DYNAPAC. MAINTENANCE INSTRUCTIONS VIBRATING ROLLER CA 25 Caterpillar D 3208 NA diesel engine Deutz F6L 912 diesel engine CONTENTS Lubricants ... Maintenance schedule, Caterpillar Maintenance schedule, Deutz . As necessary .e.seeeee Daily . Weekly sess... Page Every 100 hours of operation ... 14 Every 150 hours of operation ... 17 Every 200 hours of operation ... 19 Every 500 hours of operation ... 24 Every 1000 hours of operation .. 25 Every 2000 hours of operation .. 28 Read through the inetruots: Proper maintenance is essential to ensure satisfactory service and the instructions followed. Also keep the relevant engine instruction LUBRICANTS Always use good-quality lubricants in the will cause parts to run hot, thus causing AB A A Aas A eter to the ns before commencing any service work, that the roller will give many years of given here should therefore be carefully manual near at hand. stated amounts, Excessive grease or oil rapid wear. maintenance schedule. AX GREASE vith Lithium base and EP additive (lead oleate), NLGI No. 2, Shell Alvania EP Grease 2. ENGINE OIL for API Service CD/SE, SAE et eee ed The instructions for the diesel en m32°G and above maeitoa/so rine (oil change intervals, ete.) de- Mi9°¢ to OPC SE 10% eovibed in the mamifacturer's instruc so to 43200 Baz 20 tion manual should be followed, in ad- above 232°C EaEESO dition to the measures d hore. iN a AX prake FLUID If the roller is to be used under exceptionally hot or cold conditions, get in touch with DYNAPAC for additional lubrication recommendations. DYNAPAC Dynapac Heavy Equipment AB PO Box 604-S-371 23 KARLSKRONA‘SWEDEN Tel. 0455-229 20-Telex 43041 dynkar TTelacopier 0485-295 99 HYDRAULIC OIL, Shell Oi1 T 68 with anti-wear additive - LUBRICATING OIL SAE 90 HD Shell Donax HB ¥-10055-2 Eng Replaces M-10055~1MAINTENANCE SCHEDULE Roller with Caterpillar engine 12 34 56 7 8 3 9 CAT.D-3208 36 «25 22 «21 201928 18173516 15 ww 13 12 Fig. 1 Service points on rollers with Caterpillar engines ca 25-12262-3 1 Coolant filler cap 19 Tyre pressures 2 Fuel filter 20 Wheel nuts 3. Engine 21 Oil levels in rear axle 4 Air cleaner 22 Engine oil filter 5 Hydraulic oi filters (two) 23° Fuel tank filler pipe 6 Hydraulic oil filler cap 24 Engine V-belts 7 Handbrake, foot brake 25 Fuel tank drain plug 8 Battery 26 — 9 Brake cylinder (foot brake) a 10 Indicating pin (drum oil level check) 28 Brakes 11 Filler plug - drum oil 29 Scraper 12 Sight glass - drum oil 30 Engine valves 13 Frame bearing 31 — 14 Rubber element and retaining bolts 32 Cooling system 15 Steering pivot 33. Tachometer cable 16 Steering cylinder 34 Drum gearbox (only on CA 25D 17 3-speed gearbox and pump drive and CA 25 PD) 18 Universal joint 35 Vibration valve filter 36 Fuel system water trap 2 CA 25. ¥-10055-2 EngRef.no Lubricant infig.1 Operation Page see page 1 DAILY (every 10 hours of operation) 1 Check the coolant Level 6 3 Check the engine oil level 6 B 6 Check the oil Level in the hydraulic oil tank 8 c 7, 28 Test the handbrake and the foot brake 8 23° Fill the fuel tank 8 29 Adjust the scraper setting 6 36 Drain the water trap (from roller Serial No 4972250, incl.) 7 EVERY WEEK (every 50 hours of operation) 3 Change the engine oil* uv B 4 Clean the air cleaner filter element. Check that oil hoses and connection do not leak. 9 6 Check that the hydraulic oil tank breather holes are not clogged 10 8 Check the battery u LW Check the oil level in the drum u D 4 Check the rubber element and retaining bolts 2 3 Lubricate the steering pivot 2 A 16 Lubricate the steering cylinder mountings 2 A 18 Lubricate the universal joint 3 A 19 Check the tyre pressures B 20 Check the wheel nuts B 22 Change the engine oil filter* 18 24 Check the tension of the fan and alternator V-belts 10 EVERY 14 DAYS (every 100 hours of operation) 3 Check the engine valve clearances See the engine instr. manual 32 Clean the outside of the radiator 4 34 Check the drum gearbox oil level (only CA 25D and CA 25PD after serial No. 4972262, incl.) 4 D EVERY THIRD WEEKS (every 150 hours of operation) 3 Change the engine oil 7 B 22 Change the engine oil filter 18 EVERY MONTH (every 200 hours of operation) 4 Clean the air cleaner dust collector 20 5 Change the hydraulic oil filters (two) 19 7, 28 Check and, if necessary, adjust the brakes 8,21 9 Check the fluid level in the brake cylinder 21 wv Check the oil level in the 3-speed gearbox and pump drive 2 D 21 Check the oil level in the rear axle planetary gears 24 D 21 Change the oil level in the rear axle differential 24 D 33 Lubricate the tachometer cable 22 B * Only on new or reconditioned engines. | | CA 25. M-10055-2 Eng 3aRef.no : Lubricant infig.1 Operation Page see page 1 EVERY THREE MONTHS (every 500 hours of operation) 1 Top up the coolant system with corrosion inhibitor See the engine instr. manual 3 Adjust the engine valve clearances - 35 Change the hydraulic oil filter in the vibration valve pilot line (from serial No. 4972128,incl.) 24 EVERY SIX MONTHS | (every 1000 hours of operation) u Change the oil in the drum 26 D 25 Drain the fuel tank 26 34 Change the oil in the drum gearbox (only CA 25D ‘and CA 25PD from serial No. 4972262, incl.) 27 D EVERY YEAR | (every 2000 hours of operation) 2 Change the fuel filter 28 3 Bleed the fuel system 28 6 Change the oil in the hydraulic oil tank 30 c v7 Change the oil in the pump drive and 3-speed gearbox 32, 33 D 21 Change the oil in the rear axle differential 35 D 2 Change the oil in the rear axle planetary gears 34 D 32 Flush the cooling system 29 - Inspect the crankcase ventilation diaphragm See the engine instr. manual 3b . CA 25 M-10055-2 EngMAINTENANCE SCHEDULE Roller with Deutz engine 2°34 56 7 mw 25 26 2722 21 201928 18173516 15 33° 9 |DEUTZ FEL 912 “B12 CA 25-12874~2 Fig. 2. Service points on rollers fitted with Deutz engines 1 20 Wheel nuts 2 Fuel filter 21 Oil levels in rear axle 3 Engine 22 Engine oil filter 4 Air cleaner 23 Fuel tank filler pipe 5 Hydraulic oil filters (two) 24 Engine V-belts 6 Hydraulic oil filler cap 25 Fuel tank drain plug 7 Handbrake, foot brake 26 Diesel fuel feed pump 8 Battery 27 Injection pump 9 Brake cylinder (foot brake) 28 Brakes 10 Indicating pin (drum oil level check) 29° Scraper 11 Filler plug ~ drum oil 30 Engine valves 12 Sight glass - drum oil 31 Engine cooling fins 13 Frame bearing 32 Hydraulic oil cooler 14 Rubber element and retaining bolts 33 Tachometer cable 15 Steering pivot 34 Drum gearbox (only on CA 25D and 16 Steering cylinder cA 25PD) 17 3-speed gearbox and pump drive 35. Vibration valve filter 18 Universal joint 36 V-belt monitor 19 Tyre pressures CA 25 M-10055-2 EngRipe _epenton 7 DAILY (every 10 hours of operation) 3 Check the engine oil level 7 B 6 Check the oil Level in the hydraulic oil tank 8 c 7, 28 Test the handbrake and the foot brake 8 23 Fill the fuel tank 8 29 Adjust the scraper setting 6 EVERY WEEK (every 50 hours of operation) 3 Change the engine oil * 19 B 4 Clean the air cleaner filter element, Check that oil hoses and connections do not leak. 9 6 Check that the hydraulic oil tank breather holes are not clogged 10 8 Check the battery 1 2 Check the oil level in the drum LL > 14 Check the rubber elements and retaining bolts 12 15 Lubricate the steering pivot 12 A 16 Lubricate the steering cylinder mountings 12 a 18 lubricate the universal joint 13 A 19 Check the tyre pressures 3 20 Check the wheel nuts B 22 Change the engine oil filter * 19 EVERY 14 DAYS (every 100 hours of operation) 24 Check the tension of the fan and alternator V-belts 15 26 Clean the feed pump strainer Ts 27 Check the oil Level in the injection pump 15 B 31 Clean the engine cooling fins 15 32 Clean the outside of the hydraulic oil cooler 15 34 Check the oil level in the drum gearbox (only CA 25D and CA 25PD from serial No. 4972070, incl) 4 D 36 Check the V-belt monitor 16 EVERY MONTH ! (every 200 hours of operation) 3 Change the engine oil 19 B 4 Clean the air cleaner dust collector 20 5 Change the hydraulic oil filters (two) 19 7,28 Check and, if necessary, adjust the brakes 8,21 9 Check the fluid level in the brake cylinder 21 EB v7 Check the oil level in the 3-speed gearbox 22 D Wv Check the oil level in the pump drive 22 21 Check the oil level in the rear axle planetary gears 24 21 Check the oil level in the rear axle differential 24 D 2 Change the engine oil filter 19 | 30 Check the engine valve clearances 20 | 33 Lubricate the tachometer cable 22 B EVERY THREE MONTHS (every 500 hours of operation) 35 Change the hydraulic oil filter in the vibration valve pilot line (from serial No. 4972128, incl) 24 * Only on new or reconditioned engines CA 25 M-10055-2 EngLubricant Ref.no “ fig.1 Operation Page see page 1 EVERY SIX MONTHS ‘(every 1000 hours of operation) 2 Change the fuel filter element 25 3 Bleed the fuel system 25 il Change the oil in the drum 26 D 25 Drain the fuel tank 26 34 Change the oil in the drum gearbox (only CA 25D and CA 25PD from serial No. 4972070, incl) 27 D EVERY YEAR (every 2000 hours of operation) 6 Change the oil in the hydraulic oil tank 30 7 Change the oil in the pump drive and in the 3-speed gearbox 32,33 D a Ghange the oil in the rear axle differential 35 D 21 Change the oil in the rear axle planetary gears 34 D CA 25 N-10055-2 EngAS NECESSARY Adjusting the scraper Fig. 3 DAILY (every 10 hours of operation) CATERPILLAR 3208 ENGINE Radiator — checking the coolant level Checking the oil level at Fig. 5 1 Dipstick _ 2 Filler cap Adjust the scraper setting as follows: 1 Back off all four retaining bolts. 2 Set the scraper approx. 10 mm away from the drum. 3 Tighten the retaining bolts. ‘The scrapers on certain machines may be individually adjusted, Carry out adjustment to the same dimension as above, The cooling system should be at operating temperatu- re and the engine should be stationary. 1 Place a piece of cloth or the like over the fil- Jer cap and turn the cap to the first stop. When the pressure has fallen, press down the cap, turn it and remove it. The coolant level should reach the level tab in the radiator. 2 If necessary, top up with water and corrosion in- hibitor (CAT 3P044 or equivalent). In winter, add anti-freeze, CAUTION! The coolant ia pressurised. If the cap is removed quickly, coolant will be released in the form of steam and may cause sertous injury. Use gloves and protective goggles. 1 Drive the roller onto a level surface and switch off the engine. 2 Remove the dipstick (1) and check the oil level. 3. If the oil is close to the lower mark, top up with type A\ oil as recommended in the section entitled "Lubricants" on page 1. CA 25 M-10055-2 Eng F 3208 NACaterpillar 3208 NA. ———_______4 Deutz F6L 912 ‘Draining the water trap eo ae ca ase1332e1 DEUTZ F6L 912 ENGINE Engine — checking the oil level Fig. 7 Checking the oil level 1 Upper Level mark 2 Lower level mark 3 Dipstick 4 Drain plug 5 Oil filler cap CA 25 M-10055=2 Eng Open the drain cock (1) and let the water flow out. The glass container must never be more than half- full of water. 1 Drive the roller onto a level surface and stop the engine. 2 Remove the dipstick (1) and check the oil level. 3. If the oil is close to the lower mark, top up with type A\ oil as recommended in the section entitled "Lubricants" on page 1.Hydr. oll tank — checking the level Drive the roller onto a level surface and check the level of the oil in the sight glass. If the of1 is close to the LOW mark, top up to the FULL mark with type A\ oil as recommended in the section entitled "Lubricants" on page 1. Fig. 8 Oil level - llydraulic tank A Full B Low Filling up with fuel 1 Fill the fuel tank up to the lover edge of the filler pipe every day. Use diesel fuel. a 25-19320-1 Fig. 9 Filler pipe Handbrake — adjustment 1 The brake is correctly adjusted when it is just possible to pull the lever right up. Adjust the brake by turning the lever handle clockwise. The handbrake on rollers equipped with a Renondin gearbox may be adjusted in three ways: a By turning the brake lever handle. Fig. 10 b By adjusting both of the brake cable connections. © By adjusting the brake Fig. 11 Foot brake — testing Test the action of the foot brake. If necessary, ad- just in accordance with the instructions on page 21. 