sd110 operator manual eng_gb_20026436

sd110

SD110

operator's manual

Ref. no. Pub 200264362010.03Volvo, India

EnglishCST

English

Serial No. 52332- 58001-

ForewordThis Operator's Manual is intended as a guide for the correct use andmaintenance of the machine. Therefore, study it carefully before startingand operating the machine, or before carrying out any preventivemaintenance. Keep the manual in the manual box, so that it always is athand. Replace it immediately if it is lost. The manual describes theapplications for which the machine primarily is intended and is written toapply for all markets. We therefore ask you to disregard the sections whichare not applicable to your machine or to the work for which you use yourmachine.

NOTICEIf this manual includes more than one machine, the information applies toall machines, unless otherwise stated.

Many hours are spent on design and production to make a machine thatis as efficient and safe as possible. The accidents which occur in spite ofthis, are mostly caused by the human factor. A safety conscious personand a well maintained machine make a safe, efficient and profitablecombination. Therefore, read the safety instructions and follow them. Wecontinually strive to improve our products and to make them more efficientthrough changes to their design. We retain the right to do this withoutcommitting ourselves to introduce these improvements on products, whichhave already been delivered. We also retain the right to change data andequipment, as well as instructions for service and other maintenancemeasures without prior notice.

Safety regulationsIt is the operator's obligation to know and follow the applicable nationaland local safety regulations. The safety instructions in this manual onlyapply to cases when there are no national or local regulations.

WARNINGThe warning symbol above appears at various points in the Operator'sManual together with a warning text. Read the text carefully, your safetydepends on it! It is the obligation of the operator to make sure that allwarning decals are in place on the machine and that they are readable.

CAUTIONIndicates a potentially hazardous situation which may result in machinedamage.

NOTICEIs used to notify of installation, operation, or maintenance informationwhich is important but not hazard related.

Get to know the capacity and limits of your machine!

OPERATOR'S MANUAL

Table of contents

Presentation

Instrument panels

Other controls

Operating instructions

Operating techniques

Safety when servicing

Service and maintenance

Specifications

Alphabetical index

OPERATOR'S MANUAL

Table of contents

Presentation

Instrument panels

Other controls





Specifications

Alphabetical index

SD110

Ref. No. PUB 20026436-A2011.10

Copyright © 2010, Volvo Construction Equipment Customer Support. All rights reserved.

Identification numbersEnter the product identification number (PIN) of machine, manufacturercode and engine serial number. These numbers must be specified whencontacting the manufacturer to order spare parts. For positions andexplanation of the PIN plate, see page Product plates.

Manufacturer Volvo India Private Limited7 & 8, Peenya Industrial AreaBangalore- 560058.

PIN of machineManufacturer codeEngine serial number

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Foreword

Identification numbers

Please send comments about the Operator’s Manual to [email protected]

Table of contentsForeword ................................................................. 1

Identification numbers ......................................................... 2

Table of contents ..................................................... 3Presentation ............................................................ 5

Machine view ..................................................................... 13CE-marking, EMC-directive ............................................... 16Product plates ................................................................... 17Information and warning decals ........................................ 19USA federal clean air act ................................................... 23

Instrument panels .................................................. 26Other controls ........................................................ 30

Controls ............................................................................. 30ROPS ................................................................................ 31Operator comfort ............................................................... 32

Operating instructions ............................................ 33Safety rules when operating .............................................. 33Measures before operating ............................................... 57Starting engine .................................................................. 61Hydraulic system, warming up .......................................... 62Vibration ............................................................................ 63Operating ........................................................................... 64Braking .............................................................................. 66Stopping ............................................................................ 67Measures after operating .................................................. 68Parking .............................................................................. 69Measures in case of machine failure ................................. 71Retrieving and towing ........................................................ 76Transporting machine ........................................................ 81

Operating techniques ............................................ 84Eco driving ......................................................................... 85Signalling diagram ............................................................. 86

Safety when servicing ............................................ 88Service position ................................................................. 92Before service, read .......................................................... 95Preparations before service ............................................ 102Entering, leaving and climbing the machine .................... 103Fire prevention ................................................................ 104Handling hazardous materials ......................................... 109Handling line, tubes and hoses ....................................... 115

Table of contents 3

Service and maintenance .................................... 116General inspection of machine ........................................ 124Engine ............................................................................. 125Fuel system ..................................................................... 131Engine air cleaner ........................................................... 133Cooling system ................................................................ 141Electrical system ............................................................. 144Transmission ................................................................... 156Axles ................................................................................ 158Brake system ................................................................... 163Steering system ............................................................... 164Wheels ............................................................................ 165Drum ................................................................................ 167Hydraulic system ............................................................. 174Greasing .......................................................................... 180Lubrication and service chart .......................................... 184

Specifications ...................................................... 188Recommended lubricants ................................................ 189Service capacities and change intervals ......................... 195Brake ............................................................................... 197Wheels ............................................................................ 198Drum ................................................................................ 199Specifications .................................................................. 200Machine weights .............................................................. 204Dimensions ...................................................................... 205Service history ................................................................. 208

Alphabetical index ............................................... 211

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Table of contents

PresentationDescription, complete machine

WARNINGPersons who do not follow the safety instructions and do not payattention to the warnings in this service manual must make surethat their work method is safe. Otherwise, there is a serious riskof serious accidents and, at worst, fatalities.

V1100904

SD110 compactor machine

Machine description: SD110The SD110 is a single-drum vibratory soil compactor, is poweredby a Volvo D5D GA E3 water cooled diesel engine, driving threehydraulic pumps. First pump powers propulsion system, secondpump powers the vibration system and the third pump powerssteering system. Engine rpm is controlled by the throttle lever.Machine forward, reverse direction and speed is controlled bypropulsion control lever and machine dual speed is controlled bytwo speed switch. Drum vibration frequency and amplitude iscontrolled by vibration control lever. Machine steering action iscontrolled by steering wheel.

The compactor uses the positioning of the propulsion control leverto STOP position as a service brake. An independent springapplied hydraulically released axle brake serves as a parkingbrake.

Standard equipment includes an emergency switch to shut downthe engine and apply the parking brake in an emergency situation.

Roll-over protective structure (ROPS), railing assembly and seatbelt provides operator safety.

NOTICEFor a complete listing of currently supplied / available standardand option features contact your nearest Volvo authorized dealer.

Presentation 5

EngineThe SD110 series compactor is powered by 99 kw (133 hp) VolvoD5D GA E3 water cooled diesel engine.

A dry type, two-stage air cleaner system provides clean air to theengine. A dust discharging evacuator valve is provided on the aircleaner. Air filter clog indicator is provided on the control console.When it glows, it indicates that air filtration system needsattention.

The engine rpm is controlled by the throttle lever located at rightside of the operator seat.

Electric starter and belt driven alternator are standard. Engineshutdown is by an ignition key or an emergency switch in case ofemergency.

Main FrameThe machine is built with rear frame assembly and a front frameassembly, connected by a swivel frame with two articulation pinsand one oscillation pin.The rear frame is a welded assembly on which hydraulic tank, fueltank, battery compartment, control valves, engine assembly withpropulsion pump, vibration pump, steering pump and axle withtyre assembly are mounted.The front frame is a welded assembly on which drum assemblyand scraper bar are mounted.

DrumDrum fitted with the machine is a smooth drum. Vibration istransmitted to the drum by an eccentric assembly which ismounted inside the drum and is powered by a hydraulic vibrationmotor. Amplitude and frequency of drum vibration is controlledthrough vibration control lever.

NOTICEDrum drive and pad foot is a option, Contact your nearest Volvodealer for more information.

ControlsAll operator controls, gauge and indicators are provided in theoperator compartment for operator’s convenience and comfort.

The propulsion control lever, vibration control lever and enginethrottle lever are located on the right side of the operator seat.

The control console has control switches, light switches,indicators, hourmeter, emergency switch, ignition key switch,mobile charger plug, fuel gauge and steering control unit mountedon it.

TransmissionThe machine is equipped with a hydrostatic transmission andhydraulic motor which consists of the drive engine and anadjustable flow pump in a closed hydraulic circuit. The speed ofthe machine and the direction of machine travel is controlled by

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Presentation

the FSR propulsion control lever, engine speed selector and aspeed selector switch.

Vibration SystemThe drum vibration system consists of an eccentric assemblymounted internally and is powered by an hydraulic motor. Thissystem has dual amplitude capability. Selection of high or lowamplitude is by operating the vibration control lever provided onthe right side of the operator seat. High amplitude isrecommended for thick lift compaction while low amplitude is forthinner lift and sensitive compaction area.

Operator can select different vibration frequencies for high or lowamplitude depending on the requirement. To have a differentdrum vibration frequency with high amplitude, vibration controllever to be operated in forward direction, similarly to have differentdrum vibration frequency with low amplitude, vibration controllever to be operated in backward direction. To stop the drumvibration, vibration control lever should be in neutral position.

GradeabilityGradeability of this machine is the result of a powerful torque-balanced hydrostatic propulsion system, which includes machinetwo–speed range capability and use of the high engine rpmselection. Engine low rpm selection is for idling only. Themachine’s low speed range is recommended for compactingwhile the high speed range for travelling.

BrakeThe standard parking brake is a part of the axle and is designedto use as a parking brake/emergency brake. The parking brakeis spring applied and hydraulically released. Loss of engine powerfor any reason or loss of hydraulic pressure to the brake circuitwill allow the parking brake to apply. The positioning of thepropulsion control lever to “STOP” position acts as a servicebrake. Drum drive motor will have additional spring appliedhydraulically released brake in case of machine with drum driveoption.

See page Service and maintenance of this operator’s manual foradditional information.

ServiceabilityMachine maintenance and service, as described in Service andmaintenance of this operator’s manual, will require placing themachine in the service position and need to open the engine hoodto access the engine, oil filter, fuel filters, battery, etc. Tilting ofthe operator’s seat is necessary for servicing hydraulic oil filters.

Railings/ROPS/Seat BeltThe machine is provided with railings, roll-over protectivestructure (ROPS) and a seat belt for operator safety. ROPS used

Presentation 7

in conjunction with a seat belt will lessen the possibility of deathor serious injury in the event of a rollover.

NOTICEBefore handling the machine, See page 33 .

Intended use

The machine (soil compactor) is intended to be used only for thecompaction of soil. Use of the machine for any other purpose,such as for towing other vehicles or equipment, is contrary to itsdesignated use. The manufacturer and local authorized dealer ordistributor cannot be held responsible for any damage resultingfrom such use.

If it is used for other purposes or in potentially dangerousenvironments, for example explosive atmosphere, flammableenvironment or areas with dust containing asbestos, etc., specialsafety regulations must be followed and the machine must beequipped for such use. Contact the manufacturer's localauthorized dealer or distributor for further information.

The risk of misuse lies entirely with the user.

Environmental requirements

Be aware of the environment when operating and during serviceand maintenance of the machine. Always follow local and nationalenvironmental legislation applicable to all handling of themachine.

Additional Icons

NOTICESome symbols shown in this section may not appear on yourmachine.

Machine specific symbols

Symbol Description Symbol DescriptionDrum vibration Anti-wheel spin

Drum vibration control Anti-drum spin

High amplitude Manual vibration control

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Presentation

Symbol Description Symbol DescriptionLow amplitude Auto vibration control

Frequency (vibration) Vibration control

Ignition switch Caution

Tie-down points and tow points

International symbols

Symbol Description Symbol DescriptionOn/start Seat (lap) belt

Off/stop Linear

On/Off Rotational

Plus (positive) Volume empty

Minus (negative) Volume half full

Horn Volume full

Battery condition Grease

Presentation 9

Symbol Description Symbol DescriptionHourmeter Oil lubrication point

Lift point Engine oil temperature

Jack or support point Engine coolant

Filling or emptying Engine coolant level

Read Operator's Manual Coolant temperature

Engine oil Engine rotations (rpm)

Engine oil pressure Gas inject (cold start)

Engine oil pressure – failure Engine air filter

Engine oil level Engine air filter – failure

Engine oil filter Fan belt – failure

Emergency engine stop Reverse direction

Engine start Parking brake

Engine on/run Brake on

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Presentation

Symbol Description Symbol DescriptionStart switch Brake off

Transmission Primer (start aid)

Transmission oil level Hydraulic oil

High gear Hydraulic oil pressure

Low gear Hydraulic oil level

Forward direction Hydraulic oil filter

Hydraulic oil temperature Control lever – multi-direction

Diesel fuel Clockwise rotation

Fuel level Counterclockwise rotation

Fuel filter Engine electrical preheat

Work light Fast speed

Presentation 11

Symbol Description Symbol DescriptionFlashing beacon Slow speed

Control lever – dual direction

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Presentation

Machine view

Directional termsThe terms left and right, when used in this manual, indicate thesides of the machine as seen from the operator seat facing thefront of the machine.1 Front2 Rear3 Left4 Right

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2

3 4

V11053 79

Machine view

Presentation

Machine view

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Location of components

V1100949

1

2

11

13

12

14

15

3

4

56

7

89

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1617

Location Of Components1 Engine area2 ROPS3 Operator control console4 Articulation lock pin5 Drum scraper

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Presentation

Machine view

6 Drum7 Torque hub / Drum drive motor8 Eccentric drive9 Shock mount10 Hydraulic tank11 Emergency stop switch12 Propulsion and Vibration control13 Axle and brake assembly14 Battery15 Battery disconnect switch16 Fuel tank17 Throttle lever

Operator's protective structure, componentlocations

V1104340

1

2

3

4

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Operator's protective structure1 Railing assembly2 Seat assembly3 Roll over protective structure (ROPS)4 Control group assembly5 Steering wheel6 Control box

Presentation

Machine view

15

CE-marking, EMC-directive

CE-markingIf this machine is CE-marked, this means that, when delivered,the machine meets the applicable “Essential Health and SafetyRequirements,” which are given in the EU Machinery Directive,2006/42/EC.

Any person carrying out changes that affect the safety of themachine is also responsible for the same.

As proof that the requirements are met, an EU Declaration ofConformity and a sound certificate regarding sound level in dB (A)are supplied with the machine. The sound certificate includes bothmeasured external values and guaranteed sound level. Thesedeclarations are issued by Volvo Construction Equipment foreach individual machine. This EU declaration also coversattachments manufactured by Volvo Construction Equipment.The documentation is a valuable document, which should be keptsafe and retained for at least 10 years. The document shouldalways accompany the machine when it is sold.

EU's EMC directive

The electronic equipment of the machine may in some casescause interference to other electronic equipment, or suffer fromexternal electromagnetic interference, which may constitutesafety risks.

The EU’s EMC-directive about “Electromagnetic Compatibility,”2004/108/EC, provides a general description of what demandscan be made on the machine from a safety point of view, wherepermitted limits have been determined and given according tointernational standards.

A machine or device which meets the requirements should be CE-marked. Our machines have been tested particularly forelectromagnetic interference. The CE-marking of the machineand the declaration of conformity also cover the EMC-directive.

If other electronic equipment is fitted to this machine, theequipment must be CE-marked and tested on the machine withregard to electromagnetic interference.

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Presentation

CE-marking, EMC-directive

Product plates

Machine identification

ManufacturerVolvo India Private Limited,7 & 8 , Phase 1, Peenya Industrial area,Bangalore- 560058,India.Phone: +91 80 2219 2500Fax :+91 80 2839 4651

Name & Machine typesSD110 Series of Single-Drum, Vibratory Soil Compactors.

Serial number and product rangeThe serial number effectivity for the SD110 Series of compactorscovered in this manual is outlined below.

Compactor Series Effective with Serial NumberSD110 Effective from S/N 52332 — 99999SD110 Effective from S/N 58000 — 99999

Product identification plateThe product identification plate is located on the front side of therear frame, in the articulation area.The product identification plate contains product identificationnumber (PIN). The PIN contains important information about themachine including the model number, the manufacturing codeand machine serial number.This information should be recorded and kept in a convenientlocation for future reference.When ordering spare parts, and in all telephone enquiries orcorrespondence the PIN must always be quoted.

Product identification plate

Presentation

Product plates

17

Engine, identification

Engine identification plateThe engine serial number and important information related toengine are available on the name plate which is fixed on crankcase. Open the engine hood to access engine identification plate.

The following important information should be recorded and keptin a convenient location for reference when contacting the localVolvo authorized service centre while ordering the parts.

Table. Reference numbers:ENGINE TYPERATING KW/HP @ RPMRATING STDGOVERNING CLASSENGINE No.

Engine identification plate

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Presentation

Product plates

Information and warning decalsThe operator should read, understand and follow the informationand warning decals which are positioned on the machine.

The decals must be kept free from dirt so that they can be readand understood. If they have been lost or no longer are legible,they must be replaced immediately. Refer to the Parts Cataloguefor this machine which identifies the proper location and partnumber (order number) of all decals. Contact your manufacturer’slocal authorized dealer or distributor for additional information orassistance as required.

Presentation

Information and warning decals

19

International decals1 Do not sit on rail. Never sit on railing around operator

compartment.

2 Crush area. Can cause serious injury or death. Installarticulation lock pin before servicing.

3 Improper operation of this equipment can cause serious injuryor death. Read and understand the operator and safetyinstructions before operating and servicing.

4 Rotating fan and belt. Can cause serious injury. Do not operatewith guards or shields removed. Stop machine beforeperforming maintenance.

5 Rollover of this machine can cause serious injury or death. Donot operate this machine near or on an inclined surface. Arollover can occur. If this machine has a rollover protectivestructure (ROPS), seat belts must be worn to avoid seriousinjury or death from being thrown out.

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Presentation


6 Radiator (expansion tank). Injury can result when removingthe expansion tank pressure cap. Steam or fluid escaping fromthe expansion tank can burn. Inhibitor contains alkali. Avoidcontact with skin and eyes. Always shut down the engine andallow to cool before removing the expansion tank pressurecap. Remove the expansion tank pressure cap slowly torelieve pressure. Avoid contact with steam or escaping fluid.

7 WARNINGUse of ether may cause explosion or severe injury. This engineis equipped with an electric heater starting aid. Do not useether.

Presentation


21

Decals/Plates and reflectors

V1100949

Location of Decals/Plates

REF NO. DECAL QUANTITY LOCATION1 Checklist 1 Cowling frame2 Warning: Rollover 1 Steps on hydraulic tank3 Warning: Do not sit on Rails 2 Railings4 Lube chart 1 Hydraulic tank5 Warning: Misoperation 1 Console6 Warning: Crushing hazard (each on both side) 2 Machine side frame7 Warning: Runaway machine 1 Console

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Presentation


USA federal clean air actThe Federal Clean Air Act Section 203.a (3) prohibits the removalof air pollution control devices or the modification of an EPA-certified non-road engine to a non certified configuration.The Federal regulations implementing the Clean Air Act for non-road engines, 40 CFR 89.1003(a)(3)(i), reads as follows:

The following acts and the causing thereof are prohibited:

For a person to remove or render inoperative a device or elementof design installed on or in a non-road engine vehicle orequipment in compliance with the regulations under this part priorto its sale and delivery to the ultimate purchaser or for a personknowingly to remove or render inoperative such a device orelement of design after the sale and delivery to the ultimatepurchaser.

The law prescribes a fine of up to $2,750 USD for each violation.

An example of a prohibited modifications is the recalibration ofthe fuel system so that the engine will exceed the certifiedhorsepower or torque.

You should not make a change to an EPA-certified non-roadengine that would result in an engine that does not match theengine configuration certified to meet the Federal Standards.

Customer AssistanceVolvo Construction Equipment wishes to help assure that theEmission Control System Warranty is properly administered. Inthe event that you do not receive the warranty service to whichyou believe you are entitled under the Emission Control SystemWarranty, you should contact the nearest Volvo ConstructionEquipment regional office for assistance.

Normal non-road engine useThe maintenance instructions are based on the assumption thatthis conventional machine will be used as designated in theoperator's instruction manual and operated only with the specifiedfuel and lubrication oils.

Non-road engine maintenanceThis is a non-road engine of conventional design and any localdealer may perform the necessary non-road emission controlmaintenance as defined in this manual.

Volvo recommends that the purchaser use the service programfor the non-road engine, known as preventative maintenance,including the recommended engine emission controlmaintenance.

In order to document that the proper regular maintenance hasbeen performed on the non-road engine, Volvo recommends thatthe owner keep all records and receipts of such maintenance.These records or receipts should be transferred to eachsubsequent purchaser of the non-road engine.

Presentation

USA federal clean air act

23

Service performed by your local dealerYour local dealer is best suited to give you good, dependableservice since he has trained service technicians and is equippedwith genuine original manufacturer's parts and special tools andthe latest technical publications. Discuss your servicing andmaintenance requirements with your local dealer. He can tailor amaintenance program for your needs.

For scheduled service or maintenance, it is advisable to contactyour local dealer in advance to arrange for an appointment toensure availability of the correct equipment and servicetechnician to work on your machine. In this way you will assistyour local dealer in reducing the time required to do service onyour machine.

Preventive maintenance programIn order for the conventional non-road engine to retain thereliability and performance parameters such as noise level andemission levels it had when delivered, it is essential that itreceives regularly scheduled service, inspections, adjustments,and maintenance.

Fuel systemFuel recommendations:The fuel used must be clean, completely distilled, stable and non-corrosive. Distillation range, cetane level and sulfur content aremost important when selecting fuel for optimum combustion andminimum wear.

Engine working conditions and ambient temperature influence theselection of the fuel with respect to cold handling properties andcetane levels.

In cold weather conditions, below 0 ºC (32 ºF), the use of lighterdistillate or higher cetane level fuel are recommended. (Finalboiling point maximum 349 ºC (660 ºF) and cetane minimum 45.).

In order to avoid excessive sedimentation and to minimize theemissions of sulfur dioxide, the fuel's sulfur content should be aslow as possible. The diesel fuels recommended for use shall meetASTM designation: D 975 no. 1D (C-B) or no. 2D (T-T) with acetane level above 42 and sulfur content not exceeding 0.05percent by weight.

Check for fuel leaks (with the engine running at high idle):Visually check unions and hose connections.

Check the condition of the fuel hoses for:AgeingCracksBlistersScuffing

Check the condition of the fuel tank:Drain condensation water.Check for cracks.Check for leaks.Check the mounting.

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Presentation


Check the turbocharger:Visually check for leaks in the intake hoses and exhaust pipeof the turbocharger.

Presentation


25

Instrument panelsInstrument panels

Control box which is mounted on control console has followingcontrol switches, emergency stop switch, ignition key switch, fuellevel gauge, horn, various indicators mounted on it. Hourmeterand mobile charger plug are mounted on the left side of the controlconsole.

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V1100601

1 2 5 6 7 9

1011 12

14 15 16 17 18 19 20 21 22

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Control box

1 Two speed switch 14 Air filter clog indicator2 Beacon light switch (Option) 15 Seat belt indicator3 Hazard switch 16 Engine preheat indicator4 Park brake test switch 17 High engine coolant indicator5 Park brake switch 18 Left turn signal indicator6 Front head lamp switch (high / Low beam) 19 Right turn signal indicator7 Rear working lights switch 20 Engine oil low pressure indicator8 Position lights switch 21 Battery no charge indicator9 Turn indicator lights switch 22 Front light high beam indicator10 Emergency stop switch 23 Mobile charger plug11 Ignition key switch 24 Hourmeter12 Fuel gauge13 Horn switch

1. Two speed switchIt is a two position (HIGH/LOW) rocker switch. A decal is placedon it to show HIGH and LOW position. All compaction work must

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Instrument panels

be done with the switch in the LOW position, while the HIGHspeed position is used for travelling.

NOTICEThe two speed switch position change should be done only whenthe machine is stationary and on level ground, with the parkingbrake in the “applied” position.

2. Beacon lamp switch (option)It is two position (ON/OFF) rocker switch. When the switch ispositioned to ON , beacon lamp starts flashing and revolving.

3. Hazard switchIt is two position (ON/OFF) rocker switch. When hazard switch ispositioned to ON , all turn indicating lamps flash simultaneously.

NOTICEWhen hazard switch is on, turn indicating lamps do not work asturn indicators.

4. Parking brake test switchIt is a rocker momentary switch, that provides the operator to testthe working of parking brake.

5. Parking brake switchIt is a rocker switch, that provides the operator with the means tomanually engage the parking brake. Red light is provided on theswitch which illuminates, when the parking brake switch is inON position. .

NOTICEMachine will not start, if the parking brake switch is in OFFposition.

6. Front head lamps switch (high / low beam)It is a three position (HIGH/LOW/OFF) rocker switch. When it ispositioned to HIGH activates front lights to high beam, When it ispositioned to LOW activates front lights to low beam, when it ispositioned to OFF, front lights are off.

7. Rear working lights switchIt is a two position (ON/OFF) switch. When it is positioned toON rear lights are on, when it is positioned to OFF, rear lights areoff.

9. Turn light Indicator switchIt is a three position (LEFT/OFF/RIGHT) rocker switch. Whenmoved to right, right side indicator lamps of the machine activatesand when moved to left, left side indicator lamps of the machineactivates.

Instrument panels 27

10. Emergency stop switchIt connects and disconnects electrical power from vehicle circuits.This provides the operator with a means to shutdown the vehicleoperation. When the button is pressed down, the main current isturned off, causing the machine to immediately shutdown and theparking brakes to get engaged.

Emergency stop switch should be set to normal position to restartthe machine

NOTICEEmergency stop switch must be used in case of emergency only .

11. Ignition key switchIgnition key is inserted/removed at the STOP position. Ignition keyswitch energizes the electrical system to preheat the engine,when turned anti-clockwise to the PREHEAT position. Thisactivity is for engine cold-startIgnition key switch energizes the electrical system, when turnedclockwise to the RUN position. When turned further clockwise tothe START position the starter motor is engaged. When theignition key is released the Ignition switch returns to the RUNposition automatically, . Turning the ignition key back to theSTOP position, turns off the electrical system and stops theengine.

12. Fuel level indicator

WARNINGStop the engine before filling fuel.

It indicates the fuel level in the fuel tank. It is an analogue gauge,with indication of “E” red colour, “1/2” mark and “F”.If the indicator shows fuel level in “E” red area, fill the fuel.

13. Horn push buttonPress the horn button to sound the horn and alert personnel tothe approaching machine or when changing direction.

14. Air filter clog indicatorIt glows when air filter is clogged.

15. Seat belt indicatorIt blinks if operator does not wear the seat belt or seat belt is notput properly. Operator has to wear the seat belt properly.

16. Engine preheat indicatorIt glows while preheating the engine.

17. Engine coolant indicatorIt glows when engine coolant temperature is high. Stop themachine immediately and check the coolant level.

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Instrument panels

18. Left turn signal indicatorIt indicates LEFT turn light indicators are on. It blinks when turnlight indicator switch is pressed ‘LEFT’ until it is pressed ‘OFF’.

19. Right turn signal indicatorIt indicates RIGHT turn light indicators are on. It blinks when turnlight indicator switch is pressed ‘RIGHT’ until it is pressed ‘OFF’.

20. Engine oil low pressure indicatorIt indicates the engine oil pressure is low.

21. Battery no charge indicatorIt glows, when alternator is not charging the battery.

22. Front lights high beam indicatorIt glows when front lights high beam switch is ON.

23. Mobile charger plugIt is mounted on the left side of control console. This is to facilitatemobile charging. It is directly connected to the battery. It does notwork if battery cut-off switch is OFF.

24. HourmeterIt is mounted on the left side of control console. It displays theengine run time in hours with a resolution of 0.1 hour.

Instrument panels 29

Other controlsControls

Travel control lever1 Travel control lever.

The Propulsion (TRAVEL) Control lever is located at the rightside of the operator’s seat. This control varies machinedirection and speed of travel. It also functions as the controlfor hydrostatic braking. The control has three positions,Forward (F) , Stop (S), and Reverse (R) with variable speedranges in either direction. To propel the machine forward,gradually move the control to the Forward position. To stop thetravel of the machine, move the control slowly back to the Stop(S) position. This also provides hydrostatic braking. To propelthe machine in reverse, gradually move the control backwardto the Reverse position. To stop the travel of the machine,move the control slowly back to the Stop (S) position. There isalso an electrical interlock switch on the control that allows theengine to be started only with the control lever in Stop (S).

2 Vibration control lever (VPM)The Vibration (VPM) Control is located at the right side of theoperator’s seat beside the Propulsion (Travel) control lever.The Vibration (VPM) Control lever varies the vibrations perminute of the drum.Vibration control lever helps operator to select high or lowamplitude and variable vibration frequency depending on therequirement. To have a varying drum vibration frequency withhigh amplitude, vibration control lever to be operated inforward direction, similarly to have a varying drum vibrationfrequency with low amplitude, vibration control lever to beoperated in backward direction, and for no drum vibrationmode, vibration control lever to be in neutral position.

Throttle control

The THROTTLE Control is located on the right side of the consolein front of operator seat. It is connected to the engine governorthru a cable. Move the control upward to obtain engine “HIGHRPM” and move the control downward to obtain engine “LOWRPM”.

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2

V1090832

Propulsion control lever.1 Propulsion control lever.2 Vibration control lever.

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Other controls

Controls

ROPS

ROPS

WARNINGRisk of crushing.The machine can tip over. This could result in serious injury.Ensure the ROPS is correctly installed.

WARNINGStructural damage caused by the machine rolling over or byunpermitted modification weakens the cab ROPS. Contact anauthorised Volvo dealer workshop if the ROPS has beendamaged or modified.

The machine is provided with roll-over protective structure(ROPS). ROPS used in conjunction with a seat belt will lessen thepossibility of death or serious injury in the event of a rollover.

Other controls

ROPS

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Operator comfort

Operator seat

WARNINGAdjusting the seat should always be done when the machine isstationary.

The machine is equipped with a suspension seat that features twoadjustments. The entire suspension seat assembly and attachedcontrol console can be positioned forward or reverse bypositioning the handle outward, locating the seat and thenreleasing the handle. Operator comfort, resistance to lowering,can be adjusted by rotating the handle clockwise for moreresistance and counterclockwise for less resistance to lowering.

Operator's manual, storage

Operator's manual storage is located in front of operators seat inthe control console. Keep the manual in the storage compartmentso that it is always at hand.

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Other controls

Operator comfort

Operating instructionsSafety rules when operating

Danger zone

The danger zone of this machine is the immediate area or zonesurrounding the machine, machine accessories or extensionswhich would allow contact with the machine if the machine,machine accessories or extensions were to move. Trained andauthorized personnel must first notify the operator of theirpresence and are permitted within the danger zone duringmachine operation. All other persons are not permitted in thedanger zone during machine operation.

