DYNAPAC
CA 150
Box 504, SE-371 23 Karlskrona, Sweden
Phone: +46 455 30 60 00, Fax: +46 455 30 60 30
www.dynapac.com
M150EN2
MAINTENANCE
19
ILF015WO1
Vibratory Roller
CA 150
Maintenance
M150EN2, A ugust 2002
Diesel engine:
CA 150: Cummins 4BT 3.3C
These instructions apply from:
CA 150 PIN (S/N) *73X20150*
Reservation for alterations.
Printed in Sweden
CA 150 is Dynapac’s light vibratory soil compactor. Available in D (smooth drum) and
PD (padfoot) versions. The PD version has its widest range of application on cohesive
material and rockfill materials.
All types of supporting and reinforcement courses can be compacted, and the
interchangeable drums, ie, D to PD and vice versa, give enhanced versatility in the
choice of application.
This manual describes the cab and safety-related accessories. Other accessories,
such as the compaction meter, etc. are described in separate instructions.
KEEP THIS MANUAL FOR
FUTURE REFERENCE
2 CA 150 M150EN2
It is important that the roller is maintained correctly to
ensure proper function. It should be kept clean so that any
leakage, loose bolts and loose connections can be
discovered in time.
Make a habit of walking round the roller to check it every
day before starting the first shift – including under the
machine. This is often the easiest way of discovering any
leakage.
SPARE A THOUGHT FOR THE
ENVIRONMENT! Do not let oil, fuel and other
environmentally hazardous substances contaminate the environment.
This manual contains instructions for periodic attention
which should normally be carried out by the roller operator.
There are additional instructions relating to the
diesel engine, for which the manufacturer’s
instructions are detailed in the engine manual.
This is found under a separate flap in the roller’s
product binder.
CONTENTS
GENERAL
WARNING SYMBOLS
Safety instruction – Personal Safety
Special caution – Machine or component damage
CAUTION
WARNING
Read through the entire manual before
starting any maintenance operations.
CAUTION
WARNING
WARNING
Ensure good ventilation (air extraction) if the
diesel engine is run indoors.
Page
Lubricants and symbols ................................................... 3
Technical specifications ............................................... 4-6
Maintenance schedule ..................................................... 7
Maintenance Measure ..................................................8, 9
Every 10 operating hours (daily) ...............................10-13
Every 50 operating hours (weekly) ...........................14-16
Every 250 operating hours (monthly) ........................17-20
Every 500 operating hours (every three months) .......... 21
Every 1000 operating hours (every six months) .......22-24
Every 2000 operating hours (every year) ................ 25, 26
Long-term storage .......................................................... 27
Special instructions ........................................................ 28
Electrical system, fuses ........................................... 29, 30
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its
constituents are known to the State of
California to cause cancer, birth defects,
and other reproductive harm.
3CA 150 M150EN2
LUBRICANTS AND SYMBOLS
ENGINE OIL Shell Universal SAE 15W/40 or equivalent
API Service CF-4/SG, (CD/CE)
HYDRAULIC FLUID
ambient air temperature Shell Tellus Oil TX68 or equivalent
-10°C – +40°C (14°F - 104°F)
ambient air temperature Shell Tellus Oil TX100 or equivalent
above +40°C (above 104°F)
BIODEGRADABLE Shell Naturelle HF-E46
HYDRAULIC FLUID When it leaves the factory, the machine may be filled
with biologically degradable fluid. The same type of
fluid must be used when changing or topping off.
TRANSMISSION OIL
ambient air temperature Shell Spirax SAE 80W/90, HD API, GL-5
-15°C – +40°C (5°F - 104°F)
ambient air temperature Shell Spirax HD85W/140 or equivalent
above +40°C (above 104°F)
DRUM OIL
ambient air temperature Shell Spirax SAE 80W/90, HD API, GL-5
-15°C – +40°C (5°F - 104°F)
ambient air temperature Shell Spirax HD85W/140 or equivalent
above +40°C (above 104°F)
GREASE SKF LGHB2 (NLGI Class 2) or equivalent for
articulated joint. Shell Retinax LX2 or equivalent
for other lubrication points.
FUEL See the engine manual
COOLANT Shell Anti-Freeze 402 or equivalent
mixed 50/50 with water Anti-freeze protection down to about -35°C (-31°F).
50
/
50
Always use high-quality lubricants, in the quantities specified. Excess grease or oil can
promote overheating, resulting in premature wear.
When driving in extremely high or low ambient tempe-ratures, other lubricants are needed.
Refer to the chapter entitled “Special Instructions” or contact Dynapac.