8 CA 25 M-10055-2 EngEVERY WEEK (every 50 hours of operation) Aircleaner — cleaning the filter element Fig 12 Air cleaner — ea2suaeea Overcentre catch Wing nut with sealing washer Inner cover Filter element Filter housing Cleaning with compressed air Fig. 13. Blowing the filter element clean with compressed air Cleaning by washing Discard the filter element after it has been washed 6 vines. Do not fit a filter element that has been waahed in deter- gent, until tt ta completely ary. Release the overcentre catches (1) and remove the outer cover. Remove the wing nut (2) with sealing washer. Remove the inner cover (3) if it is loose. If the inner cover te firmly attached to the fil- ter element, tt will not be necessary to remove tt except when changing the element. Remove the filter element (4). Check whether any dust has penetrated the filter. vase adhering to the inside of the engine induc tion pipe indicates dust penetration. If dust has penetrated the filter, thie will be a sign that the connection, hoses ov the element teak and mist therefore be changed. Wipe the inside of the filter housing and the in- duction pipes clean, using a clean cloth. Check that the connections and the hoses between the filter housing and the engine are intact and do not leak. Fit the hose clips in patre (in opposite direc tions) and tighten then securely. Use compressed air at a maximum pressure of 0.7 MPa (7 kgf/cm’). Play the compressed air up and down along the folds of the paper on the outside of the filter element. Hold the nozzle at least 2-3 cm away from the element to avoid blowing the paper to pieces. If the filter element is sooty or oily, it should be washed in a solution of water and non~foaming detergent, such as "Donaldson D-1400". Immerse the element in the detergent solution and leave it for at least 15 minutes. Raise and lower the element in the solution from time to time to improve the cleaning effect. CA 25 M-10055-2 Eng10 Check that the filter element is intact before refitting it. If it has any holes or if the seals are defective, fit a new element. 11 Wipe the inner cover clean, fit the element into the filter housing and tighten the element and the inner cover firmly by means of the wing nut. 12 Wip the outer cover clean and refit it. Check the outer cover seals and replace any that are damaged. Fig. 14 Filter element - checking for tightness V-belt tension — checking 1 Check the tension of the cooling fan, water pump and alternator V-belt by pressing them down with the thumb at a point mid-way between the: alterna~ tor pulley and the water pump pulley. It should not be possible to depress the belts by more than 6-7 mm. Fig. 15 Tensioning the V-belts 1 Back off the alternator retaining bolts A slight- ly. 2 Press the alternator outwards until the V-belts are again correctly tensioned. 3 Tighten bolts A. If the fan guarde have been removed, they met be Tes-uusi replaced before the engine 12 started and the Fig. 16 Tensioning the V-belts roller te moved. 1 Alternator 3, Crank shaft 2 Water pump +—_________ Caterpillar 3208 NA. ———________, Hydraulik tank filler cap — breather holes 1 Remove the filler cap and check that the breather holes are not clogged. If necessary, wash the filler cap in hydraulic oil or diesel fuel and blow it dry with compressed air. Fig. 17 Filler cap ~ hydraulic oil tank 1 Breather holes 10 CA 25 M-10055-2 EngBattery — checking the electrolyte level 1 2 3 [Tt 10mm ‘GA 25-12879-1, 3 Fig. 19 Battery electrolyte level 4 1 cell plug 3 Plate 2 Blectrolyte level 5 se a naked flame when ecking the electrolyte Level Drum — checking the oil level — L ? 2 3 2 3 N ee t Fig. 20 Checking the oil level in the drun 1 Level. pin 2 Sight glass 3. Filler plug CA 25 M-10055~2 Eng Tip the seat forward. Wipe the top of the battery clean. Remove the cell plugs and check that the level of the electrolyte is approx, 10 mm above the plates, Check all the cells. If the level is lower, top up to the correct le~ vel with distilled water. If the air temperature is below freezing, run the engine for a while after adding the distilled water, since the water may otherwise freeze, Check that the breather holes in the cell plugs are not clogged, Then replace the plugs. The cable terminals should be clean and securely tightened. If they are corroded, clean then and coat them with petroleum jelly. brive the roller onto a level surface, so that the red pin (1) is level with the beam. The oil level should reach approximately halfway up the sight glass (2), Top up as necessary, using type Ad oil as recon mended in the section entitled "Lubricants" on page 1, but not more than half-way up the sight glass. ulShock absorbes and retaining screws = checking ‘Steering pivot — lubrication oan Fig. 21 Grease nipples - steering pivot Make eure that nobody te in the vicinity of the eteering pivot while the engine 12 running. ‘They could be crushed tf the steering is operated. Steering cylinders — lubrication Fig. 22 Grease, nipples ~ steering cylinders Check that the shock absorbers are undamaged and that the retaining screws are firmly tightened. Change the shock absorbers when the cracks in them are 20-25 mm deep. 1 ‘urn the drum section to the left so that all the steering pivot grease nipples on the right- hand side are accessible. Wipe any dirt and grease off the four » 3 Grease each nipple with five strokes of the grease gun, Check that grease enters the bearings. 4 Turn the drum section to the right and apply grease to the nipples on the left-hand side of the steering pivot in the same manner. use type A\ grease as recommended in the section entitled "Lubricants" on page 1. Leave a little grease on the nipples after grea~ sing, to prevent dirt from entering them. If the grease does not enter the bearings, tt may be necessary to relieve the ateering pivot of load, using a jack, and then repeat the lubrica- tion procedure. Grease the left-hand steering cylinder mounting inmediately after greasing the steering pivot. 1 Wipe any dirt and grease off the two nipples. 2 Grease each nipple with three strokes of the grease gun, Check that grease enters the bearings. Use type A\ grease as recommended in the section entitled "Lubricants" on page 1. Leave a little grease on the nipples after grea~ sing, to prevent dirt from entering them. 3 Grease the two nipples on the right-hand steering cylinder in the same manner. Check that grease enters the bearings. 12 cA 25 M-10055-2 Engjiversal joint — lubrication The grease nipples on the universal joint are acces- sible from underneath the roller. 1 Crawl urider the roller and check that the grease nipples are accessible with the grease gun. It may be necessary to drive the roller forward slightly, to rotate the universal joint and move the nipples into an accessible position. cau TOW! er work under the rotler while running. 2 Wipe any dirt and grease off the two nipples. 3. Grease each nipple with two strokes of the grease gun. Check that grease enters the bearings. Use type A\ grease as recommended in the section ca aunanea entitled "Lubricants" on page 1. Leave a little grease on the nipples to prevent dirt from ente~ ring them, Fig. 23 Grease nipples ~ universal joint ‘Tyre pressures Check the tyre pressures, using the tyre pressure gauge included in the roller tool kit. The minimum,tyre pressure should be below 0.11 MPa (1.1 kgf/cm) and the maximum tyre pressure should not exceed 0.15 MPa (1.5 kgf/cm). Fig. 24 Wheel 1 Air valve 2 Wheel nut Wheel nuts — tightening Check that the wheel nuts are tightened with a tor~ que of 550 Nm (55 kgf m). CA 25 NM+10055-2 Eng 1BEVERY 14 DAYS (every 100 hours of operation) Drum gearbox — checking the oil level Fig. 25 Topping up with oil 1 2 Level/drain plug Filler plug Radiator — cleaning the outside Feed pump strainer — cleaning Fig. 26 Feed pump 1 2 3 4 4 Retaining bolt cover Gasket Strainer thie only applies to roltera with serial Nos. above 492 22 62 or 497 20 70. 1 Drive the roller onto a level surface so that the filler plug (2) is at its uppermost position on the drum, Wipe any dirt and grease away from the area around the plugs. 3 Remove the plugs and check that the oil level is up to the level plug. 4 If necessary, top up with type A, oil in accor- dance with the section entitled "Lubricants" on page 1. 5 Replace the plugs. check that air can flow freely through the radiator. If the radiator is dirty, clean it by flushing with water or blowing with compressed air. After cleaning, check that any seals and sound-ab- sorbers are not damaged. 1 Back off the bolt (1). 2 Remove the cover (2). 3 Remove the strainer (4) and wash it in diesel fuel. 4 lubricate the gasket (3) with clean diesel fuel. 5 Assemble in the reverse order. 6 Bleed the fuel system (see the section entitled "Bleeding". Start the engine and check that there is no leakage. CA 25 M-10055-2 Eng Deutz F6L 912Deutz F6L 912 Y Injection pump — checking the oil level Fig. 27 Injection pump 1 Level plug 2 Oil filler plug Engine cooling fins — cleaning ‘ig. 28 Engine ~ cooling fins Hydraulic oil cooter — cleaning the outside ALTERNATOR V-BELT TENSION Checking This only applies to e cation, ines without central lubrt- 1 Back off the plug (1) about 3 turns, so that any surplus oil and fuel mixture will run out. 2 Top up with type A\ oil as recommended in the section entitled "Lubricants" on page 1, through filler plug hole (2) up to level plug (1). 3° Refit both plugs and tighten them. Oil volume: approx. 0.48 litres. 1 Remove the rear engine compartment cover on the left-hand side of the roller and open the bonnet. 2 Release the catches and remove the air ducting from the engine. 3 Clean the cooling fins carefully, preferably using compressed air. Check that air can flow freely through the cooler. If the cooler is dirty, clean it by flushing it with water or blowing it clean with compressed air, Open the "cooler door" when carrying out cleaning. After cleaning, check that seals and sound-absorbers are not damaged. 1 Check the V-belt tension by pressing the belt midvay between the alternator pulley and the crankshaft pulleys. It should not be possible to depress the belt by more than 10-15 mm. If the deflection is greater, the belt must be tensioned. At the same time, check that the V-belt monitor for the fan belt operates satisfactorily. The horn should sound when the V-belt monitor contact (2 in Fig. 31) is depressed. If the V-belt monitor does not operate satisfac~ tordly, tt should be repaired tnmediately. Fig. 29 Checking V-belt tension CA 25 M-10055-2 Eng 15Adjusting Fig. 30 Tensioning the alter- nator V-belt COOLING FAN V-BELT V-belt monitor Fig. 31 Checking the V-belt and V-belt monitor 1 Belt tensioner 2 V-belt monitor V-belt monitor — checking V-belt failure or replacement 1 Back off the alternator retaining bolts B and ¢ and nut D. 2 Then press the alternator outwards until the belt is again correctly tensioned (see above). 3. Then tighten bolts B and C and nut D. Zeneion a new alternator V-belt again after 40 houre of operation, The V-belt is tensioned by a spring-loaded belt ten- sioner (1). If the V-belt should break, the belt ten sioner will be moved outwards by the spring and will actuate the switch on the V-belt monitor (2) causing the horn to sound. The V-belt monitor is also operative when the con- tact key is in the "OFF" position, Deutz F6L 912 Depress the switch (2 in Fig. 31). The roller horn should sound. If the alarm device is defective, it should be repaired inmediately. 1 Stop the roller immediately. Stop the diesel engine. 3 Disconnect the battery lead from the battery, to stop the horn. 4 Fit anew V-belt (see the engine manufacturer's instruction manual). 5 Refit the battery lead and secure it. 16 GA 25 M-10055-2, Eng,EVERY THIRD WEEK (every 150 hours of operation) CATERPILLAR 3208 ENGINE Engine — deviations from the normal oil changing interval Ivveepective of the mmber of hours of operation, the engine ott and engine ofl filter m be changed every stz months. The ott filter must aluays be replaced when the engine ott ta changed. Engine — changing the oil Fig. 32 Filling up with oil - engine L Oil filler cap Lis Sy Fig. 33 Draining the engine oil 1. prain plug Oil change intervals depend on the grade of the lubricating oil and the sulphur content of the fuel. Changing the oil every week or every 150 hours of operation is conditional on the use of engine oil of grade "For API Service CD, SAE" and on the use of diesel fuel of good quality, with a sulphur content below 0.42. | | If oil of grade "For API Service CC/SC, SAE" is used or if the sulplyr content of the diesel fuel is 0.4% or above, the oil should be changed earlier and more frequently (see the engine manufacturer's instruc~ tions). 1 Warm up the engine thoroughly before draining the oil. Impurities in the lubricating system will then be well mixed with the oil and will be removed with it, Furthermore, the ofl flows more readily when it is hot. 2 Clean the area around the oil filler cap (1) and then remove the cap. 3 Clean the area around the drain plug (1) and place a receptacle under the plug. This recep- ' tacle should hold at least 15 litres. 4 Remove the drain plug and allow the oil to drain into the receptacle. Allow the oil to drain out while changing the oil filters. 5 Wipe the drain plug clean, Fit it back into place and tighten it securely. CA 25 N-10055-2 Eng 17Engine — changing the oil filter Fig. 34 Oil filters - engine 1 Oil filters Do not tighten the filters too hard, since thts may danage the seale. Engine — filling up with oil Fig. 35 Oil level - engine 1 Oil filler cap 2 Dipstick 1 Remove both oil filters (1) and discard them. They are of disposable type and cannot be clean- ed. Ensure that the old seats are not left on the filter head since leakage will then occur be tween the new and old seat. 2 Clean the sealing surfaces of the filter head with a clean, lint-free cloth. 