Safety when handling the machine

Volvo Construction Equipment is only responsible if:- The machine has been used correctly and has been

maintained according to instructions in Service Manuals andthe Operator's Manual.

- Prescribed service and prescribed inspections have beenperformed at the stipulated points in time.

- The lubricant recommendations in the manual have beenfollowed.

- No security seals have been broken by unauthorized persons.- All modifications and repairs have been performed as

prescribed by Volvo.- Only Volvo genuine spare parts/accessories or attachments

that meet Volvo's requirements have been used.

WARNINGFor safety, observe the following rules.

DO NOT operate this machine if the sunshade assembly/ROPSor railing assembly got structurally damaged, shows cracks, is notproperly secured as originally installed, or has been involved in arollover.

DO NOT repair, modify, drill, weld on or add attachments to thesunshade assembly/ROPS, railing assembly or on the machineassembly unless authorized in writing by the manufacturer.

DO NOT operate the machine unless the seat belt conforming toSAE and/ or ASAE standards is fastened.

GeneralThe manufacturer cannot ensure for all possible circumstancesthat might lead up to a potential hazard. Therefore, thecombination of warnings listed in this manual and those placedon the machine itself are not intended to be all inclusive.

Operators and maintenance personnel must be alert to recognizeand avoid potential hazards. They should also havecomprehensive training, required skills and necessary tools toproperly perform their functions.


Safety rules when operating

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The machine is built in accordance with state-of-the-art standardsand recognized safety rules. Nevertheless, its misuse mayconstitute a risk to life and limb of the user or of third parties, andmay cause damage to the machine or other material property.

The machine must be used in accordance with its designated useas described in the operating manual. The machine must only beoperated by safety-conscious persons who are fully aware of therisks involved in operating the machine. Any functional disorders,especially those affecting the safety of the machine, must becorrected immediately.

The machine is designed exclusively for the compaction of soil.Use of the machine for purposes other than that mentioned (suchas for towing other vehicles/equipment) is considered contrary toits designated use. The manufacturer/supplier cannot be heldliable for any damage resulting from such use. The risk of suchmisuse lies entirely with the user.

Operating the machine within the limits of its designated use alsoinvolves compliance with the inspection and maintenancedirectives contained in the operating manual.

Selection and qualification of personnel

WARNINGMachine operators must have sufficient skills and knowledge ofthe content in the Operator's Manual before operating themachine.It is important that the operator reads and follows the instructionsin the machine's Operator's Manual.An untrained operator may cause serious injuries and fatalities.Never operate a machine for which there is no Operator's Manualavailable.Learn to understand the warning plates, symbols and operatinginstructions for the machine before you start operating.

Work on and with the machine must be performed by qualifiedpersonnel only. Statutory minimum age limits must be observed.

Individual responsibilities of the personnel responsible foroperation, setup, maintenance and repair of the machine shouldbe stated clearly.

Define the machine operator’s responsibilities - also with regardto observing traffic regulations - the operator should have theauthority to refuse instructions by third parties that are contrary tosafety.

Do not allow persons being trained or instructed in the operationor maintenance of the machine to work without permanentsupervision by an experienced person.

Work on the electrical system and equipment of the machine mustbe done only by a skilled electrician or by instructed personsunder the supervision and guidance of a skilled electrician andmust be in accordance with electrical engineering rules andregulations.

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Work on the mainframes, brake, hydraulic and steering systemsmust be performed by skilled personnel with special knowledgeand training for such work.

Organizational measuresSTOW manuals in the manual pouch/box provided on themachine. Manuals must always be available at the site where themachine is used.

OBSERVE AND INSTRUCT the user in all other generallyapplicable legal and mandatory regulations relevant to accidentprevention and environmental protection. These compulsoryregulations may also deal with the handling of hazardoussubstances, issuing and/or wearing of personal protectiveequipment, and traffic regulations.

SUPPLEMENT operating instructions with detailed workinginstructions pertaining to the specific work location.

ALWAYS be sure that persons entrusted with work on themachine have read the operating instructions and in particular thechapter on safety before beginning work. Reading the instructionsafter work has begun is too late. This is especially important forpersons who work only occasionally on the machine, e.g. duringset up or maintenance.

MAKE CERTAIN personnel are working in compliance with theoperating instructions and are alert to risks and safety factors.

ALWAYS tie back or otherwise secure long hair, wear close-fittinggarments and avoid wearing jewelry such as rings. Injury mayresult from clothing, hair, or jewelry being caught up in themachinery.

USE protective equipment wherever required by thecircumstances or by law. OBSERVE all safety instructions andwarnings attached to the machine.

BE SURE all safety instructions and warnings attached to themachine are complete and perfectly legible.

STOP the machine immediately in the event of any malfunction.REPORT the malfunction to the proper authority/person.

NEVER provide service or maintenance to the machine unlessthe drum and wheels are adequately chocked, articulation lockbar/pin is in locked position, and parking brake is applied.

NEVER make any modifications to the machine which mightaffect safety without the manufacturer’s approval. This applies tothe installation and adjustment of safety devices and valves aswell as to welding work on load bearing elements.

ALWAYS ADHERE to prescribed intervals or those specified inthe operating instructions for routine checks and inspections.

Safety when operating on public roads

Road signs, traffic restricting arrangements and other safetydevices, which may be required when considering traffic speedand intensity or other local conditions, must be used.



35

Rotating warning beacon may be used:- on vehicle during road maintenance work- when the vehicle constitutes a hindrance or impedes other

traffic- when working on or by the side of the roadway.

Electrocution hazard

DANGERRisk of electrocutionWorking near or making contact with overhead power lines maylead to electrical flash-over and electrocution.Always keep the minimum clearance from overhead power lines.

Operating the machine near overhead power lines requiresspecial precautions. Electrical flash-over may occur and causeserious injury to the operator and may also damage the machineand attachments even at great distances from the overheadpower lines. See page No.55 for overhead power line minimumclearances and procedures when operating near overhead powerlines.


GeneralThis machine has been carefully designed and built to provide asafe working environment when all safety warnings areunderstood and followed.

Prior to starting, operating or maintaining the machine, read andunderstand this manual, particularly the safety instructions.

Contact supervisor or manufacturer’s local authorized dealer ordistributor with any questions. Never guess about how to safelyoperate and maintain this equipment.

Make sure the machine is operated and maintained only bysafety-conscious persons who have been authorized, properlytrained, and have the required skills and tools to do their jobs. Allpersonnel must be alert to, recognize, and avoid potential hazardsassociated with performing their work.

Always wear or use proper personal protective equipment whileoperating or maintaining the machine.

Operate the machine only when it is in good condition. Anyfunctional disorders, especially those affecting the safety of themachine, must be corrected immediately. The machine must beused in accordance with its designated use as described in thisoperation and maintenance manual.

Make sure the machine is used only as intended by themanufacturer. Use of the machine for any other purpose, such asfor towing other vehicles or equipment, is contrary to itsdesignated use. See page No. 8 for an explanation of the intendeduse. The manufacturer and local authorized dealer or distributorcannot be held responsible for any damage resulting from suchuse. The risk of such misuse lies entirely with the user.

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Selection and qualification of personnelMake sure only qualified personnel work on and with the machine.Statutory minimum age limits must be observed.

Describe clearly the responsibilities of individuals who operate,setup, maintain and repair the machine.

Define the machine operator responsibilities for safe machineoperation, including observing traffic regulations. The operatorshould have the authority to refuse instructions by third partiesthat are contrary to safe practices.

Do not allow persons being trained or instructed in the operationor maintenance of the machine to work without continuoussupervision by an experienced person.

Allow only skilled electricians, or persons instructed by them, towork on the electrical system or electrical components of themachine. All electrical work must be performed in accordancewith electrical engineering guidelines and local regulations.

Be sure that work on the machine chassis, brake, hydraulic andsteering systems is performed only by skilled personnel trainedto perform such work.

Organizational measuresAlways make this operation and maintenance manual availablewhere this machine is used. Store it in the compartment providedon the machine.

Observe and instruct users of the machine in all generallyapplicable legal and mandatory regulations relevant to accidentprevention and environmental protection. These compulsoryregulations may also deal with the handling of hazardoussubstances, the issuing and/or wearing of personal protectiveequipment, and traffic regulations.

Supplement operating instructions with detailed work instructionsfor specific work activities and locations.

Always be sure that persons who operate or work on the machinehave read the operating instructions and especially, the safetyinformation. Reading the instructions after work has begun is toolate. This is especially important for persons who onlyoccasionally work on the machine, such as during set up ormaintenance.

Make certain personnel work in compliance with the operatinginstructions and are alert to risks and safety factors.

Be aware of personal safety hazards. Always tie back orotherwise secure long hair, and wear close-fitting garments.Avoid wearing jewellery such as rings, bracelets and necklaces.Injury may result from clothing, hair, or jewellery being caught inthe machinery.

Use personal protective equipment whenever required by workcircumstances or by law.

Observe all safety instructions in this manual and on decalsattached to the machine.



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Be sure all safety Warning and instruction decals attached to themachine are complete and readable.

Stop the machine immediately in the event of any malfunction.Report the malfunction to the proper supervisory personnel. Thecontinued operation of a machine that is not working properly maycause extensive damage to the machine or significantly increasehazards to operating personnel due to abnormal operatingconditions.

Never perform service or maintenance on the machine in anymanner other than that which is described in this manual.

Never make any modifications, additions or conversions to themachine which might affect safety without the manufacturer’sapproval in writing. This applies to the installation and adjustmentof safety devices and valves as well as to welding work on load-bearing components.

Always adhere to prescribed intervals listed in the operatinginstructions and maintenance instructions for routine checks,inspections and maintenance procedures. Performing scheduledpreventive maintenance consistently will extend the life of themachine.

Observe all fire fighting procedures.

Mandatory safety measuresNever clean, lubricate or service the machine when it is running.

Do not operate the machine while under the influence of drugs oralcohol.

Always use personal protective equipment, such as hard hats,safety shoes, eye and ear protection, while operating ormaintaining the machine.

Do not wear radio or music headphones while operating themachine.

Do not wear jewellery while operating the machine.

Replace any guards and shields removed, mount them securely,and clear all maintenance tools before starting the engine aftermaintenance.

Contact supervisor, or any manufacturer’s authorized dealer ordistributor, if there are any questions about the operation ormaintenance of this machine. Never guess – always check!

Remember, failure to adhere to these safety instructions mayresult in serious injury or even death.

Pre-start inspectionInspect the machine daily. Ensure that routine maintenance andlubrication procedures are dutifully performed.

Repair or replace any malfunctioning, broken, or missing parts.Refer to the preventive maintenance schedule located inmaintenance instructions in this manual.

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Verify that all safety warning and instruction decals are in placeand readable. These instructions are as important as any otherequipment on the machine. Refer to the decal location drawing inthe safety section of this operation and maintenance manual atsafety related decals.

Ensure that all safety and protective devices are in place and ingood working order.

Use caution when refuelling. Never fill the fuel tank with theengine running, while the machine is located near an open flame,or while operating personnel are smoking. Smoking is prohibitedwithin 15 m (50 feet) of the machine while refuelling.

Always fill the fuel tank either outside or in an adequatelyventilated room.

Always wipe up any spilled fuel.

Check for any maintenance and repair warning tags placed onthe machine. Do not operate the machine until repairs have beenmade and the warning tags have been removed by authorizedpersonnel.

Remove any dirt, debris or foreign material from the operatorplatform to reduce the danger of slipping.

Know the location of the emergency stop (E-Stop) switch.

Know the capabilities and limitations of the machine with respectto speed, gradeability, steering, and braking.

Be aware of the dimensions of the machine. This includes theheight and width of the overall machine, as well as the transporterdimensions and weight.

Working within dangerous areasCheck for dangerous conditions in the work area, such as holes,banks, underground culverts, manhole covers, water melt pits, orcurb and street boxes. Avoid any operation that might sacrificesafety.

This machine should only be brought into service where themachine is applicable to the situation and conditions of theconstruction site. This includes the stability and condition of theground, width of the driving lane, and any objects which wouldinterfere with the movement of the machine both above groundlevel and below ground level such as curbstones or ditches.

Safety instructions governing operationAvoid any operating mode or procedure that might sacrificesafety.

Avoid any operation that might risk machine stability.

Ensure that all necessary precautions are taken to ensure thatthe machine is used only when in a safe and reliable condition.

Operate this machine only if all safety and protective devicesoriginally provided by the manufacturer are in place and in goodcondition. This includes removable safety devices, emergencyshut off equipment, soundproofing elements and exhausts.



39

Make sure there is sufficient clearance when moving the machinethrough tunnels, underpasses, and under power lines.

Make sure bridges are rated to hold the weight of this machinebefore crossing them.

Check the machine at least once each shift for damage and reportdamage to your supervisor. If the machine is not operatingproperly, shut down the machine immediately. The continuedoperation of a machine that is not working properly may causeadditional damage to the machine or significantly increase thehazards to operating personnel due to abnormal operatingconditions.

Check the surrounding area for pedestrians. Make sure no one isin danger or at risk before starting the machine or setting it inmotion.

Check that braking, steering, signalling and lighting systems arefully functional before moving the machine.

Check that accessories have been safely stowed away beforesetting the machine in motion.

Observe all the valid traffic regulations when traveling on publicroads. Always make sure the machine is in a condition that meetsthose regulations.

Always keep a safe distance away from the edges of building pitsand slopes.

Always secure the machine to prevent inadvertent movement andunauthorized use before leaving it.

Provide an observer when loading and unloading the machinefrom a truck or trailer, or lifting it with a crane.

StartingAlways use hand rails and steps to get on and off the machine.Always maintain a three-point contact when climbing onto or offof the machine as shown.

Always wear the seat belt when operating the machine.

Read and follow all safety warning and instruction decals.

Turn on the lighting system in conditions of poor visibility and afterdark.

Check the surrounding area for pedestrians. Make sure no one isin danger or at risk before starting the machine or setting it inmotion.

Before attempting to start the engine, Ensure that the forward-stop-reverse (FSR) propulsion control lever is in the S (stop)position.

Watch the indicators during start-up and shutdown procedures inaccordance with the operating instructions. See operatinginstructions in this manual.

Before starting the engine, ensure that the parking brake controlis in the “applied” position, See page No. 26 for parking brakecontrol details.

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Start the engine only while at the operator console.

Boost starting

WARNINGNever boost-start the machine by connecting directly to the startermotor. This may result in uncontrolled machine movements.When using another machine to boost-start, it must not touch themachine that is being started.

Avoid equipment damage by making sure that the machinereceiving a boost-start does not come in contact with the machinesupplying the boost-start.

Never boost-start a frozen battery, it will explode.

Be aware that lead acid batteries generate explosive gases whilecharging. Keep sparks, flames and lighted smoking materialsaway from batteries.

Always wear eye protection when working on or near batteries.

Follow these procedures when boost-starting the machine.1 Connect the Positive (+) terminal of the booster battery to the

Positive (+) terminal of the discharged battery.2 Connect the Negative (–) terminal of the booster battery to the

best ground point on the machine, away from the battery.3 Follow all recommended engine starting procedures.4 Remove the booster cables in the reverse order of their

connection as soon as the engine has started.

OperatingMake sure no person or obstruction is in your line of travel beforemoving the machine.

Look in all directions before changing your direction of travel.

Never climb on or off the machine while it is operating or moving.

Use extreme caution and be observant when operating themachine in close quarters or in congested areas.

No riders. Never carry passengers.

Know the hand signals used (required) for particular machineoperations and machine travel, and know who has theresponsibility for signalling.

Know the area in which you are working. Familiarize yourself withwork site obstructions and any other potential hazards in the area.

Always remain seated with the seat belt on when operating themachine whether compacting, travelling, or loading andunloading.

Close all sound baffles during operation.

Do not work in the vicinity of overhanging banks or on grades thatcould cause the machine to slide or roll over.

Avoid side hill travel. Always operate up and down slopes. Neverchange to a lower gear on a slope; always change before



41

reaching it. Always keep the FSR propulsion control lever in lowspeed range close to the S (stop) position when climbing ordescending hills.

Never allow anyone to stand within the machine’s articulationarea when the engine is running.

Control the machine travel speed with the FSR propulsion controllever.

Control engine speed with the throttle control. Always performcompacting operations at high engine speed.

Do not tow the machine except as explained in the operatinginstructions of this manual.

Do not run the engine in a closed building for an extended lengthof time. Exhaust fumes can kill.

Read and follow all safety warning and instruction decals.

StoppingAlways park the machine on solid level ground. If this is notpractical, park the machine at a right angle to the slope and blockthe drum and wheels.

Reduce the travel speed by moving the FSR propulsion controllever slowly toward the S (stop) position. To stop the machine,slowly push the FSR propulsion control lever to the S (stop)position. Apply the parking brake. Install the articulation lock pin.Position the throttle control to “idle rpm”. Turn ignition switch toOFF, and lock all lockable compartments.

Always be sure that all control switches are in the OFF positionand that the engine is shut down before leaving the machine.

Always retract the seat belt fully before leaving the operatorstation.

Always mount and dismount the machine using walkways, stepsand handrails provided. Never jump from the operator platform tothe ground.

Always maintain a “three-point contact” when climbing on or offthe machine. Refer to safety rules for starting.

Use proper flags, barriers, and warning devices to warn others ofthe machine, especially when parking in areas of heavy traffic.

MaintenanceFollow the start-up and shutdown procedures set forth in theoperating instructions before performing any work on themachine. This includes the operation, conversion or adjustmentof the machine and its safety oriented devices, and any workrelated to maintenance, inspection and/or repair.

Ensure that the maintenance area is adequately secured asoutlined below.

Secure the machine against inadvertent starting, if it is completelyshut down for maintenance and repair work. See page No. 92

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for procedure to secure the machine for maintenance and repairwork.

Check de-energized parts for the presence of power. Ground orshort circuit any parts found to contain residual power. Insulateadjacent live parts and elements.

Check and inspect machine electrical equipment at regularintervals. Faults, such as loose connections or scorched cables,must be corrected immediately.

Lifting the machine – When raising the machine off the ground,apply the parking brake. Attach the lifting apparatus only to themachine’s designated lifting points using properly rated liftingstraps, cables, or chains. Use spreader bars to ensure equalweight distribution during lifting as well as avoid contact with themachine.

Use care when attaching and securing lifting tackle to individualparts and large assemblies being moved for replacementpurposes to avoid the risk of accidents. Use lifting gear that is inproper operating condition and with adequate lifting capacity.Never work or stand under suspended loads.

NOTICELifting the machine must only be carried out by trained personnel.

Perform maintenance and repair work only if the machine ispositioned on stable and level ground and has been secured toprevent movement.

Keep all platforms and standing surfaces free from mud, dirt,snow and ice.

Always use the correct tools and workshop equipment whenperforming maintenance on the machine.

Clean the machine at the end of each workday while it is stillwarm.

Clean the machine, especially connections and threaded unions,of any traces of oil, fuel or preservatives before carrying outmaintenance or repair. never use aggressive detergents. Use lintfree cleaning rags.

Cover or tape all openings which – for safety and functionalreasons – must be protected against water, steam or detergentpenetration before cleaning the machine with water, steam jet(high pressure cleaning) or detergents. Special care must betaken with electric motors and switch gear cabinets.

Ensure during cleaning of the machine that temperature sensorsdo not come into contact with hot cleaning agents.

Remove all covers and tapes applied for that purpose aftercleaning the machine.

Examine all fuel, lubricant, and hydraulic fluid lines for leaks,loose connections, chafe marks and damage after cleaning.

Repair or replace faulty parts immediately.

Tighten any screwed connections that have been loosened duringmaintenance and repair.



43

Replace and check any safety devices removed during setup,maintenance or repair activities. Do this immediately uponcompletion of the maintenance and repair activity.

Avoid servicing, cleaning, or examining the machine with theengine running, whenever possible.

Do not perform service or maintenance on the machine unlessthe drum and wheels are adequately blocked, the articulation lockpin is in the locked position, and the parking brake is applied. Besure the machine is adequately secured to prevent movement,See page No. 92.

Never fill the fuel tank of the machine with the engine running. Donot permit sparks, open flames or smoking within 15 m (50 feet)of the machine while refuelling. Always wipe up any spilled fuel.

Do not alter the engine governor settings from those indicated inthe engine manual and the engine option plate.

Always replace damaged or lost warning and instruction decals.It is dangerous to operate the machine without these decals.Refer to the parts manual for the proper location and part numberof all decals.

Disconnect the battery cables when working on the electricalsystem.

Be sure the battery area is well ventilated (clear of fumes) shouldit be necessary to connect a jump battery or battery charger.Fumes from the battery can ignite by a spark and explode.

Be sure the battery charger is turned off when making theconnections if battery charging is required.

Inspect and check the machine’s electrical equipment at regularintervals. Faults, such as loose connections or scorched cablesmust be corrected immediately.

Inspect hydraulic hose assemblies visually at regular intervals.Replace them if they show signs of chafing, cracking, brittleness,deformation, blistering, leakage, fitting separation, corrosion orother damages which may affect their function and strength.

Inspect hydraulic hoses and screwed connections regularly. Lookfor leaks and signs of damage. Replace faulty parts immediately.

Remember that hot hydraulic fluid will cause serious burns. Waitfor hot hydraulic fluid to cool down before disconnecting hydrauliclines.

Do not work on hydraulic lines while the engine is running and thesystem is under pressure. The hydraulic fluid remains underpressure long after the engine has been stopped. Do not work onany hydraulic hose or fitting until the pressure has been relievedcorrectly.

Never use your hands to check for hydraulic leaks wheninspecting an hydraulic system. Use a piece of cardboard tocheck for leaks, and always wear gloves and eye protection whilechecking.

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Remember that fluid penetration from a pin-hole leak can causeserious injury or death. Get immediate treatment if hydraulic fluidhas been injected under your skin.

Depressurize the hydraulic system sections to be serviced beforeservicing them. Follow the manufacturer’s instructions for thespecific equipment involved.

Lay and fit hydraulic lines properly. Ensure that no connectionsare interchanged. The fittings, lengths and quality of the hosesmust comply with the technical requirements.

Observe all product related safety regulations when handling oil,grease and other chemical substances.

Ensure that all consumable and replaced parts are disposed of inan environmentally safe manner and in accordance with localguidelines and regulations.

Use only original fuses with the specified current rating. Switchoff the machine immediately if trouble occurs in the electricalsystem.

Allow only a skilled electrician, or instructed person working underthe supervision and guidance of a skilled electrician, to work onthe electrical system of the machine. All work must be done inaccordance with electrical engineering guidelines and localregulations.

Remove electrical power to components of the machine beforeperforming inspection, maintenance and repair work. Followestablished lockout, tagout procedures.

Be careful when handling hot fluid or parts to avoid burning orscalding. Wear appropriate personal protective equipment.

Use only genuine original equipment manufacturer’s replacementparts. This will protect the warranty and ensure the safe operationand optimum performance of the machine.

Welding safely on the machineProper welding procedures are necessary in order to avoiddamage to the electronic controls and to the bearings.

Allow only qualified and authorized personnel to weld, flame cutor perform any grinding work on the machine. There may be a riskof explosion and fire.

Clean the machine before starting welding, flame cutting andgrinding operations. Remove dust and other flammablesubstances and make sure that the premises are adequatelyventilated to avoid the risk of fire and explosion.

Make sure all welding work is carried out by fully trained,instructed, qualified and authorized personnel. All regulations andsafety stipulations must be strictly adhered to as well as thegenerally recognized standards for performing welding work.

Disconnect the battery cables when welding on the machine.

Ensure the clamp on the earth cable (ground) has a good contactnear the joint to be welded.



45

Ensure that the welding current does not flow through anybearings.

Transporting, towing, and roadingSecuring the machine for transport – When securing the machinefor transport, use only the designated tie-down locations to fastenthe to the transport vehicle. Decals on the machine indicate thelocations to tie the machine down. Use only properly rated tie-downs and securing equipment. Place blocks at the front and rearof the machine while securing to the transport vehicle. If thetransport vehicle will be stationary for an extended period of timewithout being moved, do not remove the blocks until transportingthe machine.

Use only appropriate means of transport and lifting gear ofadequate capacity.

Entrust to experienced persons only the fastening of loads andthe instructing of crane operators. The personnel giving theinstructions must be within sight or sound of the operator.

Do not attempt to load the machine on the transporters withoutknowledge and experience with the operation of the machine.

Always use a ramp when loading the machine on the transporter.Be sure ramps are of adequate strength, low angle, and properheight and width.

Be sure that the transporter is on level ground when loading themachine.

Use proper blocks in front and rear of the wheels of the transporterwhen loading the machine.

Ensure the transporter is on level ground. Approach thetransporter loading ramps squarely to make sure the machinedoes not drop off the side of the ramp.

Keep the transporter deck clean of clay, oil, mud, ice, frost andother material that can become slippery.

Use proper blocks to secure the drum and rear wheels of themachine once it is loaded onto the transporter.

Shut the engine down, apply the parking brake, and lock alllockable compartments.

Ensure the articulation lock pin is secured in the locked positionbefore transporting the machine.

Know the overall height of the machine and transporter. Observeheight and weight regulations, and at overhead objects be sureyou can safely pass beneath them. Refer to operating instructionsof this manual for proper brake release procedures.

Obey all traffic regulations and be sure that the proper clearanceflags, lights, and warning signs, including the “Slow MovingVehicle” emblem, are properly displayed when moving themachine on public access roads.

Know the approximate stopping distance at any given speed.

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Never turn corners at excessive speeds. Look in all directionsbefore reversing direction of travel.

Position the machine on the transporter centred from side to sideand apply the brake.

Refer to operating instructions of this manual for proper towinginstructions.

Safe operation of the machine

Pre Start InspectionINSPECT your machine daily. Ensure that the routinemaintenance and lubrication are being dutifully performed. Haveany malfunctioning, broken, or missing parts repaired or replacedbefore use.

VERIFY that all instruction and safety labels are in place andreadable. These are as important as any other equipment on themachine.

NEVER fill the fuel tank with the engine running, while near anopen flame, or while smoking.

ALWAYS wipe up any spilled fuel.

CHECK for WARNING tags placed on the machine. DO NOToperate the machine until repairs have been made and theWARNING tags have been removed by authorized personnel.

Check the seat belt regularly for wear or damage. Inspect belthardware and fabric. Replace if hardware is damaged or if strapis nicked, frayed or loose stitching is found. Check that mountinghardware is tight.

CLEAN any foreign material from the operator’s platform toreduce the danger of slipping.

KNOW the location of the Emergency Shut-Down Control if themachine is so equipped.

ALWAYS know the capabilities and limitations of your equipment-speed, gradeability, steering, and braking.

BE AWARE of the dimensions of your machine height and weight,as well as your transporter dimensions and weight.

Never smoke when refueling or expose diesel fuelto open flames

Check the seat belt regularly for wear or damage



47

CHECK for any job site conditions that could be dangerous suchas; holes, banks, underground culverts, manhole covers, watermeter pits, curb and/or street boxes.

Safety precautionsAVOID any operational mode that might sacrifice safety.

TAKE all necessary precautions to ensure that the machine isused only when in a safe and reliable condition.

OPERATE the machine only if all protective and safety orienteddevices, such as removable safety devices, emergency shut offequipment, soundproofing elements and exhausts, are in placeand fully functional.

START the machine from the driver’s seat only and always wearthe seat belt.

WATCH the indicators during start up and shutdown proceduresin accordance with the operating instructions.

MAKE SURE no one is at danger or risk before starting up orsetting the machine in motion.

CHECK that braking, steering, signalling and lighting systems arefully functional before starting work or travelling with the machine.

CHECK that accessories have been safely stowed away beforesetting the machine in motion.

OBSERVE the valid traffic regulations when travelling on publicroads and ways and MAKE SURE the machine is in a conditioncompatible with these regulations.

ALWAYS SWITCH ON the lighting system in conditions of poorvisibility and after dark.

MAKE SURE there is sufficient clearance when crossingunderpasses, bridges and tunnels or when passing underoverhead lines.

ALWAYS KEEP at a distance from the edges of building pits andslopes.

AVOID any operation that might be a risk to machine stability.

NEVER CHANGE the speed on a slope, always change beforereaching it. On sloping terrain, always adapt your travelling speedto the prevailing ground conditions.

ALWAYS SECURE the machine against inadvertent movementand unauthorized use before leaving the driver’s seat.

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StartingALWAYS USE three point contact, hand rails and steps to get onand off the machine.

READ and FOLLOW ALL instruction decals.

ALWAYS be seated with the lap-type seat belt on when operatingthe machine.The seat and seat belt is designed for use by one adult, not more.

BEFORE starting the engine, ENSURE that the propulsion controllever is in the “STOP” position.

BEFORE starting the engine, ENSURE that the parking brakecontrol is in the “Applied” position.

START the engine from the operators position only.

WARNINGNever boost-start the machine by connecting directly to the startermotor. This may result in uncontrolled machine movements.When using another machine to boost-start, it must not touch themachine that is being started.

NOTICESevere injury or death could result from the machine lurchingforward or backward and running over the person/s attempting tojump start the machine. Normal safety devices are bypassedwhen jump starting directly to the starter or starter solenoid.

NEVER jump start a frozen battery, as it will explode. Whilecharging, lead acid batteries generate explosive gases.

Always maintain a three-point contact whenclimbing on or off of the machine

Seat belt must be fastened at all times whenoperating the machine



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KEEP SPARKS, flames and lighted smoking materials away frombatteries. While charging, lead acid batteries generate explosivegases.

ALWAYS wear safety glasses when working on or near batteries.

PROCEED as follows when jump starting the machine:Connect the Positive (+) terminal of the booster battery to thePositive (+) terminal of the discharged battery.Connect the Negative (-) terminal of the booster battery to thebest ground point of the machine away from the battery.Follow all recommended engine starting procedures.Remove the jumper cables in the reverse order of theirconnection as soon as the engine has started.

OperatingALWAYS make sure that no person or obstruction is in your lineof travel before starting the machine in motion.

NEVER CLIMB onto or off of the machine while it is in motion.

ALWAYS remain seated with the seat belt on when operating themachine whether compacting, travelling, or loading/unloading.

USE EXTREME CAUTION and be very observant whenoperating in close quarters or congested areas.

NEVER carry passengers.

CLOSE all sound baffles during operation.

KNOW the area in which you are working. Familiarize yourselfwith work site obstructions and any other potential hazards in thearea.

