~I

I MAINTENANCE MANUAL
I
I VIBRATING ROLLER CA35
12DG

I CONTENTS page page

Lubricants 01 Every 600 hours of operation 27

I Every 10 hours of operation. . . . . . . . . ..

Every 50 hours of operation. . . . . . . . . ..
Every 200 hours of operation
04
08
17
Every 1000 hours of operation
Every 2000 hours of coerat ion
29
29

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I READ ALL THROUGH THE INSTRUCTIONS BEFORE COMMENCING ANY SERVICE WORK.

I Proper maintenance is essential to ensure that the roller will give rrany years of sat i.s

I factory service and the instructions given here should therefore be carefully followed.

I Also keep the Caterpillar instruction manual near at hand.

I LUBRICANTS

Always use good-qua Li ty lubricants in the amounts indicated. Too mich grease or oiI

I will cause parts to run hot with rapid wear as a result.

J. A B C and D refer to the maintenance schedule.

A GREASE with Li, 'thium base and EP additive (lead oleate), NLGI No.2.
I Shell Alvania EP Grease 2

I B ENGINE OIL for API Service CC/SE, SAE

Viscosity at different air temperatures when starting:

I -
-
32~

12~
C and above
C - 0 C
SAE 10W/30
SAE lOW

I -

above
7 C - + 32
+ 32
C
C
SAE 20
SAE 30

I C HYDRAULIC OIL with anti-wear additive Shell Tellus TOil 68

D llJBRICATING OIL SAE 90 EP

I -01-

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39
29
19
2 32 1 8 20
33 35
5 24 7 10 21
36
12
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22 2S 17 16 3423 15
37
38
14 6 6 I
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MAINTENANCE SCHEDULE
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lItem Operation Page seel
in Fig.
Iubr .
page 1. I
Every day (every 10 hours of operation)
1 Check the engine oil level 5 B I
2 Check V-belt tension 6
3
4
O1eck the fuel level
Check the coolant level 4
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5
6
Check the oil in the hydrauli.c oil tank
Check the adjustment of the scrapers
5 C
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7 Adjust the parking brake

-02-
7
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I IItem
~n fig.
Operation Page
Lubr. see
page 1

I Every 50 hours of operation

8 Clean the air cleaner filter element 8

I 10
9 Inspect the breather holes in the hydra. tank filler cap
Check the battery electrolyte level
11
11

I 11
12
Check the oil level in the eccentric housing
Check the oil level in the drum torque hub
13 D
D
13 Check the cI:rum shock absorbers 14
I 14 Grease the steering pivots 14 A
15 Grease the steering cylinders 15 A

I 16
17
Grease the universal joint
Check the tyre pressure
15
16
A

I 18 Check the wheel nuts 16

Every 200 hours of operation

I 19 Change the engine oil and oil filters 17 B

20 Clean the' air cleaner dust collector 20
I 21
22
Check the fluid level in the brake cyli.nder
Check the adjustment of the emergency brake
21
23

I 23
24
Check the oil level in the 3-speed gearbox
Check the oil level in the pump drive
25
25
D
D

I 25 Check the oil level in the planetary gears and differential

Every 600 hours of operation

26 D

I 27
28
Change the hydraulic oil filters
Cnanze the oU in the eccentric housing
27
27 D

I Every 1000 hours of operation

30 Drain the water in the fuel tank 29

I Every 2000 hours of operation

29
I 32
33
Change the fuel filter
Change the oil in the hydraulic oil tank and clean
3J C
I 34 Change the oil in the 3-speed gearbox 33 D
35 Change the oil in the pump drive 33 D

I 36
37
Change the oil in the cI:rum gearing
Change the oil in the planetary gears
3'l
35
D
D

I 38
39
Change the oil in the differential
Inspect the crankcase ventilation diaphragm
36 D
See engine instr. manual

I 40 Flush the cooling system

-03-
37

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 11
DAILY
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(every 10 hours of operation)
I
Radiator - coolant level

1. Remove the filler cap

I
CAUTION!
I
Exercise care when opening the filler
cap if the engine is hot and allow the
I
pressure to escape slowly.
It this is not done steam may spurt
I
out wiht force and cause scalding
injuries. I
Fig. 2 Coolant filler cap
2. Check that the coolant level is
approx. 1 cm below the filler pipe.
I
To up as necessary. I
NOTE: Exercise care when pouring cold
water in the radiator if the
I
engine is hot, as this may cause
craking or deformation of the
I
cylinder head.

Always use one of the following two

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coolant mixtures:

Clean water and corrosion-inhibiting

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agent
Clean water and anti-freeze I
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Engine - Oil Level
I When checking the engine oil level the roller should

I be standing on a level surface and the engine should

have been switched off sometime beforehand.

I O1eck the oil level on the dipstick (2)

The level should be between the ADD and FULL marks.

I If the oil level is close to ADD, top up with fresh

oil to the FULL mark.

I Fill up with type "B" oil as described under "Lubri

cants" on page 1.