3. Apply a thin layer of clean engine oil to the new filter seals. Tighten the filters by hand until the seal seats against the filter head. Then tighten an addi- tional half-turn, 1 Fill up with fresh type A\ oil as recommended in the section entitled "Lubricants" on page 1. Oil required: 12.5 litres when changing the fil- ters. 11.4 litres when the filters are not changed. The quantities of oil required for engines with se~ rial Nos, above 90N44128 or with recalibrated dip- sticks are: 14.5 litres, when changing the filters 13.5 litres, when the filters are not changed 2 Check the engine oil level with the dipstick (2). ‘The level should be up to the FULL mark. Do not overfill since this may cause damage to the cranl shaft packing boxes. 3 Refit the filler cap (1). Tighten it firmly, en suring that it seals satisfactorily. 4 Start the engine and warm it up. Check that there are no oil leaks. 18 CA 25 M-10055-2 Eng 3208 NA,Deutz F6L 912 Y EVERY MONTH {every 200 hours of operation) Hydraulic system — changing the filter Fig. 36 Oil filter 1 Oil filter - return 2 Oil filter - suction DEUTZ F6L 912 ENGINE Engine — changing the oil ai: Fig. 37 Changing the oil 1 Upper level mark 2 Lower level mark Dipstick Drain plug Oil filler cap Engine — changing the oil filter Fig. 38 Changing the oil filter 1 Remove the oil filters (1) and (2). Discard the filters. They are of disposable type and cannot be cleaned, Enoure that the old seate are not Left in post tion, Leakage will othemvize occur between the nev and old seals, 2 Thoroughly clean the sealing surfaces of the fil- ter holders, 3. Apply a thin layer of hydraulic oil to the seals of the new filters. 4 Screw the filters into place by hand. First screw the filter in until its seal seats against the filter head. Then tighten an additio~ nal half-turn, 5 Start the engine and check that no hydraulic oil leaks out around the filters. When the engine is hot, remove the rear engine com- partment cover on the left-hand side of the roller. 1 Remove the filler cap (5). 2 Remove the drain plug (4) and allow the oil to drain out into a suitable receptacle while re~ placing the oil filter. 3 Clean the drain plug (4) and refit it into place. 4 Fit a drift or screwdriver into the shoulder on filter A and slacken the filter. Then unscrew the filter by hand. 6 Clean the sealing surfaces on the filter holder. 7 Lightly oil the rubber seal B on the new filter. 8 Screw the filter into place by hand until the rubber seal seats correctly and then turn an addi- tional half-turn. CA 25 ¥-10055-2 Eng 19Engine — filling up with oil Valve clearances — checking and adjusting g- 39 Engine ~ adjusting the valve clearances 1 Adjusting screw 2 Locknut 3 Push-rod 4 Rocker arm 5 Valve 6 Feeler gauge Air cleaner — cleaning the dust” collector Under extremely dys condi- tione the dust--dllector should be-teaned every week Fig. 40 Air cleaner catch Dust. collector "Donaclone" tubes Filter housing Self-discharging valve 9 Fill up with new type AX oil as recommended in the section entitled "Lubricants" on page 1. Oil required: Approx. 12 litres. 10 Check the oil level with the dipstick (3). The level should be at the upper mark - 1. If neces~ sary, top up with more oil. 11 Refit the filler cap. 12 Start the engine and wart it up. Check that there are no oil leaks. Open the bonnet and lift up the lower engine com- partment cover. Remove the rocker covers. Adjust the valve clearances as follows, when the en- gine is cold: 1 Fit a 36 mm non-adjustable spanner to the crank shaft nut and use it to turn the engine until both valves in one cylinder are fully closed. (The push-rods (3) are then under no load and can be turned easily with the fingers.) Deutz F6L 912 2 Use a feeler gauge to check that the valve clear- ance is 0.15 mm at the exhaust and inlet valves. 3 If necessary, adjust the clearances by backing off the locknut (2) by 1-2 turns. Then turn the adjusting screw (1) until the feeler gauge (0.15 mm) can be withdrawn against slight resistance. ‘Tighten the locknut again. 4 Repeat this procedure on the other cylinders. 1 Release the catch (1) and remove the dust collec~ tor (2). 2 Empty the dust collector and wipe it clean, 3. Clean the "Donaclone" tubes (3), using a bottle~ cleaning brush or equivalent. If the tubes cannot be cleaned, remove the housing (4) for the "Donaclone" tubes. The tubes can then be blown clean with compressed air or washed in water at a maximum temperature of 65°C. 4 Assemble in the reverse order. Check the seals and replace any that are damaged, Check that the hoses and connections do not leak. The duat collector ts fitted with a self-diecharging valve (5). This valve diechargee dust and water con- tinuously. 20 CA 25 M-10055-2 EngBrake cylinder — checking the fluid level Fig. 41 Checking the fluid le~ 1 vel ~ brake cylinder Filler cap Foot brake — adjusting Never work under the roller while the engine ie running. Fig. 42 Adjusting the brake L shoes cams Thoroughly clean the area around the filler cap (1) and remove the cap. Check that the fluid is up to the bottom of the filler hole. If necessary, top up with brake fluid. Use type A\ brake fluid in accordance with the section entitled "Lubricants" on page 1. If the fluid level is normal and there is no leakage in the braking system, but the brake pedal must be depressed a long way before the brakes act, it will be necessary to adjust the brake shoes. This adjustment compensates for brake lining wear. Adjustment is carried out by means of the cams on the backplate. These are accessible from underneath the roller. ‘There are two cams on each brake - one for each brake shoe, All cams must be adjusted. 1 Turn the cam (1) until the brake lining is in contact with the brake drum. Turn the cam (1) until the brake lining is in contact with the brake drum. Turn the cam back until the brake lining is just clear of the drum, Adjust the other brake shoes in the same manner. Drive the roller a few hundred metres, without using the brakes, Feel the brake drums with your hand. If a brake drum is hot, this is a sign that one or both of the brake shoes are in contact with it. In this case, turn the cam back a little further. Allow the brake drums to cool and then give the voller another trial run in the same manner. ‘Then drive the roller and apply the brakes to check that they act satisfactorily. CA 25 M-10055-2 Eng 21Tachometer cable — lubricating 3-speed gearbox — checking the oil level Fig. 43. Checking the oil level = 3-speed gearbox 1 Level plug 2 Drain plug Funk pump drive — checking the oil level Fig. 44 Checking the oil level 1 Filler plug 2 Level plug 3. Drain plug Release the cable at the tachometer and pour type ‘A\ oil in between the sheath and the cable. The 3-speed gearbox is available in two versions, ive, Funk and Renondin, These instructions apply to both versions. 1 Engure that the roller is standing on a level surface when checking the oil level. 2 Clean the area around the level plug (1) and re~ move it, 3 Check that the oil reaches up to the plug hole. If the ofl level is low, top up with type A\ oil as recommended in the section entitled "Lubri- cante" on page 1. Top up with oil through the level plug (1) hole. Refit the plug and tighten it securely. Ensure that the roller is standing on a level sur~ face. 1 Clean the area around the level plug (2) and back the plug off a few turns. Oil should run out if the oil level is correct. 2 If necessary, top up with oil through the filler plug (1) hole until the of1 runs out through the level plug (2) hole. Clean the area around the filler plug and before removing the plug. Fill up with type.A\ oil as recommended in the section entitled "Lubricants" on page 1. A level plug ts located on each aide of the pum drive. The ott level need only to be checked on one side. 22 CA 25 M-10055-2 EngPrometheus pump drive — checking the oil level HOR 259133261 Fig. 45 Checking the oil Level 1 Filler plug 2 Level plug with dipstick 3. Drain plug Renondin pump drive — checking the oil level 3. Gh as-19329-1 Fig. 46 Checking the oil level 1 Filler plug 2 Level plug 3. Drain plug Dynapac pump drive — checking the oil level 25-13330-1, Fig. 47 Checking the oil level 1 Filler plug 2 Level plug 3__Drain plug CA 25 10055-2 Eng Ensure that the roller is standing on a level sur- face before checking the oil level. 1 Clean the area around the level plug (2) and re~ move the plug, using a 14 mm socket wrench, The level plug is fitted with a dipstick. 2 Remove the dipstick and check the oil level. It should be up to the mark on the dipstick (only on the Prometheus pump drive). 3 If necessary, clean the area around the filler plug (1), remove it and top up with oil through the filler plug (1) hole. Use type A\ oil as recommended in the section entitled "Lubricants" on page 1. 4 Refit the filler plug and the level plug with dipstick. 23Rear axle planetary gear — checking the oil level 2z pererestty Fig. 48a Checking the oil le- vel - planetary gear 1 Filler and level plug 2. Drain plug 3. Mark ~ oil Level Rear axle differential — checking the oil level Fig. 48> Checking the oil le~ vel - differential 1 Level plug 2 Drain plug EVERY THREE MONTHS (every 500 hours of operation) Vibration valve pilot line — changing the filter element (rollers with serial No, 4972128 and above) Filter. Og ca 25-19301-1 Fig. 49 Pilot line Drive the roller onto a level surface until the level plug (1) on one of the planetary gears is in the correct position, The mark (3) on the pla~ netary gear housing should then be horizontal. Remove the level plug and check that the oil is up to the plug hole. If the of1 level is low, top up with oil to the correct level through the level plug hole. ‘Top up with type A\ oil as recommended in the section entitled "Lubricants" on page 1. Check the oil Level on the planetary gear on the other side in the same manner. Ensure that the roller is standing on a level surface, Remove the level plug (1) and check that the oil is up to the level plug hole. If the level is low, top up with oil to the cor~ rect level through the level plug hole. Top up with type A\ oil as recommended in the section entitled "Lubricants" on page 1. cavrron Never work under the roller while the engine ts running. 1 Clean the area around the filter. 2 Remove the filter housing and replace the filter’ element. 3 Refit the filter. Start the engine and check that the filter does not leak. 24 CA 25 M-10055~:Deutz F6L 912 EVERY SIX MONTHS | (every 1000 hours of operation) DEUTZ F6L 912 ENGINE Fuel filter — replacement Fig. 50 Replacing the fuel filter Start the engine and check that the filter does not Leak, Fuel system — bleeding Fig. 51 Fuel systen 1 Screw 2 Pump lever Fig. 52 Bleeding the pressure Lines 1 Coupling nut 1 Unserew filter A with care, since fuel will flow from the filter. 2 Clean sealing surface B 3 Apply clean diesel fuel to the rubber gasket on the new filter. 4 Screw the new filter into place by hand until the rubber gasket has seated correctly and then turn, an addition half-turn, 5 Bleed the fuel system (see below). 1 Back off the bolt (1). 2 Manually operate the pump lever (2) on the feed pump until the fuel flowing out at the bolt (1) is free from air bubbles. 3. Retighten the bolt (1). If no fuet flows out past the bolt when the hand pump ts operated, turn the engine over using a 36 mm non-adjustable epanner fitted to the crankshaft mut. 4 If the pressure lines have been disconnected, they must also be bled. 5 Back off the pressure line coupling (1) a couple of turns and run the starter motor until bubble free fuel flows out past the nut. The throttle should be in the fully open position. 6 ‘Tighten the pressure line connection. 7 Bleed the other pressure lines in a similar man- ner, if necessary. CA 25 M-10055-2 Eng 25Drum — changing the oil 2 Fig. 53a Changing the oil 2 sight glass 3. Drain plug —_— Fig. 53b Filling up with oil 1 Level pin 2 Sight glass 3. Filler/drain plug Fuel tank — draining the water 1 ca as-azses-2 Fig. 54 Fuel tank 1 Drain plugs 1 Drive the roller onto a slight incline, so that the drain plug (3) is in the lowest position. 2 Remove the plug and drain the oil. Drain the ott into a euttable receptacle. 3 Screw the plug back into place and drive the rol- ler onto a level surface so that the red pin (1) is opposite the bean. 4 The normal oil level is half-way up the sight glass. 5 Fill up with type A\ lubricating oil as recom mended in the section entitled "Lubricants" on page 1, although not beyond half-way up the sight glass (2). 6 Change the oil in the other side of the drum as described in 1-5 above. Water and sediment in the fuel tank can be drained through the drain plugs (1) in the bottom of the fuel tank. The water should be drained when the roller has been stationary some time - such as overnight. he roller should preferably be left with one side slightly higher than the other, so that the water and sediment will collect at one of the drain plugs. Drain as follows: 1 Clean the area around the lower drain plug. 2 Remove the plug and drain the water and sediment until only clean diesel fuel flows out of the Grain plug hole. Then screw the plug back into place. Do not drain all the fuel, since air may then en: the fuel ayatem. 