KNOW and USE the hand signals required for particular jobs andknow who has the responsibility for signalling.

DO NOT work in the vicinity of overhanging banks or on gradesthat could cause the machine to slide or roll over.

AVOID side hill travel. ALWAYS operate up and down slopes.ALWAYS keep the two speed switch in low speed position andpropulsion control lever in low speed range close to the STOPposition when climbing or descending hills.

NEVER allow anyone to stand within the machine's articulationarea when the engine is running.

USE the left hand side provision as an emergency exit in case ofa rollover of a machine .

ALWAYS LOOK in all directions BEFORE changing your directionof travel.

DO NOT attempt to control compactor travel speed with thethrottle control. When operating the compactor maintain theengine speed at full “Operating rpm.”

For towing a machine, See page No. 76, and the instructions inthe machine Operator's Manual.

DO NOT run the engine in a closed building for an extendedlength of time. EXHAUST FUMES CAN KILL.

Do not smoke near batteries

50



Accidents

WARNINGOnly the operator, seated in the operator's seat, may be in thecab when operating. All other personnel must keep at a safedistance from the machine.

Accidents and also incidents should be reported to the sitemanagement immediately.

If possible leave the machine in position.

Only take necessary action so as to reduce the effect ofdamage, especially personal injuries. Avoid action which maymake an investigation more difficult.

Take part in the emergency plan for the working site or otherinstructions about measurements in case of accidents.

Wait for further instructions from the site management.

Operator duties


1 Read and understand the Operator's manual.2 NEVER make any modifications to the machine which might

affect safety without the VOLVO’s approval. This applies to theinstallation and adjustment of safety devices and valves aswell as to welding work on load bearing elements.

3 The machine is designed exclusively for the compaction ofsoil. Use of the machine for purposes other than thatmentioned (such as for towing other vehicles/equipment) isconsidered contrary to its designated use. The VOLVO/supplier cannot be held liable for any damage resulting fromsuch use. The risk of such misuse lies entirely with the user.

4 The machine operator's must operate the machine in such away that the risk of accidents is minimised both for theoperator, other road users and person present at the work site

5 Never allow an untrained or unqualified person to operate themachine

6 The machine operator must be thoroughly familiar with how tooperate and maintain the machine and should undergorequired training on the machine.

7 The machine operator must follow the rules andrecommendations given in the operator's manual, but also payattention to any statutory and national regulations or specificrequirements or risks that apply on the work site.



51

8 The machine operator must be thoroughly rested and mustnever operate the machine under the influence of alcohol,medicine or other drugs.

9 The machine operator must be in charge of the working areaof the machine, Prevent person from walking or standing nearthe machine while operating the machine ..

10 Do not allow persons being trained or instructed in theoperation or maintenance of the machine to work withoutpermanent supervision by an experienced person.

Accidents1 Accidents and also incidents should be reported to the site

management immediately.2 If possiable leave the machine in proper position.3 Only take necessary action in order to reduce the effect of

damage, especially personal injuries. Avoid action which maymake an investigation more difficult.

Machine operator safety1 AVOID any operational mode or procedure that might sacrifice

safety.2 TAKE all necessary precautions to ensure that the machine is

used only when in a safe and reliable condition.3 The machine must be operational, i.e fault which can cause

accidents must be rectified.4 ALWAYS wear or use the proper safety items required for your

personal protection.5 ALWAYS tie back or otherwise secure long hair, wear close-

fitting garments and avoid wearing jewelry such as rings. Injurymay result from clothing, hair, or jewelry being caught up inthe machinery.

6 CHECK the seat belt regularly for wear or damage. Inspectbelt hardware and fabric. Replace if hardware is damaged orif strap is nicked, frayed or loose stitching is found.

7 USE protective equipment wherever required by thecircumstances or by law.

8 OBSERVE all safety instructions and warnings attached to themachine.

9 OBSERVE all safety instructions and warnings attached to themachine.

10 BE SURE all safety instructions and warnings attached to themachine are complete and perfectly legible.

11 STOP the machine immediately in the event of safety relevantmalfunction or change in machine behavior during operation.REPORT the malfunction to the proper authority/person.

12 NEVER provide service or maintenance to the machine unlessthe drum and wheels are adequately chocked, articulation lockbar/pin is in locked position, and parking brake is applied.

13 ALWAYS SWITCH ON the lighting system in conditions ofpoor visibility and after dark.

14 MAKE SURE there is sufficient clearance when crossingunderpasses, bridges and tunnels or when passing underoverhead lines.

15 ALWAYS KEEP at a safe distance from the edges of buildingpits and slopes.

16 AVOID any operation that might be a risk to machine stability.17 NEVER CHANGE to a lower speed on a slope always change

before reaching it. On sloping terrain, always adapt yourtravelling speed to the prevailing ground conditions.

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18 ALWAYS SECURE the machine against inadvertentmovement and unauthorized use before leaving the driver’sseat.

19 During electrical storms, do not enter or exit the machine.If you are off the machine, stay well away from the machineuntil the storms passes.If you are in the machine, remain seat with the machinestationary until the storm passes. Do not touch controls oranything metals.

20 AVOID personnel injury by making sure the compactor doesnot touch the other machine while it is being jump started.

21 NEVER jump start a frozen battery, as it will explode. Whilecharging, lead acid batteries generate explosive gases.

22 KEEP SPARKS, flames and lighted smoking materials awayfrom batteries. While charging, lead acid batteries generateexplosive gases.

23 ALWAYS wear safety glasses when working on or nearbatteries.

Handling hazardous materials

The following information is provided to assist the machineowners and operators. Further information may be obtained bycontacting the local manufacturer’s authorized distributor. Thefollowing substances, shown in below, are contained in or emittedby this machine and may be hazardous to health if exposed to orused incorrectly.

Substance PrecautionAntifreeze Avoid ingestion, skin contact and breathing fumesHydraulic oil Avoid ingestion, skin contact and breathing fumesEngine lubricating oil Avoid ingestion, skin contact and breathing fumesPreservative grease Avoid ingestion, skin contact and breathing fumesRust preventive Avoid ingestion, skin contact and breathing fumesEngine fuel Avoid ingestion, skin contact and breathing fumesBattery electrolyte Avoid ingestion, skin contact and breathing fumesSAE gear oil Avoid ingestion, skin contact and breathing fumesThe following substances may be produced during the operation of this machine and may be hazardous to health.

Substance PrecautionEngine exhaust fumes Avoid breathing fumesEngine exhaust fumes Avoid buildup of fumes in confined spacesElectric motor dust (brushes/ insulation) Avoid breathing during maintenance



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Battery disposal

WARNINGThe battery electrolyte contains caustic sulphuric acid. If thiscomes in contact with your skin rinse it off with soap and lots ofwater. If acid has come in contact with your eyes or other sensitiveparts of your body rinse off with lots of water and seek medicaladvice as quickly as possible.

Batteries contain substances dangerous to your health and theenvironment. Dispose of batteries marked with the symbol shownbelow according to local and national regulations. Rememberbattery electrolyte is corrosive. Do not dispose as general trash.

Electrocution hazard

WARNINGWorking near power lines may lead to electrical flash-over.Remain in the machine while it is in contact with the power line.Do not touch any metal surfaces in the cab. Warn personneloutside the machine not to touch it.

When operating the machine, maintain a safe distance fromoverhead electric lines. If work is to be carried out close tooverhead lines, keep this machine away from them.

Observe the following procedure if your machine comes in contactwith electric power lines:

Stay in the operator seat.Do not touch any part of the machine.Warn other workers to stay away and not touch any control orany other part of the machine.If contact can be broken, drive the machine away from thedanger zone.If contact cannot be broken, stay in the operator seat until toldthat the power is off.

Failure to obey this Warning could result in electrocution or death.

Suffocation hazard

WARNINGExhaust fumes contain carbon monoxide, a colorless, odorlessgas, which is fatal when inhaled in a confined area. Avoidbreathing exhaust fumes and be sure engine operation will notcause a concentration of toxic emissions.

Breathing exhaust fumes from internal combustion engines canlead to loss of consciousness, carbon monoxide poisoning andsuffocation.

Never operate internal combustion engines in an enclosed areawith poor ventilation.

Failure to obey this Warning could result in carbon monoxidepoisoning and death.

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Power lines, minimum clearance

DANGERRisk of electrocutionWorking near or making contact with overhead power lines maylead to electrical flash-over and electrocution.Always keep the minimum clearance from overhead power lines.

High voltage is lethal and may be powerful enough to destroymachine and attachments. Always contact your local authoritybefore starting work operations near overhead power lines.

Operating the machine near overhead power lines requiresspecial precautions.Consider all overhead power lines to be 'live' with electric power,even those that are supposed to be without electric power.Contact with overhead power lines may cause the power to tripout temporarily and power may be re-energised automaticallywithout warning. Electrocution is possible if anyone touches boththe machine and the ground.Always be aware of the very serious risk if your machine comesin contact with high voltage. Remember that the voltage in thepower line determines the safety distance. Electrical flashoversmay damage the machine and injure the operator at relativelygreat distances from the power line. Always keep the minimumclearance from overhead power lines, see the table below.

Minimum clearance from overhead power lines

Voltage of overhead powerlines

Volt (V)

Minimum distancem ft

up to 50,000 3 1050,000 to 69,000 4 13

69,000 to 138,000 5 16.4138,000 to 250,000 6 20250,000 to 500,000 8 26500,000 to 550,000 11 35550,000 to 750,000 13 43more than 750,000 14 46

Know the location and voltage of all overhead power lines at thejob site before operating the machine.Contact your local authority if there is any question whether thepower lines are energised or their voltage.

Keep the following in mind to ensure safety when operating:Operate the machine at slower than normal operation in thevicinity of power lines.Consider the long-span power line, which can sway and reducethe clearance.Pay attention when travelling over uneven ground that couldcause the machine to lose balance.



55

Keep all persons away from the machine whenever it is closeto power lines.Prohibit persons from touching the machine or its load beforeit is confirmed to be safe.

If your machine comes in contact with overhead power linesStay in the operator seat while the machine is in contact withthe power line.Warn personnel outside the machine not to touch any part ofthe machine and to stay away.Stay in the operator seat and lower any raised parts in contactwith the overhead power lines, or drive the machine out of theoverhead power lines if you can.If contact cannot be broken, stay in the operator seat until toldthat the power is off.If you need to get out because of fire, jump out as far as youcan without touching any wires or the machine — keep uprightand away.Find out what actions need to be taken if a person has beenexposed to an electrical flashover.

Failure to follow this instruction can result in electrocution ordeath!

56



Measures before operating

Safety when handling the machine

Volvo Construction Equipment is only responsible if:- The machine has been used correctly and has been

maintained according to instructions in Service Manuals andthe Operator's Manual.

- Prescribed service and prescribed inspections have beenperformed at the stipulated points in time.

- The lubricant recommendations in the manual have beenfollowed.

- No security seals have been broken by unauthorized persons.- All modifications and repairs have been performed as

prescribed by Volvo.- Only Volvo genuine spare parts/accessories or attachments

that meet Volvo's requirements have been used.


DO NOT operate this machine if the sunshade assembly/ROPSor railing assembly got structurally damaged, shows cracks, is notproperly secured as originally installed, or has been involved in arollover.

DO NOT repair, modify, drill, weld on or add attachments to thesunshade assembly/ROPS, railing assembly or on the machineassembly unless authorized in writing by the manufacturer.

DO NOT operate the machine unless the seat belt conforming toSAE and/ or ASAE standards is fastened.

GeneralThe manufacturer cannot ensure for all possible circumstancesthat might lead up to a potential hazard. Therefore, thecombination of warnings listed in this manual and those placedon the machine itself are not intended to be all inclusive.

Operators and maintenance personnel must be alert to recognizeand avoid potential hazards. They should also havecomprehensive training, required skills and necessary tools toproperly perform their functions.

The machine is built in accordance with state-of-the-art standardsand recognized safety rules. Nevertheless, its misuse mayconstitute a risk to life and limb of the user or of third parties, andmay cause damage to the machine or other material property.

The machine must be used in accordance with its designated useas described in the operating manual. The machine must only beoperated by safety-conscious persons who are fully aware of therisks involved in operating the machine. Any functional disorders,especially those affecting the safety of the machine, must becorrected immediately.

The machine is designed exclusively for the compaction of soil.Use of the machine for purposes other than that mentioned (such



57

as for towing other vehicles/equipment) is considered contrary toits designated use. The manufacturer/supplier cannot be heldliable for any damage resulting from such use. The risk of suchmisuse lies entirely with the user.

Operating the machine within the limits of its designated use alsoinvolves compliance with the inspection and maintenancedirectives contained in the operating manual.

Selection and qualification of personnel


Work on and with the machine must be performed by qualifiedpersonnel only. Statutory minimum age limits must be observed.

Individual responsibilities of the personnel responsible foroperation, setup, maintenance and repair of the machine shouldbe stated clearly.

Define the machine operator’s responsibilities - also with regardto observing traffic regulations - the operator should have theauthority to refuse instructions by third parties that are contrary tosafety.

Do not allow persons being trained or instructed in the operationor maintenance of the machine to work without permanentsupervision by an experienced person.

Work on the electrical system and equipment of the machine mustbe done only by a skilled electrician or by instructed personsunder the supervision and guidance of a skilled electrician andmust be in accordance with electrical engineering rules andregulations.

Work on the mainframes, brake, hydraulic and steering systemsmust be performed by skilled personnel with special knowledgeand training for such work.

Organizational measuresSTOW manuals in the manual pouch/box provided on themachine. Manuals must always be available at the site where themachine is used.

OBSERVE AND INSTRUCT the user in all other generallyapplicable legal and mandatory regulations relevant to accidentprevention and environmental protection. These compulsoryregulations may also deal with the handling of hazardoussubstances, issuing and/or wearing of personal protectiveequipment, and traffic regulations.

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SUPPLEMENT operating instructions with detailed workinginstructions pertaining to the specific work location.

ALWAYS be sure that persons entrusted with work on themachine have read the operating instructions and in particular thechapter on safety before beginning work. Reading the instructionsafter work has begun is too late. This is especially important forpersons who work only occasionally on the machine, e.g. duringset up or maintenance.

MAKE CERTAIN personnel are working in compliance with theoperating instructions and are alert to risks and safety factors.

ALWAYS tie back or otherwise secure long hair, wear close-fittinggarments and avoid wearing jewelry such as rings. Injury mayresult from clothing, hair, or jewelry being caught up in themachinery.

USE protective equipment wherever required by thecircumstances or by law. OBSERVE all safety instructions andwarnings attached to the machine.

BE SURE all safety instructions and warnings attached to themachine are complete and perfectly legible.

STOP the machine immediately in the event of any malfunction.REPORT the malfunction to the proper authority/person.

NEVER provide service or maintenance to the machine unlessthe drum and wheels are adequately chocked, articulation lockbar/pin is in locked position, and parking brake is applied.

NEVER make any modifications to the machine which mightaffect safety without the manufacturer’s approval. This applies tothe installation and adjustment of safety devices and valves aswell as to welding work on load bearing elements.

ALWAYS ADHERE to prescribed intervals or those specified inthe operating instructions for routine checks and inspections.


- Read the Operator's manual.- Carry out daily service. In cold weather, make sure that the

freezing point of the coolant is sufficiently low and that thelubricating oil is intended for winter use.

- Clean the dust around engine, battery and cooler.- Check the level of hydraulic fluid, refill if required.- Check that there is sufficient fuel in the fuel tank.- Check that there are no faulty, loose parts or leaks, which can

cause damage.- Check that the battery disconnected switch is switched on.- Check for cracks on frame.- Check that hoods and covers are closed.- Make sure fire extinguisher if equipped is fully charged.- Inspect steps and handholds for damage or loose parts. Make

necessary repairs if needed.- Check that there are no persons in the vicinity of the machine.- Adjust the operator seat and fasten the seat belt.- Adjust and clean the mirrors.

V1065709



59

- Inspect working and other lights for proper operation.- Travel alarm should be on before operating the machine.- Inspect the failure of gauges in the instrument panels.

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Starting engine

NOTICEBEFORE starting the engine, ENSURE that the propulsion(travel) control is in the “STOP” position and parking brake controlis in the “Applied” position.

WARNINGRemove all unauthorised personnel from the working area of themachine. Keep a good lookout in all directions to avoid runninginto personnel or objects. Do not touch control levers or switchesduring start. Sound the horn before beginning operation.

CAUTIONDo not crank the starting motor for more than 15 seconds to avoidoverheating the motor. Wait 30 seconds before a new attempt.

CAUTIONIf the engine sounds or runs strangely or if strong vibrations arise,the ignition switch must be turned to stop position immediately.

Position the Throttle Control Lever to the “Low” or “Idle RPM”Make sure the Parking Brake Switch is in applied position.Place Vibration Control Lever in “OFF” position.Pull up on the Emergency Stop SwitchTurn the key to run position.Sound the horn and let other workers and bystanders know youare starting the machine.Turn the key to the starting position.Release the key when the engine has started.

NOTICEAllow the engine to run at low or idle rpm for a few minutesbefore normal operation. Never rise the engine during thewarm up period.

Warm up the machine.


Starting engine

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Hydraulic system, warming up

CAUTIONDo not rush the warming up of the oil, as forced warming up maydamage the machine.

The oil in the hydraulics of the machine is used for operating thehydraulic cylinders of the equipment as well as the hydraulicmotors for travelling. When the oil is cold it is viscous.

The hydraulic functions of the machine therefore operate slowerthan when the oil is warm.

If one or more of the machine functions are forced against theend-of-stroke position without having first warmed up the system,this may result in malfunctions.

It is important that the oil in the hydraulic system is properlywarmed up before operating the machine.

Apply the parking brake and leave the engine idling so that theoil in the engine, transmission, hydraulic system and axles iswarmed up and becomes sufficiently fluid to provide properlubrication.To race the engine immediately after it has been started mayalso endanger the lubrication and cooling of the turbochargerwith great risk of bearing seizure as a consequence.

Moving the machine a short distance (for example when loadingonto or off a trailer) can be done without a complete warm up.These operations must be executed with great care. In suchsituations, the engine speed must not exceed 1200 rpm.

1 Apply the parking brake.2 Start the engine and let it idle for five minutes.

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Hydraulic system, warming up

Vibration

Vibration

Drum vibration amplitude selectionMove the vibration lever to choose desired amplitude setting(High or Low).

Select high amplitude for initial or thick soil compaction by movingthe vibration lever to High position. Select low amplitude for finalor thin layer of soil, and when soil is loose and granular, by movingvibration lever to Low position.

Drum vibration frequency selection

Material Natural FrequencyTYPE OF SOIL NATURAL FREQUENCY

Sand Uniformly 1900 vpm 32 HzSand Graded 1400 vpm 23 HzSand Wet 1300 vpm 22 Hz

Sandy Gravel Dry 1500–1700 vpm 25–28 HzClay (Pad Foot) 1200 vpm 20 Hz

Silt Firm 1500–1700 vpm 25–28 HzSilt Loose 900–1300 vpm 15–22 Hz

V1092791

Vibration lever


Vibration

63

Operating

Operating instructions1 ALWAYS make sure that no person or obstruction is in your

line of travel before starting the compactor in motion.2 NEVER CLIMB up or climb down the compactor while it is in

motion.3 ALWAYS remain seated with the seat belt on when operating

the compactor whether compacting, traveling, or loading/unloading.

4 USE EXTREME CAUTION and be very observant whenoperating in close quarters or congested areas.

5 NEVER carry passengers.6 CLOSE all sound baffles during operation.7 KNOW the area in which you are working. Familiarize yourself

with work site obstructions and any other potential hazards inthe area.

8 KNOW and USE the hand signals required for particular jobsand know who has the responsibility for signaling.

9 DO NOT work in the vicinity of overhanging banks or on gradesthat could cause the compactor to slide or roll over.

10 AVOID side hill travel. ALWAYS operate up and down slopes.ALWAYS keep the propulsion (travel) control lever in lowspeed range close to the “STOP” position when climbing ordescending hills.

11 NEVER allow anyone to stand within the compactor’sarticulation area when the engine is running.

12 ALWAYS LOOK in all directions BEFORE changing yourdirection of travel.

13 DO NOT attempt to control compactor travel speed with thethrottle control. When operating the compactor maintain theengine speed at full “Operating rpm.”

14 DO NOT run the engine in a closed building for an extendedlength of time. EXHAUST FUMES CAN KILL.

PROPELLING THE MACHINE1 Check the travel and work area for people and obstructions.2 Remove and stow the Articulation Lock Pin in it’s stowed

position.3 Move the throttle Control lever to the low operating RPM..4 Position the Two-Speed Control Switch to LOW position. The

compactor is to be on solid, level ground and the Parking brakeis to be in the applied position. The HIGH speed is to be usedonly for “roading” the compactor.

5 Push the Parking Brake Switch to Off position, this will releasethe Brake.

6 Move the Propulsion Control Lever to achieve the desireddirection and safe speed of travel as determined by theconditions. The further the control is moved from the S or“STOP” position, the greater the speed in that direction. Returnthe control to S or “STOP” for normal braking.

64


Operating

7 Once the compactor is in motion, move the vibration controllever to the desired eccentric rotation direction and amplitude.

NOTICEWhen the eccentrics are engaged/disengaged, or the directionof rotation is changed, there is a noise clunk that will be heard.This is a normal condition and is caused by the eccentricweights changing position.

SHUTDOWN PROCEDURE1 Move the Vibration Control lever to the stop position.2 Move the propulsion control lever to S or stop position.3 Apply parking brake and make sure the parking brake indicator

is glowing.4 Install the Articulation Lock Pin in it’s locked position.5 Position the throttle control lever to the ‘Idle RPM position.

Allow the engine to idle for a few minutes to avoid high internalheat rise and allow for heat dissipation.

6 Turn the Ignition Switch to the OFF position.7 Choke the machine drum and wheels with suitable wedges.8 Fill the diesel fuel tank with clean Diesel Fuel to prevent

condensation in the tank.9 Lock all lockable compartments and remove the ignition key.


Operating

65

Braking

Parking brake, description

The parking brake system on this machine consist of a springapplied brake located in the rear axle of the machine. The parkingbrake is released by hydraulic pressure supplied from the chargepump of the propulsion pump.The parking brake is turned ON and OFF by means of a switchlocated on the instrumental panel. The parking brake is releasedwhen the engine is running and the park brake switch is movedto the OFF position. Once the switch is placed in the OFF position,electrical current is supplied to the brake-destroke valve and valveis actuated. This allows the charge pressure of the charge pumpto flow into the brake release circuit. Once the charge reliefpressure is obtained, the oil supplied to the brake at the axle viaa hydraulic hose will overcome the force of the brake spring. Thiswill in turn release the brake pressure and the machine is free tomove as directed.

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Braking

Stopping

Stopping1 ALWAYS park the compactor on solid level ground. If this is

not possible, always park the compactor at a right angle to theslope and chock the wheels and/or drums.

2 AVOID leaving the operator’s platform with the enginerunning. ALWAYS move the propulsion control lever to“STOP” position , apply the parking brake, install thearticulation lock pin, position the throttle control to “low /idlerpm”, turn ignition switch to OFF and lock all lockablecompartments.

3 USE proper flags, barriers and warning devices, especiallywhen parking in areas of heavy traffic.


Stopping

67

Measures after operating


Perform the following precautions each day after work in additionto the daily routine maintenance on the lubrication and servicechart.

NOTICEIn any work concerning the operation, conversion or adjustmentof the machine and its safety oriented devices or any work relatedto maintenance, inspection and repair, always observe the startup and shutdown procedures set out in the operating instructionsand the information on maintenance work.

Fill fuel tank to prevent condensation problems.Clean drum scrapers of accumulated material.If available, lock all vandal protection devices on the machine.

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Parking

Storage

Short termPerform this maintenance when the machine will be shut downfor a short term (2 weeks or less) parking or storage.1 Position the machine on level ground.2 Apply the parking brake.3 Place all switches and controls in the OFF position.4 Shut down the engine and remove the key.5 Remove all valuable items from the machine which can be

easily stolen.6 Close and lock all doors and accessible areas.7 Place the battery disconnect switch in the OFF position.

Long termPerform this maintenance when the machine will be shut downfor a long term (more than 2 weeks) parking or storage for anextended period, such as for the off-season. The sequence of thesteps may change dependent on storage location.1 Lubricate the machine.2 Fill the fuel tank and hydraulic tank to the maximum level.3 Wash the machine and allow it to dry.4 Touch up the paint finish to avoid rusting.5 Position the machine on level ground.6 Apply the parking brake.7 Place all switches and controls in the OFF position.8 Shut down the engine and remove the key.9 Remove all valuable items from the machine which can be

easily stolen.10 Close and lock all doors and accessible areas.11 Place the battery disconnect switch in the OFF position.12 Treat exposed parts with anti-rust agent which can be easily

removed at a later date.

NOTICEFollow all safety instructions for application and removal of theanti-rust agent provided by the agent manufacturer.

13 Protect the tyres and all exposed rubber components againstdirect sunlight.

14 Plug exhaust pipe.

Prepare machine for use from storage.Perform this maintenance before bringing the machine back intoservice following storage.1 Inspect machine for any damage or missing components.

Correct as required.2 Inspect machine for any damage or missing components.

Correct as required.3 Remove all tyres and rubber protective covers


Parking

69

4 Remove anti-rust material.

NOTICEFollow all safety instructions for application and removal of theanti-rust agent provided by the agent manufacturer.

5 Check all fluid levels and add as necessary.6 Check tyre pressure and correct if necessary.7 Check alternator belt tension and correct if necessary.8 Check air cleaner elements condition. Correct as required9 Place the battery disconnect switch in the ON position.

70


Parking

Measures in case of machine failure

Starting with booster batteries

The battery is located at the extreme rear side of the machine, inthe battery compartment of the rear frame. See page No. 147 toaccess the battery.

Before connecting the booster cablesBefore connecting the booster cables, be sure to check thefollowing:

Booster cables and clamps must be appropriately dimensionedfor the size of the battery.Check booster cables and clamps for damage, corrosion, etc.Make sure that cables and clamps are tightly connected.Make sure that the ignition switch is in OFF position.Make sure that the parking brake is in applied position.Make sure that the propulsion control lever is in STOP position.Make sure that the vibration control lever is in neutral position.Make sure that the battery disconnect switch is in OFF position.The booster battery must have the same voltage as the batteryfor the engine requiring the jump starting.Make sure that the machines do not come into contact with oneanother.

Connection of the booster cablesTo start with the booster battery following steps must be followed.

WARNINGBattery charging generates hydrogen gas, which may beexplosive. Short-circuiting, an open flame or a spark near thebattery may cause a powerful explosion.Make sure ventilation is adequate when charging batteries. Neversmoke near batteries.

WARNINGBatteries may explode due to the current surge if a fully-chargedbattery is connected to a completely discharged or frozen battery.Personal injuries may be sustained.

1 Check that the booster battery or any other power source hasthe same voltage as the battery on the machine.

2 Do not under any circumstances disconnect the cables fromthe batteries on the machine.

3 Connect the positive (+) terminal of the booster battery to thepositive (+) terminal of the battery of the machine to be jumpstarted with a booster cable “A” .

4 Connect the negative (-) terminal of the booster battery to thegrounding of the machine to be jump started.

NOTICEMake sure that the clamps are tightly connected with thebattery terminals.



71

NOTICEWhen connecting the cables, make sure that the positive (+)and negative (-) clamps do not touch.

V1076862

B

A

BOOSTER BATTERY BATTERY OF THE MACHINETO BE JUMP STARTED

MACHINE TO BE JUMP STARTED

Connection of booster cables

5 Turn the battery disconnect switch to ON position .6 After the cables are connected, wait 5 minutes before starting

the machine.7 Start the engine with the booster battery, then attempt to start

the engine that needs to be jump started.8 Crank the engine of the machine to be jump started for a

maximum of 30 seconds. Wait two minutes between startingattempts.

9 Once the engine has started, turn OFF the machine withbooster battery.

10 Remove the negative clamp cable “B” first, then the positiveclamp cable “A”.

Troubleshooting, general

Pre-start checkPrior to attempting to start the engine refer to the checklist decallocated in the operator area, see page Decal locations forchecklist decal location. Failure to follow directions listed on thischecklist may prevent the operator from starting the engine.

72




WARNINGAlways read safety instructions and warnings before operating.

Improper operation and maintenance is the most frequent causeof machinery faults and problems. In the event of a fault, it isrecommended to read through this manual. If the cause of theproblem or solution cannot be determined when following thetroubleshooting chart below, contact the manufacturer’s localauthorized dealer or distributor.

Troubleshooting charts

Engine will not start

Symptom Possible cause SolutionStarter does not rotate Emergency stop switch pushed

downCheck emergency stop switch/resetif required

sensing parking brake is appliedcondition

Parking brake release switch

Turn ignition key on and offFSR lever not in stop position Move FSR lever to stop positionFuse FL1 and F1defective Check console fuses and replaceBattery discharged Service must be performed by

authorised and trained personnelBattery disconnect switch off Turn switch onBattery cable connections loose ordisconnected

Clean and tighten terminalconnections

Starter relay fault Service must be performed byauthorised and trained personnel.Ignition switch defective

Starter solenoid or starter defectiveStarter does rotate Empty fuel tank Fill, see page No. for specifications

196Defective wiring Service must be performed by

authorised and trained personnel.



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Difficult starting and poor/irregular performance

SYMPTOM POSSIBLE CAUSE SOLUTIONDifficult starting and poor/irregularperformance

Low battery power Service must be performed byauthorised and trained personnel

Battery discharged Service must be performed byauthorised and trained personnel orsee page No.71 for boost starting

Battery cable connections loose ordisconnected

Clean and tighten terminalconnections, see page No. 147

Using too high a viscosity oil in lowambient temps

Use appropriate oil grade forambient temperature conditions,see page No.194 for engine oilspecifications

Fuel line blockage due to waxseparation in winter

Change fuel filters, and bleed fuelsystem, check for fuel line leaks andloose connections, see page .Always use winter grade fuel inwinter, see page No.129 .

Blocked air cleaner element Clean or replace element, see pageNo. 136

Incorrect valve clearance Service must be performed byauthorised and trained personnelDefective fuel injectors

Fuel pump failureDefective turbo charger

Engine making excessive fumes

SYMPTOM POSSIBLE CAUSE SOLUTIONEngine making excessive fumes Engine oil level too high Drain engine oil to correct level, see

page No. 194 for engine oilspecifications

Blocked air cleaner element Clean or replace element, see pageNo.136

Low compression due to the poorcondition of the valves or incorrectclearance

Service must be performed byauthorised and trained personnel

Engine overheats — stop engine immediately

SYMPTOM POSSIBLE CAUSE SOLUTIONEngine overheats — stop engineimmediately

Excessive dirt on cooling system Clean the cooling fins

Engine coolant level too low Check coolant level, see page No.141.