I NOTE: Do not add too much oil as this may da!mge

1 Oil filler cap
the crankshaft packing boxes.
I 2 Dipstick

I Fig. 3 Oil level - engine

I
I Hydraulic oil tank O1eck the oil level when the roller is standing on a
Oil level level surface.
I The oil level should be between the FULL and LDW
marks on the sight glass
I If the oil level is close to ~V, fill up with fresh
oil to the FULL marks.
I Fill up with type "C" oil as described under "Lubri-

I cants" on page 1.

Approximately 30 litres of oil will be required to

I raise the oil level from ~V to FULL:

NaIE: Do not drive the roller if the oil level is

I below the WV mark as this may damage the
hydraulic system through overheating.
I Fig. 4 Oil level - hydraulic
Oil tank

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I -05--

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3,4 and 5 Retaining screws - alternator
Fig. 5 Checking and adjusting V-Belt tension
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V-Bel t tension - Checking Press the V-Belts between the alternator and I
fan belt pulleys with your thumb.

Depress on belt at a tiJre. I

If correctly tensioned, it should be possible
to depress the belt 6-7 om. I
V-Belt tension - adjusting Carry out adjustment as follows:
I
1. Ease off the alternator retaining bolts
(3), (4) and (5).
I
2. Rotate the alternator about the bolt (4)
until the correct belt tension is obtained.
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Then tighten the belt (5).
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3. O1eck the belt tension and adjust as necessary.

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I 4. Tighten all retaining bolts (3), (4) and (5).

I
Also check that the belts are clean and intact.
I Cracked or oily belts should be replaced.

I NOI'E: Always change both belts at the sane time.

If only the worn belt is replaced the new

I belt will carry the entire load since it will
not have been stretched as much as the old
I one. Both belts will then wear out rapidly.

I
I
I PARKING BRAKE - Adjusting
B It should be just possible to pull the brake lever
I to an upright position when the brake is correctly
adjusted.

I If negligible resistance is encountered when applZ

ing the brake, turn the handle in the direction of
I the arrow marked + until the brake is. correctly
adjusted. If resistance is excessive, turn the
o
I o
handle in the direction of the arrow marked -.

I A Released
B Applied
I Fig. 6 Parking brake

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I -07-

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EVERY 50 HOURS OF OPERATION
I
Air cleaner - Cleaning the filter
elerrent. I
1. Release the overcentre catch (1)
and renovs the outer cover.
I
Rerrove the wing nut (2).
I
2. Rtm:>ve the inner cover (3) and clean it.
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3. Rtm:lve the filter elerrent (4)

Check wnether any dust has penetrated I

in the filter housing (5).
Fig. 7 Air filter Dust adhering to the inside of the I
1. Overcentre catch engine intake pipe, indicates dust
2. Wing nut
3. Inner cover
penetration. I
4. Filter elerrent
5. Filter housing
Check if the green dot on the plastic
wing nut is red.
I
Whenever it comes to red the safety
element must be replaced. I
4. Wipe the inside of the filter housing I
and clean the intake pipes, using a clean
cloth.
I
Check that the connections and the hoses
are in good condition. I
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I 5 Clean the filter elerrent with compressed
air-max. pressure 0.7 MPa (7 Kgf/ cru2) .
I Play the air up and down along the paper folds
on the outside of the filter elerrent. Hold the
I nOZZle at least 2-3 em away to avoid blo.ving
the paper to pieces.

I
I Fig. 8 Cleaning the filter
elerrent with compressed
air
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Sooty and filter
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If the filter elerrent is sooty and/or oily it
I should be washed in a solution of water and a
non-sudsing detergent such as "Dona.l.dson D-1400':

I Immerse the filter elerrent in the detergent

solution for at least 15 minutes. Move i t up

I and down in the solution now and again to dislodge

the dirt.

I Then rinse the filter elerrent in clean water.

Allow it to dry in the air or in a stream of hot

I air-max. 70 9C. Never use compressed air or

eletric light bulbs to dry the filter element.

I Nom: Discard the filter element when it has

been washed six times.
I
6 Check that no dust has passed through the

I filter.
If dust has passed through the filter this
I will be indicated by deposit is of dust on
the inside of the engine induction pipe.

I Nom: If dust has passed through i t is a sign

that the filter element is not intact and
I a replacement must be fitted.

I -09--

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7 Wipe the inside of the filter housing clean
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with a clean rag.
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8 Check that the connections between the filter
housing and engine are intact and tight. I
9 Check that the filter element is intact before
fitting it in place.
I
Cracks or holes in the filter paper can be
detected by holding a JJCM'erful electric light
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bulb approx. 200W - inside the filter element.
Switch on light and inspect the filter paper
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\V-\// from the outside.
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\
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~-----
) -I ~y ~
Cracks and holes will be plainly visible as
light spots or lines.

Also check that the seals are intact.