26 CA 25 M+10055-2 EngDrum gearbox — changing the oi ca 25-19926-1 Fig. 55 Draining the oil 1 Drain/level plug 2 Filler plug 4 Fig. 56 Filling with oil 1 Level/drain plug 2 Filler plug This only applies to rollers with serial Nos. 437 20 62 and above or 497 20 70 and above. The system should be at operating temperature before the oil is drained. 1 Drive the roller onto a level surface so that the drain/level plug (1) is at the lowest position. Clean the area around the plugs. Place a receptacle under the drain plug (1) and drain the oil. The receptacle should hold 3.5 litres. Also remove plug (2). Move the roller backwards so that filler plug (2) is in the highest position. Fill up with oil through the filler plug hole (2) until the ofl level reaches the level plug (1). Use type A\ oil as recommended in the sec~ tion entitled "Lubricants" on page 1. Oil required: approx. 3 litres. Refit the plugs. CA 25 M-10055-2 Eng 27EVERY YEAR (every 2000 hours of operation) CATERPILLAR 3208 ENGINE Fuel filter — replacememt Fig. 57 Fuel filter 1 Filter Fuel system — bleeding Fig. 58 Bleeding the fuel system 1 Bleed screw Fig. 59 Bleeding the fuel sys~ tem 1 Hand pump 1 Remove the fuel filter (1) and discard it. It is of disposable type and cannot be cleaned, 2 Clean the sealing surface of the filter holder. Ensure that the old seal te not Left én poattion on the filter head, since tt will cause Leakage between the new and the old ceala, 3. Apply a thin film of diesel fuel to the new fil- ter seal. 4 Serew the filter into place by hand. First screw the filter into place, until the seal seats against the filter head and then tighten an additional half-turn, 5 Bleed the fuel ‘system (see below). If air has entered the fuel system, the engine will either fail to start or it will misfire. The fuel system must then be bled. 1 Stop the engine, 2 Back off the bleed screw (1) on the top of the fuel pump. 3 Operate the hand pump (1) until the fuel flowing out at the bleed screws flows in a steady strean and is completely free from air bubbles. Do not pump out more fuel than necessary. Do not use the hand pump uhen the bleed screw te tightened. The pump handle is secured in the closed position. To release it, turn the handle anti-clockwise un~ til it is loose. When the bleeding operation is complete, secure the handle again by pressing it in and turning it clockwise until resistance is met. 28 CA 25 .M-10055-2 EngFig. 60 Bleeding a fuel line 1 Nut 2 Fuel line Engine — flushing the cooling system Fig. 61 Draining the cooling system L Filler cap 2 Drain plug - radiator 3 Drain plugs caurron! The coolant ie pressurised. If the radiator cap ta removed quickly, coolant will flow out in the form of ateam and may cause serious injury. Use gloves and protective goggles. 4 Tighten the bleed screw. 5 Start the engine. If the engine misfires or runs unevenly, bleed the lines to the injection nozzles. @ To do this, back off the nut (1) at the injec~ tion nozzle and allow fuel to flow freely un- til it does so evenly and contains no air bubb- les, Then tighten the nut again. Bleed one line at a time, until all the lines have been bled. © Bleed the fuel lines while the engine is run~ ning. The cooling system should be cleaned once a year, to flush out flakes of rust and sediment. ‘The coolant must also be changed once a year, as the corrosion inhibitor loses its effiectiveness. The cooling system should be cleaned when the engine ta cold.. 1 Drive the roller onto a level surface. 2 Remove the radiator filler cap (1). 3. Open the drain cock (2) at the bottom of the ra~ diator. 4 Renove the four drain plugs (3) in the cylinder block and on the engine oil coole @ One at the bottom connection to the radiator @ Two in the cylinder block ~ one on each side, near the flywheel casing @ One in the engine oil cooler (underneath) 5 Flush the cooling system with clean water. Insert a hose into the radiator filler neck and flush the system with water until the water flowing out at the drain plug holes is complete~ ly free from flakes of rust and sediment. If there are hard depostte of lime or rust in the cooling system, the eysten may be cleaned using a special radiator cleansing agent. Use a good cleansing agent from a reputable manufacturer and follow the manufacturer's inatructions. See also CAT instructions GEG 051 00-01. CA 25 M-10055-2 Eng 29Hydraulic system — changing the oil The strictest cleanliness is essential uhen servicing the hydraulic system, to ensure trouble-free operation of the roller. Draining Fig. 62 Draining the hydraulic oil tank 1 Drain plugs 6 Refit the drain plugs and shut off the radiator drain cock. 7 Inspect the coolant hoses. Replace hoses that are cracked or show any other signs of defect. 8 Fill up with coolant to the level tab in the ra~ diator. The lime content of the water should be as low as possible. Always fill the cooling system with one of the following two coolants: © Clean water and corrosion inhibitor (cAT 3P2044 or its equivalent). @ 50 % clean water and 50 % anti-freeze (con- taining a corrosion inhibitor). 9 Start the engine and run it for 10 minutes. 10 Check the Level of the coolant and, if necessary, top it up to the correct level. 11 Check that the cooling system does uot leak. En- sure that any leaks are sealed. 12 Refit the filler cap. Change the oil in the hydraulic system when it is hot - at the end of a shift, for example. Oil £lows more freely when it is hot and any impuri- ties will then be well mixed with the oil and they will flow out with it when the oil is drained. 1 Thoroughly clean the outsides of the tank drain plugs. 2 Procure a receptacle to hold at least 220 litres, to collect the oil. An empty oil drum or the like is a suitable re- ceptacle. Place the drum beside the roller and allow the oil to flow in a hose from the drain plug to the oil drum. 3 Remove the drain plug which is in the lower posi- tion (1). Let the oil drain out. 30 CA 25 M-10055-2 Eng5 Fig. 63 Hydraulic tank 1 Cover plate 2 Filler cap 6 7 1 Fig. 64 Suction strainer 1 Suction strainer 8 10 Remove the cover plate (1) on top of the hydrau- Lic ofl tank, Take care to prevent impurities from entering the tank, Clean the tank filler cup and filler strainer. Check that the strainer is intact. Remove the suction strainer (1) and wash it in hydraulic oil, The suction strainer is bolted to the bottom of the hydraulic oil tank and is accessible when the cover plate has been removed. Clean the tank. The best way of doing this is to draw up the se~ diment from the bottom of the tank by means of a filter unit, I£ cloths or brusches are used they must be com~ pletely clean and free from dust. If the tank te rinsed out with hydraulic ott, alt connections in the bottom of the tank must be plugged to prevent impurities from entering the hydraulic Lines. Do not forget to remove these plugs after cleaning. Refit the drain plug. Refit the suction strainer. Refit the cover plate. it a new gasket and use Loctite sealing compound or tte equivalent to make a good seat. Enoure that no seating compound enters the tank, CA 25 M-10055-2 Eng 3111 Fill up with oil to the FULL mark on the sight glass. The capacity of the tanks is approx. 208 litres. use type A oft as recomended in the section entitled "Lubricants" on page 1. / When filling the tank the ofl should preferably be pumped through a filter unit. 12 Start the engine and operate the various hydrau- Lic units. 13 Check the oil level and, if necessary, top up with more oil. Fig. 65 Checking the oil level = hydraulic tank A Full B Low GEARBOXES AND REAR AXLE — CHANGING THE OIL All oil changes should be carried out when the oil is hot ~ at the end of a shift, for example. Hot o41 flows more readily and any impurities will then be well mixed with the oil and will run out with it when it is drained. 3-speed gearbox — oll changing The 3-speed gearbox is available in two versions, i.e, Funk and Renondin. The instructions below apply Never work under the roller to both versions. when the engine te running 1 Drive the roller onto a level surface and stop the engine. 2 Clean the area around the filler plug (1) and the drain plug (2). 3 Place a receptacle with a capacity of about 5 litres under the drain plug (2). 4 Remove the filler plug (1) and the drain plug (2). Drain the oil into the receptacle. 5 Clean the drain plug and refit it. ‘The drain plug is magnetic and attracts any iron particles in the oil. 6 Fill up with oil, through the filler plug (1) hole, until the oil reaches up to the bottom of the hole. The gearbox holds approx. 2.8 litres ame coc Fig. 66 3-speed gearbox use type A\ oil as recommended in the section . entitled "Lubricants" on page 1. 1 Piller plug 2 drain plug 7 Refit the filler plug. i CA 25 M-10055-2 EngFunk pump drive — oil changing Fig. 67 Funk pump drive 1 Filler plug 2 Level plug 3. Drain plug Prometheus pump drive — oil changing fh 25-13328-1 Fig. 68 Prometheus pump drive 1 2 3 Filler plug Dipstick Drain plug 1 Drive the roller onto a level surface and stop the engine, 2 Glean the area around the filler plug (1), level plug (2) and drain plug (3). 3 Place a receptacle with a capacity of about 5 Litres under the drain plug. 4 Remove the filler plug (1) and drain plug (3). Allow the oil to drain into the receptacle. 5 Clean the drain plug and refit it. The drain plug is magnetic and attracts any iron particles in the oil. 6 Back off the level plug a few turns. There is @ level plug on each side of the pump drive, It is only necessary to back off one of them. 7 Fill up with of1 until it flows out at the level plug hole. Use type A oil as recommended in the section entitled "Lubricants" on page 1. 8 Tighten the level plug end refit the filler plug. The instructions below are apply to the Renondin and Dynapac pump drives. 1 Drive the roller onto a level surface and stop the engine, 2 Clean the area around the filler plug (1) and the drain plug (3). 3 Place a receptacle with a capacity of approx. 5 litres under the drain plug. 4 Remove the filler plug. 5 Remove the drain plug and allow the oil to drain into the receptacle. Clean the drain plug and, when all the oil has drained, refit the drain plug. 7 Clean the area around dipstick (2) and remove the dipstick. Leave the dipstick in the opening (on- ly on the Prometheus pump drive). CA 25 M-10055-2 Eng 33Renondin pump drive — changing the oil BrsAsn94 49 Pig. 69 Checking the oil level 1 Filler plug 2 Level plug 3. Drain plug Dynapac pump drive — the olf ea 25-19500- Fig. 70 Checking the oil level 1 Filler plug 2 Level plug 3 Drain plug Rear axle planetary gears — changing the oil Draining the oil Fig. 71 Planetary gear - draining the oil 1 Drain plug 2 Level plug Back off the level plug (2) a few turns. Fill up with oil until the level reaches the mark on the dipstick (only on the Prometheus pump drive). On Renondin and Dynapac pump drives, the oil should flow out past the level plug (2). Use type Ad: oil as recommended in the section entitled "Lubricants" on page 1. Screw in the level plug (2) and the dipstick (2) (see Fig. 68) and refit the filler plug (1). Drive the roller onto a level surface so that the drain plug (1) is at the lowest position. Stop the engine. Clean the area around the drain plug (1) and fil~ ler plug (2). Place an approx. 2 litre receptacle under the drain plug. Remove the filler plug (2) and the drain plug (1). Collect the oil in the receptacle. Clean the drain plug and, when all the oil has drained, refit the plug. 34 CA 25 M-10055-2 EngFilling up with oil Fig. 72 Planetary gear - filling up with oil 1 Level plug 2 Drain plug 3. Level mark Rear axle differential — changing the oil Never work under the roller when the engine is running Fig. 73 1 Filler and level plug 2 Drain plug Differential, Drive the roller so that the mark (3) on the pla~ netary gear housing ie horizontal. Fill up with oil through the level plug (1) hole until the oil level reaches the bottom of the hole. Use type A\ oil as recommended in the section entitled "Lubricants" on page 1. Refit the filler plug. Change the oil in the other rear axle planetary gear in the same manner. Drive the roller onto a level surface and stop the engine. Clean the area around the drain plug (2) and the filler plug (1). Place an approx. 15 litre receptacle under the drain plug. Remove the filler plug and the drain plug. Collect the oil in the receptacle. Clean the drain plug and, when all ofl has drain~ ed, refit the drain plug. Fill up with oi1 through the filler plug hole un- til the oil level reaches the bottom of the hole. The differential holds approx. 12.8 litres of oil. Use type A\ oii as recommended in the section entitled "Lubricants" on page 1. Refit the filler plug. CA 25 M+10055-2 Eng 35DYNAPAC. MAINTENANCE INSTRUCTIONS VIBRATING ROLLER CA 25 Caterpillar D 3208 NA diesel engine Deutz F6L 912 diesel engine ONTENTS: Page Page Lubricants .... oe 1 Every 100 hours of operation ... 14 Maintenance schedule, Gaterpillar.. 2 Every 150 hours of operation ... 17 Maintenance schedule, Deutz 3e Every 200 hours of operation ... 19 As necessary .. Every 500 hours of operation ... 24 Every 1000 hours of operation .. 25 Every 2000 hours of operation .. 