Engine belt broken Service must be performed byauthorised and trained personnel

Engine oil level low Check oil level, see page No. 126Thermostat defective Service must be performed by

authorised and trained personnelBlocked cooling air flow

74



Low engine oil pressure — red warning lightilluminates

SYMPTOM POSSIBLE CAUSE SOLUTIONLow engine oil pressure — redwarning light illuminates

Low engine oil level (low engine oilpressure warning light shouldilluminate)

Add oil to correct level, see page No.126 for details

Lubrication system leak Stop engine and check for leaks andtighten any loose fittings on thesystem oil

Fuses, check

If a fault occurs with a component or function, replace theassociated fuse with an exact replacement. See page No. 153for details on fuse identification, ratings and associated circuits.



75

Retrieving and towing


WARNINGAlways use classified cables, lifting straps, shackles and hookswith sufficient lifting capacity.

WARNINGIncorrect or faulty equipment or improper towing methods maycause accidents. Therefore, carefully follow the instructions givenbelow.

The following instructions are to be followed if it becomesnecessary to tow the compactor. Attach to the compactor at thetie down and tow points only. Tie down and tow point locationsare located on each side of the machine, see page No.81 forlocation of machine tie down and tow point locations.

Towing a disabled machine

NOTICEIn the event of an engine problem or other malfunction, it maybecome necessary to tow your compactor. To tow the compactorrequires disengaging the propulsion system and releasing thespring-applied brakes.

WARNINGIf the engine cannot be started, the brake and steering functionswill be severely limited. In such cases, towing should only beperformed in an emergency situation by experienced and trainedpersonnel and only for the shortest possible distance (seetowing). If possible, transport the machine on a trailer.

WARNINGIncorrect or faulty equipment or improper towing methods maycause accidents. Therefore, carefully follow the instructions givenbelow.

Disengaging the propulsion systemMake sure that the parking brake switch is in the “Applied”position.

76



Make sure that the drum and wheel chocks are in place.

Locate and gain access to the multifunction valve cartridges ofthe propulsion pump.Hold the pressure limiter housing with a 1-1/16" wrench andloosen the bypass actuator with a 1 1/4" wrench about 3revolution in counter clockwise to open the bypass valve inpropulsion pump. Do not rotate more than three revolutions, asadditional rotation will generate external leakage.Open both the bypass valves to engage the bypass function.Move the propulsion control lever in the operator'scompartment to the full “Forward” for towing the machine inforward direction.Move the propulsion control lever in the operator'scompartment to the full “Reverse” for towing the machine inreverse direction.Release the parking brake in the axle. See page No.78

NOTICEMachine runaway condition could occur. Do not leave themachine with the brakes released after towing.

Releasing the spring-applied brakes.

NOTICEWhile towing observe that the machine wheels are free to rotate,if not check for release of parking brake.

Make sure that the operator is seated in the operator's seat withseat belt put on, to control steering, when towing thecompactor.

NOTICESteering of compactor is limited, as the hydraulic system donot receive power from engine.

Check with the local regulations and laws, for the use of towchains on highways.Make sure that the vehicle, which does the towing, is at leastas heavy as the machine being towed. This will ensuresufficient braking capabilities, to be able to pull and stop bothmachines.

Propulsion pump

Propulsion pump bypass function engagement



77

Remove the chocks and tow the machine for a short distanceof 200 metersat a maximum speed of 2km/hr.

NOTICEMachine runaway condition could occur. Do not leave themachine with the brakes released after towing.

Chock the wheels and drum.To close the bypass valve in propulsion pump, tighten thebypass actuators in clockwise direction about 3 revolution.Tighten the bypass actuator to a torque value of 41 N•m (30lbf•ft).

Manual release of parking brake

NOTICEFor Drum drive option, follow the below procedure for releasingthe parking brake.

NOTICEManual release of parking brake is only for towing purpose, beforereleasing the brake manually, read the towing instructions.

ReleasingLocate the pilot pressure line on the brake valve.Disconnect the pilot pressure line and connect to the externalhand pump to brake valve pilot pressure port.

CAUTIONPlug hoses and connections immediately.

Switch the parking brake to released condition.Increase the brake line pressure using hand pump to maximumpressure of 24 bar (350 psi) to release the brake.

NOTICEDo not exceed the brake release pressure 24 bar (350 psi),excessive pressure can damage the seal

ApplyingApplying the parking brake.Release the external hand pump pressure and disconnect.Connect the pilot line to brake valve.Clean for any oil spillage.

78



Manual release of parking brake

WARNINGAlways block the wheels before mechanically releasing theparking brake to prevent the machine from rolling.

WARNINGAll changes to the adjusting screws must take place with theengine turned off. The starter inhibitor will be out of operationwhen the engine is subsequently started.

NOTICEThere are 4 set of screws and nuts are provided on the axle (2Nos. on front & 2 Nos. on rear side of the axle) to release thebrake manually during towing or emergency.

Loosen the nuts of screws provided for the manual release onthe axle.Move the nuts backwards by 8 mm.

Tighten the screws (2) so as to fasten them onto the pressureplate.Using wrench tighten the screws in an alternate sequence,considering one side at a time, either left or right side of theaxle, by 1/4 turn at a time to compress the bellevelle washersand disengage the braking units.

NOTICETighten screws maximum by one turn.

Manual release of axle brake

Axle pressure plate adjustment1 Nut2 Screw3 Seal4 Pressure plate5 Bellevelle washers

Axle brake release screw tightening



79

Parking brake adjustment after towing.

1 Remove screws complete, with nuts and seals.2 Replace the seals.3 Apply grease to the screws.4 Install all parts into the arm and tighten the screws in alternate

sequence.

5 Adjust screws to obtain a gap of 34 mm (allowable tolerance+0.5 mm) in relation to the arm.

6 Lock the screw position with the nut.

NOTICEHold the screws into the position while locking the nuts tomaintain the gap of 34 mm.

7 Make sure that the gap maintained between the axle arm andthe screw head top is 34 mm.

Actions after recovering and towing

WARNINGAll changes to the adjusting screws must take place with theengine turned off. The starter inhibitor will be out of operationwhen the engine is subsequently started.

To put back the machine to serviceTo Re-engage the propulsion system, See page No.76Parking brake adjustment after towing, See page No. 78Check the parking using parking brake switch, See pageNo.Parking brake, checking of functionPut back the machine in service.

Adjustment after manual release1 Screw.2 Nut.3 Seal.

Axle brake release screw adjustment

Axle brake release adjustment

80



Transporting machineBefore driving machine on public roads, check with a supervisorfor instructions and information with respect to local trafficregulations regarding construction machinery.

Loading the machine under its own power1 Choose level ground which will solidly support the vehicle.2 Clean the trailer surface and loading ramps.3 Before loading machine, block the wheels of the trailer.4 A signal person must assist the operator with any necessary

warnings.5 Approach the transporter loading ramps squarely to make

sure machine does not drop off side of ramp.6 Drive machine onto transporter.7 Shut down the engine, apply parking brake and lock all

lockable compartments.

Securing the machine to the transporter1 After loading the machine to the transporter, ensure that

articulation lock pin is in the locked position.2 Block the drum.3 Tie-down machine using a chain and tensioning device or

other appropriate equipment to the tie-down points.4 The driver of the transport must be aware of its total weight,

load on the axles, and the overall dimensions of the machine.

Transporting the machine

SECURING THE UNIT FOR TRANSPORT - When securing theunit for transport, use only the designated tie-down locations tofasten the unit to the transport vehicle. Decals on the unit indicatethe locations to tie the unit down. Use only properly rated tie-downs and securing equipment. Place chocks at the front andrear of the unit while securing to the transport vehicle. If thetransport vehicle will be stationary for an extended period of timewithout being moved, do not remove the chocks until transportingthe unit.


Transporting machine

81

V1100948

Lifting, Tie-down and wheel chocking locations

USE only appropriate means of transport and lifting gear ofadequate capacity.

ENTRUST to experienced persons only the fastening of loads andthe instructing of crane operators. The personnel giving theinstructions must be within sight or sound of the operator.

DO NOT attempt to load the machine on the transporters withoutknowledge and experience with the operation of the machine.

ALWAYS use a ramp when loading the machine on thetransporter. Be sure ramps are of adequate strength, low angle,and proper height and width.

POSITION the machine on the transporter or hauling vehiclecentred from side to side and apply the brake.

USE proper chock blocks in front and rear of the wheels of thetransporter when loading the machine.

ENSURE the trailer is on level ground and approach thetransporter loading ramps squarely to make sure the machinedoes not drop off the side of the ramp.

KEEP the transporter deck clean of clay, oil, mud, frost and othermaterial that can become slippery.

USE proper chock blocks on the front of the drum and rear of thewheels once loaded onto the transporter.

SHUT the engine OFF, apply the parking brake, and lock alllockable compartments.

ENSURE the articulation lock bar/lock pin is secured in the lockedposition before transporting the machine.

82



TIE-DOWN the machine using chains and tensioning devices orother appropriate equipment to the tie-down points as marked onthe machine.Ensure all transport devices, tie-down equipment and methodscomply with all applicable transport regulations in the jurisdictionswhere the equipment is loaded/unloaded or in transit.

KNOW the overall height, total weight, load on the axles and theoverall dimensions of the of the machine and hauling vehicle.For dimensions and Machine weights, See page No. 206 and204 .Observe height, width and weight regulations along the intendedroute to ensure safe passage of the equipment at all times,especially when encountering overhead objects, tunnels, bridges,intersections, and other obstacles along the intended route.



83

Operating techniquesOperating techniques


The speed of travel of a vibratory roller has a tremendous effecton the compaction results. As opposed to a static roller wherespeed of travel matters very little to the compaction process, avibratory roller needs “dwell” time for each vibration to develop itspotential.

This means that travel speed is of the utmost importance ifmaximum consolidation is to be accomplished. Travel speeds ofmore than 4.83 km/hour (3mph) usually do not develop thecompaction needed, in proportion to the increased travel speed.On the other hand it is very easy to achieve over-compaction withmultiple passes over the same plot due to the efficiency ofCompactors.

NOTICESTATICS SHOW THAT OVER-COMPACTION MAY ACTUALLYREDUCE FINAL DENSITY DUE TO MACHINE BOUNCEWHICH TENDS TO BREAK DOWN THE ALREADY ACHIEVEDDENSITY OVER-COMPACTION CAN ALSO LEAD TOEXCESSIVE WEAR ON YOUR UNIT IF IN DOUBT ABOUT THEPROPER COMPACTION TECHNIQUE, CONSULT YOURVOLVO Authorized DISTRIBUTOR/DEALER.

Watch for bystanders and never allow anyone to be near themachine while operating.

84


Eco drivingTo utilise the system in the best way and at the lowest fuelconsumption, the engine speed should be kept low when notcompacting.


Eco driving

85

Signalling diagramIf the operator's visibility is restricted, e.g., due to a big load, usea signal man.

The faster lifting, lowering, or movement that is required, thelivelier the signal man's movements should be. If two or severaloperators use the same signal man, determine ahead of time howthe lift is to be done and how signals shall be given to eachoperator.

STARTArms extended horizontally withpalms facing forward

STOPRight arm pointing up with palmfacing forward

ENDHands held together at chestheight

RAISERight arm pointing up with palmfacing forward and hand movingslowly in a circle

LOWERRight arm pointing down with palmfacing forward and hand movingslowly in a circle

VERTICAL DISTANCEHands indicate relevant distance

MOVE FORWARDBoth arms bent with palms facingup and underarms moving slowlyand repeatedly up towards thebody

MOVE BACKBoth arms bent with palms facingdown and underarms movingslowly and repeatedly down awayfrom the body

DANGER (EMERGENCY STOP)Both arms up with palms facingforward

86


Signalling diagram

OPERATE IN INDICATEDDIRECTIONArm extended horizontally withpalm facing down and smallmovements back and forth slowlyto the right

OPERATE IN INDICATEDDIRECTIONArm extended horizontally withpalm facing down and smallmovements back and forth slowlyto the left

HORIZONTAL DISTANCEHands indicate relevant distance


Signalling diagram

87

Safety when servicingSafety concerns everybody!

Always follow the instructions in the machine's operator's manual.

Volvo designs and manufactures machines with a high level ofsafety as well as effectiveness. All this work may be wasted ifanyone who is about to perform service on any of our machinesdoes not read the safety instructions, or does not follow them,e.g., does not replace guards, climbs on slippery machine partsinstead of using a ladder, uses the wrong tools for the job.

In order to maintain safe and efficient function, always usegenuine Volvo spare parts intended and adapted for the machine.If other spare parts than genuine Volvo are used thenVolvo Construction Equipment cannot be held responsible formachine damage, and warranty claims will be denied.

Machines seldom cause accidents, instead people often do.

A safety-conscious person and a well-maintained machine makefor a safe, effective and profitable combination.

Those who do not follow the safety instructions and observe thewarnings in this manual must make sure that their work methodis safe. Otherwise, there is a great risk of accidents, perhaps evenaccidents that result in fatalities.

WARNINGWARNING SYMBOL

This symbol is shown at various points throughout the manual.The appearance of it means "Warning, stay alert! Your safety maybe involved!"

Get to know the capacity and limits of your machine!


This section deals with the safety rules that must be followedwhen performing checks and service work. Volvo ConstructionEquipment rejects all responsibility if other tools, lifting devices,or work methods than those described in this publication areused.Other safety rules, information and warning texts are given ineach section.

NOTICELifting with a jack must only be carried out by trained personnel

88


WARNINGIf work must be done on the machine before it has cooled down;beware of hot fluids and hot components that can cause severeburns.

Before you begin any service work on the machine:Service work which is not carried out in the correct way isdangerous.All service work should be carried out by a qualified technicianwho is having sufficient knowledge of the machine, and trained touse the proper tools and equipment to carry out the service taskin a correct way.

WARNINGDuring service, hearing protection and safety goggles must beused.

NOTICENo work must be carried out on the machine until you haveacquired the appropriate knowledge to do so.

In any work concerning the operation, conversion or adjustmentof the machine and its safety oriented devices or any work relatedto maintenance, inspection and repair, always observe the startup and shutdown procedures set out in the operating instructionsand the information on maintenance work.

ENSURE that the maintenance area is adequately secured.

If the machine is completely shut down for maintenance andrepair work, it must be placed in the service position, See page92 and secured against inadvertent starting by:

Locking the principal control elements and removing theignition keyAttaching a warning sign to the ignition or main switchCARRY OUT maintenance and repair work only if the machineis positioned on stable and level ground and has been securedagainst inadvertent movement and buckling.LIFTING THE UNIT - When raising the unit off the ground,apply the parking brake. Attach the lifting apparatus only to theunit’s designated lifting points using properly rated liftingstraps, cables, or chains. Use spreader bars to ensure equalweight distribution during lifting as well as avoid contact withthe unit. See page 99.USE CARE when attaching and securing lifting tackle toindividual parts and large assemblies being moved forreplacement purposes to avoid the risk of accidents. USE liftinggear that is in perfect condition and with adequate liftingcapacity. NEVER work or stand under suspended loads.ALWAYS USE the correct tools and workshop equipmentwhen performing maintenance on the machine.ALWAYS USE specially designed or otherwise safety orientedladders and working platforms when doing overhead assemblywork. Never use machine parts as a climbing aid.KEEP all handles, steps, handrails, platforms, landings andladders free from mud, dirt, snow and ice.CLEAN the machine, especially connections and threadedunions, of any traces of oil, fuel or preservatives before carrying

Safety when servicing 89

out maintenance/repair. NEVER use aggressive detergents.Use lint free cleaning rags.COVER OR TAPE all openings, for safety and functionalreasons - must be protected against water, steam or detergentpenetration before cleaning the machine with water, steam jet(high pressure cleaning) or detergents. Special care must betaken with electric equipments.ENSURE during cleaning of the machine that temperaturesensors do not come into contact with hot cleaning agents.REMOVE all covers and tapes applied for that purpose aftercleaning machine.EXAMINE all fuel, lubricant, and hydraulic fluid lines for leaks,loose connections, cut marks and damage after cleaning.REPAIR or REPLACE defective parts immediately.TIGHTEN any screwed connections that have been loosenedduring maintenance and repair.REPLACE any safety devices removed for setup, maintenanceor repair purposes and checked immediately upon completionof the maintenance and repair work.ENSURE that all consumable and replaced parts are disposedsafely and with minimum environmental impact.AVOID, whenever possible, servicing, cleaning, or examiningthe machine with the engine running.

WARNINGAll forms of open fire and smoking should be avoided whenfilling the fuel tank.

DON'T fill the fuel tank with the engine running, while near anopen flame, or while smoking.ALWAYS wipe up any spilled fuel.DO NOT alter the engine governor settings from thoseindicated in the engine manual.ALWAYS replace damaged or lost decals. Refer to the partsmanual for the proper location and part number for all decals.ENSURE the safe operation, optimum performance and safetyof your warranty by using only genuine manufacturer’sreplacement parts.SWITCH OFF battery disconnect switch and DISCONNECTthe battery cables when working on the electrical system orwhen welding on the compactor.BE SURE the battery area is well ventilated (clear of fumes)should it be necessary to connect a jump battery. Fumes fromthe battery can ignite by a spark and explode.BE SURE the battery charger is “Off” when making theconnections if battery charging is required.USE only original fuses with the specified current rating. Switchoff the machine immediately if trouble occurs in the electricalsystem.WORK on the electrical system or equipment may only becarried out by a skilled electrician or by specially instructedpersonnel under the control and supervision of an electricianand in accordance with the applicable electrical engineering.CUT off the power supply to parts of the machine on whichinspection, maintenance and repair work is to be carried out.CHECK the de-energized parts for the presence of power andground or short circuit them in addition to insulating adjacentlive parts and elements before starting work.

90


INSPECT the electrical equipment of machines at regularintervals. Defects such as loose connections or scorchedcables must be rectified immediately.DO NOT weld, flame cut or perform any grinding operations onthe machine unless expressly authorized as there may be arisk of explosion and fire.CLEAN the machine and its surroundings from dust and otherflammable substances and make sure that the premises areadequately ventilated (risk of explosion) before beginningwelding, flame cutting and grinding operations.INSPECT hydraulic hoses at regular intervals and immediatelyreplace if they show signs of chafing, cracking, brittleness,deformation, blistering, leakage, fitting separation, corrosion orother damage which may affect their function or strength.DO NOT work on hydraulic lines while the engine is runningand the system is under pressure. The hydraulic fluid remainspressurized long after the engine has stopped.DO NOT work on any hydraulic hose or fitting until the pressurehas been properly relieved.WAIT for fluid to cool down before disconnecting. Hot hydraulicfluid will cause severe burns.NEVER use your hands to check for leaks when inspecting anhydraulic system. Use a piece of cardboard and always weargloves and safety glasses.GET immediate attention if fluid has been injected under yourskin. Fluid penetration from a pin hole leak can cause severeinjury or death.ENSURE hydraulic lines are laid and fitted properly. Ensurethat no connections are interchanged. The fittings, lengths andquality of the hoses must comply with the technicalrequirements.OBSERVE the product related safety regulations whenhandling oil, grease and other chemical substances.Be careful when handling hot conscionable items. (risk ofburning or scalding).

Safety when handling oil and fuelWhen changing oil in the engine or hydraulic system,remember that the oil may be hot and can cause scalding orburn injuries.Engine and hydraulic oils, as well as diesel fuel, have acorrosive effect on mucous membranes (i.e. eyes, throat andon skin). Take special care to keep oils away from thesesensitive body parts.Oils and fuels are hazardous to the environment. Take specialcare not to spill or discharge these fluids. Use approvedcontainers and methods to handle and dispose of machinefluids. Use an authorized disposal and recycling company.Be aware of the risk of fire.

Safety when servicing 91

Service position

Service position

CAUTIONBefore starting any work, park the machine on a level surface andprepare it for service by putting it into service position accordingto Safety rules for service.

NOTICERefer to all applicable safety information, as well as the service &maintenance sections in the Operator's and Service Manual,before opening up the machine areas to conduct anymaintenance or repairs to the machine.

CAUTIONMaintain greatest possible cleanliness.

NOTICEIt is important to maintain the greatest possible cleanliness in thework area and make sure that the machine is properly cleanedbefore carrying out service and maintenance procedures.The service technician must take the necessary precautions toprevent dirt and debris from entering sensitive areas of themachine, which could cause damage to expensive machinesystems and components.

For cleaning prior to repair, See page No. 116.

92


Service position

V1101141

1 26 8

3

109

7

5

4

7Service position

1 Bring the propulsion control lever to STOP position.2 Apply parking brake.3 Bring the engine throttle lever to low rpm position.4 Install the articulation lock pin.5 Shut down engine, remove and retain the ignition key.6 Attach warning tag to steering wheel.7 Block the wheels and drum.8 Allow hydraulic pressure to drop (as required).9 Turn battery disconnect switch to OFF position.10 Allow the engine to cool down.

Service Position1 Move the machine on a level and a stable surface. Bring the

propulsion control lever to STOP position.2 Apply the parking brake.

NOTICEIndicator light on the parking brake switch glows.

3 Bring the engine throttle lever to low rpm position.4 Place the articulation lock pin from the stowed to the

articulation lock position. While seated on the operator seat,turn the steering wheel slowly until the articulation lock pindrops in place and is fully engaged with swivel frame.

5 Shut down the engine. Remove and retain the ignition key.


Service position

93

6 Attach a warning tag to the steering wheel that the machine isout of service.

NOTICEFollow all local regulations concerning lockout or tag-outprocedures.

WARNINGBlock the wheels to prevent accidental machine movement.

7 Block the wheels and drum with appropriate wedges or wheelchocks.

8 Allow hydraulic oil pressures to drop, before working on thehydraulic system. See page No. 174.

NOTICEHydraulic pumps and hoses will retain pressurized oil, whenbrake is being held in the released position.

9 Disconnect battery power by turning the battery disconnectswitch to the OFF position or remove the ground terminals andcover exposed terminals before working on the machine'selectrical system. See page No. 144.

NOTICECertain troubleshooting procedures and system tests willrequire that battery terminals remain connected.

10 Allow the engine to cool.

WARNINGIf work must be done on the machine before it has cooleddown; beware of hot fluids and hot components that can causesevere burns.

NOTICEChanging of engine oil, Axle housing oil, Axle wheel end oil,Transmission oil, Drum eccentric oil, Drum carrier oil andTorque hub oil require the machine oil to be at operatingtemperature.

94


Service position

Before service, read


Prevent personal injuriesRead the instructions in the Operator's Manual before startingto work on the machine. It is also important to read and followthe information and instructions on plates and decals.Do not wear loose-fitting clothes or jewellery that may getcaught and cause injuries.Always use a hard hat, eye protection (safety glasses), glovesand protective work footwear when required by the job.Make sure that the ventilation is adequate if you are going tostart the engine indoors.Do not stand in front of or behind the machine while the engineis running.Turn off the engine before removing any protective covers oropening any engine hoods.Accumulated pressure remains in the system even when theengine has been turned off. If a system is opened without firstdepressurizing it, high-pressure fluid may jet out.Use a piece of paper or cardboard when checking for leaks,never your hands.Make sure that stepping surfaces, handholds, and slipprotected surfaces are free from oil, diesel fuel, dirt, and ice.Only step on parts of the machine that are provided with slipprotection.It is important to use the right tools and the right equipment.Defective tools or equipment must be repaired or replaced.If service work has to be done under a raised attachment, itmust first be secured. Engage the control lockout and apply theparking brake, if installed on the machine.

Prevent machine damageUse equipment with sufficient lifting capacity if the machine orparts of it are to be lifted or supported.Volvo CE will not accept any responsibility if other liftingdevices, tools, work methods, lubricants, and parts are usedother than those described in this Operator's Manual.Make sure that no tools or other objects that may causedamage have been forgotten in or on the machine.Release the pressure in the hydraulic system before beginningservice work.Machines used in environmentally contaminated or healthhazardous areas must be equipped for such operations. Aswell, special safety rules apply for service work on suchmachines.Actions in connection with electric welding, See page NO.146Make sure that all protective plates, covers, and hoods on themachine are in place before starting the engine and operatingthe machine.Use the three-point contact while claiming the machine.

Prevent environmental influenceBe conscious of the environment when carrying out service andmaintenance. Oil and other liquids dangerous to the environment



95

and released into the environment will cause damage. Oildegrades very slowly in water and sediment. One litre of oil candestroy millions of litres of drinking water.

NOTICEIn common for all points below is that all waste is to be handedover to a treatment and disposal firm approved by the authorities.

When draining, oils and liquids must be collected in suitablevessels and steps taken to avoid spillage. vessels and stepstaken to avoid spillage.Used filters must be drained of all liquid before they are passedon as waste. Used filters from machines which work inenvironments with asbestos or other dangerous dust, must beplaced in the bag supplied with the new filter.Batteries contain substances dangerous to the environmentand health. Used batteries must therefore be handled as wastedangerous to the environment.Consumables, e.g. used rags, gloves and bottles may also becontaminated with oils and liquids dangerous to theenvironment and must in that case be treated as wastedangerous to the environment.


MaintenanceBefore you begin any service work on the machine:Service work which is not carried out in the correct way isdangerous.All service work should be carried out by a qualified technicianwho is having sufficient knowledge of the machine, and trained touse the proper tools and equipment to carry out the service taskin a correct way.

WARNINGDuring service, hearing protection and safety goggles must beused.

NOTICENo work must be carried out on the machine until you haveacquired the appropriate knowledge to do so.

In any work concerning the operation, conversion or adjustmentof the machine and its safety oriented devices or any work relatedto maintenance, inspection and repair, always observe the startup and shutdown procedures set out in the operating instructionsand the information on maintenance work.

ENSURE that the maintenance area is adequately secured.

If the machine is completely shut down for maintenance andrepair work, it must be placed in the service position, See pageNo. 92 and secured against inadvertent starting by:

Locking the principal control elements and removing theignition keyAttaching a warning sign to the ignition or main switch

96



CARRY OUT maintenance and repair work only if the machineis positioned on stable and level ground and has been securedagainst inadvertent movement and buckling.LIFTING THE UNIT - When raising the unit off the ground,apply the parking brake. Attach the lifting apparatus only to theunit’s designated lifting points using properly rated liftingstraps, cables, or chains. Use spreader bars to ensure equalweight distribution during lifting as well as avoid contact withthe unit. For Safety, when lifting and supporting the machine,See page No. 99.USE CARE when attaching and securing lifting tackle toindividual parts and large assemblies being moved forreplacement purposes to avoid the risk of accidents. USE liftinggear that is in perfect condition and with adequate liftingcapacity. NEVER work or stand under suspended loads.ALWAYS USE the correct tools and workshop equipmentwhen performing maintenance on the machine.ALWAYS USE specially designed or otherwise safety orientedladders and working platforms when doing overhead assemblywork. Never use machine parts as a climbing aid.KEEP all handles, steps, handrails, platforms, landings andladders free from mud, dirt, snow and ice.CLEAN the machine, especially connections and threadedunions, of any traces of oil, fuel or preservatives before carryingout maintenance/repair. NEVER use aggressive detergents.Use lint free cleaning rags.COVER OR TAPE all openings, for safety and functionalreasons - must be protected against water, steam or detergentpenetration before cleaning the machine with water, steam jet(high pressure cleaning) or detergents. Special care must betaken with electric equipments.ENSURE during cleaning of the machine that temperaturesensors do not come into contact with hot cleaning agents.REMOVE all covers and tapes applied for that purpose aftercleaning machine.EXAMINE all fuel, lubricant, and hydraulic fluid lines for leaks,loose connections, cut marks and damage after cleaning.REPAIR or REPLACE defective parts immediately.TIGHTEN any screwed connections that have been loosenedduring maintenance and repair.REPLACE any safety devices removed for setup, maintenanceor repair purposes and checked immediately upon completionof the maintenance and repair work.ENSURE that all consumable and replaced parts are disposedsafely and with minimum environmental impact.AVOID, whenever possible, servicing, cleaning, or examiningthe machine with the engine running.AVOID, whenever possible, servicing or providingmaintenance to the compactor unless the drum and wheels areadequately chocked, the articulation lock bar/lock pin is in thelocked position, and parking brake is applied.

WARNINGAll forms of open fire and smoking should be avoided whenfilling the fuel tank.DON'T fill the fuel tank with the engine running, while near anopen flame, or while smoking.ALWAYS wipe up any spilled fuel.



97

DO NOT alter the engine governor settings from thoseindicated in the engine manual.ALWAYS replace damaged or lost decals. Refer to the partsmanual for the proper location and part number for all decals.ENSURE the safe operation, optimum performance and safetyof your warranty by using only genuine manufacturer’sreplacement parts.SWITCH OFF battery disconnect switch and DISCONNECTthe battery cables when working on the electrical system orwhen welding on the compactor.BE SURE the battery area is well ventilated (clear of fumes)should it be necessary to connect a jump battery. Fumes fromthe battery can ignite by a spark and explode.BE SURE the battery charger is “Off” when making theconnections if battery charging is required.USE only original fuses with the specified current rating. Switchoff the machine immediately if trouble occurs in the electricalsystem.WORK on the electrical system or equipment may only becarried out by a skilled electrician or by specially instructedpersonnel under the control and supervision of an electricianand in accordance with the applicable electrical engineering.CUT off the power supply to parts of the machine on whichinspection, maintenance and repair work is to be carried out.CHECK the de-energized parts for the presence of power andground or short circuit them in addition to insulating adjacentlive parts and elements before starting work.INSPECT the electrical equipment of machines at regularintervals. Defects such as loose connections or scorchedcables must be rectified immediately.DO NOT weld, flame cut or perform any grinding operations onthe machine unless expressly authorized as there may be arisk of explosion and fire.CLEAN the machine and its surroundings from dust and otherflammable substances and make sure that the premises areadequately ventilated (risk of explosion) before beginningwelding, flame cutting and grinding operations.INSPECT hydraulic hoses at regular intervals and immediatelyreplace if they show signs of chafing, cracking, brittleness,deformation, blistering, leakage, fitting separation, corrosion orother damage which may affect their function or strength.DO NOT work on hydraulic lines while the engine is runningand the system is under pressure. The hydraulic fluid remainspressurized long after the engine has stopped.DO NOT work on any hydraulic hose or fitting until the pressurehas been properly relieved.WAIT for fluid to cool down before disconnecting. Hot hydraulicfluid will cause severe burns.NEVER use your hands to check for leaks when inspecting anhydraulic system. Use a piece of cardboard and always weargloves and safety glasses.GET immediate attention if fluid has been injected under yourskin. Fluid penetration from a pin hole leak can cause severeinjury or death.ENSURE hydraulic lines are laid and fitted properly. Ensurethat no connections are interchanged. The fittings, lengths andquality of the hoses must comply with the technicalrequirements.OBSERVE the product related safety regulations whenhandling oil, grease and other chemical substances.