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NOTE: If there are holes in the paper or if
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the element seals are damaged, the
element should be replaced. I
-- lJIll'

10 Insert the filter element. I

Fig. 9 Filter element
detecting craks and
NOTE: If the filter element has been washed in
a detergent solution it should not be
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holes
fitted until completely dry.
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11 Clean the inner cover and tighten the filter
element and inner cover finnly by means of I
the wing nut.
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I 12 Clean the outer cover and fit it back
in place. Also inspect the outer cover
HYDRAULIC OIL TANK-breather holes seals and fit replacements if damaged.
I in filler cap

I
Rerrove the filler cap and check that the
I breather holes are not clogged.
If necessary, wash the filler cap in
I hydraulic oil or diesel fuel and blow i t dry
with compressed air.

I
I 1 Breather holes
Fig. 10 Filler capp - hydraulic
oil tank
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I BATI'ERY-electrolyte level

I 1 Tip the driver's seat forward.

I 2 Wipe the top of the battery and clean.

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I Fig. 11 Battery

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3 RenDve the cell plugs and check that the
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level of the electrolyte is approx.10 mm
above the plates.
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CAUTION ! I
Never use a naked flame when inspecting
the electrolyte level. Explosive gas is
I
fonned in the battery during charging.
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1 Cell plug If the electrolyte level is low, top it
2 Electrolyte level up with distilled water. I
3 Plate
Check the level in all cells.
Fig. 12 Electrolyte level in
If t lB ambient temperature is below
I
battery
freezing point, run the engine for a
while after adding distilled water to I
the baterry as there will otherwise be
a danger of the water freezing. I
4 Check that the ventilation holes in the
cell plugs are not clogged. Then replace
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the plugs.
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5 Also check the cable terminals.
cable terminals should be clean and firmly
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tightened. If the cable terminals are
corroded, clean then and coat them with I
vaseline.
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 •
• ECCEN'IRIC HOUSING-OIL LEVEL

• Checking the oil level

1. Drive the roller onto a level surface

• unti'L the level bar (1) is at the frame

side upper edge as shown in the fig.

•'.
- ,
2. Clean the area round the level plug (1)
and back it off about three turns.

3. Oil Should then ooze out at the plug if

• there is the right amount of oil.

• 1 Level bar
NCYrE: Cneck this orrboth sides of the drum.

• Fig. 13 Checking the oil level

in drum
4. Tigl1t*n the level plug.

•
•
• Filling up with oil

• 1. Drive the roller onto a level surface until

• ~
the filler plug (3) is at top dead as
shown in the fig.
3

• 2. Thoroughly clean the area round the filler

plug (3) and the level plug (2).

•I 1 Level bar
3. Back off the level plug (2) about three turns
and remove the filler plug (3).

I; 2 Level plug
3 Filler plug
4. Fill up with oil until it oozes out at the
level plug. Fill up with type "D" oil as
described under "Lubrificants" on page 1.
Fig. 14 Drum oil filling
I 5. Tighten the level plug (2) and fit the filler

I -13-
plug (3) back in place.

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RUBBER ELEMENTS I
Check that the shock absorbers are intact and
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free from cracks.
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Replace the shock absorbers i f the cracks in the
rubber are 15-20 !TIn deep.
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Also check that all retaining screws are properly
tightened. I
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STEERING HITClI-IlJBRICATION

1. Turn "the drum section slightly to the left I

so as to provide access to all the grease
nipples on the steering hitch. I
D:J not turn to full lock as this will make
o it difficult to grease the steering cylinder I
on the left-hand side.

CAUTION !
I
Make sure that nobody is around the steering
hitch while the engine is running. They
I
might get crushed i f the steering system is
operated.
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Fig. 17 Grease nipples- 2. Wipe all dirt and grease off the four nipples. I
steering hitch

3. Grease each nipple with five strokes of the I

grease gun.
Use type "A " grease as described under
"Lubricants "on page 1.
I
Leave a slight arrount of grease on the nipples
as this prevents the entry of dirt.
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-14-
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I STEERING CYLINDFRS-llJBRICATION

I Grease the right-hand steering cylinder immediately

after greasing the steering hitch.

I 1. Wipe all dirt and grease off the two nipples

I 2. Grease each nipples with three strokes of the

grease gun. Use type "A "grease as described

I under "Lubricants" on page 1.

3. Walk around the roller and grease the two

I nipples of the left-hand steering cylinder
in the sarre manner.
I
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I UNIVERSAL JOINT-LUBRICATION

The grease nipples on the universal joint are

I accessible from ~derneath the roller.

I 1. Crawl under the roller and check that the

grease nipples are accessible with the'
I grease gun.

It may be necessary to drive the roller

I forward slightly, causing the universal joint
to rotate and bringing the nipples into an

I accessible position.

I CAUTION!

Fig. 19 Grease nipples- Never work under the roller while the engine
I universal joint is running.

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2. Wipe all dirt and grease off the two nipples.

3. Grease each nipple Vii. th two strokes of the

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grease gun.