Engine, oil level Tire pressure
Engine, oil filter Air filter
Hydraulic fluid tank, level Battery
Hydraulic fluid filter Recycling
Transmission, oil level Fuel filter
Drum, oil level Coolant, level
Oil for lubrication
CAUTION
CAUTION
4 CA 150 M150EN2
TECHNICAL SPECIFICATIONS
Weight and sizes CA150 CA150D CA150PD CA150P
Operating mass with ROPS, EN500, kg (lbs) 6930 (15,300) 7130 (15,700) 7430 (16,400) 7230 (16,000)
Operating mass without ROPS, kg (lbs) . 6600 (14,600) 6800 (15,000) 7100 (15,700) 6900 (15,200)
Operating mass with cab, kg (lbs) ........... 7150 (15,800) 7350 (16,200) 7650 (16,900) 7450 (16,400)
Length, standard-equipped roller, mm (in) 4776 (188) 4776 (188) 4871 (192) 4871 (192)
Width, standard-equipped roller, mm (in) . 1852 (73) 1852 (73) 1852 (73) 1852 (73)
Height, with ROPS, mm (in) .................. 2784 (110) 2784 (110) 2825 (111) 2825 (111)
Height, with silencer, mm (in) ................ 2525 (99) 2525 (99) 2540 (100) 2540 (100)
Height, with cab, mm (in) ....................... 2815 (111) 2815 (111) 2857 (112) 2857 (112)
Fluid volumes (Liters) (gal or qts)
Rear axle:
• Differential ................................................. 7,0 (7.4 qts)
• Planetary gearing ...................................... 0,8/side (0.8 qts) /each side
Drum oil .......................................................10,5 (11.1 qts)
Hydraulic reservoir ...................................... 52 (13.7 gal)
Fluid in hydraulic system (D, PD) ............... 18,0 (4.8 gal)
Lubricating oil, Diesel engine ....................... 8,0 (8.5) qts)
Coolant, Diesel engine ................................ 12,5 (13.2 qts)
Fuel tank ..................................................... 225 (59.4 gal)
Electrical system
Battery ......................................................... 12 V, 170 Ah
Alternator ..................................................... 14 V, 60A
Fuses ..........................................................See under main heading: Electrical system
Tires
Tire size ...................................................... 420/70 B24 (Std type) 14,9-24T461 8 ply (Tractor type)
Air pressure ................................................ 110 kPa (1,1 kp/cm
2
) (16 psi)
As extra equipment, the tires can be filled with liquid (extra weight up to 350 kg/tire)
(770 lbs/tire). Remember this extra weight when you perform service.
Compaction data CA150 CA150D CA150PD/P
Static linear load ......................... kg/cm (pli) 21,2 (118.7) 21,7 (121.5) –
Amplitude (High).............................. mm (in) 1,7 (0.067) 1,7 (0.067) 1,7 (0.067)
Amplitude (Low) .............................. mm (in) 0,8 (0.031) 0,8 (0.031) 0,8 (0.031)
Frequency (High amplitude) ......... Hz (vpm) 29 (1740) 29 (1740) 29 (1740)
Frequency (Low amplitude) .......... Hz (vpm) 40 (2400) 40 (2400) 40 (2400)
Centrifugal force (High amplitude) .... kN (lb) 100 (22,500) 100 (22,500) 124 (27,900)
Centrifugal force (Low amplitude)..... kN (lb) 94 (21,150) 94 (21,150) 118 (26,550)
WARNING
5CA 150 M150EN2
Tightening torque
Hydraulic system
Bolt dimension: M20 (P/N 50 02 26)
Strength category: 8.8
Tightening torque: 330 Nm (243 lbf.ft)
(for Dacromet treated)
ROPS
Opening pressure, MPa (psi)
Drive system ........................ 38,0 (5,500)
Charge system ....................... 2,0 (290)
Vibration system................... 33,0 (4,800)
Steering system ................... 17,5 (2,540)
Brake disengagement ............ 1,4 (200)
TECHNICAL SPECIFICATIONS
Tightening torque in Nm (lbf.ft) for oiled, bright
galvanized bolts tightened with a torque wrench.
M STRENGTH CLASS
thread 8.8 10.9 12.9
M6 8,4 (6.2) 12 (8.9) 14,6 (10.8)
M8 21 (15.5) 28 (20.7) 34 (21.1)
M10 40 (15.5) 56 (41.3) 68 (25.1)
M12 70 (51.6) 98 (72.3) 117 (86.3)
M16 169 (124.7) 240 (177) 290 (213.9)
M20 330 (243.4) 470 (346.7) 560 (413.1)
M24 570 (420.4) 800 (590.1) 960 (708.1)
M30 1130 (833.5) 1580 (1165.4) 1900 (1401.4)
M36 1960 (1445.7) 2800 (2065.3) –
CAUTION
ROPS bolts must always be tightened dry.