98



Be careful when handling hot conscionable items. (risk ofburning or scalding).

Safety when lifting and supporting completemachine

Place the machine in service position, see page No. 92

WARNINGOnly use lifting devices with adequate capacity.

WARNINGDo not work under a hanging or suspended load!

Use only lifting devices with sufficient capacity to safely supportthe expected weight you are lifting.All lifting devices (straps, slings, chains, ratchet blocks, etc.)must comply with applicable regulations and certifications. Wecan accept no responsibility for the use of sub-standardequipment and work practices.If you use a jack, the floor or ground must be even and ofsufficient strength to support the expected load.Use the lifting eyes or lifting points that are located on certainpoints of the machine. See page No. 81

WARNINGNever work under/on machines without using recommendedsupport equipment.

Lifting and supporting rear axle.Use a suitable lifting device or jack with proper rated capacity forthe job to raise the machine as required for wheel removal.

NOTICEThe machine must be lowered from the jack onto an appropriatestand before the wheel is removed. Do not use the jack to supportthe weight of the machine when removing the wheel.

Secure the machine with a stand under the end of the axle on theside that the wheel is to be removed.

Secure the machine under the frame if the axle is to be removed.Make sure it is positioned correctly and has safe ground supportfor the expected load.

NOTICENever position jacks or stands under the fuel tank or engine.

Lift the front frame at appropriate lifting points.Place support stands under the frame, before removing the drumor when separating the machine to work on the articulation framejoint and pivot pins.



99

Front frame support, (drum installed)Support the front drum frame with appropriate stands on bothsides of the frame when working on the drum components withthe drum installed, (such as replacing shock mounts, or drumvibration or drive motors).When lifting the front drum frame use appropriated lifting devicewith proper rated capacity.

Front frame support, (drum removed)Use a suitable lifting device with proper rated capacity to supportthe front drum frame when the drum is removed from the machine,or when separating the machine, (i.e. for replacing articulation oroscillation pins).

Some simple rules regarding tyre handling

TYRE INFLATION - Check the unit tyre pressure when cold andinflate to the recommended pressure. Remove the wheel from theunit whenever pressure is below 80% of the recommendedpressure. Place the tyre in a cage and inflate using a clip-on aircheck and remove tyre pressure gauge. Do not overinflate;otherwise the tyre may explode causing severe injury or death.

InflatingNever stand to the side of the tyre while inflating. Use a self-locking outlet with a hose long enough to allow you to standoutside of the hazard zone during inflation, see the illustration.Make sure that the hazard zone is clear when the tyre isinflated.The machine must be unladen when checking tyre pressure.Tyres and rims suspected of being damaged should not beinflated with the wheel attached to the machine.

Fitting of tyres and rimsHandling of tyres should be performed by authorised personnelonly.

The tyre should be deflated before removal from the machine.

Never install a tyre on a rim that has not been recommendedfor that tyre.

Use a lubricant recommended by the tyre manufacturer whenfitting onto the rim.

Repairing tyres and rimsNever cut, weld nor heat the wheel parts in any manner.Exercise caution when using bead breakers and hydraulicjacks. Remain outside the hazard zone when removing foreignobjects from the tyres. A bead breaker that releases can causesevere personal injury and may result in death.

V1021831

Never stand to the side of the tyre while inflating

100



Working in environmentally contaminatedareas

Machines that are used in environmentally contaminated and/orhealth-hazardous areas shall be specially equipped for operationin such an environment.

Used engine air filters from machines working in environmentswith asbestos or other hazardous dust shall be put into tight-sealing plastic bags that the new filters come in, then leave theused filters for destruction.

Environmental handling for the future

The world stands before gigantic challenges on environmentalmatters where clean water, climate change, and use of chemicalsare some of the most important issues. Volvo has an importantfunction in meeting these challenges and contributing to a moreecologically sustainable development. Quality, safety andenvironment are Volvo core values and have for a long time beenintegral parts of our company and our products.Volvo Construction Equipment works with continuousimprovement of the machines' environmental performance. Animportant factor to retain the machine's performance is theservice offered by the workshops. This service manual containsrecommendations, warning texts, etc. to facilitate your work forthe environment.V1032979



101

Preparations before service

Articulation hinge

The articulation lock is used to prevent accidental articulation ofthe machine. The articulation lock pin must be in the lockedposition prior to shipment and before performing any checks orservice operations. Place the articulation lock pin in the stowedposition for compaction operations.

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Preparations before service

Entering, leaving and climbing themachine

Entering, leaving and climbing the machine


Do not jump on/off a machine, especially never get on / offwhen the machine moves.Never grasp the control lever to get on / off.Use hand holds and steps when entering, leaving or climbingthe machine.Use the three-point grip, that is two hands and one foot or twofeet and one hand.Always face the machine.Always wipe mud and oil off all footboards, handrails and yourfootwear, rear view mirrors and lights.Clean your boots and wipe your hands before getting on themachine.

Three point contact.


Entering, leaving and climbing the machine

103

Fire prevention

WARNINGUsing the machine in environments with high risk of fire orexplosion requires special training and equipment.

There is always a risk of fire. Find out what kind of fire extinguisheris used on your working site and how to use it. If the machine isequipped with a fire extinguisher, it should be kept near theoperator’s seat on the left side of the operator.

Fire prevention measuresDo not smoke or have an open flame near a machine whenfilling with fuel or when the fuel system is opened and in contactwith the surrounding air.Diesel fuel oil is flammable and must not be used for cleaning.Use conventional car care products meant for cleaning ordegreasing. Also bear in mind that certain solvents can causeskin rashes, damage to the paint finish and constitute firehazard.Keep the place clean where the service is to be carried out. Oiland water can make the floor slippery and is also dangerous inconnection with electrical equipment or electrically poweredtools. Oily and greasy clothes are a serious fire hazard.Check daily that the machine and the equipment, for exampleunderbelly plates are free from dust and oil. Besides reducingthe risk of fire, it is also easier to detect faulty or loosecomponents.

NOTICETake great care if a high-pressure wash is used for cleaning.Electrical components and electrical leads can be damagedeven at a moderately high pressure and temperature. Protectelectrical leads in an appropriate way.

Take extra care when cleaning a machine working in a fire-sensitive environment, for example saw-mill and refuse dumps.The risk of spontaneous combustion can be further reduced byinstalling insulation of the silencer guard.It is important that the fire extinguisher is maintained in orderto work when it is needed.

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Fire prevention

Check that fuel lines, hydraulic and brake hoses and electricalcables have not been damaged by chafing or are not in dangerof being damaged in that way because of incorrect installationor clamping. This applies particularly to unfused cables, whichare red and marked R (B+) and routed:- between the batteries- between battery and starter motor- between alternator and starter motor

Electrical cables must not lie directly against oil or fuel lines.Do not weld or grind on components which are filled withflammable liquids, for example tanks and hydraulic pipes.Exercise care with such work also in the proximity of suchplaces. A fire extinguisher should be kept near to hand.

Actions in case of fireIf the circumstances permit and your own safety is notjeopardised, take the following steps at the slightest sign of fire:1 Stop the machine, if the machine is in motion.2 Move the propulsion control lever to stop position.3 Turn the ignition key to stop position.4 Exit the from the machine.5 Call the fire brigade.6 Turn off the battery disconnect switch.7 Attempt to put out the fire, if possible. Otherwise, move away

from the machine and out of the danger zone.

Actions after fireWhen handling a machine which has been damaged by fire orbeen exposed to intense heat, the following protective measuresmust be followed:

Use thick, protective gloves made of rubber and wear goggles.Never touch burnt components with your bare hands in orderto avoid contact with melted polymer materials. First washthoroughly with plenty of lime water (a solution consisting ofcalcium hydroxide, that is slaked lime in water).Handling heated fluoro-carbon rubber, see page No.109.


Fire prevention

105

Fire prevention measures

GeneralThere may always be a risk of fire. Learn the correct type of fireextinguisher to use, how to use it, and where it is kept,if themachine is equipped.If the machine is provided with a hand-held fire extinguisher, itshould meet local requirements.Any on-board fire extinguisher must be kept fully charged andin good working order at all times.

Any on-board fire fighting equipment should be considered asa complement to the operator's own fire fighting efforts. It is nota replacement.Never expose diesel fuel to open flame or smoking materials,especially when refuelling or the fuel system is open to the air.Never use diesel fuel as a cleaner, use an approved cleaningsolvent.Certain solvents are usually flammable and can cause skinrashes or other conditions. Do not inhale solvent vapours.Never use engine starting aids, especially if the machine isequipped with an automatic preheating intake air system.Ensure the machine is properly equipped for working in dry orforested areas. Equipment such as a spark arrester may berequired.At the first sign of a fire, take the following actions if the situationwill safely permit:- Drive the machine away from the danger area.- Shut down the engine with the ignition key switch.- Leave the operator platform quickly and safely.- Turn the battery disconnect switch off.- Begin extinguishing the fire and call for assistance if

required.

CleanlinessCleanliness is important to effective machine service.Contamination introduced to machine systems can shortencomponent service life and cause the machine to malfunction.Keep the service area clean. Oil or water on the floor can createa dangerous work environment, increasing the risk of falls andelectrocution. Oily and greasy clothing and shop rags are a firehazard.

1017936

Fire extinguisher

Do not smoke when refuelling or expose diesel fuelto open flames

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Fire prevention

The machine should be inspected daily for the build-up offlammable debris. This will reduce the chance of a fire, and willmake it easier to detect loose or leaking parts.

CAUTIONIf a high-pressure washer is used when cleaning, workcarefully since damage may be caused to electricalcomponents and insulation of the electrical cabling even atrelatively moderate water pressure and temperature. Protectelectrical cabling in a suitable manner.

Take special care to keep machines clean in applications suchas coal mines where the risk of fire is greatest. In suchapplications, suitable equipment to reduce the risk of fireshould be installed and maintained.

Electrical systemInspect wiring for chafing, breakage, and any routing conditionthat could expose wiring to damage. This is especiallyimportant for positive electrical wires that could make contactwith the frame (ground). Pay special attention to the cablesbetween the batteries, from the batteries to the starter, andbetween the alternator and starter.When reconnecting wires, it is important to connect, route andsecure them so they are protected from damage and wear.They must not be routed in contact with fuel or oil hoses.If any auxiliary electrical equipment is installed on the machine,wiring must be fused, connected and routed to avoid exposureto wear or damage.

Fuel, hydraulic and brake systemsCheck to make sure fuel, hydraulic and brake hoses are notworn or damaged, and are routed to avoid rubbing.

Welding and grinding work

CAUTIONA fire extinguisher should be easily accessible during allwelding work.

Move the machine to a clean, safe area before welding,grinding or using an oxy/acetylene torch on it. This type of workshould only be done in a clean area and not in places thatcontain combustible liquids, such as fuel tanks, hydraulic pipesor similar.Work with extra care when welding, grinding or torch cuttingnear flammable objects.Welding on painted surfaces releases dangerous fumes, andresults in a poor weld joint, that can result in failure andpotential accidents. Always remove paint from areas to bewelded. See also

Check list after fire or heat exposureAs a precaution, all o-rings and seals should be handled as ifthey were made of fluor rubber. See page No.112.


Fire prevention

107

WARNINGAvoid splashing when washing a machine damaged by fire.For this reason, never use high-pressure washing equipment.

Never touch burnt components or parts with your bare handswhen there is a risk that you may be exposed to contact withburnt fluor rubber. See page No.112.Wear thick, protective neoprene gloves, goggles, andapproved respirator.First, wash thoroughly with plenty of lime water (a solution or asuspension of calcium hydroxide, i.e. slaked lime).Seek medical attention if skin contact with burnt fluor rubber issuspected. The affected skin should be treated withHydrofluoric Acid Burn Jelly or similar.Symptoms may not appear until several hours after contactwith burnt fluor rubber.Wash with lime water, then discard protective gloves, rags andother items that may have contacted burnt fluor rubber.

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Fire prevention


Heated paint

WARNINGHeating of painted surfaces, rubber or plastics parts may causethe formation of substances dangerous to health or environment.Take care when, for example, welding, grinding or gas cutting.Wear protective equipment.

Heated paint gives off poisonous gases. Therefore, paint must beremoved from an area with a radius of at least 10 cm (4 in) beforecarrying out welding, grinding or gas cutting. In addition to thehealth hazard, the weld will be of inferior quality and strength,which, in the future, may cause the weld to break.

Methods and precautionary measures when removing paintBlasting- use respiratory protective equipment and protective gogglesPaint remover or other chemicals- use a portable air extractor, respiratory protective equipment

and protective glovesGrinding machine- use a portable air extractor, respiratory protective equipment

and protective gloves and goggles

Never burn painted parts after they have been discarded. Theyshould be disposed of by a licensed disposal plant.

Heated rubber and plasticsPolymer materials can, when heated, form compounds which aredangerous to health and environment and must therefore neverbe burned when scrapped.

If gas cutting or welding is to be carried out near such materials,the following safety instructions must be followed:- Protect the material from heat.- Use protective gloves, protective goggles and respiratory

protective equipment.



109

Heated fluoro-carbon rubber

WARNINGSeals that can withstand high temperatures may be made offluoro-carbon rubber. At very high temperatures fluoro-carbonrubber forms substances, which are very corrosive to skin andlungs. Wear protective equipment.

When handling a machine which has been damaged by fire orbeen exposed to intense heat, the following measures should betaken:

Use thick, rubber gloves and wear protective goggles.Discard gloves, rags and other items that have been in contactwith heated fluoro-carbon rubber after first having washedthese items in lime water (a solution of calcium hydroxide, thatis slaked lime in water).The area around a part which has been very hot and which maybe made of fluoro-carbon rubber should be decontaminated bythorough and ample washing with lime water.As a precaution, all seals (O-rings and other oil seals) shouldbe handled as if they were made of fluoro-carbon rubber.The hydrofluoric acid may remain on the machine parts forseveral years after a fire.If swelling, redness or a stinging feeling appears and onesuspects that the cause may be contact with heated fluoro-carbon rubber, contact a medical doctor immediately. Severalhours may pass, however, before any symptoms appear andthere is no immediate warning.The acid cannot be rinsed or washed off from the skin. Treatinstead with Hydrofluoric Acid Burn Jelly or similar beforecontacting a medical doctor.

Batteries

WARNINGHandling batteries may lead to that electrolyte comes into contactwith eyes, skin or clothes. Wear protective equipment. Electrolytesplashes in eyes must be rinsed off with water immediately.Electrolyte on skin must be washed off with soap and waterimmediately. Seek medical advice.

Batteries develop explosive gases. Therefore, do not smokeand avoid naked flames and sparks when working in the vinicityof batteries.Make sure that metal objects such as tools, rings and wristwatches do not come into contact with the battery terminals.Ensure that the caps are always mounted on the batteryterminals.Do not tilt batteries as otherwise the battery acid may escape.Discharged batteries must never be connected to fully chargedbatteries. Danger of explosion.Keep the battery surface clean and dry.Immediately wash any leaked battery acid with soda dissolvedin water.Batteries contain materials that are damaging to health and theenvironment. The batteries must therefore be disposed of inaccordance with the applicable national regulations.

110



When dismantling a battery, the mass cable must bedisconnected first and, for installation, the last to be connectedin order to prevent the formation of sparks.Used batteries must be disposed of in accordance with theapplicable national regulations.Disconnect the batteries from the machine before loading themfrom an external source.For the charging of batteries, see page 150.For starting using auxiliary batteries, see page Starting withbooster battery.

Environmentally safe handling

Always choose an environmentally friendly alternative where oneis available, e.g., biodegradable oils.

Always follow national and local environmental regulations.

All waste shall be brought to a waste handling company,approved by the authorities.

Oils and fluidsOils and fluids, e.g., coolant, that are not reused shall be collectedin tight-sealing containers and left for destruction.

FiltersOil and fuel filters shall be drained and put into sealed containersbefore they are left for destruction.

Batteries

WARNINGRisk of serious corrosive injuries!

Batteries contain environmentally hazardous substances andcorrosive acid. Shall be left for recycling.

ChemicalsChemicals, paints, glue, cleaning agents, etc. shall be left forrecycling and destruction.

Rubber and plasticsRubber materials and plastics may not be burned. Shall be left forrecycling.Tyres shall be handled according to special rules.

V1033092

Corrosive acid



111

ElectronicsElectrical and electronic waste, e.g., circuit boards and bulbs,shall be left for recycling.

Waste handling

Contribute to careful use of natural resources by following thesteps below when handling waste.If possible, deposit the waste for recycling.

REUSE of products is the best from an environmental aspect.

MATERIAL RECYCLING for use in new products is a goodenvironmental alternative.

ENERGY RECOVERY by burning combustible materials is agood alternative when recycling is not possible.

DESTRUCTION is used for hazardous waste. Destruction isperformed in special facilities.

DEPOSITION is the worst from an environmental aspect andshould be avoided as much as possible.

STORAGE is a temporary measure until a suitable recyclingmethod has been developed.

Health hazards with paint, plastics and rubber

Work on painted surfacesNever weld or cut with a torch on painted surfaces. All paintdecomposes, when heated and generates a vast number ofdifferent substances, that may be irritating and, in case ofrepeated exposure, be very hazardous to health.

The following safety actions shall be followed:Remove the paint by sandblasting at least 10 cm (4 in) aroundthe welding or cutting point (use breathing mask).If the paint cannot be removed by sandblasting, then removethe paint in another way, e.g., with paint solvent/remover.

NOTICEWhen using paint remover/solvent, use air extraction,breathing protection and protective work gloves.

Grinding machines with high-speed grinding discs also heatthe paint and may only be used if there is an air extractor onthe grinder. Use breathing protection as well.

112



Rubber and plastics

WARNINGWhen heated, rubber and plastics can give off substances thatare hazardous to personal health and the environment.

The following safety instructions shall be followed:Do not weld or cut with a torch near polymer materials (plasticsand rubber) without first protecting them from the heat.

Never burn polymer materials when scrapping them.

Be careful when handling machines that have been exposedto fire or other intense heat. See page No.107.

Always use gloves, protective safety glasses and breathingprotection.

Fluor rubber


WARNINGWhen hydrogen fluoride rubber is heated, there is a risk ofhydrogen fluoride gas build-up already at approx. 320 °C (610 °F).When inhaled, the gas is extremely corrosive to respiratory tracts.

Certain seals designed to withstand high operating temperatures(e.g., in engines, transmissions, axles, brakes, hydraulic motorsand pumps) may be made of fluor rubber which, when heated tohigh temperatures, generate hydrogen fluoride and hydrofluoricacid.

Hydrofluoric acid is highly acidic and corrosive. It cannot be rinsedor washed off the skin and causes very severe burn and corrosiveinjuries that take a very long time to heal. As a rule, injured tissuemust be removed surgically.

Hydrofluoric acid may remain on machine parts for a very longtime (several years) after a fire.

NOTICEIn case of contact with hydrofluoric acid, it may take several hoursbefore any symptoms appear.

If swelling, redness or burning sensations appear and contact withheated fluor rubber is suspected to be the cause, seek immediatemedical attention. If a machine or a component for a machine hasbeen exposed to fire or other intense heat it shall be handled byspecially trained personnel.

For all handling of machines after a fire, use heavy-duty glovesmade of neoprene rubber and effective safety goggles.



113

WARNINGBurning of painted parts, plastic or rubber parts constitutes ahealth hazard.

See page 111 for environmentally safe handling.

DecontaminationThe area around a heated part that is suspected to be made offluor rubber shall be decontaminated by thorough and amplewashing with lime water ( a solution or suspension of calciumhydroxide, that is, slaked lime) in water. After completing thedecontamination work, wash the gloves in the lime water and thendiscard them.If the machine has been exposed to a fire or other intense heat,the safety actions in the following checklist shall be followedunconditionally at all times, See page 107.

Asbestos informationThe components in Volvo CE's machines are free from asbestos,that is why it is important to use genuine Volvo spare parts.

Safety when handling oil and fuelWhen changing oil in the engine or hydraulic system,remember that the oil may be hot and can cause scalding orburn injuries.Engine and hydraulic oils, as well as diesel fuel, have acorrosive effect on mucous membranes (i.e. eyes, throat andon skin). Take special care to keep oils away from thesesensitive body parts.Oils and fuels are hazardous to the environment. Take specialcare not to spill or discharge these fluids. Use approvedcontainers and methods to handle and dispose of machinefluids. Use an authorized disposal and recycling company. Seepage No.101 for environmental handling for the future.Be aware of the risk of fire.

114



Handling line, tubes and hoses

WARNINGIf oil or fuel leaks from high pressure hoses or loose screws isfound, stop operations immediately and contact an authorizedVolvo dealer workshop.

Do not bend high pressure lines.Do not strike high pressure lines.Do not install any lines that are bent or damaged.Check lines, tubes and hoses carefully.Do not reuse hose, tube and fittings.Do not use your bare hand to check for leaks.Tighten all connections. Consult your Volvo CE dealer for therecommended tightening torque.

If any of the following conditions are found, replace the parts.Consult your Volvo CE dealer.

End fittings are damaged or leaking.Outer coverings are chafed or cut.Strengthening wires are exposed.Outer coverings are ballooning.Flexible part of the hoses are kinked.End fittings are displaced.Foreign material is embedded in the coverings.

CAUTIONMake sure that all clamps, guards and heat shields are correctlyinstalled. This contributes to preventing vibrations, chafingagainst other parts and excessively strong generation of heat.


Handling line, tubes and hoses

115

Service and maintenanceService history

After each completed service at a workshop authorised by VolvoCE, the service history should be filled in, see page 208. Servicehistory is a valuable document, which can be referred to when forexample selling the machine.

Cleaning prior to repair

The machine should be cleaned regularly with conventional carcare products in order to eliminate the risk of damage to the paintfinish and other surfaces on the machine.Cleaning the machine prior to conducting repairs is especiallyimportant in order to reduce the risk of contaminants from enteringsensitive areas of the machine.Dust, dirt and other debris entering into the fuel, lubrication,cooling and hydraulic systems can cause premature wear,corrosion, blockages and overheating, which will damageexpensive machine components and cause machine systems tofail.

CAUTIONAvoid using strong cleaning agents or chemicals in order tominimise the risk of damage to the paint finish.

NOTICEDaily clean the areas on the machine where dust, chips andsimilar may collect in order to minimize the risk of fire. See page117.Daily cleaning will be required if material is adhering to the drum,or has become jammed between the drum and its scraper.

Recommendations for cleaning the machine1 Park the machine in a place intended for cleaning.2 Remove any material jammed between the drum and its

scraper.3 Open the air filter access cover and clean the air cleaner

evacuator valve and inspect the rubber for cracks. (Replaceas required).

4 Install protective covers, barriers or safety cap plugs to protectsensitive components and machine areas from water entry.

NOTICEProtect all electrical components, control panels and leads inan appropriate way to prevent entry of water or steam whenusing high pressure cleaning methods.

5 Follow the instructions supplied with the car care product.6 The water temperature must not exceed 60 °C (140 °F).7 If high-pressure wash is used, keep a distance of at least 20–

30 cm (8–12 in) between nozzle and machine surface.Excessive pressure and too short a distance may causedamage.

8 Use a soft sponge.9 Clean the whole machine with water only.

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After cleaning:1 Remove all protective materials (covers, barriers, tape, plastic

wrap or safety cap plugs etc.) added for protection againstwater entry.

2 Always lubricate the machine immediately after washing,especially in the areas that water or contaminants may haveentered. These areas include the vertical and horizontal swivelpins and bushings and cylinder pins if the fittings are notplugged with a pipe plug.

NOTICEPlugs indicate a maintenance free bearing.

3 After washing, run the engine until it is warm. This will help todry out engine components and electrical connections.

4 Perform the daily or as required maintenance checks.5 Touch-up the paint finish when required.

Cleaning of engine compartment

Machines operating in dusty environment require daily attentionand cleaning of the engine compartment and surrounding areas.

Cleaning tipsChecking and cleaning should preferably be carried out at theend of the working shift, or prior to startup if the machine hasbeen parked for an extended period of time.The machine should be parked in a place intended for cleaning,away from bystanders and other equipment.Place the machine in the service position, see page No.92(Shut down Engine and switch OFF battery disconnect).Use personal protective equipment such as protective goggles,gloves and respirator.Begin with the highest areas and end with the lowest on top ofthe fuel tank and areas near the fuel tank.Remove exterior dirt and debris first, then open all covers andhoods to access interior areas for cleaning.Loose material is removed with compressed air.After cleaning, check and rectify any leaks or maintenanceissues.Close all covers and hoods, and place the machine back inservice.

Precaution when working on the electricalsystem

Before working on the electrical system of the machine,carefully read and follow all instructions in the safety section ofthis service manual.Do not attempt to repair, test or adjust the electrical systemunless you are a qualified service electrician.Before carrying out any work involving testing or removal andfitting of components in the electrical system, place themachine in the service position. See page No. 92 and turn thebattery disconnect switch to the OFF position.Use only test instruments with light-emitting diode (LED)displays to trace electrical faults. Do not use test equipment

Service and maintenance 117

that uses light bulbs. The voltage characteristics of light bulbscan destroy sensitive and expensive electronic components.When installing a two-way radio, mobile telephone and similarequipment, follow the manufacturer's installation instructions inorder to eliminate interference with the function of theelectronic system and components on the machine.Before any tests are carried out on the alternator, the batteriesand electrical leads must be checked for insulation faults, poorcontacts or corrosion. Check the alternator belts. Correct anyvisible faults before beginning electrical checks.During all tests of alternating current equipment, secureconnections must be used. One loose lead may damage thealternator.Never disconnect the main lead of the alternator or the lead toit’s field winding while the engine is running. Damage mayresult.If the current output terminal of the alternator is connected tothe mainframes while the engine is running, alternator damagewill result.Use only charged batteries to test the electrical system.Before working with the batteries See page No.144.Test the battery acid for specific gravity using a hydrometer.When installing or replacing a battery, make sure that correctpolarity is followed. Always disconnect the negative (ground)cable first and reconnect it last.If a booster battery is required for starting the engine, follow theinstructions in the Operator’s Manual and See pageNo.Starting with booster battery.Before welding on the machine or attachments connected tothe machine, See page No.146.

Cleaning machine

CAUTIONIf a high-pressure washer is used when cleaning, work carefullysince damage may be caused to electrical components andinsulation of the electrical cabling even at relatively moderatewater pressure and temperature. Protect electrical cabling in asuitable manner.

Clean the machine regularly with conventional car care products.Avoid using strong cleaning agents or chemicals to minimize therisk of damage to the paint finish and other surfaces on themachine.

Clean the machine prior to conducting repairs to reduce the riskof contaminants from entering sensitive areas of the machine.

Dust, dirt and other debris entering into the fuel, lubrication,cooling and hydraulic systems can cause premature wear,corrosion, blockages and overheating. This will result in damage

118


to expensive machine components and cause machine systemsto fail.

NOTICEClean the areas daily on the machine where dust, chips andsimilar may collect in order to minimize the risk of fire.

NOTICEKeep all exterior and interior window surfaces clean to ensureproper visibility.Clean any dirt and debris from the seals and sealing surfacesperiodically to ensure proper performance.

Measures before cleaning the machine1 Remove any material jammed between the drum and the drum

scraper.2 Check that the air cleaner evacuator check valve on the air

cleaner is clean and that rubber is not cracked. Replace asrequired.

Recommendations for cleaning the machine:1 Place the machine in a place intended for cleaning.2 Follow the instructions supplied with the car care product.3 The water temperature must not exceed 60 °C (140 °F).4 If a high pressure washer is used, keep a distance of at least

20–30 cm (8–12 in) between the nozzle and the machinesurface. Excessive pressure and too short a distance maycause damage.Protect electrical leads in an appropriate way.

5 Use a soft sponge.6 Finish by rinsing the whole machine with water only.

Measures after cleaning the machine1 Remove all material added for protection from water entry

during machine washdown.2 Always lubricate the machine after washing. Grease fittings

immediately. Do not grease optional self-lubricating bearings.3 Check for defects in the air cleaner ducts and correct as

required.4 Check air intake for accumulation of debris that could restrict

air flow and clear.5 Check air cleaner mounting hardware for security and correct

as required.6 Check all hoses for cracks, chafing, or deterioration and

replace at the first sign of probable failure.7 Touch up the paint finish when required.

Touch-up paintingClean the machine.Check for faults to the paint finish that may expose bare metal.Carefully repair any faults to the paint finish.


Periodic maintenance

NOTICEThe following list provides references and links to periodic or “asrequired” maintenance procedures not covered at the specifichourly intervals listed in the service programme and described inthis section of the service manual.For further information on these procedures, See service andmaintenance section in this manual or follow the links provided tothe appropriate maintenance procedure for the items listed below.

As required maintenance1 Check the air cleaner connections and ducts for leaks.2 Check/clean the air cleaner primary filter as required when the

clog indicator in the shows red or more frequently in extremelydusty conditions. See page No.. 133.

3 Replace the air cleaner primary filter element for every 500hours, or if damaged or heavily soiled beyond cleaning. Seepage No. 136.

4 Replace air cleaner secondary (safety) filter element afterthree primary filter element changes, or if air cleaner elementsare damaged or heavily soiled. See page No. 138.

NOTICEChange interval maximum is reached when records indicatedthat the primary element has been replaced 3 times or 1 yearduration has passed since the last replacement.

5 Clean and wash the machine. See page No. 116.6 Clean the engine compartment See page No. 117.7 Torque any loose bolted connections. See page No. 202 and

201 .8 Check the battery disconnect switch. See page No. 145.9 Inspect the drum shock mounts. See page No.169.10 Place the machine back in service.

Maintenance service, general

To prevent minor irregularities from developing into seriousconditions, several other services or checks are recommendedfor the same intervals as the periodic lubrication. The purpose ofthese services or checks is to ensure the uninterrupted and safeoperation of the unit by revealing the need for adjustment causedby normal machine operation and wear.