Use type "A" grease as described under "Lubri

I
cants" on page 1.

Leave a slight arrount of grease on the nipples

I
to prevent dirt entering them.
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TYRE PRE'lSURES
I
Normal tyre pressure is 0,25 MPa(2.5 kgf/cm
2). I
Minimum permissible tyre pressure is 0.12 MPa
550 Nm - - 55Kpm
0.2 kgf/cnh. I
Check tyre pressure with the tyre pressure gauge
included in the roller toolkit. I
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Fig. 20 Wheel
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WHEEL NUTS- TIGfITENING Check that the wheel nuts are tightened at a
torque of 550 Nm (55 kgfm). I
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I EVERY 200 HOURS OF OPERATION

I Engine-changing the oil and

oil filters The normal changing interval

I Intervals between oil changing depend on the grade

of oil and sulphur content of the fuel.

I Oil changes at intervals of 200 hours

of operation are recarrnended on the assumption

I that the grade of rrotor oil used is "For API

Service CD, SAE"and that diesel fuel of good

I quality with a sulphur content below 0,4% is

used.

I If the grade of oil used is "For API Service a:;/SC,

SAE"or if the sulphur content of the diesel fuel

I is 0,4 % or higher, oil should be changed at rrore

frequent intervals as shown in the table below:

I
I "API Service. SAE"
oil grade
Sulphur content of fuel
I CD CC/SC

< 0.4% 200 hours 150 hours

I 0.4 - 1% 100 hours 75 hours
> 1% 50 hours 37 hours
I
I NOTE: Ordinary diesel fuel of good quality has
a sulphur content less than 0,4%.

I Fuel oils, etc. have a higher sulphur

content.

I NOTE: Regardless of the number of hours of

operation, the engine oil and the oil
I fil ters should be changed every six
rronths .
I Always change the oil filters when
changing the engine oil.
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Changing the engine oil and the oil filters I
1. Thoroughly warm up the engine before draining
the oil.
I
Impurities in the lubricating system will then
be well-mixed with the oil and will be carried
I
out with it. Furthenmre, the oil f'l.cws rrore
readily when it is hot.
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2. Clean the areaaround the oil filler cap (1) I
and then remove it.
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1. Oil filler cap
Fig. 21 Filling up with oil-
engine
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3. Clean the area around the drain plug (1) and
then place a receptacle beneath the plug. I
This receptacle should hold at least 15 litres
I
4. Rerrove the drain plug and allow the oil to
run out into the receptacle.
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_._-._-- Let the oil continue to run while changing
the oil filters. I
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1 Drain plug
Fig. 22 Draining the engine oil I
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BIBLIOTECA
I EXmANGE OIL FILTERS
TECNICA

I 5. Remove both oil filters (1).

I NaTE: Make sure that the sealing rings are

not left behind on the filters heads
I as leakage will then occur between
the new and old seals.

I Discard the oil filters

I They are disposable type and cannot be cleaned.

I 6. Clean the sealing surfaces of the filter

heads with a clean lintfree rag.
I 1 Oil filters 7. Smear the seals of the new filters with a

I Fig. 23 all filters-engine thin layer of fresh motor oil.

8. Tighten the filters by hand until the seals

I seat against the filter heads. Then tighten
them an additional halfturn.
I
NaTE: Do not tighten the filters too hard as

I this may damage the seals.

I 9. Wipe the drain plug clean and fit it back in

place.
Make sure that it is finnly tightened.
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I -19-

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10. Fill up with fresh oil of type "B" as described
under "Lubrificants"on page 1. I
Oil required : 12 .5 litres when changing the
filters I
11.4 litres without changing
the filters. I
:=!:J=---1
Do not fill up with too mich oil as this may
cause damage to the crankshaft packing boxes. I
11. Check the engine oil level with the dipstick. I
The level should be at the FULL marks.
Add nore oil if necessary. I
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1 Oil filler cap
I
2 Dipstick
Fig. 24 Oil level-engine I
12. Fit the filler cap back in place.

Tighten it firmly ensuring that it makes a I

good seal.

13. Start the engine and warm it up. Check that

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there is no oil leakage.
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Air Cleaner-Cleaning the dust
collector
I--
1. Release the catch and ranove the cover.
2. Clear the cover
I
I . 3. Replace the element.
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4. Assemble in the reverse order.
!
5. Check the seals and replace any that ar
damaged. I
Check that the hoses and connections do not
leak. I
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-20-
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I EVERY 100 HOURS OF OPERATION
Radiator - Cleaning the exterior Check that air can flow freely through the
I radiator, If the radiator is dirty, clean
it by flUShing wi th water or by blowing

I compressed air through it,

After cleaning, check that any seals,

I
I Drum gearbox oil level-check

L Drive the roller onto a level surface

I so that the filler plug (2) is at its
upperrros't position on the drum
I 2, Clean any dirt and grease away fran

I the area around the plugs,

I 3, Remove the plugs and check that the

oil level is up to level plug (1),

A= ~::~
I /@. I <, ~\ 4, If necessary, replenish with type ''0''

! 2 \ oil as recarrnended on page 1 in

I (':J
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~ ©)
/
,'Lubricants'!