6 CA 150 M150EN2
TECHNICAL SPECIFICATIONS
The vibration values are measured in conformance
with the driving mode described in EU directive
2000/14/EC on EU equipped machines, on soft
polymer material with vibration switched ON and
the operator’s seat in transport mode.
Operator’s station, vibration, hand/arm (steering
wheel/lever):
Below limit value.
Limit value: <2.5 m/s2.
Operator’s station, vibration, entire body (operator’s
seat):
Below limit value.
Limit value: <0.5 m/s2.
Vibrations - Drivers seat
(ISO 2631)
CA 150 107 89 90
The acoustic values are measured in conformance with EU directive
2000/14/EC on EU-equipped machines, on soft polymer material
with vibration switched ON and the operator’s seat in transport
mode.
Acoustic values
Model Guaranteed
acoustic
power level
dB(A) Lw(A)
Acoustic
pressure level,
operator’s ear
(platform)
dB(A) Lp(A)
Acoustic
pressure level,
operator’s ear
(cab) dB(A)
Lp(A)
Noise level can vary when driving on different
courses and with different seat positions.
Vibration levels may vary when driving on
different courses and with different seat
positions.
CAUTION
CAUTION
7CA 150 M150EN2
1. Radiator grille
2. Fuel filter, initial fuel filter
3. Drive belts, cooling, alternator
4. Oil level, diesel engine
5. Air filter
6. Hydraulic reservoir, sight glass
7. Breather filter
8. Drain, hydraulic reservoir
9. Hydraulic fluid, filling
10. Forward/reverse lever
11. Fuse box
12. Drum oil, filling
13. Scrapers
14. Drum oil, level plug, x1
15. Rubber elements and fastening screws
16. Steering joint
17. Steering cylinder, x1
18. Hydraulic filter, x1
19. Flywheel casing, hydraulic pumps
20. Wheel nuts
21. Tire pressure
22. Rear axle, differential
23. Rear axle, planetary gearing, x2
24. Rear axle suspension, two sides
25. Feed pump, fuel
26. Oil filter, diesel engine
27. Draining, fuel tank
28. Engine suspension, x4
29. Diesel fuel, filling
30. Battery
31. Radiator
32. Hydraulic fluid cooler
MAINTENANCE SCHEDULE
1 2 3 4 5 6 7 8 9 10 11 12
28 27 26 25 24 23 22 21 20 19 18 17 16 15 14
13
32
31
30
29
Fig. 1 Service and maintenance points
8 CA 150 M150EN2
MAINTENANCE MEASURES
Periodic maintenance shall be carried out at the
specified intervals, that is to say either every day,
every week etc., or after the specified number of operating hours, whichever comes first.
Always first remove all exterior dirt before
filling up fluids etc., and before checking oil
and fuel levels, and also when lubricating with
grease or oil.
The engine manual specifies additional service/maintenance instructions which relate to
the diesel engine.
Item. in Measu re See page Comments
fig. 1
Before the day’s first start
13 Check scraper setting 10
1 Check for free circulation of cooling air 11
31 Check coolant level 11 See engine manual
4 Check diesel engine oil level 12 See engine manual
29 Top up fuel tank 12
6 Check fluid level in hydraulic tank 12
Check brakes 13
Every 10 operating hours (daily)
Item. in Measu re See page Comments
fig. 1
Check that hoses and couplings are not leaking
7 Clean the filter element of the air cleaner 14 Replace as required
16 Lubricate steering joint 15
17 Lubricate the steering cylinder brackets 15
20 Check the wheel-nuts are tightened 16
21 Check tire pressure 16
After the first 50 hours of operation,
change only the drum oil and all the oil filters.
Every 50 operating hours (weekly)
CAUTION
CAUTION
CAUTION
9CA 150 M150EN2
MAINTENANCE MEASURE
Item. in Measure See page Comments
fig. 1
23 Check the oil level in rear axle/planetary gearing17
14 Check the oil level in drum 17
32 Clean the radiators 18
20, 24 Inspect and tighten bolted joints 18 Applies only to new and
repaired components
15 Inspect rubber elements and bolted joints 18
26 Change engine oil and oil filter 19 See engine manual
30 Inspect the battery 19, 20
Every 250 operating hours (monthly)
Item. in Measure See page Comments
fig. 1
18 Change the hydraulic fluid filters 22
27 Drain condensate from fuel tank 23
5 Replace air cleaner main filter 23
8 Drain condensate from hydraulic tank 24
22 Change oil in rear axle differential 24
24 Change oil in rear axle planetary gears 24
Check diesel engine valve clearance See engine manual
3 Check belt tension for drive belt system See engine manual
Every 1000 operating hours (every six months)
Item. in Measure See page Comments
fig. 1
8, 9 Change fluid in hydraulic tank 25
12 Change oil in roller 25
10 Lubricate Forward/Reverse control 26
Every 2000 operating hours (every year)
Item. in Measure See page Comments
fig. 1
2 Replace fuel filter See engine manual
2 Clean the initial fuel filter 21
7 Check bleeder filter on hydraulic tank 22
Every 500 operating hours (every three months)
10 CA 150 M150EN2
EVERY 10 OPERATING HOURS (Daily)
1
2
2 1 1 2
1
2
Never work under the roller with the engine
running. Park on a level surface. Block the
wheels securely.