NOTICEPrior to starting any work on the machine, observe the followingWarnings and Cautions:

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WARNINGAlways read the booklet Safety before proceeding.

WARNINGAny person who does not follow the safety instructions and whoignores warnings in this manual must make absolutely sure thattheir work method is safe. Otherwise, there is a great risk ofserious accidents and injuries, perhaps even fatalities.

CAUTIONBefore starting any work, park the machine on a level surface andprepare it for service by putting it into service position accordingto Safety rules for service.

CAUTIONRead the environment section in the "Safety" booklet

CAUTIONDo the work in an environmentally safe manner.

Observe the following operational procedures.Do not speed the engine when it is cold.Always chock the wheels when parking the machine.Do not grease the machine while the engine is running.Always perform safety checks prior to starting/using themachineAlways operate the machine at full engine speed whencompacting or traveling the machine.Never operate the machine across slopes.On machines equipped with a Rollover Protection Structure(ROPS), wear seat belt at all times.Before starting the engine, always check that the propulsioncontrol is in the STOP position and the parking brake is ON .Always sound the horn before moving the machine to alertpersonnel, and allow sufficient time before putting the machineinto motion.Always use protective clothing such as gloves, goggles andsafety helmet when performing service maintenance.


Maintenance service, dailyPlace the machine in service position. See page No. 92.Check the engine oil level. See page No. 126.Drain the water from the water separator. See page No. 131.Check engine coolant level and add if necessary. See page No.141.Clean the radiator and cooler fins. See page No. 142.Switch on battery disconnect-switch and turn ignition keyswitch to the ‘ON’ position and check workings of electricalbasic components. See page No. 145Check the air cleaner clog indicator in control console for airfilters clogging. Also check the air cleaner system. See pageNo. 133.Test parking brake using the parking brake test switch. Seepage No. 163 .Check fuel level on the fuel level gauge. Add if necessary.Check for leakages, physical damage to any machinecomponents.Check condition of the drum and clean it if necessary. See pageNo. 167.Place the machine back in service.

Maintenance service, every 50 hours1 Place the machine in service position. See page No. 92 .2 Perform daily maintenance service. See page No. 122.3 Check the battery electrolytes, cables and terminals. See

page No. 151 .4 Check for air cleaner system integrity. See page No. 1335 Check the tyre pressure. See page No. 165.6 Check the wheel nuts torque. See page No. 165.7 Check the hydraulic oil level. See page No. 175.8 Check the torque hub oil level. See page No. 167 .9 Check the drum eccentric oil level. See page No. 168.10 Lubricate the swivel pins with grease. See page No. 180.11 Lubricate the steering cylinder pins with grease. See page No

180.12 Lubricate Shift linkage. See page No. 182 .13 Clean carrier breather. See page No. 169.14 Place the machine back in service.

Maintenance service, every 100 hoursPlace the machine in service position. See page No. 92.Perform daily and 50 hours maintenance service. See page No122 and 122.Check axle housing oil level. See page No. 158 .Check transmission oil level. See page No. 158 and 156.Check wheel end/axle hubs oil level. See page No. 158.Place the machine back in service.

Maintenance service, every 250 hoursPlace the machine in service position. See page No. 92 .Perform the daily, 50 hours and 100 hours maintenanceservice. 122, 122 and 122Clean the axle breather. See page No. 161.

122


Change the engine oil. See page No. 126.

NOTICEAfter engine oil is changed, do not start the engine until theengine oil filter is replaced.

Change the engine oil filter. See page No. 128.Change the fuel filters. See page No. 129Change the water separator. See page No. 131.Change the hydraulic oil filters. See page No. 175.Place the machine back in service.

Maintenance service, every 500 hoursPlace the machine in service position. See page No. 92.Perform the daily, 50 hours, 100 hours and 250 hoursmaintenance service. See page No. 122, 122, 122 and 122Check the tension in fan and alternator belt. See page No.130.Change the engine air cleaner primary element. See page No.136.Torque the articulation vertical nuts. See page No. 201.Torque the horizontal swivel nut. See page No. 201.Check torque of the axle mounting bolts. See page No. 201.Change the axle transmission oil. See page No. 156.Change the axle housing oil. See page No. 160.Change the axle wheel end/axle hubs oil. See page No. 158.Change drum torque hub oil. See page No. 170.Change the drum carrier oil. See page No. 169.Change the drum eccentric oil. See page No. 172.Test run the machine.Check for the changed oil levels.Place the machine back in service.

Maintenance service, every 1000 hoursPlace the machine in service position. See page No. 92.Perform the daily, 50 hours, 100 hours , 250 hours and 500hours maintenance service. See page No. 122, 122, 122,122 and 123Clean the suction strainers and replace if necessary. See pageNo. 178.Change the hydraulic oil. See page No. 176.Place the machine back in service.


General inspection of machine

Lap type seat belt, checking and maintenance

Ensure that the mounting hardware is tight.

Check the seat belt regularly for wear or damage. Inspect the belthardware and fabric. Replace the seat belt if the hardware isdamaged or if the strap is nicked, frayed or loose sticking is found.

Seat belt assemblies should be replaced every 3 years regardlessof appearance. Seat belt strength degrades over time and usedue to exposure to weather, ultraviolet (UV) and abrasives (dirt).

124


General inspection of machine

Engine

Engine hood, opening and closing

To open the engine hood

CAUTIONRisk of engine hood falling down. Do not operate the machine witha completely or partly open engine hood.

Pull down the latches on both sides of the machine to releasethe hood.

WARNINGRisk of crushing injuries

NOTICENever reach into the engine compartment or work under a partlyraised engine hood supported only by the tension springs.

Hold the engine hood at the cutout provided at rear end andraise it completely upward.

To Close the engine hood

NOTICEMake sure there are no persons under the engine hood and alltools and equipments are removed from the engine compartmentbefore lowering the engine hood.

Pull down the engine hood with help of retractor strap till it sitson the frame.

1 Latches2 Engine hood3 Cutout


Engine

125

Hold the engine hood at the cutout and slowly push down untilthe hood is lowered to the fully closed position.Pull up the latches on both sides of the machine to draw thehood down and press them forward to close the latches andsecure the hood.

Engine oil level, check

CAUTIONAlways handle oils and other environmentally hazardous fluids inan environmentally safe manner.

WARNINGHot liquids and machine parts can cause burns. Allow themachine to cool before beginning any work.

Place the machine in service position. See page No.92.Open the engine hood.Remove the dipstick, wipe it with a lint-free dry cloth and insertit back.Remove the dipstick again, check the engine oil level and insertthe dipstick back.

NOTICEThe engine oil level must be maintained between the markson the dipstick. Never overfill the oil level or let it drop belowthe minimum level.

Fill the engine oil if necessary. See page No. for fillinginstruction in 126.Close the engine hood.Place the machine back in service.

Retractor strap

Dipstick

126


Engine

Engine Oil Change


WARNINGBe careful when changing oil since hot oil may cause severeburns to unprotected skin.

DrainingPlace the machine in service position. See page No. 92.Warm up the engine to the normal operating temperature.

WARNINGNever work under/on machines without using recommendedsupport equipment.

Remove the plug.

Attach a (hose connection) to the drain valve and drain theengine oil in a suitable container. For engine oil quantity Seepage No . 196.Remove the hose and plug the drain valve.Open the engine hood. For engine hood opening See page No.125 .Open the engine oil filler cap and fill the engine oil. For oilspecification See page No. 194.

NOTICEThe engine oil level must be maintained between the markson the dipstick. Never overfill the oil level or let it drop belowthe minimum level.

Close the engine oil filler cap.Clean the spillage, if any.Run the engine at idle rpm for 2 min.Check for the leakage.Check the engine oil level and fill if necessary.

NOTICEAllow sufficient time for engine oil to settle down in the sump.

Drain plug

Engine oil filler cap


Engine

127

Close the engine hood. For engine hood closing See page No.125.

FillingPlace the machine back in service.

Engine oil filter, replacing

CAUTIONTake care of filters, oils and liquids in an environmentally safeway.


Place the machine in service position. See page No. 92.Open the engine hood. For engine hood opening See page No.125.Place a suitable container to collect the oil while removing theengine oil filter.Disconnect the engine oil pressure switch connection for easyaccess.Remove the engine oil filter using .Clean the engine oil filter head sealing surface.Apply a thin film of oil to the engine oil filter seal.Fill the engine oil filter with clean engine oil. For engine oilspecification See page No. 194.Screw the engine oil filter until its seal touches the sealingsurface and tighten further half turn by hand.

NOTICEDo not over tighten the filter.

Connect the engine oil pressure switch connection.Clean the spillage if any.Run the engine at idle rpm for 2 min.Check for the leakage.Check the engine oil level. See page No. 126 . Fill oil ifnecessary. For filling instructions, See page No. 126.

NOTICEAllow sufficient time for engine oil to settle down in sumpbefore checking the engine oil level.

Close the engine hood. For engine hood closing See page No.125.Place the machine back in service.

Fuel system, bleeding

Manual Air Bleeding


1 Engine oil pressure switch2 Engine oil filter

128


Engine

Use a suitable container, or a plastic hose and absorbentmaterials to collect and clean up any fuel that escapes during thebleeding procedure.

Place the machine in service position. See page 92.Open the engine hood.Loosen the air vent screws of the fuel filters.

Prime the fuel system with the plunger provided on waterseparator until the fuel flows without air bubbles through thefuel filters.Tighten the air vent screws of fuel filters.Pump the fuel some more with plunger pressing for 3–4 times.Start the engine and run it at idle rpm for around 5 minutes.

NOTICEMake sure that the system it completely free from air.

Shut down the engine.Clean the spillage if any.Place the machine back in service.

Fuel filter, replacing



CAUTIONMaintain greatest possible cleanliness when working on the fuelsystem.

Place the machine in service position. See page 92.Open the engine hood.Place a suitable container to collect the fuel while removing thefilters.

Air vent screws

Plunger on water separator


Engine

129

Remove the filters using oil filter wrench.Clean the filter head sealing surfaces.Apply a thin film of oil on to the each filter seal.Screw the filter until its seal touches the sealing surface andtighten further half turn by hand.

NOTICEDo not over tighten the filter.Screw the second filter until its seal touches the sealing surfaceand tighten further half turn by hand.

NOTICEDo not over tighten the filter.Loosen the air vent screws and prime the fuel system.Tighten the air vent screws.Clean the spillage if any.Run the engine at idle rpm for 5 min.Check for the leakage.Close the engine hood.Place the machine back in service.

Alternator belt, checking1 Place the machine in service position. See page No.922 Open Engine hood of the machine. See page No.1253 Check and make sure that the belt is properly aligned on the

pulleys.4 Inspect the drive belt for damage. Transverse (across the belt

width) cracks & Longitudinal (direction of the belt length)cracks are not acceptable and the belt must be replaced.

5 Inspect for worn-out areas and if found or a piece of the beltis missing the belt must be replaced. Refer to engine manualfor fan belt and alternator belt replacing.

6 Place the machine back in service.

Fuel filters location1 Fuel filters2 Air vent screws

Belt1 Transverse cracks2 Longitudinal cracks

130


Engine

Fuel system

Water separator, drain


Place the machine in service position. See page 92.Open the engine hood.Connect a suitable hose to water separator drain port.Place a suitable container to collect the water.Loosen the drain valve and pump the fuel until water getsdrained out.Close the drain valve.Remove the hose.Clean the spillage if any.Close the engine hood.Place the machine back in service.

Water separator, changing



CAUTIONMaintain greatest possible cleanliness when working on the fuelsystem.

Place the machine in service position. See page 92.Open the engine hood.Drain the water from the separator. See page 131.Place a suitable container to collect fuel while removing the fuelwater separator.

Water separator


Fuel system

131

Remove the water separator with the help of oil filter wrench.Clean the water separator head sealing surface.Apply a thin film of oil on the water separator seal.Screw the water separator until its seal touches the sealingsurface and tighten further half turn by hand.

NOTICEDo not over tighten the water separator.Loosen the air vent screw and prime the fuel system.Tighten the air vent screw.Clean the spillage if any.Run the engine at idle rpm for 5 min.Check for the leakage.Close the engine hood.Place the machine back in service.Fuel water separator

132


Fuel system

Engine air cleaner

Engine, air cleaner maintenance

Maintenance of the air cleaner is due when the clog indicatorglows in the control box. This indicates that the air cleaner isplugged and requires attention.

CAUTIONThe air filter maintenance intervals depend on the amount of dustin the air and can therefore not be determined precisely. Underextremely dusty conditions daily cleaning may be required.

The air cleaner is a dry type with two filter elements. A primaryfilter element, which is replaceable or can be cleaned, and asecondary (safety) filter element that should only be replaced anddo not be cleaned. The secondary (safety) filter element shouldbe replaced after every third primary filter element change.See page No. 133 for primary filter cleaning.See page No. 136 for Air cleaner primary filter replacement.See page No. 138 for Air cleaner secondary filter replacement.

Air cleaner system, checkingPlace machine in the service position. See page No. 92 .Open the engine hood. For engine hood opening. See page No125.Check the connections between air cleaner and the engine,make sure all clamps are tight and secure.Check the air cleaner hoses for cracks, bulges or otherdamage.Check air cleaner clog indicator on the control box. If air cleaneris clogged, clean the air cleaner primary filter. See page No.133 .Close the engine hood. For engine hood closing. See page No.125.Place back the machine in service.

Air cleaner primary filter, cleaning

Maintenance of the air cleaner is due only when the air cleanerclog indicator glows or every 500 hours, whichever is early. Clog


Engine air cleaner

133

indicator indicates that the air cleaner is clogged and requiresattention.

CAUTIONThe air filter maintenance intervals depend on the amount of dustin the air and can therefore not be determined precisely. Underextremely dusty conditions daily cleaning may be required.

NOTICEThe air cleaner is a dry type with two filters. Air cleaner primaryfilter, that is replaceable or can be cleaned, and air cleanersecondary filter that should only be replaced and never cleaned.The air cleaner secondary filter element should be replaced afterevery third air cleaner primary filter element change.

CAUTIONDo not, under any circumstances, run the engine without a filteror with a damaged one. Always have a spare filter at hand andkeep it well protected from dirt.


Place machine in the service position. See page 92 .Remove the mounting screws of operator seat platform, tiltopen the operator seat platform and secure it with a stopperrod.

Remove the air cleaner access cover by removing knobs.

CAUTIONRemove any dust from the air cleaner cover by squeezing therubber ejector valve, located at the bottom of the cover. Thisjob should be carried out regularly, based on experience.

1 Mounting screw2 Operator seat platform3 Knob4 Air cleaner access cover

134


Engine air cleaner

Squeeze the rubber ejector valve, then release. This will dumpdust and dirt from the rubber ejector valve. Repeat if needed.

Pull the lock, rotate the air cleaner end cap in counter clockwisedirection and remove it.Carefully remove the air cleaner primary filter by pulling itstraight out of the air cleaner housing.

Carefully clean the air cleaner housing.Check air cleanerprimary filter for any damage. Replace it, if damaged. See page136.

CAUTIONThe secondary filter must be replaced, never cleaned. Neverremove it unless it is to be replaced.

1 Rubber ejector valve2 Lock3 Air cleaner end cap

1 Air cleaner housing2 Air cleaner primary filter


Engine air cleaner

135

Remove air cleaner secondary filter, if damaged. Replace it.See page Engine air cleaner secondary filter, replacing.

WARNINGCompressed air. Never direct to bare skin. Use protectiveequipment.

Clean air cleaner primary filter with compressed air.

NOTICEAir cleaner primary filter should be cleaned from inside tooutside. Compressed air should not exceed 5 bar (72.51 psi).

Carefully install the cleaned air cleaner primary filter by pushingit straight into the air cleaner housing over the air cleanersecondary filter.

NOTICEMake sure the air cleaner primary filter is properly seated.

Check the evacuator valve so that it is not inverted, damagedor plugged.Install the air cleaner end cap, rotate in clockwise direction andpush the lock.Install the air cleaner access cover.Place back the operator seat platform and secure withmounting screws.Place the machine back in service.

Air cleaner primary filter, change


CAUTIONDo not, under any circumstances, run the engine without a filteror with a damaged one. Always have a spare filter at hand andkeep it well protected from dirt.

Place the machine in service position. See page 92.

Air cleaner secondary filter

Air cleaner primary filter cleaning

136


Engine air cleaner

Remove the mounting screws of operator seat platform, tiltopen the operator seat platform and secure it with a stopperrod.Remove the air cleaner access cover by removing knobs.



Pull the lock, rotate the air cleaner end cap in counter clockwisedirection and remove it.Carefully remove the air cleaner primary filter by pulling itstraight out of the air cleaner housing.Remove air cleaner secondary filter, If damaged. Replace it ,See page Engine air cleaner secondary filter, replacing.


Carefully install the new air cleaner primary filter by pushing itstraight into the air cleaner housing over the air cleanersecondary filter.

NOTICEMake sure primary filter is properly seated.

1 Mounting screw2 Operator seat platform3 Knob4 Air cleaner access cover




Engine air cleaner

137

Make sure the rubber ejector valve is not inverted, damaged orplugged.Install the air cleaner end cap, rotate it clockwise direction andpush the lock.Install the air cleaner access cover.Place back the operator seat platform and secure withmounting screws.Place the machine back in service.

Air cleaner secondary filter, replacing



Place machine in the service position. See page 92.Remove the mounting screws of operator seat platform, tiltopen the operator seat platform and secure it with a stopperrod.

Remove the air cleaner access cover by removing knobs.



1 Mounting screws2 Operator seat platform3 Knob4 Air cleaner access cover

138


Engine air cleaner

Pull the lock, rotate the air cleaner end cap in counter clockwisedirection and remove it.

Remove the air cleaner primary filter. See page 136 .

Carefully clean the inside of the air cleaner housing.Remove the air cleaner secondary filter out of the air cleanerhousing.Carefully install a new air cleaner secondary filter by pushingit straight into the air cleaner housing.

NOTICEMake sure the air cleaner secondary filter is properly seated.

Carefully install the cleaned or new air cleaner primary filter bypushing it straight into the air cleaner housing over the aircleaner secondary filter.

NOTICEMake sure the air cleaner primary filter is properly seated.

Make sure the rubber ejector valve is not inverted, damaged orplugged.Install the air cleaner end cap, rotate in clockwise direction andpush the lock.Install the air cleaner access cover.



Air cleaner secondary filter


Engine air cleaner

139

Place back the operator seat platform and secure withmounting screws.Place the machine back in service.

140


Engine air cleaner

Cooling system

Coolant level, check1 Place the machine in service position. See page 92.2 Open the engine hood. For engine hood opening. See page

125.3 Check the coolant level.

NOTICEThe coolant level must be between center and top of thecoolant level gauge.

4 Fill the coolant if necessary. See page 141.5 Close the engine hood. For engine hood closing. See page


Coolant, changing


WARNINGHot oil and hot engine coolant can cause severe burns!

Draining1 Place machine in the service position. See page 92.2 Open the engine hood. For engine hood opening. See page

1253 Locate the coolant drain plug below the frame and place a

suitable container to collect the coolant. For quantity see page196

Coolant level gauge

Coolant drain plug


Cooling system

141

WARNINGBefore removing the radiator cap, stop the engine and let itcool down sufficiently. When removing it, turn it slowly torelease the pressure.

4 Open the coolant filling cap.5 Remove the coolant drain plug and drain the coolant in the

container.6 Plug the drain port.

Filling

CAUTIONDo not mix different coolants or corrosion protection as this mayresult in engine damages.

1 Fill the radiator with coolant till top of the coolant level gauge.For specification and quantity, See page 194 and 196.

2 Close the coolant filling cap.3 Clean the spillage if any.4 Start the engine and let it warm up at idle rpm to the normal

operating temperature.5 Check the coolant level and fill coolant if necessary.

NOTICEEngine should be at the ambient temperature before checkingthe coolant level.

6 Close the engine hood. For engine hood closing. See page125.


Radiator and coolers, cleaning


Place the machine in service position. see page No.92.Open the engine hood. For engine hood opening, see page No.125.

1 Coolant filling cap2 Coolant level gauge

142


Cooling system

WARNINGUse safety glasses.

Check the sign of clogging of exposed cooling fins on theradiator and cooler. Remove any loose debris from the radiatorand cooling fins.If clogging is dried on dirt use a suitable brush to remove fromcooling fins. if dry dust is present, use compressed air.

CAUTIONWhen using compressed air, keep the nozzle at a distancefrom the fins to prevent damage. Damaged fins may causeleakage or overheating.

In case of severe clogging (due to fluid leaks) apply acommercial cleaning detergent. Let it soak in, then wash it offwith water spray and dry with compressed air.

CAUTIONTake care not to damage the cooling fins of the radiator core.

NOTICEWhen using compressed air, water jets or steam cleaningmethods, ensure that appropriate protective clothing is wornto protect eyes and exposed parts of the body.

Close the engine hood. For engine hood closing, see page No.125Place the machine back in service.


Cooling system

143

Electrical system

Special instructions for working on theelectrical system

Do not attempt to repair, test or adjust the electrical systemunless you are a qualified electrician.Use only fully charged and otherwise satisfactory batteries totest the electrical system.The battery disconnect switch should be switched to OFFposition when testing the battery acid for specific gravity usinga hydrometer.When installing or replacing a battery, make sure that thecorrect polarity is followed. Always disconnect the negative(ground) cable first and reconnect it last.Before any tests are carried out on the alternator, the batteriesand electrical leads must be checked for insulation faults, poorcontacts or corrosion. Check the alternator belts. Correct anyvisible faults before beginning electrical checks.During all tests of alternating current equipment, secureconnections must be used. One loose connection lead maydamage the alternator.Do not disconnect the main lead of the alternator or the lead toit's field winding while the engine is running. Damage mayresult.If the current output terminal of the alternator is connected tothe mainframes while the engine is running, alternator damagewill result.Before removing or fitting components in the electrical systemswitch OFF the battery disconnect switch.Before welding on the compactor machine Refer to electricwelding .

Safety when working with batteries


Batteries contain sulphuric acid which is very corrosive to thehuman body and parts of the machine. In addition, batteries giveoff hydrogen gas when they are loaded (supplying electricity) orbeing charged.Together with the oxygen in the air, hydrogen gas forms a veryexplosive mixture.

This combination, corrosive acid and explosive gas, means a highrisk of accidents during all work with batteries used in vehicles.Therefore, it is very important that you take great care and followthe rules below when you are working with batteries.

L64558A

Battery charging

144


Electrical system

Follow these instructions when charging batteries:Batteries give off explosive gases. Never smoke near batteries.

Begin by disconnecting the ground lead when removing abattery. In order to reduce the risk of sparks that can cause fire,always connect the ground lead last when fitting a battery.

Never tilt a battery to any great extent in any direction. Batteryelectrolyte may leak out.

Do not connect a discharged battery in series with a fullycharged battery. The current surge can cause the batteries toexplode.

Do not allow metal objects (such as tools, rings, wristwatches)to come in contact with battery terminals. Risk of fire andpersonal injury.

Always cover the top of the battery with a rag or other non-conducting material when you work close to the batteries.

Always refit the terminal caps on the batteries.

Batteries contain substances hazardous to health and theenvironment. Therefore, discarded batteries be handledaccording to governing local/national regulations. See page111.

Explosion hazard

When a battery is being charged, a potentially explosive mixtureof oxygen and hydrogen gas is formed. A short circuit, open flameor spark near the battery can cause a powerful explosion. Alwaysturn off the main power to the battery charger beforedisconnecting the charging clamps. Ventilate the area well,especially if the battery is being charged in a confined space.

Electrical components, basic check1 Place the machine in service position. See page 92.2 Switch on the battery cutoff switch.3 Switch on the ignition key.4 Check the workings of the following electrical components.

Indicating signals on the control panelHazard indicating signalFront head lamp, low beam and high beamRear working lampsFront and rear indicating lampsParking lampsHornReverse alarm

5 Start the engine.6 Check for the hour meter working.7 Check for the emergency stop switch working.8 Shut down the engine if it is running after emergency stop

switch check.9 Switch off the battery cutoff switch.10 Place the machine back in service.

Do not smoke near batteries!


Electrical system

145

Battery disconnect switch (main switch), check

The battery disconnect switch provides a means to disconnectthe machine electrical system for added security, when themachine is not in use.Battery disconnect switch is connected between the negativebattery cable and machine ground. It is located at the rear side ofthe machine. To access battery disconnect switch rear hood tobe opened. If the machine is to be left unattended, turn the batterydisconnect switch to the '“OFF” position.

Place the machine in service position. Refer to 92.Open the rear hood of the machine .

NOTICERear hood will fall back if it is not lifted to the full extent.

Open the battery box cover.Periodically check the condition of the cables and wiringharness to the battery disconnect switch. Inspect the cablesand connections for cracks, corrosion or exposed anddamaged wires. Make sure that the cable connections are tight.Replace damaged cables as required.Check the function of the battery disconnect switch and verifythat all power to the machine is “OFF” when the batterydisconnect switch is in the “OFF” position.

NOTICEDo not bypass the battery disconnect switch. Replace thebattery disconnect switch if it is not working properly.

CAUTIONDo not turn off the battery disconnect switch when the engineis running. The electrical system may be damaged.

CAUTIONTurn off the electric power with the battery disconnect switchbefore starting any work. Also remove the fuse for respectivecomponent.

Close the battery box cover.Secure the rear hood back in place.Place the machine back in service.

Electric welding

If the service procedure includes welding, disconnectthe following items:1 Battery ground connection and battery disconnect switch with

battery disconnect switch turned off.2 Connectors for all electronic control units.3 Connect the welding unit ground cable as close as possible to

the work area. Close the battery box cover. After completingyour welding procedures, connect the above items in the

Battery disconnect switch

146


Electrical system

reverse order. Make sure that the battery disconnect switch isconnected last.

WARNINGBattery charging generates hydrogen gas, which may beexplosive. Short-circuiting, an open flame or a spark near thebattery may cause a powerful explosion.Make sure ventilation is adequate when charging batteries. Neversmoke near batteries.

See page No.105 and 109.

Battery description

The electrical system uses one 12 V battery. The battery ismounted to the rear main frame. It is located at the rear side ofthe machine. Battery disconnect switch provides a means todisconnect the machine electrical system for added security whenthe machine is not in use.The battery should be in good condition when troubleshooting theelectrical system. If needed charge the batteries , See page150.

V108862 0

Battery Location


Electrical system

147

Safety when working with batteries


Batteries contain sulphuric acid which is very corrosive to thehuman body and parts of the machine. In addition, batteries giveoff hydrogen gas when they are loaded (supplying electricity) orbeing charged.Together with the oxygen in the air, hydrogen gas forms a veryexplosive mixture.

This combination, corrosive acid and explosive gas, means a highrisk of accidents during all work with batteries used in vehicles.Therefore, it is very important that you take great care and followthe rules below when you are working with batteries.

Follow these instructions when charging batteries:Batteries give off explosive gases. Never smoke near batteries.

Begin by disconnecting the ground lead when removing abattery. In order to reduce the risk of sparks that can cause fire,always connect the ground lead last when fitting a battery.

Never tilt a battery to any great extent in any direction. Batteryelectrolyte may leak out.

Do not connect a discharged battery in series with a fullycharged battery. The current surge can cause the batteries toexplode.

Do not allow metal objects (such as tools, rings, wristwatches)to come in contact with battery terminals. Risk of fire andpersonal injury.

Always cover the top of the battery with a rag or other non-conducting material when you work close to the batteries.

Always refit the terminal caps on the batteries.

Batteries contain substances hazardous to health and theenvironment. Therefore, discarded batteries be handledaccording to governing local/national regulations. See 191,Environmentally safe handling

Charging batteriesExplosion hazardWhen a battery is being charged, an explosive mixture of oxygenand hydrogen is formed. A short circuit, open flame or spark nearthe battery can cause a powerful explosion. Always turn off thecharging current before disconnecting the charging clamps.Ventilate well, especially if the battery is charged in a confinedspace.

L64558A

Battery charging

Do not smoke near batteries!

148


Electrical system


Corrosive sulphuric acidThe battery electrolyte contains corrosive sulphuric acid.Electrolyte spilled on bare skin must be removed immediately.Wash with soap and plenty of water. If electrolyte gets into youreyes or any other sensitive body part, rinse immediately withplenty of water and seek immediate medical attention.

Battery, maintenance1 Top of the battery must be kept clean and dry.2 Petroleum jelly should be applied to cable clamps and

terminals. Do not apply grease.3 Get the fan belt, electrical wiring, alternator and regulator

setting checked regularly.4 Alternator charging voltage setting across battery terminals

must be maintained at 12.00±0.20 Volts.5 In case of any drop in electrolyte level, distilled or deionized

water. Do not add acid.

Battery Care

Keep batteries topped upMaintaining a sufficient electrolyte level ensures the electrolyte isneither too high or too low. Use distilled or deionized water andnever over fill. Maintenance free batteries will usually not requiretopping up. Low maintenance batteries require the addition ofdeionized water only once or twice per year depending onconditions.

Check electrical connectionsMake sure that the battery terminals and cable connections areclean and tight. The application of a thin layer of petroleum jellycan help reduce corrosion.

Avoid overchargingOvercharging produces rapid deterioration and corrosion whichshortens battery life. A battery needing to be topped upcontinuously with deionized water is a sure sign that the machineelectrical system requires careful checking, this may also affect amaintenance free battery.

Keep batteries clean and dryDirt on a battery's surface leads to discharge and corrosion. Avoidspilling oil or grease onto the top of the battery. To remove dirt ormoisture, wash with a solution of sodium bicarbonate and water.

V1033092

Corrosive acid


Electrical system

149

PrecautionsTo avoid short circuit, metallic objects should not be placed ontop of the battery. Batteries contain hydrogen gas and air in avolatile mixture which is easily ignited.

Keep flames or sparks away from the battery at alltimesBattery contain sulphuric acid. Do not add acid to cells and keepacid away from eyes, skin, clothing or any other material whichmay become damaged. If contamination occurs, use largeamount of water to neutralize and flush acid away.

Battery liftingBattery is heavy - make sure correct lifting procedures are usedwhen moving battery.

NOTICEIt is recommended to return the old battery to the authorizedbattery manufacturer / dealer / smelter during purchase of a newbattery.

