save the oil and dispose of it in an approved manner.
Page 97: Controls - Lubrication
Maintenance - 2000h Controls - Lubrication Grease Forward/Back- throttle mechanical mechanism. Take away the outer hatch down below the seat by loosening the screws (2). Grease the workings with oil. Refit the hatch. Fig. F/B control 2. Screws 2012-11-05 ICA270-IN2EN1.pdf...

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