28 Daily sess Weekly .. Read through the instructions before commencing any service vork. Proper maintenance is essential to ensure that the roller will give many years of satisfactory service and the instructions given here should therefore be carefully followed. Also keep the relevant engine instruction manual near at hand. LUBRICANTS Always use good-quality lubricants in the stated amounts. Excessive grease or oil will cause parts to run hot, thus causing rapid wear. Zs Ad A Avmns AS cater to the vaincenance sched. AX GREASE with Lithium base and EP additive (lead oleate), NLGI No. 2, Shell Alvania EP Grease 2. AX ENGINE OIL’ for API service CD/SE, SAE Air temperature | Viscosit: . : ee a a The instructions for the diesel en- -32°c and abowe | saz 101/30 gine (oil change intervals, eto.) d Bro onp cai amoed| SAE 10M sortbed in the manufacturer's instruo- = 78¢ to +32°c | saz 20 tion manual should be fotloved, in ad- megs ee || een dition to the measures Listed here. A\ HYDRAULIC OIL with anti-wear additive - Shell Oi] T 68 AX LUBRICATING OIL SAE 90 HD AX BRAKE FLUID shell Donax 18 If the roller is to be used under exceptionally hot or cold conditions, get in touch with DYNAPAC for additional lubrication recommendations. DYNAPAC reseed Replaces Dynapac Heavy Equipment AB 1 10055-1 PO Box 504°S-971 28 KARLSKRONA-SWEDEN Tel. 0455-229 30-Telex 43041 dynkar Telecopier 0455-295 39MAINTENANCE SCHEDULE Roller with Caterpillar engine 12,3 4 56 7 8 3B 9 CAT.D-3208 36 «25 22 «21 201928 18173516 15 % 13 12 Fig. 1 Service points on rollers with Caterpillar engines A 25-12262-3 1 Coolant filler cap 19 Tyre pressures 2 Fuel filter 20 Wheel nuts 3 Engine 21 Oil levels in rear axle 4 Air cleaner 22 Engine oil filter 5 Hydraulic oil filters (two) 23 Fuel tank filler pipe 6 Hydraulic oil filler cap 24 Engine V-belts 7 Handbrake, foot brake 25 Fuel tank drain plug 8 Battery 26 — 9 Brake cylinder (foot brake) 7 10 Indicating pin (drum oil level check) 28 Brakes 11 Filler plug - drum oil 29 Scraper 12 Sight glass - drum oil 30 Engine valves 13 Frame bearing 31 14 Rubber element and retaining bolts 32 Cooling system 15 Steering pivot 33 Tachometer cable 16 Steering cylinder 34 Drum gearbox (only on CA 25D 17 3-speed gearbox and pump drive and CA 25 PD) 18 Universal joint 35 Vibration valve filter : 36 Fuel system water trap 2 CA 25 M-10055-2 EngRef.no Lubricant infig.1 Operation Page see page 1 DAILY (every 10 hours of operation) 1 Check the coolant level 6 3 Check the engine oil level 6 B 6 Check the oil level in the hydraulic oil tank 8 c 7, 28 Test the handbrake and the foot brake 8 23° Fill the fuel tank 8 29 Adjust the scraper setting 6 36 Drain the water trap (from roller Sérial No 4972250, incl.) 7 EVERY WEEK (every 50 hours of operation) 3 Change the engine oil* v B 4 Clean the air cleaner filter element. check that oil hoses and connection do not leak. 9 6 Check that the hydraulic oil tank breather holes are not clogged 10 8 Check the battery ll 2 Check the oil level in the drum u Dd 14 Check the rubber element and retaining bolts 2 15 Lubricate the steering pivot 2 a 16 lubricate the steering cylinder mountings 2 A 18 Lubricate the universal joint 13 A 19 Check the tyre pressures B 20 Check the wheel nuts 3B 2 Change the engine oil filter* 18 24 Check the tension of the fan and alternator V-belts 10 EVERY 14 DAYS (every 100 hours of operation) 3 Check the engine valve clearances See the engine instr. manual 32 Clean the outside of the radiator 14 34 Check the drum gearbox oil level (only CA 25D and CA 25PD after serial No. 4972262,incl.) 14 D EVERY THIRD WEEKS (every 150 hours of operation) 3 Change the engine oil WV B 2 Change the engine oil filter 18 EVERY MONTH (every 200 hours of operation) 4 Clean the air cleaner dust collector 20 5 Change the hydraulic oil filters (two) 19 7, 28 Check and, if necessary, adjust the brakes 8,21 9 Check the fluid level in the brake cylinder a E uv Check the oil level in the 3-speed gearbox and pump drive 2 D a Check the oil level in the rear axle planetary gears 24 D au Change the oil level in the rear axle differential 24 D 33 Lubricate the tachometer cable 22 B * Only on new or reconditioned engines. CA 25 M-10055-2 Eng 3aRef.no intig.1 Operation Lubricant ae, see page 1 EVERY THREE MONTHS (every 500 hours of operation) - Inspect the crankcase ventilation diaphragm See the 1 Top up the coolant system with corrosion inhibitor See the engine instr. manual 3 Adjust the engine valve clearances a 35 Change the hydraulic oil filter in the vibration valve pilot line (from serial No. 4972128, incl.) 24 EVERY SIX MONTHS | (every 1000 hours of operation) u Change the oil in the drum 26 D 25 brain the fuel tank 26 34 Change the oil in the drum gearbox (only CA 25D ‘and CA 25PD from serial No. 4972262, incl.) 27 D EVERY YEAR (every 2000 hours of operation) 2 Change the fuel filter 28 3 Bleed the fuel system 28 6 Change the oil in the hydraulic oil tank 30 © v Change the oil in the pump drive and 3-speed gearbox 32, 33 D 21 Change the oil in the rear axle differential 35 D 21 Change the oil in the rear axle planetary gears 34 D 32 Flush the cooling system 29 engine instr. manual 3b! CA 25 M-10055-2 EngMAINTENANCE SCHEDULE Roller with Deutz engine IDEUTZ FEL 912 4 13 12 ca 25-12874-2 2 Service points on rollers fitted with Deutz engines Fuel filter Engine Air cleaner Hydraulic oil filters (two) Hydraulic oil filler cap Handbrake, foot brake Battery Brake cylinder (foot brake) Indicating pin (drum oil level check) Filler plug - drum oil Sight glass - drum oil Frame bearing Rubber element and retaining bolts Steering pivot Steering cylinder 3-speed gearbox and pump drive Universal joint ‘Tyre pressures 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 Wheel nuts Oil levels in rear axle Engine oil filter Fuel tank filler pipe Engine V-belts Fuel tank drain plug Diesel fuel feed pump Injection pump Brakes Scraper Engine valves Engine cooling fins Hydraulic oil cooler Tachometer cable Drum gearbox (only on CA 25D and cA 25PD) Vibration valve filter V-belt monitor CA 25 M-10055-2 Eng 3emre? Operation Page papel DAILY (every 10 hours of operation) 3 Check the engine oil level 7 B 6 Check the oil level in the hydraulic ofl tank 8 c 7, 28 Test the handbrake and the foot brake 8 23 Fill the fuel tank 8 29 Adjust the scraper setting 6 EVERY WEEK (every 50 hours of operation) 3 Change the engine oil * 19 B 4 Clean the air cleaner filter element. Check that oil hoses and connections do not leak. 9 6 check that the hydraulic oil tank breather holes are not clogged 10 8 Check the battery aL 2 Check the oil level in the drum u D 4 Check the rubber elements and retaining bolts 12 15 Lubricate the steering pivot 12 A 16 Lubricate the steering cylinder mountings 12 A 18 Lubricate the universal joint 13 A 19 Check the tyre pressures 3 20 Check the wheel nuts 13 22 Change the engine oil filter * 19 EVERY 14 DAYS (every 100 hours of operation) 24 Check the tension of the fan and alternator V-belts 15 26 Clean the feed pump strainer 4 27 Check the oil level in the injection pump 15 B 31 Clean the engine cooling fins 15 32 Clean the outside of the hydraulic oil cooler 15 34 Check the oil level in the drum gearbox (only CA 25D and CA 25PD from serial No, 4972070, incl) 14 D 36 Check the V-belt monitor 16 EVERY MONTH ! (every 200 hours of operation) 3 Change the engine oil 19 B 4 Clean the air cleaner dust collector 20 5 Change the hydraulic oil filters (two) 19 7,28 Check and, if necessary, adjust the brakes 8,21 9 Check the fluid level in the brake cylinder 21 E uv Check the oil level in the 3-speed gearbox 22 D uv Check the oil level in the pump drive 22 21 Check the oil level in the rear axle planetary gears 24 2 Check the oil level in the rear axle differential 24 D 22 Change the engine oil filter 19 30 Check the engine valve clearances 20 33 lubricate the tachometer cable 22 B EVERY THREE MONTHS (every 500 hours of operation) 35 Change the hydraulic oil filter in the vibration valve pilot line (from serial No. 4972128, incl) 24 * Only on new or reconditioned engines CA 25 M-10055-2 EngRef.no Lubricant intig.1 Operation Page see page 1 EVERY SIX MONTHS ‘(every 1000 hours of operation) 2 Change the fuel filter element 25 3 Bleed the fuel system 25 1 Change the oil in the drum 26 D 25 Drain the fuel tank 26 34 Change the oil in the drum gearbox (only CA 25D ‘and CA 25PD from serial No. 4972070, incl) 27 D EVERY YEAR (every 2000 hours of operation) 6 Change the oil in the hydraulic oil tank 30 c 7 Change the oil in the pump drive and in the 3-speed gearbox 32,33 D a Change the oil in the rear axle differential 35 D 21 Change the oil in the rear axle planetary gears 34 D CA 25 M-10055-2 Eng 5AS NECESSARY Adjusting the scraper Fig. 3 DAILY (every 10 hours of operation) CATERPILLAR 3208 ENGINE Radiator — checking the coolant level Checking the oil level Fig. 5 1 Dipstick 2 Filler cap Adjust the scraper setting as follows: 1 Back off all four retaining bolts. 2 Set the scraper approx, 10 mm away from the drum. 3. Tighten the retaining bolts. The scrapers on certain machines may be individually adjusted. Carry out adjustment to the same dimension as above, The cooling system should be at operating temperatu- re and the engine should be stationary. 1 Place a piece of cloth or the like over the fil- ler cap and turn the cap to the first stop. When the pressure has fallen, press dow the cap, turn it and remove it. The coolant level should reach the level tab in the radiator. 2 I£ necessary, top up with water and corrosion in- hibitor (CAT 3P044 or equivalent). In winter, add anti-freeze. CAUTION! The coolant is preseurtsed. If the cap te removed quickly, coolant will be released in the form of steam and may cause sertoue injury. Use gloves and protective goggles. 1 Drive the roller onto a level surface and switch off the engine. 2 Remove the dipstick (1) and check the oil level. 3. If the ofl is close to the lower mark, top up with type A\ oil as recommended in the section entitled "Lubricants" on page 1. CA 25 M-10055~2 EngDraining the water trap Fig. 6 ch 25-1321 DEUTZ F6L 912 ENGINE Engine — checking the oil level Fig. 7 Checking the oil Level Upper level mark Lower level mark Dipstick Drain plug Oil filler cap ‘The glass container must never be more than half- full of water. 1 Drive the roller onto a level surface and stop the engine. Remove the dipstick (1) and check the oil level. If the oil is close to the lower mark, top up with type A\ oil as recommended in the section entitled "Lubricants" on page 1. CA 25 M-10055~2 EngHydr. oil tank — checking the level I Drive the roller onto a level surface and check the level of the oil in the sight glass. A — 2 I£ the oil is close to the LOW mark, top up to B| the FULL mark with type A\ oil as recommended in the section entitled "Lubricants" on page 1. Fig. 8 Oil level - Hydraulic tank A Full B Low Filling up with fuel 1 Fill the fuel tank up to the lower edge of the filler pipe every day. Use diesel fuel. Fig. 9 Filler pipe Handbrake — adjustment I 1 The brake is correctly adjusted when it is just possible to pull the lever right up. | 2 Adjust the brake by turning the lever handle clockwise. 3 The handbrake on rollers equipped with a Renondin gearbox may be adjusted in three ways: a By turning the brake lever handle. Fig. 10 b By adjusting both of the brake cable connections. © By adjusting the brake Fig. 1 Foot brake — testing Test the action of the foot brake. If necessary, ad- just in accordance with the instructions on page 21. 8 A 25 M-10055-2 EngEVERY WEEK (every 50 hours of operation) Aircleaner — cleaning the filter element Fig 12. Air cleaner 1 overcentre catch 2 Wing nut with sealing washer 3 Inner cover 4 Filter element 5 Filter housing A 7 Cleaning with compressed air 8 Fig. 13. Blowing the filter element clean with compressed air Cleaning by washing 9 Discard the filter element after tt has been washed 6 times. Do not fit a filter element that has been washed in deter- gent, until tt is completely dry. CA 25 M-10055-2 Eng Release the overcentre catches (1) and remove the outer cover. Remove the wing nut (2) with sealing washer. Remove the inner cover (3) if it is loose, If the inner cover te firmly attached to the fil- ter element, ib will not be necessary to remove it except when changing the element. Remove the filter element (4). Check whether any dust has penetrated the filter. gust adhering to the inside of the engine induc~ tion pipe indicates dust penetration. If dust has penetrated the filter, thie will be a eign that the connection, hoses or the element Leak and mist therefore be changed. Wipe the inside of the filter housing and the in- duction pipes clean, using a clean cloth. Check that the connections and the hoses between the filter housing and the engine are intact and do not leak. t the hose clips in paire (in oppoatte direc- tions) and tighten them securely. Use compressed air at a maximum pressure of 0.7 MPa (7 kgf/cm”). Play the compressed air up and down along the folds of the paper on the outside of the filter element. Hold the nozzle at least 2-3 cm away from the element to avoid biowing the paper to pieces. If the filter element is sooty or oily, it should be washed in a solution of water and non~foaming detergent, such as "Donaldson D-1400" Immerse the element in the detergent solution and leave it for at least 15 minutes. Raise and lower the element in the solution from time to time to improve the cleaning effect.10 Check that the filter element is intact before refitting it. If it has any holes or if the seals are defective, fit a new element. Ll Wipe the inner cover clean, fit the element into the filter housing and tighten the element and the inner cover firmly by means of the wing nut. 12 Wip the outer cover clean and refit it. Check the outer cover seals and replace any that are damaged, iter element ~ checking for tightness Fig. 14 V-belt tension — checking 1 Check the tension of the cooling fan, water pump and alternator V-belt by pressing them down with the thumb-at a point mid-way between the alterna~ tor pulley and the water pump pulley. It should not be possible to depress the belts by more than 6-7 mn. Fig. 15 _ Tensioning the V-belts 1 Back off the alternator retaining bolts A slight ly. 2 Press the alternator outwards until the V-belts are again correctly tensioned. 