& ('j/
I -, ©
'~
/ 5, Refit the plugs,

I Replenishing With oil

L Level/drain plug
2, Filler plug
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I -21-

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EMERGENCY BRAKE-ADJUSTIJIG
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The emergency brake is controlled by buttom
located. on the dash board right hand side.
A light will come on whenever the buttom is
I
depressed. The brake is applid:

- When the drive system pressure dorps.

I
- When the engine is shutted off
When the battery is missing or is run out.
I
If the charge pressure is normal , and no I
leakage in the drive system and all linkage
in the brake lever assembly is operating, it I
is quite good reason to check brake lining
wear. I
Pull the red buttom
Turn on the engine and maitain at idling
I
speed.
E&.l- Right hand side brake adjusting. I
Remove the pin (2) from the connecting rod
(5) and the adjusting lever (4) on the left I
hand side.

Turn the eccentric pin as indicated on fig. I

2 (the both marks should be at shortest
distance) . I
Apply the brake by the adjusting bolt (1)
on the adjusting lever turning it on counter I
clock wise until the wheel cannot be turned
(locked). So turn back the bolt slightly
stop turning back as the wheel sets free
I
to turn.
Slacken off the lock nut from the eccentric
I
pin and turn the eccentric pin, one by one,
on the direction as indicated on fig. 3
I
performing on the same way as described
fonnely. I
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I Turn the eccentric pin until lock the
wheel after this procedure, turn back the
I PUNC"."'IELJ
POI/opTS"
I
:/
YEIl71~;q, CEJlrE,IlIIl'fF aRM'
eccentric pin to set free the wheel.
Lock the nut by torque 17.2 to 23.0 kgm

I rJ\·~
,
or 1,500 to 2,000 lb x in.
Be careful when locking not to change any
,

I '-0~
ANCHOA UAlK' PJwJ -
adjusted position.

Apply the brake by adjusting bolt as done

I J'LiA.2. before but this time al Iow the lining only

touch the brake drum, not totally locked

I (the wheel should offer sare resitence

when turning).

I Replace the left hand side lever pin.

Left hand side brake adjusting
I Rerrove pin (2) fran connecting rod (5) and
adjusting lever (4), fran the right hand
I side (roller).

Repeat step perfonned for right hand side

I brake adjusting.

Replace pin (2) reroved fran right hand

I side (roller).

Apply and release the brake. Check the brake

I cylinder rod play. It should not be IIDre
than 23mn.'
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I -23-

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Nom:
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1. Do not adjust the brake by adjusting
bolt (1).
I
If the brake cylinder rod is not canple-

FIG 4
tely extended fig.4. I
CV I 0
Turn on the engine and pull the brake
~

buttan and cylinder rod will care out to I

extended position, or you can do so by
cylinder bolt. I
B
2. Fig. 4 shows you the brake cy linder .
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.A

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CVLIHOER STROKE: A - Q
3. Check every 1. 000 operating hours.
If necessary it. can be adjusted by bolt
(1) on the adjusting lever (4).
I
4. For the major adjustment perform by
eccentric bolt (3) for. E. G. whenever
brake lining on brake shoes are replaced.
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Tachareter Cable-Lubricating
Release the cable at the tachaneter and I
pour type "B"oil in between the seath
and the cabel. I
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-24_
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I 'IHREE-SPEED GEAROOX - OIL LEVEL

I Make sure that the roller is standing on a level'

surface before checking the oil level.

I 1. Clean the area round the level plug (1)

I 2. RenDve the plug and check that the oil

o 00 reaches up to the hole.

I If the oil level is low, top up with type

"D"oil as described under "Lubricants"on
I page 1.
Add oil via the level plug (1) hole.

I 1 Level plug
2 Drain plug c:==r-- 2 3. Fit the plug back in place
Fig. Checking oil in the
I the 3-speed gearbox

I PUMP DRIVE-OIL lEVEL

I Make sure that the roller is standing on e

level surface before checking the oil level.
2
I 1. Clean the area round the level plug (1) and
back it off a few turns.
I If the pump drive contains the right arrount
of oil it should ooze out at the plug.

I 2. If necessary, add oil via the filler plug (2)

I until it runs out at the level plug.

Clean the area round the filler plug before

I backing it off.
Fill up with type ''D'' oil as described under
1 level plug "Lubricants" on page 1.
I 2 Filler plug
Fig. Checking oil level in Note: There is a level plug on each side of
I pump drive the pump drive. It is only necessary
to check the oil level on one side.