It is important to consider movement of the
drum when the machine turns, ie, the scrapers
can be damaged or wear of the drum may
increase if adjustment is made closer than the
values stated.
If necessary, adjust distance to the drum as follows:
the scraper is integrated with the beam.
Loosen the four screws (2) on the frame side, then adjust the beam to about 20 mm (0.8 in) from the drum.
Tighten the screws.
Scrapers
– Check/Adjust
Fig. 2 Scrapers
1. Scraper beam
2. Screws
Soft scrapers (Optional)
Loosen the screws (2) and adjust to light contact
against the drum. Tighten the screws.
Fig. 4 Scrapers
1. Scraper blade
2. Screws
Fig. 3 Scrapers
1. Scraper blade
2. Screws
CA 150 PD/P
Loosen the four screws (2) on the frame side, then adjust the beam to about 25 mm (1 in) between the teeth
and the drum.
Tighten the screws.
CAUTION
WARNING
11CA 150 M150EN2
Check that the diesel engine has free circulation of
cooling air through the grille in the engine compartment.
Open the cover (1) fully upward. Make sure that the red
safety catch on the right side is latched.
Air circulation – Check
Fig. 5 Grille
1. Cover
Fig. 6 Radiator
1. Max. level
2. Min. level
3. Filler cap
Check that level of the coolant is between the max. and
min. marks.
Danger of scalding. Take great caution if
the radiator cap must be opened while the
engine is hot. Wear protective gloves and
goggles.
Fill with a mixture of 50% water and 50% anti freeze.
See lubricant specification and in the engine manual.
Flush the system every other year and
change the coolant. Ensure also that air can
flow unrestricted through the radiator.
13
2
Coolant level – Check
1
EVERY 10 OPERATING HOURS (Daily)
WARNING
CAUTION
12 CA 150 M150EN2
1
Fig. 8 Fuel tank
1. Filler pipe
2. Initial fuel filter
2
1
Fig. 9 Hydraulic fluid reservoir
1. Sight glass
2. Filler pipe
Position the roller on a level surface and check that the
sight glass reading (1) is between the max. – min.
marks. Top off with hydraulic fluid according to the
lubricant specification if the level is too low.
2
1
EVERY 10 OPERATING HOURS (Daily)
Park the machine on a level surface. The
engine should be switched off and the
parking brake engaged during all inspection and adjustment operations on the
machine, unless otherwise stated.
Watch out for contact with hot engine
parts and the hot radiator when the oil
dipstick is being removed. There is a risk
of burn injuries.
The dipstick is on the left-hand side of the engine.
Pull up the dipstick (1) and check that the oil level is
between the upper and lower marks. For further details,
refer to the engine manual.
WARNING
WARNING
Fig. 7 Engine compartment
1. Oil dipstick
Diesel engine
– Check oil level
Fuel tank – Filling
Refuel every day. Top off to the lower edge of the filler
pipe. Use diesel fuel in accordance with the engine
manufacturer’s specifications.
Stop the diesel engine. Short (press) the
filler gun against a non-insulated part of
the roller before refueling, and against the
filler pipe (1) while refueling is in progress.
The fuel tank holds 225 litres (59,4 gal).
Check that there is no sediment or water in the
fuel pre-filter (2).
Clean the pre-filter if required, see under "500
hours of operation".
WARNING
CAUTION
Hydraulic reservoir
– Check fluid level
13CA 150 M150EN2
Fig. 10 Control panel
1. Reserve-/parking brake knob
2. Forward/reverse lever
3. Warning lamp
1
3
2
EVERY 10 OPERATING HOURS (Daily)
Check operation of the brakes as follows:
Drive the roller slowly forward.
Push the reserve/parking brake knob (1); the warning
lamp (3) on the instrument panel should light and the
roller should stop.
After testing the brakes, set the forward/reverse lever
(2) in neutral.
Pull up the reserve-/parking brake knob.
The roller is now ready for operation.
WARNING
Brake function – Check
14 CA 150 M150EN2
EVERY 50 OPERATING HOURS (Weekly)
Replace or clean the air cleaner’s main filter if
the warning lamp on the instrument panel lights
up when the diesel engine is operating at full
speed.
Undo the three locking braces (1). Then pull off the
cover (2) and pull out the main filter (3).
Do not remove the safety filter (4).
If the main filter is to be cleaned, compressed air at
max. 5 bar (72 lbs/sq in) pressure should be used.