3 Tighten bolts A. If the fan guards have been removed, they must be Trius replaced before the engine te started and the Fig. 16 Tensioning the V-belts roller is moved. 1 Alternator 3. Crank shaft 2 Water pump ater Hydraulik tank filler cap — breather holes Remove the filler cap and check that the breather holes are not clogged. I£ necessary, wash the filler cap in hydraulic oil or diesel fuel and blow it dry with compressed air. Fig. 17 Filler cap ~ hydraulic oil tank 1_ Breather holes 10 CA 25 M-10055-2 EngBattery — checking the electrolyte level 1 Tip the seat forward. 2 Wipe the top of the battery clean. Fig. 18 Battery 3. Remove the cell plugs and check that the level of the electrolyte is approx. 10 mm above the plates. Check all the cells. If the level is lower, top up to the correct le~ ! vel with distilled water. If the air temperature 10mm is below freezing, run the engine for a while after adding the distilled water, since the water einem?) may otherwise freeze. Fig. 19 Battery electrolyte level 4 Check that the breather holes in the cell plugs Pane eee are not. clogged. Then replace the plugs. Seta 5 The cable terminals should be clean and securely tightened. If they are corroded, clean them and Hever use ¢ naked flane when coat then with petroleum jelly. checking the electrolyte Level since explosive gas ts formed in the battery when it ie being charged. Drum — checking the oil level 1 Drive the roller onto a level surface, so that the red pin (1) is level with the beam. 2 The oil level should reach approximately halfway up the sight glass (2). 3 Top up as necessary, using type Ay oil as recom mended in the section entitled "Lubricants" on page 1, but not more than half-way up the sight glass. Fig. 20 Checking the oil level in the drum 1 Level pin 2 Sight glass 3. Filler plug CA 25 M-10055-2 Eng 1‘Shock absorbes and retaining screws = checking Steering pivot — lubrication Fig. 21 Grease nipples ~ steering pivot, Hake sure that nobody is in the vicinity of the eteering pivot while the engine is running. They could be crushed if the ateering 1s operated. Steering cylinders — lubrication Fig. 22. Grease, nipples ~ steering cylinders Check that the shock absorbers are undamaged and that the retaining screws are firmly tightened. Change the shock absorbers when the cracks in them are 20-25 mm deep. 1 Turn the drum section to the left so that all the steering pivot grease nipples on the right- hand side are accessible. Wipe any dirt and grease off the four nipples 3 Grease each nipple with five strokes of the grease gun. Check that grease enters the bearings. 4 ‘Turn the drum section to the right and apply grease to the nipples on the left-hand side of the steering pivot in the same manner. use type A\ grease as recommended in the section entitled "Lubricants" on page 1. Leave a little grease on the nipples after grea~ sing, to prevent dirt from entering them. If the grease does not enter the bearings, tt may be necessary to relieve the steering pivot of load, using a jack, and then repeat the lubrica~ tion’ procedure. Grease the left-hand steering cylinder mounting immediately after greasing the steering pivot. 1 Wipe any dirt and grease off the two nipples. 2 Grease each nipple with three strokes of the grease gun. Check that grease enters the bearings. use type A\ grease as recommended in the section entitled "Lubricants" on page 1. Leave a little grease on the nipples after grea~ sing, to prevent dirt from entering them. 3 Grease the two nipples on the right-hand steering cylinder in the same manner. Check that grease enters the bearings. 12 CA 25 M-10055-2 EngUniversal joint — lubrication Fig. 23. Grease nipples - universal joint Tyre pressures 2 550Nm (Sskom) Fig. 24 Wheel 1 Air valve 2 Wheel nut Whee! nuts — tightening The grease nipples on the sible from underneath the 1 Crawl urider the roller nipples are accessible It may be necessary to universal joint are acces~ roller. and check that the grease with the grease gun. drive the roller forward slightly, to rotate the universal joint and move the nipples into an accessible position. ‘TOW! Hever work under the roller while the engine is running. 2 Wipe any dirt and grease off the two nipples. cau! 3. Grease each nipple with two strokes of the grease gun, Check that grease enters the bearings. Use type A\ grease as recommended in the section entitled "Lubricants" on page 1. Leave a little grease on the nipples to prevent dirt from ente~ ring them. Check the tyre pressures, using the tyre pressure gauge included in the roller tool kit. ‘The minimum,tyre pressure should be below 0.11 MPa (1.1 kgf/em*) and the maximum tyre pressure should not exceed 0.15 MPa (1.5 kgf/cm*) Check that the wheel nuts are tightened with a tor~ que of 550 Nm (55 kgf m). CA 25 M-10055-2 Eng 13EVENT 14 VATS (every 100 hours of operation) Drum gearbox — checking the oil level Fig. 25 Topping up with oil 1 2 Level/drain plug Filler plug ' Radiator — cleaning the outside Feed pump strainer — cleaning Fig. 26 Feed pump Retaining bolt Gover Gasket Strainer This only applies to rollers with sertal Nos. above 492 22 62 or 497 20 70. Drive the roller onto a level surface so that the filler plug (2) is at its uppermost position on the drum, Wipe any dirt and grease away from the area around the plugs. Remove the plugs and check that the oil level is up to the level plug. If necessary, top up with type As oil in accor- dance with the section entitled "Lubricants" on page 1. Replace the plugs. Check that air can flow freely through the radiator. If the radiator is dirty, clean it by flushing with water or blowing with compressed air. After cleaning, check that any seals and sound~ab- sorbers are not damaged. 1 Back off the bolt (1). 2 Remove the cover (2). 3 Remove the strainer (4) and wash it in diesel fuel. 4 Lubricate the gasket (3) with clean diesel fuel. 5 Assemble in the reverse order. 6 Bleed the fuel system (see the section entitled "Bleeding"). Start the engine and check that there is no leakage. CA 25 M-10055-2 EngInjection pump — checking the oil level This only applies to engines without central lubrt- cation. 1 Back off the plug (1) about 3 turns, so that any surplus oil and fuel mixture will run out. 2 Top up with type A\ ofl as recommended in the section entitled "Lubricants" on page 1, through filler plug hole (2) up to level plug (1). 3. Refit both plugs and tighten them. Oil volume: approx. 0.48 litres. Fig. 27. Injection pump 1 Level plug 2 Oil filler plug Engine cooling fins — cleaning 1 Remove the rear engine compartment cover on the left-hand side of the roller and open the bonnet. 2 Release the catches and remove the air ducting from the engine. 3 Clean the cooling fins carefully, preferably using compressed air. Fig. 28 Engine - cooling fins Hydraulic oll cooler — cleaning the Check that air can flow freely through the cooler. ee If the cooler is dirty, clean it by flushing it with water or blowing it clean with compressed air. Open the "cooler door" when carrying out cleaning. After cleaning, check that seals and sound-absorbers are not damaged. ALTERNATOR V-BELT TENSION Checking 10-15mm 1 Check the V-belt tension by pressing the belt midway between the alternator pulley end the crankshaft pulleys. Tt should not be possible to depress the belt by more than 10-15 am. If the deflection is greater, the belt must be tensioned. At the same time, check that the V-belt monitor for the fan belt operates satisfactorily. The horn should sound when the V-belt monitor contact (2 in Fig. 31) is depressed. If the V-belt monitor does not operate satisfac- tovily, it should be repaired immediately. Fig, 29 Checking V-belt tension CA 25 M-10055-2 Eng 15Adjusting Fig. 30 Tensioning the alter- nator V-belt COOLING FAN V-BELT ‘V-belt monitor Fig. 31 Checking the V-belt and V-belt monitor 1 Belt tensioner 2 V-belt monitor V-belt monitor — checking V-belt failure or replacement 1 Back off the alternator retaining bolts B and C and nut D. 2 Then press the alternator outwards until the belt is again correctly tensioned (see above). 3 Then tighten bolts B and C and nut D. Tension a new alternator V-belt again after 40 hours of operation, ‘The V-belt is tensioned by a spring-loaded belt ten- sioner (1). If the V-belt should break, the belt ten sioner will be moved outwards by the spring and will actuate the switch on the V-belt monitor (2) causing the horn to sound. The V-belt monitor is also operative when the con- tact key is in the "OFF" position. Deutz Fel 12 Depress the switch (2 in Fig. 31). The roller horn should sound. If the alarm device is defective, it should be repaired immediately. 1 Stop the roller inmediately. Stop the diesel engine. Disconnect the battery lead from the battery, to stop the horn. 4 Fit anew V-belt (see the engine manufacturer's instruction manual). 5 Refit the battery lead and secure it. 16 GA 25 M-10055-2 EngEVERY THIRD WEEK (every 150 hours of operation) CATERPILLAR 3208 ENGINE Engine — deviations fromthe normal oi1 change intervals depend on the grade of the dil changing interval lubricating oil and the sulphur content of the fuel. Trreepective of the number of Changing the oil every week or every 150 hours of houre of operation, the engine operation is conditional on the use of engine oil 21 and engine ott filter met of grade "Sor API Service CD, SAE" and on the use of be changed every ed months, diesel fuel of good quality, with a sulphur content The otf filter must aluaye be below 0.42. veplaced when the engine oti ie changed. If oil of grade "For API Service CC/SC, SAB" is used or if the sulplyr content of the diesel fuel is 0.4% or above, the oil should be changed earlier and more frequently (see the engine manufacturer's instruc— tions). Engine — changing the oil 1 Warm up the engine thoroughly before draining the oil. Impurities in the lubricating system will then be well mixed with the oil and will be removed with it, Furthermore, the oil flows more readily when it is hot. 2 Clean the area around the oil filler cap (1) and then remove the cap. Fig. 32 Filling up with ofl - engine 1 Oil filler cap Clean the area around the drain plug (1) and place a receptacle under the plug. This recep~ tacle should hold at least 15 litres. Remove the drain plug and allow the oil to drain into the receptacle. Allow the oil to drain out while changing the oil filters. Wipe the drain plug clean. Fit it back into place and tighten it securely. Pig. 33 Draining the engine oil 1 Drain plug CA 25 N-10055-2 Eng 7Engine — changing the oil filter 1 a 25-1288L-1 Fig. 34 Oil filters ~ engine 1 oil filters Do not tighten the filters too hard, since this may damage the seals. Engine — filling up with oit Fig. 35 Oil level - engine 1 Oil filler cap 2 Dipstick 1 Remove both oil filters (1) and discard them, They are of disposable type and cannot be clean~ ed. Eneure that the old seals are not left on the filter head since leakage will then occur be~ tween the new and old seals. 2 Clean the sealing surfaces of the filter head with a clean, lint-free cloth. 3. Apply a thin layer of clean engine oil to the new filter seals. 4 ‘Tighten the filters by hand until the seal seats against the filter head. Then tighten an addi- tional half-turn. 1 Fill up with fresh type A\ oil as recommended in the section entitled "Lubricants" on page 1. Oil required: 12.5 Litres when changing the fil- ters. 11.4 litres when the filters are not changed. The quantities of oil required for engines with se- rial Nos. above 90N44128 or with recalibrated dip- sticks art 14,5 litres, when changing the filters 13.5 litres, when the filters are not changed 2 Check the engine ofl level with the dipstick (2). The level should be up to the FULL mark. Do not overfill since this may cause damage to the crank shaft packing boxes. 3 Refit the filler cap (1), Tighten it firmly, en- suring that it seals satisfactorily. 