I
I -25-

I
 I
PLANETARY GEAR-OIL lEVEL
I
1. Drive the roller onto a level surface until I
the level plug (1) on one of the planetary
gears is in the right position. I
The mark (3) on >'the planetary gear housing
should then be horizontal. I
2. Back off the level plug and check that the
oil reaches up to the plug hole.
I
If the oil level is low, top up via the
level plug to the correct level.
I
1
2
Filler and level plug
Drain plug
Top up with type "D" oil as described under
"Lubricants" on page 1.
I
3
Fig.
Oil level mark
O1ecking oil level in
3. Check the level of the oil in the planetary
I
the planetary gear
gear on the other side in the sane manner.
I
I
DIFFERENTIAL - OIL lEVEL
1. Make sure that the roller is standing on
level surface.
I
2. Back off the level plug (1) and check that
I
the oil reaches up to the plug hole.

If the oil level is low, top up via the

I
level plug to the correct level.
Top up with type ''D'' oil as described under
I
"Lubricants"on page 1.
I
CAUTION
1 Level plug
2 Drain plug 2-:-_-...:::::,.=---,""
Never work under the roller \\hile the engine
I
Fig. Checking oil level in
the differential,
is running.
I
I
I
I
 I
I EVERY 600 HOURS OF OPERATICN

I Hydraulic system-filter changing

1. Remove the oil filters (1) and (2)

I Discard the filter. They are of disposable
1
type and cannot be cleaned.
I
NOTE: Make sure that the old sealing rings
I are not left in place. Leakage will
other-wise occur between the new and

I old seals.

I 2. Throughly clean the sealing surfaces of the

fil ter holder,

I 1

Fig.
Oil filter

Oil filter
3. Smear the seals of the new filter with a
thin layer of clean hydraulic oil.
I
4. Screw the filters in place by hand.

I First screw the filter in place until the

seal seats against the filter head. Then
I tighten an additional half-turn.

I 5. Start the engine and check that no hydraulic

oil leaks out round the filters.

I
I
ECCENTRIC HOUSING-OIL CHANGING
I \
1. Drive the roller onto a level surface until
the level bar (1) is at f'rame upper edge.

I 2, Throughly clean the area round the drain

I plug

1 Level bar
I 2 Sight glass
Fig. Draining the oil in the vibration drum
I -27-

.,1
 I
3. Slacken the plug about three turns. I
4. Place a receptacle below the drain plug. I
This receptacle should hold at least 30 litres.

5. Rerrove the drain plug and collect the oil in

I
the receptacle.
I
6. Drain the oil at the other side of the drum
in the same rmnner. I
7. When all oil has run out drive the roller I
until the drain plug is at top dead centre.

NOTE: To prevent any impurities entering

I
the eccentric housing while the
roller is in motion the plugs should
I
be fitted temporarily in place.
I
h~2·.1
8. Fill up with oil via the drain/filler plug

I:"; 0
o
(1) until oil runs out at the level plug (2) I
Fill up with type "D" oil as described under
"Lubricants" on page 1. I
1 Drain/filler plug
2 level plug
Each drum eccentric housing holds approx. 27
litres of oil. I
Fig. Oil filling vibration
drum 9. Fill oil at the other side of the drum in I
the same manner.

10. Fit the plugs back in place.

I
I
I
I
I
I
-28-

.,
 I
I 1lTERY 1000 HOURS OF OPERATION

I Fuel tank - draining water

I Water and sediIrent in the fuel tank can be drained

off via the drain plugs (1) in the bottom of the
tank. Draining should be carried out when the
I roller has not been used for some tinE- such as
overnight.
I The roller should preferably be left with one side
slightly higher than the other so that water and
I sediment will collect at one of the drain plugs.

Carry out draining as follows:

I 1 Drain plugs
1. Clean the area round the Iowest drain plug.
I Fig. Fuel tank

2. Rem:lve the plug and drain off the water and

I sediment until only clean diesel fuel runs
.out of the hole. Then screw the plug back

I in place.

NOTE: Do not drain off all the fuel as air

I may then enter the fuel system.

I EVERY 2000 HOURS OF OPERATION

I Fuel system - bleeding

IVhen air has entered the fuel system the engine

I will either fail to start or misfire.

In such event it will be necessary to bleed the

I fuel system as follows:

I 1. Stop the engine.

2. Back off the bleed screw (1) on top of the

I' fuel pump
1 Bleed screw
I Fig. Bleeding the fuel system

I
I
 I
I
3. Operate the hand pump (1) until the fuel
emerging at the bleed screw is completely
free of air bubbles and runs out in a
I
steady flow.
I
NarE Only use the hand pump when the l!ileed
screw -is open. Do not pump out rrore I
fuel than necessary.
I
NarE: The pump handle is secured in the

1 Hand pump
closed position. To release it, tum
the handle anti-clockwise until it comes
I
Fig. Bleending the fuel system away. On completion of bleending,
secure the handle again by pressing
I
it in and turning it clockWise until
resistance is encountered. I
4. Tighten the bleed screw. I
5. Start the engine.
I
If the engine misfires or runs unevenly, bleed
the lines to the injection nozzles.
I
Back off the nut (4) on the injection nozzle
and let the fuel run out until i t flows evenly
and contains no air bubbles. Then tighten
I
1. Nut
the screw again.
Bleed one line at a tima until they have all
I
2. Fuel line
Fig Bleeding a fuel line
been bled.
Bleed the fuel lines while the engine is I
running.
I
HYDRAULIC SYSTEM-OIL CHANGING
Change the oil in the hydraulic system when it is
hot-at the end of a workshift, for example. I
Oil f'l.ows IIDre freely when it is hot and any
impurities are then in suspension with it and will 'I
be carried out with the oil when it is drained.