Blow up and down along the paper creases on the inside of the filter.
Hold the nozzle at least 2–3 cm (0.8-1.2 in) away from
the paper creases so that the paper does not tear under the pressure of air.
Use protective goggles when working with
compressed air.
Dry the inside of the cover (2) and filter housing (5).
Check that the hose clamps between the filter
housing and inlet hose are tightened and that
they do not leak. Check the entire length of the
hose all the way to the engine.
Once the main filter has been cleaned a maximum of 5 times, it must be replaced.
Main filter – Cleaning with
compressed air
Fig. 12 Main filter
23
Fig. 11 Air cleaner
1. Locking braces
2. Cover
3. Main filter
4. Safety filter
5. Filter housing
1 4 5
Air cleaner
– Check/clean
Fig. 13 Air filter
4. Safety filter
Safety filter – Replacement
4
Replace the safety filter with a new one at every 5th
replacement or cleaning of the main filter. The safety filter cannot be cleaned.
When replacing the safety filter (4), pull out the old filter
from its holder, insert a new one and refit the air cleaner
in the reverse order to the instructions given in the
figure above.
WARNING
CAUTION
CAUTION
CAUTION
15CA 150 M150EN2
EVERY 50 OPERATING HOURS (Weekly)
Steering joint and steering
cylinder – Lubrication
Fig. 14 Steering joint, left side
Place the roller on a level surface. Switch the
engine off and push in the reserve/parking
brake knob for all checking and adjustments
on the roller, unless otherwise specified.
Allow no one to get near the steering joint
when the engine is running. Danger of
being crushed when steering is operated.
Push the reserve/parking brake knob before lubricating.
Turn the steering wheel fully to the right to gain access
to all six lubricating nipples on the left side.
Use grease recommended in Lubricant Specification.
Wipe all the nipples clean from dirt and grease.
Lubricate each nipple (1) with five strokes of the grease
gun. Make sure that grease penetrates the bearings.
If grease does not penetrate through the bearings, it
may be necessary to relieve the load on the articulated
joint with a hydraulic jack and then repeat the greasing
process.
Steering joint – Lubrication
Steering cylinder
– Lubrication
Fig. 16 Steering cylinder, left side
2. Lubricating nipples, cylinder
brackets (x2)
Fig. 15 Steering joint, left side
1. Lubricating nipples,
steering joint (x4)
Wipe nipples clean from dirt and grease.
Lubricate each nipple (2) with three strokes of the grease gun.
Allow a little grease to remain on the nipples after
greasing. This will prevent contaminants from entering
the nipples.
1
1
2
CAUTION
WARNING
WARNING
16 CA 150 M150EN2
EVERY 50 OPERATING HOURS (Weekly)
Tires – tire pressure
Wheel nuts – tightening
Fig. 17 Wheels
1. Air valve
2. Wheel nut
1
2
Check the tire pressures using a pressure gauge.
If the tires are filled with fluid, the air valve (1) must be
in the “12 o’clock” position during pumping.
The relevant tire pressures are given under the heading
“Specifications”.
Check both tires.
When changing the tires it is important that
both of them have the same rolling radius. This
is necessary to ensure proper functioning of
the anti-slip in the rear axle.
Check the tightening torque of the wheel nuts (2) at 470
Nm (350 lbf.ft). Check both wheels and all the nuts.
(Applies only to new machine or recently fitted wheels.)
Check the safety manual that accompanies
the roller before filling the tires with air.
CAUTION
WARNING
17CA 150 M150EN2
Rear axle differential
– Check oil level
Fig. 18 Oil level check – differential
housing
1. Oil level/Filler plug
Rear axle planetary gears
– Check oil level
Fig. 19 Oil level check – planetary gear
1. Oil level/Filler plug
Fig. 20 Right side of drum
1. Filling plug
2. Number plate
3. Sight glass
Position the roller on a flat surface so that the filler plug
(1) and number plate (2) on the right side of the drum
are straight up.
Oil level should reach up to the sight glass (3).
Top off as required through the filler plug (1) halfway on
the sight glass.
Clean the magnetic filler plug (1) from any metal particles before refitting it.
See lubricant specification for the right grade of oil.
Do not overfill with oil, risk of overheating.
Drum
– Checking the oil level
1
3
2
1
1
Place the roller on a level base. The engine
must be switched off and the parking brake
applied for all checking and adjustments
on the roller unless stated otherwise.
Never work under the roller with the engine running. Park on a level surface. Block
the wheels securely.
Wipe clean and remove the level plug (1) and check
that the oil level reaches the lower edge of the plug
hole. Top off with oil to the right level if the level is low.
Use transmission oil according to the lubricant
specification.
Position the roller with the level plug (1) in the planetary
gears at 9 o’clock.