Battery storage

When a battery is at rest, there is a spontaneous electricaldischarge that increases with storage temperature. A fullycharged battery, stored at a temperature of -20°C (-4°F) losesinsignificant charge during a 3 month period. If the same batteryis stored at +30°C (86°F), it is only half charged after 3 months.To help reduce this discharge, always store batteries in a cool,dry place in an upright position.If a battery becomes severely discharged, the electrolyte canfreeze if it is stored below -7°C (+20°F). To prevent damage dueto freezing, do not allow batteries to become discharged or to bestored below -7°C (+20°F).Allowing batteries to stand for an extended period of time withoutrecharging them, will result in reduced performance and servicelife. To preserve optimum battery performance and life, rechargebatteries when the open circuit voltage drops to 12.4 volts.

150


Electrical system

Battery, charging

WARNINGDuring battery charging, hydrogen gas is formed. Hydrogen gasis flammable and may be explosive. A short-circuit, open flame orspark near the battery can cause a powerful explosion. Therefore,ventilate well. Never smoke near batteries.

WARNINGThe battery electrolyte contains corrosive sulphuric acid.Electrolyte spilled on bare skin should be removed immediately.Wash the affected area with soap and plenty of water. Ifelectrolyte gets into your eyes or any other sensitive body part,rinse immediately with plenty of water and seek immediatemedical attention.

Battery charging

Batteries must only be charged using a battery charger.Check the battery terminal connections, and make sure thatthey are adequately tightened, and free from corrosion and dirt.Check the battery voltage, when the battery is at rest, that is,before starting, make sure that the battery must be at least half-charged.If the battery is extremely cold, allow it to come to roomtemperature, as an extremely cold battery will not accept anormal charge, until the temperature rises.

CAUTIONAlways disconnect the electric power to the battery charger beforethe charging clamps are removed.

CAUTIONAlways turn off the current to the battery charger beforedisconnecting the charging clamps.


Electrical system

151

Battery, checking electrolyte

WARNINGCorrosive sulphuric acidThe battery electrolyte includes corrosive sulphuric acid.Electrolyte spilled on bare skin must be removed immediately.Wash with soap and plenty of water. If electrolyte gets into youreyes or any other sensitive body part, rinse immediately withplenty of water and seek immediate medical attention.

Place the machine in service position. See page No. 92.Open the engine hood. For engine hood opening See page No.125.Remove the battery access cover.Check the electrolyte level indicator on the batteries.a If the indicator is green, battery is OK.b If the indicator turn white, battery need to be charged.c If the indicator turns red, open the service plugs, add distilled

water to maximum level and close the service plugs or callthe service person.

NOTICEUse a suitable washer to open and to close the service plugs.

Install the battery access cover.Close the engine hood. For engine hood closing. See page No.125.Place the machine back in service.

Battery access cover

Battery electrolyte level indicator

152


Electrical system

Component location, fuses

2 3

1110987654

1

V110079 5

1314

15

12

Fuses1 Fuse F12 Fuse F23 Fuse F34 Fuse F45 Fuse F56 Fuse F67 Fuse F78 Fuse F89 Fuse F910 Fuse F1011 Fuse F1112 Fuse F1213 Fuse, FL114 Fuse, FL215 Fuse, FL3


Electrical system

153

Component list, Fuses

SI NO. Fuse Ampere rating Circuit protected1 F1 40 A Power relay, Park brake, Park brake test, Brake

dump, Brake lights relay, Pump-Destroke circuit,Brake-latching relay Circuit, Horn, V-belt switch,Tachometer, Engine oil pressure gauge, Engineoil temperature gauge, Hourmeter, Two speedsolenoid, Seat switch, Fuel gauge, rear lightswitch, position light switch

2 F2 10 A Mobile charger3 F3 15 A Front high beam lights4 F4 15 A Rear lights5 F5 10 A Reverse lights6 F6 10 A Flasher7 F7 10 A Beacon light8 F8 10 A Cluster and air filter9 F9 10 A Audible alarm10 F10 7.5 A Position light11 F11 15 A Low beam front lights12 F12 10 A Fuel solenoid13 FL1 60 A Main fuse14 FL2 60 A Glow plug15 FL3 100 A Battery charging circuit

For fuse locations, See page No.153.

Component list, Relays

SI NO. Relays Location1 Power relay Control box2 Front light low beam relay Control box3 Alarm relay Control box4 Brake latching relay Control box5 Brake light relay Control box6 Hazard relay Control box7 Reverse light relay Control box8 Flasher relay Control box9 Position light relay Control box10 Rear light relay Control box11 Front light high beam relay Control box12 Seat timer relay Control box13 Starter relay Battery compartment14 Glow plug relay Battery compartment

For relay locations, See page No.155.

154


Electrical system

Component location, relays

2 3 4 5 67 8

1110

9

V1100735

1

12

1413

Relays1 Power relay2 Low beam relay3 Alarm relay4 Brake latch relay5 Brake lights relay6 Hazard relay7 Reverse light relay8 Flasher relay9 Position light relay10 Rear light relay11 High beam relay12 Seat switch timer relay13 Starter relay14 Glow plug relay


Electrical system

155

Transmission

Transmission, checking oil levelPlace the machine in service position. See page No. 92.Allow axle transfer case to cool.


Clean around the transmission oil fill/level plug.Remove the transmission oil fill/level plug.Check the transmission oil level, oil level must be at bottomedge of the transmission oil fill/level hole.Clean and apply thread sealant to transmission oil fill/levelplug. required, add oil through transmission oil level/fill hole.See page No. 194.Fix back the transmission oil fill/level plug.Clean for the oil spillage.Place the machine back in service.

Transfer gearbox case1 Oil fill/level plug2 Oil drain plug

156


Transmission

Transmission, changing oil

NOTICEOil must be at normal operating temperature when draining

Run the machine until the transmission oil reaches operatingtemperature.Place the machine in service position. See page No. 92.Place a suitable container below the transmission oil case.Remove the transmission oil fill/level plug.

WARNINGWork carefully when changing oil as hot oil can cause severeburns to unprotected skin.

Remove transmission oil drain plug and drain the transmissionoil.Clean and apply thread sealant to transmission oil drain plug.Place back the transmission oil drain plug.Fill the transmission oil case with transmission oil through thetransmission oil fill/level hole, until the oil level is at the bottomedge of the oil fill/level port. See page No. 194 and 196.Clean and apply thread sealant to transmission oil fill/levelplug.Test run the machine.Check the transmission oil level. See page No. 156 .Clean for the oil spillage.Make sure that the transmission oil level is at correct level.Place the machine back in service.

Transmission oil case1 Transmission oil fill/level plug2 Transmission oil drain plug

CAUTIONAlways handle oils and other environmentallyhazardous fluids in an environmentally safemanner.


Transmission

157

Axles

Axles, checking oil levelPlace the machine in service position. See page No. 92.


Allow the axle housing to cool.Locate and clean around both the oil level plugs.Remove any one of the axle housing oil level plug.Check the axle housing oil level, it must be at the bottom edgeof the axle housing oil level port.Add axle housing oil through the oil fill hole if required. Seepage No. 194 .Clean the axle housing oil level plug and apply thread sealantto it.Fix back the oil level plug and tighten it.Clean around the oil level plugs for oil spillage.Place the machine back in service.

Axle hubs, checking oil levelPark the machine service position. See page No. 92.

NOTICEMake sure that the rear wheel is positioned with the axle wheelend hub oil fill/level plug in the 9 o'clock position beforeshutting down the engine.

Allow axle wheel end hub oil to cool.Place a suitable container bellow the axle wheel end hub oil fill/level plug.Clean around the axle wheel end hub oil fill/level plug.Remove the axle wheel end hub oil fill/level plug.Check and make sure that the oil level is at bottom edge of theaxle wheel end hub oil fill/level port. See page No. 158Clean the axle wheel end hub oil fill/level plug.Fix back and tighten the axle wheel end hub oil fill/level plugClean up for the oil spillage.Similarly check the oil level of other side of the axle.Place the machine back in service.

Oil level plugs of the axle

Axle wheel end hub oil fill/level hole

158


Axles

Axle hubs, changing oil


Run the machine till the axle wheel end hub oil reachesoperating temperature.

NOTICEMake sure that the wheel is positioned with the axle wheel endhub oil fill/level plug in the 6 o'clock position before securingthe machine in service position.Place the machine in service position. See page 92.Clean around the axle wheel end hub oil fill/level plug.Place a suitable container under the axle wheel end hub oil fill/level plug.

Remove the axle wheel end hub oil fill/level plug and drain theoil.

Axle wheel end hub oil fill/level plug at 6 o'clockposition

Axle wheel end hub oil, draining


Axles

159

Position the wheel end hub oil fill/level hole to the 9 o'clockposition.Fill the axle wheel end hub through oil fill/level hole, until oillevel is at the bottom edge of the fill/level port. See page 196and 158.Clean the axle wheel end hub oil fill/level plug.Place back the axle wheel end hub oil fill/level plug.Clean for any spilled oil.Repeat the procedure for the other side of the axle wheel endhub.Test run the machine.Check the wheel end hub oil level. See page 158.Place the machine back in service.

Rear axle, changing oil

Axle housing oil changing


Start the machine and run until the axle housing oil reachesoperating temperature.

NOTICEAxle housing oil must be at normal operating temperaturewhen draining.

Place the machine in service position. See page No. 92.Locate and clean around the three axle housing oil drain plugs.

Place a suitable container under the axle housing drain plugs.

Axle wheel end hub oil fill/level plug at 9 o'clockposition

Axle housing drain plugs

160


Axles

Remove the axle housing drain plugs and drain the axlehousing oil.

CAUTIONAlways handle oils and other environmentally hazardous fluidsin an environmentally safe manner.

Clean the axle housing drain plugs and apply thread sealant.Fix back the axle housing drain plugs.Clean around the axle housing drain plugs for oil spillage.Locate and clean around the axle housing oil fill plug.

V1076328

AXLE HOUSINGOIL FILL PLUG

Axle housing oil fill plug

Remove the axle housing fill plug.Fill the oil through the fill hole, until oil level is at the bottomedge of the check port. See page No. 194 and 158.Clean and apply thread sealant to axle housing fill plug.Fix back the axle housing fill plug.Test run the machine.Check the axle housing oil level. See page No. 158 .Clean up for any oil spillage.Place the machine back in service.

Axle breather, cleaningPlace the machine in service position. See page No. 92.Allow the axle to cool.


Axles

161

Locate and clean the area around the two axle breathers.

Remove the axle breathers.Protect the breather ports to avoid contaminants entering theaxle.Fix back the axle breathers.Clean the breathers with solvent and allow it to dry.Place the machine back in service.

Axle breathers

Axle breather installation

162


Axles

Brake system

Parking brake performance

The parking brake test switch must be used to verify the parkingbrake functioning.

Start the machine and position it in an area clear of personneland obstructions.

Press the parking brake switch.Press and hold the parking brake test switch and move thepropulsion control lever FORWARD or REVERSE. Themachine should NOT move. If the machine does move, shutdown engine and have the fault corrected before continuingoperation.Move the propulsion control lever to STOP position.Release the parking brake test switch.Shut down the engine.

Park brake test1 Park brake test switch2 Park brake switch

Propulsion control lever


Brake system

163

Steering system

Steering cylinder pins, greasingPlace the machine in service position. See page 92.

■ Clean steering cylinders pin grease fittings.

CAUTIONWipe off grease nipples and grease gun before greasing, so thatdirt and sand are not introduced through the grease nipples intothe bearings.

■ Apply the recommended grease to each fitting until the greaseexits from the sealing surface. See page 194 .

■ Place the machine back in service.

Cap end cover side

Rod eye end side

164


Steering system

Wheels

Tyres, wear and air pressure, checking

Before checking tyre pressures or inflating, See page No. 100.

WARNINGInflating a tyre may cause it to explode. This may lead toaccidents. Use a self-attaching air chuck with a hose long enoughto enable you, when inflating, to stand by the tyre tread, but as faraway as possible.

Park the machine on level ground with the wheel rotated so thatthe tyre inflation valve is located at the 12 o'clock position.Remove the tyre inflation valve cap.Check the tyre pressure, when tyres are cold, using anappropriate pressure gauge. Make sure that the normaloperating pressure is not above 1.1 bar (16 psi), See page198 for size and pressure of tyre.After checking the tyre pressure, place the valve caps toprevent dirt, moisture and foreign material from damaging thevalve coreAfter checking the tyre pressure, place the valve caps toprevent dirt, moisture and foreign material from damaging thevalve core.Check the wheel rim for excessive rust, cracks, missing orloose wheel bolts, or other damage which could causepremature tyre wear or failureCheck the wheel rim for excessive rust, cracks, missing orloose wheel bolts, or other damage which could causepremature tyre wear or failure

NOTICEPlacing water in tyres is an economical means of addingweight to the wheels . The addition of calcium chloride isrecommended to prevent the water from freezing. If a tyre withballast is replaced, the replacement tyre must also containballast.

Report tyre and wheel rim defects to a qualified person who isequipped and trained to perform tyre repair service.

Wheel nuts, check torquePlace the machine in service position, See page No.92.Torque the wheel nuts evenly in clockwise and diagonalpattern. For torque value See page No.201 and 202.

Tyre inflation valve


Wheels

165

NOTICEIf new or replacement wheel or wheel nuts have been installedthey may require more frequent checks until they are properlyseated.

Place the machine back in service.

V1098837

Wheel nuts

166


Wheels

Drum

Drum, checkingPlace the machine in service position. See page No.92.Perform a visual inspection of the drum assembly.Remove all adhering materials on the drum.Place the machine back in service.

Drum carrier, checking oil level

■ Place the machine in service position. See page 92.

■ Allow the carrier to cool .

■ Clean the area around the oil level check plug located on thelower side of the carrier.

NOTICEThe drain plug is located at the 6 o'clock position on the bottomof the carrier and should not be removed except for draining thecarrier oil.

■ Remove the oil level check plug and check the oil level in thecarrier. Oil should be level with the bottom edge of the level checkplug hole.

■ If it is necessary to add oil to the carrier between oil changes,remove the breather/filler plug located at the 12 o'clock positionon top of the carrier and add oil until oil runs out of the level checkplug hole.

■ Fix back and tighten the carrier oil level check plug.

■ Make sure that the breather is clean and tightened.

■ Clean up any excess oil.


Drum drive (torque hub), checking oil level

NOTICEThere are two plugs on the torque hub, one is oil level plug andother is oil fill plug.

Drum carrier plug location.1 Oil level check plug2 Oil drain plug

Drum carrier breather


Drum

167

Place the machine in service position, with the oil level plug in12 o'clock position. See page No. 92 .Clean the area around the oil level check plug.Loosen the oil level plug.Reposition the oil level plug to 3 o'clock position.Remove the oil level check plug and check that the oil level isfilled to the bottom edge of the oil level check port.

NOTICEWhen the oil level plug is in 3 o' clock position, oil fill plug willbe in 12 o' clock position.

If the oil level has dropped below the oil level check port,remove the oil fill plug which will be at 12 o'clock position.Add fresh oil through fill hole until the oil is level with the bottomedge of the oil level check port. For specification see page no194 .Close the oil level port with oil level plug.Clean the oil fill plug with solvent and apply thread sealant toit.Fix back the oil fill plug and tighten it.Reposition the oil level plug to 12 o'clock position.Remove the oil level plug.Clean the oil level plug with solvent and apply thread sealant.Fix back the oil level plug and tighten it.Clean for any oil spillage.Place the machine back in service.

Drum eccentric, checking oil level

■ Place the machine in service position, with the drum index atthe 12 o’clock position. See page 92.

Oil level fill plug

1 Drum Index2 Eccentric fill plug (at 12 o'clock)

168


Drum

NOTICEThis will also place the drain plug in the 6 o'clock position and theoil level sight gauge in the 4 o'clock position.

■ Check the oil level is to the centre of the sight gauge.

NOTICEOil level must be at the centre of the sight gauge.

■ If oil is to be added, remove the fill plug and add oil . Forspecification See page no. 194.


Drum shock mounts, checkingPlace the machine in service position. See page No.92.Check the condition of the drum shock mounts periodically forloosening or signs of deterioration.Replace shock mounts (one at a time) that have torn orexcessively cracked rubber. Torque all screws and nuts tospecification as necessary. See page No.201.Place the machine back in service.

Carrier breather, cleaningClean the area around the carrier breather located on top ofthe carrier.Remove the breather.Cover the breather port to prevent contaminants from enteringthe system.Clean the breather with solvent and allow it to dry.Fix back the breather and tighten.

Position of drum for checking eccentric oil level1 Eccentric fill plug (at 12 o'clock)2 Eccentric drain plug (at 6 o'clock)3 Eccentric oil level sight gauge (at 4 o'clock)

Drum shock mounts checking

Drum carrier breather


Drum

169

Drum carrier, changing oil

NOTICEOil must be at normal operating temperature when draining.


CAUTIONAlways handle oils and other environmentally hazardous fluidsin an environmentally safe manner.

Run the machine until the drum carrier assembly reachesoperating temperature.Place the machine in the service position. See page 92.Remove the fill / breather plug on carrier assembly.

Place a suitable container below the drain plug.Remove the drain plug and drain the oil.Clean and fix back the drain plug and tighten.Remove the level check plug.Add oil until oil runs out of the level check plug mounting hole.Fix back the level check plug.Clean the fill/breather plug with solvent.Fix back the fill / breather plug.Test run the machine and check for any leaks.Clean up for any oil spillage .Make sure that the drum carrier oil is at correct level.Place the machine back in service.

Drum carrier breather plug

Carrier oil level check plug1 Drum carrier oil level check plug.2 Drum carrier oil drain plug

170


Drum

Drum drive (torque hub), changing oil


NOTICEThere are two plugs on the torque hub, one is oil level plug andother is oil fill plug.

■ Place the machine service position with oil level plug in 12o'clock position. See page No. 92.

■ Loosen the oil level plug.

■ Reposition the oil level plug to 3 o'clock position.

NOTICEWhen the oil level plug is in 3 o'clock position, oil fill plug will bein 12 o'clock position.

Oil level plug at 12 o'clock position

Loosening of oil level plug


Drum

171

■ Remove the oil fill plug which will be at 12 o'clock position.


■ Place a suitable container under the torque hub.


■ Remove the oil level plug at the 6 o’clock position and allow theoil to drain.


■ Fill the oil through the fill port which will be at 12 o'clock position,till the oil level must be at bottom edge of the oil level port.

■ Close the oil level port with oil level plug.

■ Clean the oil fill plug and apply thread sealant to it.

■ Fix back the oil fill plug and tighten it.


■ Remove the oil level plug.

■ Clean the oil level plug with solvent and apply thread sealant.

■ Fix back the oil level plug and tighten it.

■ Test run the machine and check for any leaks.

■ Clean up any oil spillage.

■ Make sure that the torque hub oil is at correct level.


Drum eccentric, changing oil


NOTICEOil must be at normal operating temperature when draining.


Removing of oil fill plug

Oil level plug at 12 o'clock position

172


Drum

■ Run the machine so that the eccentric oil reaches operatingtemperature.

■ Place the machine on level ground in service position , with thedrum index (angle mounted on the inside of the drum) at the 12o’clock position.

NOTICEThis positioning will place the eccentric fill plug in the 12 o'clockposition. This will also bottom-out the drain plug in the 6 o'clockposition and the level indicator gauge in the 4 o'clock, level-readposition.

■ Place suitable container to collect the oil drain.

■ Remove the fill plug and the drain plug and drain the oil.


■ Clean and place back the drain plug.

■ Fill the drum eccentric with fresh eccentric oil through the fillhole.

■ Clean and fix back the fill plug.

Test run the machine and check for any leaks.

■ Clean up any oil spillage.

■ Make sure that the eccentric oil is at correct level.

■Place the machine back in service.

1 Drum Index2 Eccentric fill plug (at 12 o'clock)

1 Eccentric fill plug (at 12 o'clock)2 Eccentric drain plug (at 6 o'clock)3 Eccentric oil level sight gauge (at 4 o'clock)


Drum

173

Hydraulic system

Safety when working on hydraulic systems

The hydraulic system operates at high oil pressures. The systemmust be properly maintained to avoid the potential for accidentsand injury. It is important that each person who comes in contactwith the machine be alert to any faults.

WARNINGRisk of personal injury! Wear safety glasses and use protectivegloves.

Follow these basic precautions:Never adjust a pressure relief valve or other pressure-limitingdevice to a higher pressure than specified.Replace any hydraulic hose immediately that shows signs ofswelling, wear, leaks or damage before it bursts.Never discard a hydraulic accumulator without first carefullydrilling a 3 mm (1/8 in.) hole in the cylinder to eliminate the riskof explosion.

Releasing hydraulic pressureWhen you shut down the engine, there will still be residualpressure at various point is the hydraulic system. Neverdisconnect any hydraulic hose, fitting or component without firstrelieving residual pressure.

WARNINGIf the pressure is not released before opening the system, oilunder high pressure will jet out, resulting in serious personalinjuries.

WARNINGLeaking high-pressure hydraulic hoses may cause severeinjuries. Fine jets have high penetrating capacity on bare skin.

Never use your hands to check for oil leaks. Use a piece ofcardboard.Never tighten leaky fittings with the engine running, or beforethe residual pressure has been released.Pressure accumulators have a pressurized gas charge as wellas residual hydraulic pressure. Use extreme care whenworking with accumulators.Check valves, lock valves and similar hydraulic componentsare designed to retain pressure or oil flow.


Release pressure by completely moving the hydraulic controllevers back and forth several times. The hoses become "slack"when the hydraulic pressure is released.

174


Hydraulic system

Carefully loosen the hydraulic hose, residual pressure can still betrapped in the hydraulic system.

Hydraulic system, checking oil level

CAUTIONIt is very important to keep the hydraulic system free from anyimpurities, as these can cause abnormal wear and may lead toexpensive downtime. Greatest possible cleanliness should bemaintained during all handling of hydraulic components andhydraulic oil.

■ Park the machine on a level surface.

■ Check the hydraulic oil level by looking at the sight gauges ofthe hydraulic tank.

NOTICEOil must be filled when oil level drops down to minimum level inthe low level indicator sight gauge.

If required add fresh clean hydraulic oil through the oil fill plug.See page No. 176.

Hydraulic oil filter, changingPlace machine in service position. See page No. 92.Tilt open the operator seat platform to access the two hydraulicfilters.Secure operator seat platform with the seat stopper rod.

2

1V1092471

Hydraulic oil tank.1 High level indicator sight gauge2 Low level indicator sight gauge

Hydraulic oil filters


Hydraulic system

175

Disconnect the hydraulic oil filter hose towards filter side (toaccess to the vibration charge filter) and plug it immediately .Clean the hydraulic oil filters and filter heads before removingthem from the machine in an effort to prevent contamination ofthe hydraulic system.Place the suitable container to collect the hydraulic oil spillage.Remove the hydraulic oil filter by turning it counterclockwiseusing a filter wrench

NOTICEDiscard the filters in accordance with local environmentalguidelines.Clean the filter head and make sure that there is no gasketmaterial or other debris remaining on the filter head.Lubricate new O-ring with thin film of fresh hydraulic oil andreplace it to new hydraulic oil filter.Fill new hydraulic oil filter with fresh hydraulic oil and screw thefilter to filter head, until the O-ring just touches the sealingsurface, tighten further half by hand.

NOTICEDo not overtighten the hydraulic oil filters, as it is possible todistort the threads or damage the filter element seals.Similarly replace other hydraulic filter.Reconnect the disconnected hose.Clean for the oil spillage.Place the operator seat back in position.Start the engine and check for leaks.Make sure that there is no foaming in the hydraulic tank.

NOTICEFoaming in hydraulic tank, is an indication of air leakage, intothe hydraulic system. To check foaming, open the hydraulictank filler cap check the hydraulic oil condition with the torch.Foaming in hydraulic oil can lead to hydraulic system failure.

Hydraulic oil tank, changing oil

CAUTIONAny work on the hydraulic system requires great demands oncleanliness. Even very small particles can cause damage or clogup the system. Therefore, wipe areas in question clean beforeany work is carried out.


Run the machine until the hydraulic oil reaches operatingtemperature.Place machine in service position. See page No. 92.

Hose to be disconnected

176


Hydraulic system


Draining of hydraulic oilPlace a suitable container below the hydraulic tank drain portlocated at the bottom of the tank. See page No. Fuel, lubricantand filling capacities for capacity of the container.

Remove the drain plug and drain the hydraulic oil.Dispose the used hydraulic oil in accordance with localenvironmental guidelines.Clean and apply thread sealant to the drain plug.Fix back the drain plug.

Cleaning of hydraulic tank.Clean the hydraulic tank. See page No. 177.

Filling of hydraulic oilRemove the breather filler cap and fill hydraulic tank with cleanhydraulic oil. See page No. Fuel, lubricant and fillingcapacities.Fix back the breather filler cap and clean for oil spillage.Start the engine and check all hydraulic connections for anyleaks.Check the hydraulic oil level. See page No. 175.Place the machine back in service.

Hydraulic tank, cleaningStart the engine and run the machine until the hydraulic oilreaches operating temperature.

Hydraulic oil tank drain plug

Hydraulic oil tank fill plug


Hydraulic system

177

Place machine in service position. See page No. 92.Drain the hydraulic oil. See page No. Draining of hydraulic oilin page 176.Clean around heads of hexagonal head screws of the hydraulictank lid.Remove hydraulic tank lid by removing the screws.Remove the tank cover gasket and clean the tank cover gasketarea on the hydraulic tank.Clean inside the hydraulic tank by using clean and lint freecloth.Check gasket for damage and if found damage replace it.Apply thin film of grease on both side of the gasket and replacethe gasket.Reinstall hydraulic tank lid with the screws and tighten.Fill the hydraulic oil to hydraulic tank. Refer Filling of hydraulictank in page No. 176.Check the hydraulic oil level, See page No. 175.Place the machine back in service.

Hydraulic oil suction strainer, cleaning

CAUTIONIt is very important to keep the hydraulic system free from anyimpurities, as these can cause abnormal wear and may lead toexpensive downtime. Greatest possible cleanliness should bemaintained during all handling of hydraulic components andhydraulic oil.

Run the machine until the hydraulic oil reaches operatingtemperature.Place machine in the service position. See page No .92.

Gasket installation

178


Hydraulic system

Drain the hydraulic oil tank. See Draining of hydraulic oil inpage No. 176.Disconnect the propulsion pump and vibration pump suctionhoses on the tank side and plug the disconnected hosesimmediately.Remove the two strainers with adapter from the hydraulic oiltank.Clean the strainers with solvent, using a stiff fiber brush toremove imbedded impurities and allow the suction strainer toair dry.

NOTICEIf embedded materials cannot be removed , replace strainers.

NOTICEFollow below 2 steps when replacing the strainers.Remove the adapter from the old strainer.Apply hydraulic sealant to removed adapter and install it to thenew strainer.Apply hydraulic sealant and install the cleaned/new strainerswith adapter to hydraulic tank.Remove the plugs and reconnect the disconnected hoses tohydraulic tank.Clean the hydraulic tank. See page No. 177.Fill the hydraulic tank with clean hydraulic oil. Refer to Fillingof hydraulic oil in page No. 176.Start the engine and check hydraulic connections for leaks.

Hydraulic tank hoses to disconnect

Strainer with adapter1 Adapter2 Strainer


Hydraulic system

179

Greasing

Swivel joint (horizontal and vertical) pins,greasing

Start the engine and articulate the machine fully to the left.Shut down the engine.

CAUTIONWipe off grease nipples and grease gun before greasing, sothat dirt and sand are not introduced through the greasenipples into the bearings.

Clean the vertical and horizontal swivel pin grease fittings.Apply the recommended grease to each fitting until the greaseexits from the sealing surface. See page No. 194 for the propertype of grease.Place the machine back in service.

Horizontal swivel pin grease fittings

Vertical swivel pin grease fittings

180


Greasing

Bearings, greasing

The service life of bushings and pivot pins can be extendedconsiderably, if the machine is greased regularly and in a correctway.The greasing of bearings has two main purposes:

- Add grease to the bearing to reduce friction between pin andbushing.

- Replace old grease which may contain dirt. The grease in thespace inside the outer seal collects dirt and prevents dirt andalso water from penetrating into the bearing.

Manual greasing, digging unitGrease the points shown below every 50 hours or weekly. Duringthe first 100 hours, the compactor unit should be greased every10 hours or daily.

NOTICEUnder severe operating conditions where mud, water andabrasive material may enter the bearings, the compactor unitshould be greased every 10 hours or daily.

1 Wipe off grease nipples and grease gun to avoid dirt and sandentering the bearing.

2 Fill with grease until new, clean grease is forced out throughthe outer seals.

3 Operate all the cylinders to their end positions without any loadon the equipment.

V1090184

V1090184


Greasing

181

Lubrication points,(number of nipples in brackets)1 Steering cylinder both side

NOTICEUnder severe operating conditions where mud, water andabrasive material may enter the bearings, grease every 10 hoursor daily.

Wipe off grease nipples and grease gun to avoid that dirt andsand not are entering the greasing system.Fill with grease until new, clean grease is forced out throughthe outer seals.

Shift linkage, lubricating


1 Place the machine in service position. See page No. 92.2 Remove the mounting screws of operator seat platform, tilt

open the operator seat platform and secure it with a stopperrod.

Remove the cowling cover.Locate the shift linkage for engine throttle and lubricate with 2drops of engine oil. For engine oil specification See page No.194 .

1 Mounting screw2 Operator seat platform3 Cowling cover

182


Greasing

1 Locate the shift linkage for propulsion pump and lubricate with2 drops of engine oil. For engine oil specification See page No.194.

Locate the shift linkage for vibration pump and lubricate with 2drops of engine oil. For engine oil specification See page No.194.Install the cowling cover.Place back the operator seat platform and secure withmounting screws.Place the machine back in service.

Shift linkage for engine throttle

Shift linkage for propulsion pump

Shift linkage for vibration pump


Greasing

183

Lubrication and service chart

184




V1102328

Lubrication chart



185

Table. Periodic Lubrication ScheduleServiceinterval

Ref.no.

Description Recommended lubricant Servicerequired

Comments

10 HoursordDaily

1 Engine oil VDS-3, CL-4, 15W-40 S, A Fill to dipstick full mark. Seepage No.126.

2 Air cleaner S Check indicatorPrimary filter element clean /change when clog indicatesSecondary filter elementchange @ every 3rd change ofprimary filter element.

3 Water separatordrain

D Drain collected water. See pageNo.131

4 Fuel tank Diesel fuel S, A 285 litre ( 75 US gal)5 Engine coolant Volvo VCS coolant S, A See page No.

Change coolant at 6000 hrs/ 4yrs. See page No. 141.