NarE: Strictest cleanliness when servicing the I

hydraulic system is essential to ensure

-30-
I
I
I
I troublefree operation of the roller.

I 1. Thoroughly clean the outside of the tank.

I 2. Prepare a receptacle for collecting the oil.

It should hold at least 220 litres.

I An empty oil drum or the like makes a suitable

receptacle. Place i t beside the roller and

I empty the oil into it via a hose fran the drain

plug.

I 3. Rennve the drain plug (1) and let the oil run
out.
I Rennve the Lowest plug.

I 1. Drain plug
Fig. Draining-hydraulic oil tank

I
4. Rennve the cover plate (1) on top of the hydrau-
I lic oil tank.
Note: Take care to avoid impurities entering
I the tank.

I 5. Clean the tank cover and filler strainer.

Check that the strainer is intact.

I 1. Cover plate
2. Filler cap
I Fig. Hydraulic oil tank

I 6. Clean the tank.

The best way of doing this is to suck up the

I sediment fran the bottan.

I
I
I -31-

I
 I
I
If rags or brushes are used they must be
completely clean and free fram dust.
I
NJTE: If the tank is rinsed with hydraulic
oil, all conections in the bottom of
the tank must be plugged to prevent
I
impurities entering the hydraulic lines.

Do not forget to rerrove the p.lugs after

I
cleaning.
I
7. Fit the drain plug back in place.
I
8. Fit the cover plate back in place.
Fit a new gasket and seal with Loctite flange I
sealer or the like.

J.IKJI'E: Make sure that no sealant enters the I

tank.

9. Fill up with oil to FULL mark on the sight

I
glass.
Fill up with type "C" oil as described under
I
"Lubricants" on page 1.
Tank capacity is approx. 208 litres. I
Checking the oil level-
When filling the tank the oil should prefera-
hydraulic oil tank
bly be pumped through a filter unit. I
10. Start the diesel engine and operate the various
hydraulic functions.
I
11. Check the oil level and top up with more oil
I
as necessary.
I
GEARBOXES AND REAR AXLE-
OIL QiANGING All oil changes should be carried out when the oil I
is hot, such as at the end of a workshift.
Hot oil flows more readily
be
and any impurities will
in suspension with the oil and run out wi th i t
I
when it is drained.
I
-32-
I
I
 I
I
'IHREE-SPEED GEAROOX-OIL CHANGING

I 1. Drive the roller onto a level surface and switch

off the engine.

I CAlJrION!

I Never work under the roller when the engine is

running.

I o 0 2. Clean the area round the filler plug (1) and

drain plug (2).

I 1
3. Place a receptacle under the drain plug (2).
The receptacle should hold about five litres.
I t:==::¢~ __-2 4. Rerrove the filler plug (1) and drain plug (2).

I 1.

2.
Filler plug
Drain plug
Collect the oil in the receptacle.

5. Clean the drain plug.

I NOTE: The drain plug is magnetic and attracts
any iron particles in the oil.
I 6. Fit the drain plug back in place when all the
oil has run out.
I 7. Fill up with oil via the filler plug ·(1) until

I it reaches up to the bottom of the hole.

Fill up with type 'D"oil as described under

I "Lubricants" on page l.
The gearbox holds approx. 3 litres of oil.

I 8. Screw the filler plug back in place.

I PUMP DRIVE-OIL CHANGING

1. Drive the roller onto a level surface and switch

I o off the engine.

2. Clean· the area round the filler plug (1), level

o
I plug (2), and drain plug (3).

3. Place a receptacle under the drain plug. The

I receptacle·should hold about five litres.
4. Re!mve the filler plug.
I -33-

I
 I
I
5. Rerrove the drain plug and allow the oil to
run out into the receptacle. I
6. Clean the drain plug.
I
NOTE: The drain plug is magnetic and attracts
any iron particles in the oil. I
7. Fit the drain plug back in place when all the
oil has run out.
I
8. Back off the level plug a few turns. I
There is a level plug on each side of the
housing. It is only necessary to back off one
of the plugs.
I
9. Fill up with oil until it oozes out at the level
I
plug. Fill up with type "D" oil as described un
der "illbricants" on page 1.
I
The gearbox holds approx.3,8 litres of oa l..
I
10. Tighten the level plug and fit the filler plug
back in place. I
DRUM GEARING-OIL CHANGING
The system should be at operating temperature bef£
I
re the oil is drained.