Wipe clean and remove the level plug (1) and check
that the oil level reaches the lower edge of the plug
hole. Top off with oil to the right level if the level is low.
Use transmission oil according to the lubricant
specification.
Check the oil level in the same way in the rear axle’s
other planetary gear.
EVERY 250 OPERATING HOURS (Monthly)
WARNING
WARNING
CAUTION
18 CA 150 M150EN2
Open the engine cover to gain access to the water and
hydraulic coolers.
Ensure that the flow of air through the coolers (1) and
(2) is unobstructed.
Clean a dirty radiator using compressed air or a highpressure water jet. Blow or wash the radiator in the
opposite direction to that of the cooling air.
Take care when using a high-pressure water
jet; do not hold the nozzle too near the cooler.
The cooler may otherwise be damaged.
Wear protective goggles when working
with compressed air or high-pressure
water jet.
Fig. 21 Hydraulic cooler
1. Water cooler
2. Hydraulic fluid cooler
Coolers – Checking/cleaning
21
Bolted joints
– Checking tightening torque
Fig. 22 Right side of machine
1. Rear axle
2. Engine suspension
3. Wheel nuts
Rear axle suspension (2) 330 Nm (243 lbf.ft), oiled.
Engine suspension (3). Check that all M12 bolts (x20)
are tightened, 78 Nm (57 lbf.ft).
Wheel nuts (4). Check that all nuts are tightened, 470
Nm (347 lbf.ft), oiled.
(The above applies to new or replaced components
only.)
Check all the rubber elements (1), and replace them all if
more than 25% of the elements on the same side of the
roller have cracks deeper than 10–15 mm (0.4-0.6 in).
Use a knife blade or other pointed tool when carrying
out this check.
Check also that the screw fasteners (2) are tightened.
Fig. 23 Roller, vibration side
1. Rubber element
2. Screw fasteners
1
2
2
1
3
EVERY 250 OPERATING HOURS (Monthly)
CAUTION
WARNING
Rubber elements and screw
fasteners – Check
19CA 150 M150EN2
Fig. 24 Left side of engine
1. Drain plug
2. Oil filter
Diesel engine
– Changing the filter and oil
123 1
Make sure there are no naked flames in the
vicinity when checking the electrolyte level.
An explosive gas is formed in the battery
during the charging process.
Lift up the engine compartment cover and undo the
quick-release screws (1).
Raise the battery cover (2).
Dry the upper face of the battery.
Use protective goggles. The battery contains corrosive acid. In the event of contact, rinse with water.
12
EVERY 250 OPERATING HOURS (Monthly)
Position the roller on a level surface. Stop
the engine and apply the parking brake/
reserve brake.
The oil drain plug (1) located in a mount on the rear axle
is most easily accessible from underneath the engine.
Drain the oil while the engine is warm. Place a recepta-
cle for at least 15 litres under the drain plug.
Danger of being scalded when draining off
hot oil. Protect your hands.
Change the engine oil filter (2) at the same opportunity.
See also the engine manual.
WARNING
WARNING
Dispose of the drained oil and filter in an
approved manner.
Battery
– Check electrolyte level
Fig. 25 Battery box
1. Quick-release screws
2. Battery cover
3. Battery
WARNING
WARNING
20 CA 150 M150EN2
Remove the cell covers and check that the fluid level is
about 10 mm (0.4 in) above the plates. Check the level
in all the cells. If the level is lower, top up to the correct
level with distilled water. If the ambient air temperature
is below freezing point, the engine should be run for a
while after the distilled water is added, otherwise there
is a risk that the water might freeze.
Check that the ventilation holes in the cell covers are
not blocked, then refit the covers.
The cable terminals must be properly tightened and
clean. Corroded cable connections should be cleaned
and greased with alkaline Vaseline.
When removing the battery, always undo the
negative cable first.
When fitting the battery, always connect the
positive cable first.
Dispose of the old battery in the approved
environmentally suitable manner – batteries
contain toxic lead.
When carrying out electrical welding on
the machine, disconnect the battery’s
negative cable and then all the electrical
connections leading to the alternator.
1
2
3
10 mm
EVERY 250 OPERATING HOURS (Monthly)
WARNING
CAUTION
Fig. 26 Electrolyte level in battery
1. Cell cover
2. Electrolyte level
3. Plate
Battery cell
21CA 150 M150EN2
EVERY 500 OPERATING HOURS (Every three months)
Fig. 27 Engine
1. Screw
2. Glass bowl
3. Filter
Fuel pre-filter – Cleaning
Place the roller on a level base. The engine
must be switched off and the parking brake
applied for all checking and adjustments
on the roller unless stated otherwise.
Loosen the screw (1) and remove the bowl (2).
Take out the strainer (3) and clean using a nonflammable fluid. Reinstall the strainer and the bowl.