6 Engine coolingsystem

S Clean fins. See page No.142

50 Hoursor weekly

7 Battery Distilled water S, A ARSee page No. 151

8 Torque hub oil SAE 85W-90 LS API GL5 S,A FTLHSee page No. 167

9 Swivel andcylinder pins

MPG-EP2 grease G See page No. 164

10 Center swivel MPG-EP2 grease G See page No. 18011 Tyre pressure Compressed air S, A 1.1 bar (16 psi)

See page No. 16512 Hydraulic oil Volvo super hydraulic oil

ISO VG 46S, A FTLH

See page No. 17513 Wheel nuts S, T 475 Nm (350 lbf ft)

See page No. 16514 Eccentric oil MOBIL SHC 630 S, A FTLH

See page No. 16815 Air cleaning

system integrityS See page No. 133

16 Shift linkage Engine oil A See page No. 18217 Carrier breather CL See page No. 169

100 Hoursor monthly

18 Axle housing oil SAE 85W-90 LS API GL5 S, A ARSee page No. 158

19 Transmission oil SAE 85W-90 LS API GL5 S, A ARSee page No. 156

20 Wheel end oil SAE 85W-90 LS API GL5 S, A FTLHSee page No. 158

186



Serviceinterval

Ref.no.

Description Recommended lubricant Servicerequired

Comments

250 hoursorquarterly

21 Engine oil VDS-3, CL-4, 15W-40 D, F See page No. 12622 Engine oil filter See parts manual C See page No. 12823 Axle housing

breatherCL See page No. 161

24 Hydraulic filters See parts manual C See page No. 17525 Engine fuel filters

and waterseparator

See parts manual C See page No. 128 and 131

500 Hoursor semi-annually

26 Articulatingvertical nuts

S, T 678 Nm (500 lbf lt)See page No. 201

27 Eccentric oil MOBIL SHC 630 D, F 41 litre (10.83 US gal) maximumSee page No. 172

28 Axle housing oil SAE 85W-90 LS API GL5 D, F 11 litre (2.9 US gal) maximumSee page No. 160

29 Transmission oil SAE 85W-90 LS API GL5 D, F 1.9 litre (0.5 US gal) maximumSee page No. 156

30 Wheel end oil SAE 85W-90 LS API GL5 D, F 1.8 l (0.47 US gal) maximumSee page No .158

31 Axle mountingbolts

S, T 624 Nm (460 lbf ft)See page No. 201

32 Horizontal swivelnut

S,T 1491 Nm (1100 lbf ft)See page No. 201

33 Torque hub oil SAE 85W-90 LS API GL5 D, F FTLHSee page No. 170

34 Carrier oil MOBIL SHC 630 D, F 2 l (0.53 US gal)See page No. 169

35 Air filter primaryelement

C See page No.136

36 Poly V-belt S See page No. 1301000Hours orannually

37 Hydraulic oilchange

ISO VG 46 D, F 180 l (47 US gal)See page No. 176

38 Suction strainer CL See page No. 178Servicefunctions

S – CheckC – ChangeFTLH – Fill to level hole/markT — Torque

A – AddD – DrainCL – Clean

G – GreaseF – FillAR – As required



187

SpecificationsSpecifications, general

This section of the manual contains technical specifications forthe SD110 Series of Vibratory Soil Compactors.

For general information regarding Machine identification, Seepage No. 17.For general Machine dimensions, See page No. 206.

188

Specifications

Recommended lubricants

General information

Lubrication is an essential part of preventive maintenance,affecting to a great extent the useful life of the unit. Periodiclubrication of the moving parts reduces to a minimum thepossibility of mechanical failures.

For maximum machine life and performance, use only genuinemanufacturer-approved lubricants. See 185 and Recommendedlubricants. Different lubricants are needed and some componentsrequire more frequent lubrication than others. It is important thatthe specific instructions regarding types of lubricants and thefrequency of their application be followed.

The lubrication and service chart shows those items requiringregular service and the interval at which they should beperformed. To obtain the maximum long-life results from themachine, a regular service program should be followed asrecommended in this manual. The suggested intervals are basedon average operating conditions. In extremely severe, dusty orwet operating conditions, more frequent lubrication may benecessary.

All oil levels are to be checked with the machine parked on a levelsurface and while the oil is cold, unless otherwise specified.

On plug-type check points, the oil levels are to be at the bottomedge of the check port.

All grease fittings are SAE standard, unless otherwise indicated.Grease non-sealed fittings until grease is seen extruding from thefitting. Grease fittings that are worn and will not hold the greasegun, or those that have a stuck check ball, must be replaced.

Over-lubrication on non-sealed fittings will not harm the fittings orcomponents. But, under lubrication will definitely lead to a shortercomponent life.

Unless otherwise indicated, items not equipped with greasefittings (linkages, pins, levers, etc.) should be lubricated with oilonce a week. Motor oil, applied sparingly, will provide thenecessary lubrication and help prevent the formation of rust. Ananti-seize compound may be used if rust has not formed.Otherwise, the component must be cleaned first.

Thoroughly wash all fittings, caps, plugs, etc. with non-flammable, non-toxic cleaning solution before servicing toprevent dirt from entering while performing the service.Lubricants must be at operating temperature before draining.During regular lubrication service, visually check the entire unitto ensure that capscrews, nuts and pins are properly secured.Spot check several capscrews and nuts for proper torque. Ifany are found loose, a more thorough investigation must bemade.Stop the machine if any function does not operate or operatesincorrectly. Report the problem to your supervisor or sitemanagement. Do not continue operations until the problem iscorrected. If necessary, contact authorized distributor forresults.

Specifications


189

Fuel

Viscosity (ASTM-D-445) 1.3 to 5.8 centistokes per second at 40 °C (104 °F)Cetane number (ASTM-D-613) 40 minimum at temperatures above 0 °C (32 °F)

45 minimum at temperatures below 0 °C (32 °F)Sulfur content (ASTM-D-129 or 1552) Not to exceed 0.05% by weightWater and sediment (ASTM-D-1796) Not to exceed 0.1% by volumeCarbon residue (Ramsbottom, ASTM D-524 orConradson, ASTM-D-189)

Not to exceed 0.25% by weight on 10% volume residue

Flash point (ASTM-D-93) At least 52 °C (125 °F) or legal temperature if higherthan 52 °C (125 °F)

Density (ASTM-D-287) –1 °C to 6 °C (30 °F to 42 °F) API gravity at 16 °C (60 °F)(0.816 to 0.876 Sp. Gr.)

Cloud point (ASTM-D-97) 6 °C (10 °F) below lowest ambient temperature at whichthe fuel is expected to operate

Active sulfur Copper strip corrosion not to exceed No. 2 rating after3 hours at 49 °C (122 °F)

Ash (ASTM-D-482) Not to exceed 0.02% by weightDistillation (ASTM-D-86) The distillation curve must be smooth and continuous.

At least 90% of the fuel must evaporate at less than360 °C (680 °F). All of the fuel must evaporate at 385 °C(725 °F)

190

Specifications


Coolant

Only use Volvo Coolant VCS when topping up or changing coolant. To avoid damage to engine and coolingsystem, different coolants or corrosion protection must not be mixed.When using concentrated Volvo Coolant VCS and clean water, the mixture should contain 40–60% concentratedcoolant and 60–40% clean water. The amount of concentrated coolant must never be less than 40% of the totalmixture, see table below.

Freeze protection down to Mixed-in amount of concentrated coolant-25 °C (-13 °F) 40 %-35 °C (-31 °F) 50%-46 °C (-51 °F) 60%

The concentrated coolant must not be mixed with water that contains a high degree of lime (hard water), salt ormetals.

The clean water for the cooling system must also meet the following requirements:

Description ValueTotal number of solid particles < 340 ppmTotal hardness < 9.5° dHChloride < 40 ppmSulphate < 100 ppmpH value 5.5-9Silica < 20 mg SiO2/litre

Iron < 0.10 mg Fe/litreManganese < 0.05 mg Mn/litreElectrical conductivity < 500 µS/cmOrganic material, COD-Mn < 15 mg/litre

If there is any doubt about the water quality use ready-mixed Volvo Coolant VCS, which contains 40%concentrated coolant. Do not mix with any other ready-mixed coolants since this may result in engine damage.

Specifications


191

Hydraulic oil

Only use Volvo genuine hydraulic oil approved by Volvo Construction Equipment must be used. Do not mixdifferent brands of hydraulic oil as this can lead to damage in the hydraulic system.

For the hydraulic oil specification, see page No.194 .

Ambient temperature°C°F

-40-40

-30-22

-20-4

-10+14

0+32

+10+50

+20+68

+30+86

+40+104

+50+122

+60+140

Oil grade(B) (A) (C)

(B) (A) (C)(B) (A)

(A) : Ambient temperature recommended for general use of hydraulic system and components.(B) : Ambient temperature guide for machine operation from a hydraulic oil viewpoint only, it does not guaranteethe completion machine for other conditions like engine starting performance. In this range a warming-up periodis needed to obtain proper performance.(C) : Ambient temperature range to operate machine under special conditions, not a recommendation for generaluse conditions.

Additional recommendation for severe cold areasA field solution for severe cold condition of ambient temperature between -40°C and +20°C.

- Type : Anti-wear type hydraulic oil- Viscosity characteristic

Viscosity index : More than 130Kinematic Viscosity : Less than 5,000cSt at -40°C, More than 5.6cSt at +90°C

NOTICEThis value is approximately equivalent to ISO Viscosity grade #22.NOTICEIt is minimum theoretical recommendation without the guarantee of machine condition.

Lubricant

Extreme Pressure Multipurpose LubricantExtreme pressure (EP) multipurpose gear lubricant iscompounded to achieve high load carrying capacity and meet therequirements of either API-GL-5 or MIL-L-2105C. Unlessotherwise specified, SAE-90 viscosity oil may be used for year-round service. Low temperature usage is restricted as indicatedin the table below.

EP Multipurpose LubricantSAE Viscosity No. Min. Ambient Temp.

75W –40 °C (–40 °F)80W –26 °C (–15 °F)85W –12 °C (+10 °F)90 –7 °C (+20 °F)

192

Specifications


EP Multipurpose LubricantSAE Viscosity No. Min. Ambient Temp.

140 +5 °C (+40 °F)250 +10 °C (+50 °F)

Extreme Pressure Multipurpose GreaseExtreme pressure multipurpose grease is a lithium soap basegrease with a high load carrying capacity. The properties listed intable below are recommended.

EP Multipurpose GreaseTimken OK Load 18 kg (40 lb) minimumDropping Point 177 °C (350 °F) minimum

Oil Viscosity 75 SUS minimum at 99 °C (210 °F)Water Resistance Excellent

Under normal operating conditions, the following consistencygrades are recommended:

NLGI No. 0 ambient temp. below –18 °C (0 °F)NLGI No. 1 or No. 2 for ambient temp. –18–38 °C (0–100 °F)NLGI No. 2 or No. 3 for ambient temp. over 38 °C (100 °F)

Bearing and Gear LubricantBearing and gear lubricant provides better thermal and oxidationstability than conventional mineral oils. The lubricant has naturallyhigh viscosity indexes compared to mineral oils, providing lowerviscosity at lower temperatures and higher viscosity at highertemperatures. See table below.

Bearing and Gear LubricantLubricant ViscosityISO Viscosity Grade 220API Gravity 31.9Viscosity Index 152Viscosity:cSt at 40 °CcSt at 100 °C

21625.2

Specifications


193

Recommended lubricants, specifications

The quality of the hydraulic oil and engine oil is important to thesatisfactory performance of any hydraulic system and engine.The hydraulic oil serves as the power transmission medium,system coolant, and lubricant. Selection of the proper oil isessential to ensure proper system performance and life. For thespecifications and requirements of hydraulic oil and engine oilused in this machine should meet specification mentioned in thebelow table .

Recommended Lubricants, specificationEngine oil VDS-3, CL-4, 15W-40Hydraulic oil ISO VG 46Drum Eccentric oilDrum Carrier oil

Mobil SHC 630

Drum Drive oilAxle Housing oilAxle Brake oil

SAE 85W-90 LS

Engine Coolant VCS CoolantGrease fittings, pins, seals MPG–EP2 Grease

NOTICEFor additional information and specifications regardinglubrication, filling capacities and maintenance, See page No.196 as well as the 185.

194

Specifications


Service capacities and changeintervals

Environmentally safe handling

Handling Fluids and Oil, Fuel Filters1 When draining fluids, ensure that adequate sealable

containers are available and that every care is taken to preventspillage.

2 Always ensure waste fluids are disposed of in anenvironmentally safe manner.

3 Always ensure that used filters are stored in secure containersand disposed of in an environmentally safe manner.

Lubricant recommendation

GENERAL INFORMATIONLubrication is an essential part of preventive maintenance,affecting to a great extent the useful life of the unit. Periodiclubrication of the moving parts reduces to a minimum thepossibility of mechanical failures.

For maximum machine life and performance, we recommend theuse of genuine authorized brand lubricants.See page 185.

Different lubricants are needed and some components in the unitrequire more frequent lubricant than others. Therefore, it isimportant that the instructions regarding types of lubricant andfrequency of the application be explicitly followed.

See page 185 for lubrication and service chart. It shows thoseitems requiring regular service and the interval at which theyshould be performed. A regular service program should be gearedto the items listed under each interval. These intervals are basedon average operating conditions. In the event of extremelysevere, dusty or wet operating conditions, more frequentlubrication than specified may be necessary.

All oil levels are to be checked with the machine parked on a levelsurface and while the oil is cold, unless otherwise specified.

On plug-type check points, the oil levels are to be at the bottomedge of the check port.

All grease fittings are SAE STANDARD, unless otherwiseindicated. Grease non-sealed fittings until grease is seenextruding from the fitting.

Over-lubrication on non-sealed fittings will not harm the fittings orcomponents, but under lubrication will definitely lead to a shorterlife.

Unless otherwise indicated, items not equipped with greasefittings (linkages, pins, levers, etc.) should be lubricated with oilonce a week. Motor oil, applied sparingly, will provide thenecessary lubrication and help prevent the formation of rust. An

Specifications

Service capacities and change intervals

195

anti-seize compound may be used if rust has not formed.Otherwise, the component must be cleaned first.

Grease fittings must be replaced when they are worn to the pointthat they fail to hold the grease gun, or when they have a stuckcheck ball.

Lubrication and service schedules

To prevent minor irregularities from developing into seriousconditions, the following other services or checks arerecommended for the same intervals as the periodic lubrication:1 Thoroughly wash all fittings, caps, plugs, etc. with non-

flammable, non-toxic cleaning solution before servicing toprevent dirt from entering while performing the service.

2 Lubricants must be at operating temperature when draining.3 During regular lubrication service, visually check the entire unit

to ensure that capscrews, nuts and pins are properly secured.4 Spot check several capscrews and nuts for proper torque. If

any are found loose, a more thorough investigation must bemade.

5 If a defect is detected which requires special maintenanceservice, stop the machine operation until the defect has beencorrected. If necessary, contact the local authorized distributorfor assistance.

6 Periodic lubrication requirements and explanation oflubrication and service symbols are listed in the 185. Theserequirements include lubricant checks and greasingdesignated areas of the machine.

Fuel, lubricant and filling capacities

Filling capacitiesFuel tank 285 L (75 US gal)Hydraulic oil tank 180 L (47.5 US gal)Transmission oil 1.9 L (0.5 US gal)Engine oil 15.5 L (4.09 US gal)Axle housing oil 1.1 L (0.29 US gal)Drum eccentric oil 41 L (10.83 US gal)Drum Carrier oil 2 L (0.52 US gal)Wheel end oil 1.8 L (0.47 US gal)Radiator Coolant 22 L (5.81 US gal)

196

Specifications

Service capacities and change intervals

Brake

Brakes, specifications

Table. BrakesDescription SpecificationService brakes, Type of system. Hydrostatic through the propulsion system.Secondary/Parking brake. Spring-applied, hydraulic released.Location of secondary/parking brakes. Axle, multiple wet disc.Secondary/parking brake release pressure. 15 bar (217 psi).

Specifications

Brake

197

Wheels

Tyre sizes and pressures specifications

Tyre sizes and pressuresTyre size 23.1-26 R3, 8PRTyre pressure 1.1 Bar (16 psi)Tyre ballast With 3/4th of water

198

Specifications

Wheels

Drum

Drum, specifications

Table. VibrationDescription SpecificationsSingle vibrating drum 2134 mm (84 in.) wide x 1450 mm (59 in.) dia. x 25 mm (1 in.) thick shell

Maximum amplitude Minimum amplitudeDynamic force @ frequency SD110

25,401 kgs (56,000 lbs) @ 1,817vpm (30 Hz.) , (Variable)

SD11016,783 kgs (37,000 lbs) @ 1,817vpm (30 Hz.) , (Variable)

Dynamic force applied SD110294 kN (66,000 lbs.)

SD110209 kN (47,000 lbs.)

Nominal amplitude - eccentric SD1101.92 mm (0.076 in.)

SD1101.29 mm (0.051 in.)

Eccentric moment SD1106,878 kg/mm (597 lb-in.)

SD1104,609 kg/mm (400 lb-in.)

Specifications

Drum

199

Specifications

200

Specifications

Specifications

Critical mounting torques

Use the following recommended torque chart for bolts and nutsof SAE Grade 5 or better quality. If other torques are required,they will be indicated in the text.

Table. SAE TORQUE CHARTFunction of fastener Size Torque

N•m lbf ftAxle To Rear Frame M20 x 240 730 540Frame joint – Articulation vertical pin Nuts M48 678 500Frame joint – Articulation oscillation (horizontal pin)nut

M72 1491 1100

Engine mounting bracket front M16 229 169Mount propulsion cable mounting bracket M8 26 19Steering column to steering valve. M10 61 45Operator platform assembly to main frame M12 107 79Assembly carrier plate with shock mounting plate M16 373 275Assembly shock mount with shock mounting plateof carrier assembly

M12 x 35 149 110

Assembly torque hub and drive plate 3/4 “–16UNF 569 420Assembly motor mounting bracket and torque hub 5/8 “–11UNC 100 74Assembly bearing housing with drum M16 x 90 373 275Assembly shock mount with drum M12 x 30 149 110Assembly shock mount with drive assembly M16 149 110Assembly vibration motor with carrier assembly M12 x 35 107 79Assembly of cover with bearing housing M8 x 20 28 21Tyre mounting assembly on axle M22 523 386

Electrical system, specification

Electrical systemBattery 12 Volt, DC, Negative groundAlternator 12 VoltStarter 12 Volt, 4 kw

Frame link/articulation, specifications

Articulation / Oscillation linkArticulation angle ± 40°Oscillation angle ± 17°Gradeability (Theoretical) – Dependant on traction

Specifications

Specifications

201

Tightening torque, specifications

SAE Torque chartsUse the following recommended torque charts for bolts and nutsof SAE Grade 5 or better quality. If other torques are required,they will be indicated in the text.

8.8 Metric coarse and fine threads

Thread N•m lbf ftM6 10 7.4M8 24 18M10 48 35M12 85 63M14 140 103M16 220 160M20 430 320M24 740 550

10.9 Metric coarse and fine threads

Thread N•m lbf ftM6 12 9M8 30 22M10 60 44M12 105 78M14 175 130M16 275 204M20 540 400M24 805 549

UNC threads

Coarse thread Torque Fine thread. TorqueN•m lbf ft. N•m lbf ft

1/4 – 20 12 9 1/4 – 28 15 115/16 – 18 26 19 5/16 – 24 28 213/8 – 16 50 37 3/8 – 24 57 427/16 – 14 80 59 7/16 – 20 89 661/2 – 13 122 90 1/2 – 20 136 1009/16 – 12 176 130 9/16 – 18 197 1455/8 – 11 244 180 5/8 – 18 278 2053/4 – 10 434 320 3/4 – 16 481 3557/8 – 9 698 515 7/8 – 14 773 5701 – 8 1051 775 1 – 12 1146 8451 1/8 – 7 1492 1100 1 1/8 – 12 1668 1230

202

Specifications

Specifications

Coarse thread Torque Fine thread. TorqueN•m lbf ft. N•m lbf ft

1 1/4 – 7 2088 1540 1 1/4 – 12 2319 17101 3/8 – 6 2739 2020 1 3/8 – 12 3119 23001 1/2 – 6 3648 2690 1 1/2 – 12 4095 3020

NOTICETorque values used in this table are based on plated, yellow zinc,dicromate bolts.

NOTICEUse high strength thread locking compound on all bolts largerthan 5/16 inch.

NOTICEUse medium strength “thread locking compound” on bolts 5/16inch and smaller to fill all gaps between the engaged bolt and nutthreads.

NOTICEAll thread fasteners will have thread locking compoundapplied, except the following:

1 Wheel bolts/nuts2 Nylon insert nuts3 Whizlock bolts and nuts4 Fasteners less than 1/4-inch diameter5 If specifically instructed not to apply thread locking compound

Specifications

Specifications

203

Machine weights

Machine weights

Valid for serial numbers Model version Serial number start Serial number stop SD110 Bangalore 58001 Bangalore 99999

Table. WeightsDescription WeightOperating weight 11190 kg (24674 lb)Static weight at tyres 5078 kg (11197 lb)Static weight at drum 6112 kg (13477 lb)Shipping 10941 kg (24125 lb)

Machine weights

Table. WeightsDescription WeightOperating weight 11125 kg (24526 lb)Static weight at tires 5025 kg (11078 lb)Static weight at drum 6100 kg (13448 lb)Shipping 10876 kg (23977 lb)

204

Specifications

Machine weights

Dimensions

Specifications

Dimensions

205

Machine dimensions

The figure below provides a dimensional outline of the SD110 Tier3 machine, the values of which are defined in the dimensionstable.

B

C

D

F

I

J

N

V1100931

P

M

R

HL Q

T

U

O

V

E

SS

A

G

K

E1

W

U1

Machine dimension

Machine dimensionsLetter Description mm InchesA Front width 2310 90.94B Drum width 2134 84C Track 625 24.61D Machine width @ Tire 2100 82.67E Height, ROPS 3090 121.65E1 Height<Beacon lamp 3305 130.12

206

Specifications

Dimensions

Machine dimensionsLetter Description mm InchesF Steering wheel height 2330 91.73G Side clearance 91 3.58H Drum thickness 25 0.98I Deck Height 1420 55.9J Curb Clearance 515 20.27K Angle K 36° 36°L Front hub to bumper 995 39.17M Articulation to front Hub 1348 53.67N Articulation to rear Hub 1991 78.39O Wheel/Drum base 3342 131.57P Length overall 5640 222.4Q Rear hub to bumper 1253 49.33R Rolling radius (Tire) 705 27.75S Angle S 19° 19°T Ground clearance 495 19.48U Drum diameter 1500 59.05U1 Tyre diameter 1560 61.42V Turning radius (Inner drum edge) 3652 143.7W Turning radius (Outer drum edge ) 5960 234.64Y Articulation angle ±40° ±40°Z Oscillation angle ±17° ±17°

Specifications

Dimensions

207

Service history

Service 100 hours Type of service Signature and stampDate Hours Warranty Inspection

Service 500 hours Type of service Signature and stampDate Hours Service and maintenance

Service 1000 hours Type of service Signature and stampDate Hours Warranty Inspection








208

Specifications

Service history











Specifications

Service history

209



210

Specifications

Service history

Alphabetical indexAccidents .......................................................... 51Actions after recovering and towing ................. 80Additional Icons .................................................. 8Air cleaner primary filter, change ................... 136Air cleaner primary filter, cleaning .................. 133Air cleaner secondary filter, replacing ............ 138Air cleaner system, checking ......................... 133Alternator belt, checking ................................ 130Articulation hinge ............................................ 102Axle breather, cleaning .................................. 161Axle hubs, changing oil .................................. 159Axle hubs, checking oil level .......................... 158Axles .............................................................. 158Axles, checking oil level ................................. 158Batteries ......................................................... 110Battery description ......................................... 147Battery disconnect switch (main switch),check .............................................................. 146Battery storage ............................................... 150Battery, charging ............................................ 151Battery, checking electrolyte .......................... 152Battery, maintenance ..................................... 149Bearings, greasing ........................................ 181Before service, read ......................................... 95Brake .............................................................. 197Brake system ................................................. 163Brakes, specifications .................................... 197Braking ............................................................. 66Carrier breather, cleaning .............................. 169CE-marking, EMC-directive .............................. 16Check list after fire or heat exposure ............. 107Cleaning machine .......................................... 118Cleaning of engine compartment ................... 117Cleaning prior to repair ................................... 116Component list, Fuses ................................... 154Component list, Relays .................................. 154Component location, fuses ............................. 153Component location, relays ............................ 155Controls ............................................................ 30Coolant ........................................................... 191Coolant level, check ....................................... 141Coolant, changing .......................................... 141Cooling system ............................................... 141Critical mounting torques ............................... 201Danger zone ..................................................... 33Decals/Plates and reflectors ............................ 22Description, complete machine .......................... 5Dimensions .................................................... 205Drum ...................................................... 167, 199Drum carrier, changing oil .............................. 170Drum carrier, checking oil level ...................... 167Drum drive (torque hub), changing oil ............ 171Drum drive (torque hub), checking oil level....................................................................... 167

Drum eccentric, changing oil .......................... 172Drum eccentric, checking oil level .................. 168Drum shock mounts, checking ....................... 169Drum, checking .............................................. 167Drum, specifications ....................................... 199

Eco driving ....................................................... 85Electric welding .............................................. 146Electrical components, basic check ............... 145Electrical system, specification ...................... 201Engine ............................................................ 125Engine air cleaner .......................................... 133Engine hood, opening and closing ................. 125Engine Oil Change ......................................... 127Engine oil filter, replacing ............................... 128Engine oil level, check .................................... 126Engine, air cleaner maintenance ................... 133Engine, identification ........................................ 18Entering, leaving and climbing themachine .......................................................... 103Environmental handling for the future ............ 101Environmental requirements .............................. 8Environmentally safe handling ............... 111, 195EU's EMC directive .......................................... 16Explosion hazard ............................................ 145Fire prevention ............................................... 104Fire prevention measures .............................. 106Frame link/articulation, specifications ............ 201Fuel ................................................................ 190Fuel filter, replacing ........................................ 129Fuel system .................................................... 131Fuel system, bleeding .................................... 128Fuel, lubricant and filling capacities ............... 196Fuses, check .................................................... 75General information ........................................ 189General inspection of machine ....................... 124Greasing ......................................................... 180Handling hazardous materials .................. 53, 109Handling line, tubes and hoses ...................... 115Health hazards with paint, plastics andrubber ............................................................. 112Hydraulic oil .................................................... 192Hydraulic oil filter, changing ........................... 175Hydraulic oil suction strainer, cleaning ........... 178Hydraulic oil tank, changing oil ....................... 176Hydraulic system ............................................ 174Hydraulic system, checking oil level ............... 175Hydraulic system, warming up ......................... 62Hydraulic tank, cleaning ................................. 177Information and warning decals ....................... 19Intended use ...................................................... 8International decals .......................................... 20International symbols ......................................... 9Lap type seat belt, checking andmaintenance ................................................... 124Location of components ................................... 14Lubricant ........................................................ 192Lubricant recommendation ............................. 195Lubrication and service chart ................. 184, 185Lubrication and service schedules ................. 196Machine dimensions ...................................... 206Machine identification ....................................... 17Machine specific symbols .................................. 8Machine view ................................................... 13Machine weights ............................................ 204Maintenance service, daily ............................. 122

Alphabetical index 211

Maintenance service, every 100 hours .......... 122Maintenance service, every 1000 hours ........ 123Maintenance service, every 250 hours .......... 122Maintenance service, every 50 hours ............ 122Maintenance service, every 500 hours .......... 123Maintenance service, general ........................ 120Manual release of parking brake ................ 78, 79Measures after operating ................................. 68Measures before operating .............................. 57Measures in case of machine failure ................ 71Operating ......................................................... 64Operator comfort .............................................. 32Operator duties ................................................ 51Operator seat ................................................... 32Operator's manual, storage .............................. 32Operator's protective structure,component locations ........................................ 15Parking ............................................................. 69Parking brake performance ............................ 163Parking brake, description ................................ 66Periodic maintenance ..................................... 120Power lines, minimum clearance ..................... 55Precaution when working on the electricalsystem ............................................................ 117Preparations before service ........................... 102Product plates .................................................. 17Radiator and coolers, cleaning ....................... 142Rear axle, changing oil ................................... 160Recommended lubricants .............................. 189Recommended lubricants, specifications ....... 194Retrieving and towing ....................................... 76ROPS ............................................................... 31Safe operation of the machine ......................... 47Safety concerns everybody! ............................. 88Safety rules when operating ....................... 33, 36Safety when handling oil and fuel ............ 91, 114Safety when handling the machine ............ 33, 57Safety when lifting and supportingcomplete machine ............................................ 99Safety when operating on public roads ............ 35Safety when working on hydraulic systems....................................................................... 174

Safety when working with batteries ........ 144, 148Service capacities and change intervals ........ 195Service history ........................................ 116, 208Service position ................................................ 92Shift linkage, lubricating ................................. 182Signalling diagram ............................................ 86Some simple rules regarding tyre handling....................................................................... 100

Special instructions for working on theelectrical system ............................................. 144Specifications, general ................................... 188Starting engine ................................................. 61Starting with booster batteries .......................... 71Steering cylinder pins, greasing ..................... 164Steering system ............................................. 164Stopping ........................................................... 67Storage ............................................................. 69

Swivel joint (horizontal and vertical) pins,greasing ......................................................... 180Throttle control ................................................. 30Tightening torque, specifications .................... 202Touch-up painting .......................................... 119Towing a disabled machine .............................. 76Transmission .................................................. 156Transmission, changing oil ............................. 157Transmission, checking oil level ..................... 156Transporting machine ...................................... 81Transporting the machine ................................ 81Travel control lever ........................................... 30Troubleshooting charts ..................................... 73Troubleshooting, general ................................. 72Tyre sizes and pressures specifications ........ 198Tyres, wear and air pressure, checking ......... 165USA federal clean air act ................................. 23Vibration ........................................................... 63Waste handling .............................................. 112Water separator, changing ............................. 131Water separator, drain ................................... 131Wheel nuts, check torque ............................... 165Wheels ................................................... 165, 198Working in environmentally contaminatedareas .............................................................. 101

212

Alphabetical index

sd110 operator manual eng_gb_20026436

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