1. Drive the roller onto a level surface so that

I
@\
the drain/level plug (1) is at the lowest
position.
I
\
1
2 O@ 2. Clean the area around the plugs. I
3. Place a receptacle under the drain plug (1)

.~
\ @ and drain the oil. The receptacle should hold
3.5 litres. Also remove plug (2)
I
Draining the oil
1 drain/level plug I
2 filler plug
I
-34-
I
I
 I
I
4. Move the roller backwards so that filler plug
I (2) is in the highest position.

e
I 5. Fill up with oil through the filler plug hole

r (2) until the oil level reaches the level plug

I 2 (1) . Use type 'D" oil as reccmnended in the

section entitled "Lubricants" on page 1.
Oil required: approx 3 Ii tres .
I @ 6. Refit the plugs.
I Filling with oil
1. Level/drain plug

I 2. Filler plug

I PLANETARY GEAR-OIL ClIANGING 1. Drive the roller onto a level surface until the
drain plug (1) is at bottcm dead centre. Switch
off 'the engine.
I 2. Clean the area round the drain plug (1) and

I filler plug (2).

3. Place a receptacle under the drain plug. The

I ;
receptacle should hold about two litres.

I Planetary gear-draining the,oil

/
4. Remove the filler plug (2) and drain plug (1).
Collect the oil in the receptacle.
.
I 1.
2.
Drain plug
Level plug
5. Clean the drain plug and fit it back in place
when all the oil has' run out.

I 6. Drive the roller until the nnrk (3) on the

1 planetary gear housing is horizontal.
I 7. Fill up with oil via the level plug (1) until

I it reaches up to the bottom of the hole.

Fill up with type 'D" oil as described under
3
"Lubricants" on page 1. Each planetary gear holds
I Planetary gear-filling up with oil
approx. 1,4 litres of oil.

8. Fit the filler plug back in place.

I 1.
2.
Level plug
Drain plug 9. Change the oil-in the same mmner-in the other
planetary gear on the wheel axle.
I 3. Level mark

-35-
 I
DIFFERENTIAL-OIL QiANGING 1. Drive the roller onto a level surface and switch
I
off the engine.

CAurION !
I
Never work under the roller when the engine I
is running.

2. Clean the area round the drain plug (1) and I

filler plug (2).

3. Place a receptacle under the drain plug.

I
The receptacle should hold about 15 Lt tres .
I
4. Remove the filler plug (2) and drain plug (1)
Collect the oil in the receptacle. I
5. Clean the drain plug and fit it back in
place when all the oil has run out.
I
6. Fill up with oil via the filler plug (2) until
it reaches up to the botton of the hole.
I
Fill up with type ''D'' oil as described under
"l.J..ibricants" on page 1.
I
Differential
1 drain plug
The differential holds approx. 12,8 litres of
oil.
I
2 filler and level plugs.
7. Fit the filler plug back in place. I
I
I
I
I
I
I
-36-
I
1.4
 I
I CXXJLING SYSTEM--FLUSHING The cooling system be cleaned once a year in order

I to flush out flakes of rust and sediment.

It is also necessary to replace the coolant once a

I year as the rust-inbibiting agent gets used up.

1. Drive the roller onto a level surface.

I
2. Rerrove the radiator filler cap (1).
I 3. Open the drain cock (2) at the bottan of the

I 3 radiator,

I 4. Rerrove the drain plugs (3) in the cylinder

block and engine oil cooler.

I One at the bottom connection to the radiator.

Two in the cylinder block - one on each side
next to the flywheel casing.
I One in the engine oil cooler.

I Draining-cooling system
5. Flush the cooling system with clean water.
Insert a water hose into the filler neck of the

I 1
2
Filler cap
Drain cock-radiator
radiator and flush until the water running out
at the drain plug holes is canpletely free
3 Drain plug-engine
I from flakes of rust and sediment.

NOTE If there are hard deposits of lime or

I rust in the cooling system it should be
cleaned with a special radiator clean-
I sing agent.
Use a good cleansing agent fran a repu

I table manufacturer and follow the dire

tions on the container.

I 6. Fit the drain plugs back in place and close the

radiator drain cock.
I
7. Inspect the cooling water hoses.
I Replace any hoses that are cracked or show any
other defects.

I -37-

I
 I
I
8. Fill up with coolant until the level is about
1 em below the bottan of the filler pipe. I
Always fill the cooling system with one of the
following two coolants: I
Clean water and corrosion-inhibiting ~nt.

Clean water and anti-freeze (with corrosion- I

inhibiting ~nt).

'Ihe water should have as low a l:iIre content I

as possible.

9. Start the engine and run i t for ten minutes.

I
10. Check the level of the coolant and top up to
I
the correct level, if necessary.
I
11. Check that there is no Leakage in the cooling
system. Make sure that any leaks are sealed. I
12. Fit the filler cap back in place. I
I
I
I
I
I
I
I
I
-38-
I
I