4 Start the engine and warm it up. Check that there are no oil leaks. 18 CA 25 M-10055-2 Eng ——————— 8 2| Fig. 38 Changing the ofl filter ' EVERY MONTH (every 200 hours of opera! Hydraulic system — chan; Fig. 36 Oil filter 1 Oil filter - retu: 2 Oil filter - suct: DEUTZ F6L 912 ENGIN! Engine — changing the oil Fig. 37. Changing th Upper level mark Lower level mark Dipstick Drain plug Oil filler cap Engine — changing the ol tion) ging the filter ion e oil it filter 1 Remove the oil filters (1) and (2). Discard the filters. They are of disposable type and cannot be cleaned. Enaure that the old seals are not left in post- tion, Leakage will otherwise occur between the new and old seats. 2 Thoroughly clean the sealing surfaces of the fil- ter holders. Apply a thin layer of hydraulic ofl to the seals of the new filters. 4 Screw the filters into place by hand. First screw the filter in until its seal seats against the filter head. Then tighten an additio- nal half-turn. 5 Start the engine and check that no hydraulic oil leaks out around the filters. When the engine is hot, remove the rear engine com- partment cover on the left-hand side of the roller. 1 Remove the filler cap (5). 2 Remove the drain plug (4) and allow the oil to drain out into a suitable receptacle while re- placing the oil filter. 3 Clean the drain plug (4) and refit it into place. 4 Fit a drift or screwdriver into the shoulder on filter A and slacken the filter. 5 Then unscrew the filter by hand. 6 Clean the sealing surfaces on the filter holder. 7 Lightly oil the rubber seal B on the new filter. 8 Screw the filter into place by hand until the rubber seal seats correctly and then turn an addi- tional half-turn, CA 25 M-10055-2 Eng 19Engine — filling up with oil 9 Fill up with new type A\ oil as recommended in the section entitled "Lubricants" on page 1. Oil required: Approx. 12 litres. 10 Check the oil level with the dipstick (3). The level should be at the upper mark ~ 1. If neces- sary, top up with more oil. Ll Refit the filler cap. 12 Start the engine and wari it up. Check that there are no oil leaks. Valve clearances — checking and adjusting 4 Open the bonnet end lift up the lower engine com- p partment cover. Remove the rocker covers. Adjust the valve clearances as follows, when the en- J, 2 gine is cold: $ 3 1 Fit a 36 mm non-adjustable spanner to the crank- B e shaft nut and use it to turn the engine until Fi fee both valves in one cylinder are fully closed. (The push-rods (3) are then under no load and can be turned easily with the fingers.) NewS 2 Use a feeler gauge to check that the valve clear~ ance is 0,15 mm at the exhaust and inlet valves. 3 If necessary, adjust the clearances by backing Fig. 39 Engine - adjusting off the locknut (2) by 1-2 turns. Then turn the the valve clearances adjusting screw (1) until the feeler gauge (0.15 2 mn) can be withdrawn against slight resistance. eee Tighten the locknut again. 3, Push-rod 4 Repeat this procedure on the other cylinders. 4 Rocker arm 5 Valve 6 Feeler gauge Air cleaner — cleaning the dust 7 collector A Under extremely dyety condi- 1 Release the catch (1) and remove the dust collec- tions the dust-Ollector tor (2). should be.r7éaned every week > Empey the duet collector and wipe it clean. 3 Clean the "Donaclone" tubes (3), using a bottle~ cleaning brush or equivalent. If the tubes cannot be cleaned, remove the housing (4) for the "Donaclone" tubes. The tubes can then be blown clean with compressed air or washed in water at a maximum temperature of 65°C. 4 Assemble in the reverse order. Check the seals and replace any that are damaged. ca seas Check that the hoses and connections do not leak. Fig. 40 Air cleaner The dust collector ts fitted with a self-discharging 1 Catch valve (5). This valve discharges dust and water con- 2 Dust collector tinuously. 3 "Donaclone" tubes 4 Filter housing 5 Sel£-discharging valve 20 CA 25 M-10055~2 EngBrake cylinder — checking the fluid level Fig. 41 1 Filler cap Foot brake — adjusting Checking the fluid 1e- vel ~ brake cylinder Never work under the voller while the engine is running Fig. 42 Adjusting the brake 1 Cams shoes 1 ‘Thoroughly clean the area around the filler cap (1) and renove the cap. 2 Check that the fluid is up to the bottom of the filler hole, If necessary, top up with brake fluid. Use type A\ brake fluid in accordance with the section entitled "Lubricants" on page 1. If the fluid level is normal end there is no leakage in the braking system, but the brake pedal must be depressed a long way before the brakes act, it will be necessary to adjust the brake shoes. This adjustment compensates for brake lining wear. Adjustment is carried out by means of the cams on the backplate. These are accessible from underneath the roller. There are two cams on each brake - one for each brake shoe. All cams must be adjusted. 1 Turn the cam (1) until the brake lining is in contact with the brake drum. 1 Turn the cam (1) until the brake lining is in contact with the brake drum. 2 Turn the cam back until the brake lining is just clear of the drum. Adjust the other brake shoes in the same manner. Drive the roller a few hundred metres, without using the brakes. 5 Feel the brake drums with your hand. Tf a brake drum is hot, this is a sign that one or both of the brake shoes are in contact with it. In this case, turn the cam back a little further. Allow the brake drums to cool and then give the roller another trial run in the same manner. 6 ‘Then drive the roller and apply the brakes to check that they act satisfactorily. CA 25 M-10055-2 Eng 21‘Tachometer cable — lubricating 3-speed gearbox — checking the oil level 2 Fig. 43 Checking the oil level = 3-speed gearbox 1 Level plug 2 Drain plug Funk pump drive — checking the oil level Fig. 44 Checking the oil level 1 Filler plug 2 Level plug 3. Drain plug Release the cable at the tachometer and pour type A\ Oil in between the sheath and the cable. ‘The 3-speed gearbox is available in two versions, i.e. Funk and Renondin, These instructions apply to both versions. 1 Ensure that the roller is standing on a level surface when checking the oil level. 2 Clean the area around the level plug (1) and re~ move it. 3 Check that the oil reaches up to the plug hole. If the oil level is low, top up with type A\ oil as recommended in the section entitled "Lubri- cants" on page 1, Top up with oil through the level plug (1) hole. Refit the plug and tighten it securely. Ensure that the roller is standing on a level sur face, 1 Clean the area around the level plug (2) and back the plug off a few turns. Oil should run out if the oil level is correct. 2 If necessary, top up with oil through the filler plug (1) hole until the oil runs out through the level plug (2) hole. Clean the area around the filler plug and before removing the plug. Fill up with type.A\ oil as recommended in the section entitled "Lubricants" on page 1. A level plug ts located on each side of the pump drive. The oil level need only to be checked on one side. 22 CA 25 M-10055-2 EngPrometheus pump drive — checking the oil level Fig. 45 Checking the oil level 1 Filler plug 2 Level plug with dipstick 3. Drain plug Renondin pump drive — checking the oil level 3. Ge as-iss29-1 Figs 46 Checking the oil level 1 Filler plug 2 Level plug 3. Drain plug Dynapac pump drive — checking the oil level Figs 47 1 Filler plug 2 Level plug 3._Drain plug CA 25 M-10055-2 Eng checking the oil level Ensure that the roller is standing on a level sur~ face before checking the oil level. 1 Clean the area around the level plug (2) and re~ move the plug, using a 14 mm socket wrench. The level plug is fitted with a dipstick. 2 Remove the dipstick and check the oil level. It should be up to the mark on the dipstick (only on the Prometheus pump drive). 3. If necessary, clean the area around the filler plug (1), remove it and top up with oil through the filler plug (1) hole. Use type A\ oil as recommended in the section entitled "Lubricants" on page 1. 4 Refit the filler plug and the level plug with dipstick. 23— checking Rear axle planetary 9 the oil level 2 Dera Fig. 48a Checking the oil 1e~ vel - planetary gear 1 Filler and Level plug 2 Drain plug 3. Mark - oil level Rear axle differential — checking the oil level Fig. 48 Checking the oil 1e~ vel - differential 1 Level plug 2 Drain plug EVERY THREE MONTHS (every 500 hours of operation) Vibration valve pilot line — changing the filter element (rollers with serial No, 4972128 and above) ~ Ch 25-13301-1 Fig. 49 Pilot Line Drive the roller onto a level surface until the level plug (1) on one of the planetary gears is in the correct position. The mark (3) on the pla~ netary gear housing should then be horizontal. Remove the level plug and check that the oil is up to the plug hole, If the oil level is low, top up with oil to the correct level through the level plug hole. ‘Top up with type A\ oil as recommended in the section entitled "Lubricants" on page 1. Check the oil level on the planetary gear on the other side in the same manner, Ensure that the roller is standing on a level surface. Remove the level plug (1) and check that the oil is up to the level plug hole. If the level is low, top up with oil to the cor- rect level through the level plug hole. Top up with type A\ of1 as recommended in the section entitled "Lubricants" on page 1. CAUTION Hever work under the roller while the engine to running. 1 Clean the area around the filter. 2 Remove the filter housing and replace the filter element. 3 Refit the filter. Start the engine and check that the filter does not leak. 24 CA 25 M-10055~2 EngEVERY SIX MONTHS | (every 1000 hours of operation) DEUTZ F6L 912 ENGINE Fuel filter — replacement 1 Unscrew filter A with care, since fuel will flow from the filter. Clean sealing surface B. 3 Apply clean diesel fuel to the rubber gasket on the new filter. 4 Screw the new filter into place by hand until the rubber gasket has seated correctly and then turn an addition half-turn. Fig. 50 Replacing the fuel 5 Bleed the fuel system (see below). filter Start the engine and check that | the filter does not Leak. Fuel system — bleeding Deutz F6L 912 1 Back off the bolt (1). 2 Manually operate the pump lever (2) on the feed pump until the fuel flowing out at the bolt (1) is free from air bubbles. 3. Retighten the bolt (1). If no fuel flows out past the bolt when the hand pup te operated, turn the engine over using a 36 im non-adjustable spanner fitted to the crankshaft mut. Fig. 51 Fuel system 1 Serew 2 Pump lever 4 If the pressure lines have been disconnected, they must also be bled. 5 Back off the pressure line coupling (1) a couple of turns and run the starter motor until bubble- free fuel flows out past the nut. The throttle should be in the fully open position. 6 Tighten the pressure line connection. 4 7 Bleed the other pressure lines in a similar man~ ner, if necessary. Fig, 52 Bleeding the pressure Lines 1 Coupling nut CA 25 M-10055-2 Eng 25Drum — changing the oil 2 2 Sight glass 3. Drain plug Fig. 53a Changing the oil Fig. 53b Filling up with oil 1 2 Level pin Sight glass 3 Filler/drain plug Fuel tank — draining the water Fig. 54 Fuel tank 1 Drain plugs ¥ 1 rive the roller onto a slight incline, so that the drain plug (3) is in the lowest position. 2 Remove the plug and drain the oil. Drain the oil into a euttable receptacle. 3 Serew the plug back into place and drive the rol- ler onto a level surface so that the red pin (1) is opposite the beam. 4 The normal ofl level is half-way up the sight glass. 5 Fill up with type A\ lubricating oil as recom mended in the section entitled "Lubricants" on page 1, although not beyond half-way up the sight glass (2). 6 Change the oil in the other side of the drum as described in 1-5 above. Water and sediment in the fuel tank can be drained through the drain plugs (1) in the bottom of the fuel tank. The water should be drained when the roller has been stationary some time - such as overnight. The roller should preferably be left with one side slightly higher than the other, so that the water and sediment will collect at one of the drain plugs. Drain as follows: 1 Clean the area around the lower drain plug. 2. Remove the plug and drain the water and sediment until only clean diesel fuel flows out of the drain plug hole, Then screw the plug back into place. Do not drain all the fuel, since atv may then enter the fuel aysten, 26 CA 25 M-10055-2 EngDrum gearbox — changing the oil (ca 25139261 Fig. 55 Draining the oil 1 Drain/level plug 2 Filler plug Fig, 56 Filling with oil 1 Level/drain plug 2 Filler plug This only applies to rollers with serial Nos. 497 20 62 and above or 497 20 70 and above. The system should be at operating temperature before the oil is drained. 1 Drive the roller onto a level surface so that the drain/level plug (1) is at the lowest position. 2 Clean the area around the plugs. 3 Place a receptacle under the drain plug (1) and drain the oil. The receptacle should hold 3.5 litres. Also remove plug (2). 4 Move the roller backwards so that filler plug (2) is in the highest position. 