Start the engine and check that the pre-filter does not
leak.
Make sure there is adequate ventilation
(extraction) if the diesel engine is run indoors. Risk of carbon monoxide poisoning.
2
1
WARNING
WARNING
3
22 CA 150 M150EN2
3
2
1
EVERY 1000 OPERATING HOURS (Every six months)
Fig. 28 Hydraulic reservoir
2. Filler cap/Breather filter
3. Sight glass
Hydraulic filter
– Replacement
Fig. 29 Engine compartment
1. Hydraulic filter (x1)
Place the roller on a level base. The engine
must be switched off and the parking brake
applied for all checking and adjustments
on the roller unless stated otherwise.
Loosen the cap/breather filter (2) on top of the reservoir
to relieve any excess pressure inside.
Ensure that the breather filter (2) is not clogged, air
must have unobstructed passage through the cap in
both directions.
If clogged in either direction, clean with a little diesel oil
and blow with compressed air until free passage is
assured, or replace the cap with a new one.
Wear protective goggles when working
with compressed air.
Clean thoroughly round the hydraulic filter. Remove the
hydraulic filter (1) and scrap it. They are of the
expendable type and cannot be cleaned.
Ensure that the old sealing ring is not left on
the filter holder. Leakage may otherwise occur
between the new and the old seals.
Thoroughly clean the sealing surface of the filter holder.
Apply a thin coat of fresh hydraulic fluid on the new
filter seal.
First, screw on until the filter seal lies against
the filter holder. Then screw a further half turn.
Do not tighten the filter too hard, which could
damage the gasket.
Start the engine and ensure that there is no leakage of
hydraulic fluid from the filter. Check the fluid level in the
sight glass (3) and top off as required.
Ensure that ventilation (extraction) is
adequate if the engine is run indoors.
Risk of carbon monoxide poisoning.
WARNING
CAUTION
WARNING
CAUTION
WARNING
23CA 150 M150EN2
Water and sediment in the fuel tank are removed via
the drainage plug in the bottom of the fuel tank.
Be very careful during draining. Do not drop
the plug or else all the fuel will flow out.
Drainage should be performed when the roller has been
standing for a long period of time, for example overnight. The fuel level should be as low as possible.
The roller should preferably have been standing with
this side somewhat lower, so that water and sediment
will gather near the drainage plug (1). Drain as follows:
Place a container under the plug (1).
Undo the plug and drain off the water and sediment until
only clean diesel fuel appears through the plug opening.
Refit the plug.
Replace the main filter (3) of the air cleaner even if it
has not yet been cleaned five times, see under 50
hours for filter replacement.
CAUTION
Condensate in the hydraulic reservoir is removed via
the drainage tap (1).
Drainage should be performed when the roller has been
standing for a long period of time, for example overnight. Drain as follows:
Remove the plug (2).
Place a container under the tap.
Open the tap (1) and let any trapped condensate run out.
Shut the drainage tap.
Refit the plug.
1
23
1 4 5
1
2
EVERY 1000 OPERATING HOURS (Every six months)
Fig. 30 Hydraulic tank, underside
1. Drainage tap
2. Plug
Hydraulic tank – Drainage
Fig. 31 Fuel tank
1. Drainage plug
Fuel tank – Drainage
Fig. 32 Air cleaner
1. Locking braces
2. Cover
3. Main filter
4. Backup filter
5. Filter housing
Air filter – Replacement
24 CA 150 M150EN2
Never work under the roller with the engine running. Park on a level surface and
block the wheels securely.
Wipe clean and remove the level/filler plug (1) and all
three drain plugs (2), and drain the oil into a suitable
receptacle. The volume is about 7 quarts.
Save the oil and deposit it in an approved
manner.
Refit the drainage plugs and top up with fresh oil until
the correct level is reached.
Note: It takes a while for the oil to flow into the axle. Do
not fill the entire volume all at once.
Refit the oil-level/filler plug. Use transmission oil, see
the lubrication specification.
1
1
1
2
EVERY 1000 OPERATING HOURS (Every six months)
Fig. 33 Rear axle
1. Oil level/Filler plug
2. Drainage plugs
Rear axle differential
– Oil change
WARNING
Position the roller with the plug (1) at its lowest position.
Wipe clean, unscrew the plug (1) and drain the oil into a
suitable receptacle. The volume is about 1 litre (1.1 qts).
Save the oil and deposit it in an approved
manner.
Position the roller with the plug at 9 o’clock.
Fill with oil to lower edge of level hole. Use transmission oil. See lubricant specification.
Clean and screw in the plug. Use transmission oil. See
lubricant specification.
Change oil in the same way in the other planetary
gears of the rear axle.