5 Fill up with oil through the filler plug hole (2) until the of1 level reaches the level plug (1). Use type A\ ofl as recommended in the sec~ tion entitled "Lubricants" on page 1. Oil required: approx. 3 litres. 6 Refit the plugs. CA 25 M-10055-2 Eng 27EVERY YEAR (every 2000 hours of operation) CATERPILLAR 3208 ENGINE Fuel filter — replacememt Fig. 57 Fuel filter 1 Filter Fuel system — bleeding Fig, 58 Bleeding the fuel system 1 Bleed screw Fig. 59 Bleeding the fuel sys~ tem 1 Hand pump 1 Remove the fuel filter (1) and discard it. It is of disposable type and cannot be cleaned. 2 Clean the sealing surface of the filter holder. Ensure that the old seal ts not left in position on the filter head, since it will cause Leakage between the new and the old seals. 3. Apply a thin film of diesel fuel to the new fil- ter seal. 4 Serew the filter into place by hand. First screw the filter into place, until the seal seats against the filter head and then tighten an additional half-turn. 5 Bleed the fuel ‘system (see below). If air has entered the fuel system, the engine will either fail to start or it will misfire. The fuel system must then be bled. 1 Stop the engine. 2 Back off the bleed screw (1) on the top of the fuel pump. 3 Operate the hand pump (1) until the fuel flowing out at the bleed screws flows in a steady stream and is completely free from air bubbles. Do not pump out more fuel than necessary, Do not use the hand pump when the bleed screw is tightened. The pump handle is secured in the closed position. To release it, turn the handle anti-clockwise un- til it is loose. When the bleeding operation is complete, secure the handle again by pressing it in and turning it clockwise until resistance is met. 28 CA 25 .M-10055-2 EngFig. 60 Bleeding a fuel line 1 Nut 2 Fuel line Engine — flushing the cooling system Fig. 61 Draining the cooling system 1 Filler cap 2 Drain plug - radiator 3. Drain plugs caution! the coolant is pressurised. If the radiator cap is removed quickly, coolant will flow out in the form of eteam and may equse sertous injury. Use gloves and protective goggles. Tighten the bleed screw. Start the engine. If the engine misfires or runs unevenly, bleed the lines to the injection nozzles. @ To do this, back off the nut (1) at the injec~ tion nozzle and allow fuel to flow freely un~ til it does so evenly and contains no air bubb- les, Then tighten the nut again. ‘@ Bleed one line at a time, until all the lines have been bled. @ Bleed the fuel lines while the engine is run- ning. The cooling system should be cleaned once a year, to flush out Elakes of rust and sediment. The coolant must also be changed once a year, as the corrosion inhibitor loses its effiectiveness. The cooling system should be cleaned when the engine is cold. 1 Drive the roller onto a level surface. 2 Remove the radiator filler cap (1). 3. Open the drain cock (2) at the bottom of the ra~ diator. 4 Remove the four drain plugs (3) in the cylinder block and on the engine oil cooler: @ One at the bottom connection to the radiator @ Two in the cylinder block - one on each side, near the flywheel casing @ One in the engine oil cooler (underneath) 5 Flush the cooling system with clean water. Insert a hose into the radiator filler neck and flush the system with water until the water flowing out at the drain plug holes is complete- ly free from flakes of rust and sediment. If there are hard deposits of lime or rust in the cooling systen, the eyeten may be cleaned using a special radiator cleansing agent. Use a good cleansing agent from a reputable manufacturer and follow the manufacturer's. instructions. See also CAT instructiona GEG 051 00-01. CA 25 -10035-2 Eng 29Hydraulic system — changing the oil The strictest cleanliness ts essential uhen servicing the hydraulic eyetem, to ensure trouble-free operation of the roller. Draining Peretret Fig. 62 Draining the hydraulic oil tank 1 Drain plugs 6 Refit the drain plugs and shut off the radiator drain cock, 7 Inspect the coolant hoses. Replace hoses that are cracked or show any other signs of defect. 8 Fill up with coolant to the level tab in the ra~ diator. The lime content of the water should be as low as possible. Always £111 the cooling system with one of the following two coolants: @ Clean water and corrosion inhibitor (CAT 3P2044 or its equivalent). @ 50 % clean water and 50 % anti-freeze (con- taining a corrosion inhibitor). 9 Start the engine and run it for 10 minutes. 10 Check the level of the coolant and, if necessary, top it up to the correct level. 11 Check that the cooling system does not leak. En- sure that any leaks are sealed. 12 Refit the filler cap. Change the oil in the hydraulic system when it is hot ~ at the end of a shift, for example. Oil flows more freely when it is hot and any impuri- ties will then be well mixed with the oil and they will flow out with it when the oil is drained. 1 Thoroughly clean the outsides of the tank drain plugs. 2 Procure a receptacle to hold at least 220 litres, to collect the oil. An empty oil drum or the like is a suitable re~ ceptacle. Place the drum beside the roller and allow the oil to flow in a hose from the drain plug to the oil drum. 3 Remove the drain plug which is in the lower posi- tion (1). Let the oil drain out. 30 CA 25 M-10055-2 Eng5 Fig. 63 Hydraulic tank 1 Cover plate 2 Filler cap 6 7 A Fig. 64 Suction strainer 1 Suction strainer 10 Remove the cover plate (1) on top of the hydrau~ lic oil tank, Take cave to prevent impurities from entering the tank. Clean the tank filler cup and filler strainer. Check that the strainer is intact. Remove the suction strainer (1) and wash it in hydraulic ofl, The suction strainer is bolted to the bottom of the hydraulic oil tank and is accessible when the cover plate has been removed. Clean the tank. The best way of doing this is to draw up the se~ diment from the bottom of the tank by means of a filter unit. If cloths or brusches are used they must be com~ pletely clean and free from dust. If the tank ie rinsed out with hydraulic ott, alt connections in the bottom of the tank mst be plugged to prevent impurities from entering the Iydraulie lines. Do not forget to remove these plugs after clearing. Refit the drain plug. Refit the suction strainer. Refit the cover plate. Pet a new gasket and use Loctite sealing. compound or tte equivalent to make a good seal. Enaure that no sealing compound enters the tank. CA 25 M-10055-2 Ene 31Filling up Fig. 65 Checking the oil level - hydraulic tank A Full B Low GEARBOXES AND REAR AXLE — CHANGING THE OIL 3-speed gearbox — oil changing Never vork under the roller when the engine is running iD Fig. 66 3-speed gearbox 1 Filler plug 2 Drain plug 11 Fill up with oil to the FULL mark on the sight glass. The capacity of the tanks is approx. 208 litres, use type A\ oit as recommended in the section entitled "Lubricants" on page 1. When filling the tank the oil should preferably be pumped through a filter unit. 12 Start the engine and operate the various hydrau- lic units. 13 Check the oil level and, if necessary, top up with more oil. All of1 changes should be carried out when the oil is hot ~ at the end of a shift, for example. Hot oil flows more readily and any impurities will then be well mixed with the oil and will run out with it when it is drained. The 3-speed gearbox is available in two versions, i.e. Funk and Renondin, The instructions below apply to both versions. 1 Drive the roller onto a level surface and stop the engine. 2 Clean the area around the filler plug (1) and the drain plug (2). 3 Place a receptacle with a capacity of about 5 litres under the drain plug (2). 4 Remove the filler plug (1) and the drain plug (2). Drain the oil into the receptacle. 5 Clean the drain plug and refit it. The drain plug is magnetic and attracts any iron particles in the oil. 6 Fill up with oil, through the filler plug (1) hole, until the oil reaches up to the bottom of the hole. The gearbox holds approx. 2.8 litres of oil. Use type AN oil as recommended in the section entitled "Lubricants" on page 1. 7 Refit the filler plug. 32 CA 25 M-10055-2 EngFunk pump drive — oil changing Fig. 67 Funk pump drive 1 Filler plug 2 Level plug 3° Drain plug Prometheus pump drive — oil changing Fig, 68 Prometheus pump drive 1 Filler plug 2 Dipstick 3 Drain plug 1 Drive the roller onto a level surface and stop the engine, 2 Clean the area around the filler plug (1), level plug (2) and drain plug (3). 3 Place a receptacle with a capacity of about 5 litres under the drain plug. 4 Remove the filler plug (1) and drain plug (3). Allow the oil to drain into the receptacle. 5 Clean the drain plug and refit it. ‘The drain plug is magnetic and attracts any iron particles in the oil. 6 Back off the level plug a few turns. ‘here is a level plug on each side of the pump drive. It is only necessary to back off one of them. 7 Fill up with oii until it flows out at the level plug hole. Use type Ay oil as recommended in the section entitled "Lubricants" on page 1. 8 Tighten the level plug end refit the filler plug. The instructions below are apply to the Renondin and Dynapac pump drives. 1 Drive the roller onto a level surface and stop the engine. 2 Clean the area around the filler plug (1) and the drain plug (3). 3 Place a receptacle with a capacity of approx. 5 litres under the drain plug. Remove the filler plug. Remove the drain plug and allow the oil to drain into the receptacle. Clean the drain plug and, when all the oil has drained, refit the drain plug. 7 Clean the area around dipstick (2) and remove the dipstick. Leave the dipstick in the opening (on~ ly on the Prometheus pump drive). cA 25 M-10055-2 EngRenondin pump drive — changing the oil Bis3329-1 19 Fig. 69 Checking the oil level 1 Filler plug 2 Level plug 3 Drain plug Dynapac pump drive — the oil Fig. 70 Checking the oil level 1 Filler plug 2 Level plug 3. Drain plug Rear axle planetary gears — changing the oil Draining the oi cn ata? 5 Planetary gear ~ draining the oil Fig. 71 1 Drain plug 2 Level plug Back off the level plug (2) a few turns. Fill up with oil until the level reaches the mark on the dipstick (only on the Prometheus pump drive). On Renondin and Dynapac pump drives, the oil should flow out past the level plug (2). Use type A\' oil as recommended in the section entitled "Lubricants" on page. 1. Screw in the level plug (2) and the dipstick (2) (see Fig. 68) and refit the filler plug (1). Drive the roller onto a level surface so that the drain plug (1) is at the lowest position. Stop the engine. Clean the area around the drain plug (1) and fil- ler plug (2). Place an approx. 2 litre receptacle under the drain plug. Remove the filler plug (2) and the drain plug (1). Collect the oil in the receptacle. Clean the drain plug and, when all the oil has drained, refit the plug. 34 CA 25 M-10055-2 Eng eeFilling up with oil Z erent Fig. 72 Planetary gear - filling up with oil 1 Level plug 2 Drain plug 3. Level mark Rear axle differential — changing the oil Never work under the voller uhen the engine te running Fig. 73 Differential 1 Filler and level plug 2 Drain plug Drive the roller so that the mark (3) on the pla~ netary gear housing is horizontal. Fill up with oil through the level plug (1) hole until the ofl level reaches the bottom of the hole. Use type A\ oil as recommended in the section entitled "Lubricants" on page 1. Refit the filler plug. Change the oil in the other rear axle planetary gear in the same manner. Drive the roller onto a level surface and stop the engine, Clean the area around the drain plug (2) and the filler plug (1). Place an approx. 15 litre receptacle under the drain plug. Remove the filler plug and the drain plug. Collect the oil in the receptacle. Clean the drain plug and, when all oil has drain- ed, refit the drain plug. Fill up with oil through the filler plug hole un~ til the oil level reaches the bottom of the hole The differential holds approx. 12.8 litres of oil. Use type AX oil as recommended in the section entitled "Lubricants" on page 1. Refit the filler plug. Ph 98 MAINNRS—? Eno 35OPERATING AFTER LIFTING 25-12956-1 Fig. 28 SAFETY RECOMMENDATIONS Remove the locking devices from both sides of the roller and fit then as shown in fig. 28. ‘@ Never leave the roller unattended with the engine running. @ Always chock the drum when the roller is parked on an incline. © Never carry passengers on the roller. © Always ensure the brakes are in good working order (see the maintenance instructions). @ Never carry out repairs or adjustments to the roller with the engine running. © Ensure nobody comes between the tractor section and the drum section of the roller when the engine is running, they risk being crushed if the steering is operated. Ensure that guards are always fitted over V-belts and rotating shafts. © Be observant on site, do not allow anybody to come into the path of the roller. © Use the horn to attract attention. © The sound of the horn on Deutz-engined models may indicate that the fan belt has broken. Park the roller in a safe place and stop the engine. © Drivers must familiarise themselves with roller operating and maintenance instructions before starting or driving the roller. CA 25 0-10055-3 Eng 13