Fig. 35 Planetary gear/filling position
1. Plug
Rear axle planetary gears
– Oil change
Fig. 34 Planetary gear/drainage position
1. Plug
25CA 150 M150EN2
1
2
3
1
2
EVERY 2000 OPERATING HOURS (Every year)
Hydraulic tank
– Fluid change
Fig. 36 Hydraulic tank, underside
1. Drainage tap
2. Plug
Place the roller on a level surface. Switch the
engine off and push in the reserve/parking
brake knob for all checking and adjustments
on the roller, unless otherwise specified.
Danger of being burned when draining hot
oil. Protect your hands.
Obtain a container for collecting the used fluid. The container should have a volume of at least 60 litres (16 gal).
A suitable container may be an empty oil drum or similar item which is placed beside the roller. The fluid then
runs in a hose from the drainage plug (1) to the oil
drum, after the plug (2) has been removed and the tap
opened.
Save the oil and deposit it in an approved
manner.
Fill with fresh hydraulic fluid according to instructions
under the heading ”Hydraulic reservoir—checking the
level”. Change the hydraulic filter at the same time
Start the diesel engine and operate the various hydraulic functions.
Make sure there is adequate ventilation
(extraction) if the diesel engine is run
indoors.
(Risk of carbon monoxide poisoning)
Check the fluid level and top up if necessary.
WARNING
WARNING
WARNING
Drum – Changing the Oil
Place the roller on a level surface so that the drain plug
(1) is straight down and place a receptacle that will hold
at least 15 liters under the plug.
Save the oil and deposit it in an approved
manner.
Clean and unscrew the plug (1). Allow all of the oil to
drain off. Fill with oil according to “Drum—checking the
oil level”.
There is danger of being scalded when
draining hot oil. Protect your hands.
WARNING
Fig. 37 Drum, right side
1. Drain/Filler plug
2. Number plate
3. Sight glass
26 CA 150 M150EN2
Inspect the steering joint to detect any damage or
cracks.
Check and correct any loose bolts.
Check also for any stiffness and play.
Fig. 39 Operator’s station
1. Protective cover
2. Screws (x2)
Controls and pivoted joints
– Lubrication
2
Lubricate the forward/reverse control mechanism.
Unscrew the two screws (2) and take off the protective
cover (1). Oil the mechanism.
Refit the protective cover.
1
EVERY 2000 OPERATING HOURS (Every year)
Steering joint – Check
Fig. 38 Steering joint
27CA 150 M150EN2
LONG-TERM STORAGE
For long-term storage (longer than one month),
the following instructions should be followed.
These instructions apply for storage lasting up
to 6 months.
Before re-commissioning the roller, the points
marked with an asterisk * must be restored.
Fig. 40 Protecting the roller from the
elements
* See the manufacturer’s instructions in the engine
instruction manual, which is supplied together with
the roller.
* Remove the battery from the roller, clean it’s
exterior, check its electrolyte level and recharge it
once a month.
* Cover the air cleaner or its opening with plastic or
tape, and cover also the exhaust pipe’s opening.
This is done so as to prevent moisture from
penetrating into the engine.
Fill the fuel tank completely to prevent condensation.
Drain off any condensation water and fill the hydraulic reservoir to the upper mark.
Lubricate the steering joint bearings and the steering
cylinder’s two bearings with grease.
Grease the steering cylinder’s piston with
conservation grease.
Grease also the engine compartment cover’s hinges, the seat slide rails, the engine-speed control
and the forward/reverse control mechanism.
Check that tire pressure is 110 kPa (1,1 kp/cm2),
(16 psi).
* Place the instrument cover on the steering column.
Cover the entire machine with a tarpaulin, which
should hand some way off the ground. If possible,
store the roller indoors, preferably in a building with a
uniform temperature.
Diesel engine
Battery
Air cleaner, exhaust pipe
Covers, tarpaulin
Fuel tank
Tires (All-weather)
Steering cylinder, hinges etc.
Hydraulic reservoir
CAUTION
28 CA 150 M150EN2
SPECIAL INSTRUCTIONS
Standard lubricants and other
recommended oils
Upon delivery from the factory, the various systems
and components are filled with the oils specified see
lubricant specification and they can be used at ambient
temperatures from -10°C to +40°C (14°F - 104°F).
A maximum temperature of +35°C (95°F)
applies for biological hydraulic fluid.
When operating in hotter ambient temperatures, but up
to max. +50°C (122°F), the following instructions apply:
The diesel engine can handle this temperature with the
standard oil, but the following oils must be used in the
other components:
Hydraulic system with mineral fluid: Shell Tellus TX100
or corresponding.
Other components using transmission oil:
Shell Spirax HD 85W/140 or corresponding.
The temperature limits apply for a roller with standard
features.
Rollers with extra equipment such as noise suppressers etc. may require additional attention at the upper
temperatures.
When washing the machine, do not direct the
jet of water directly at the fuel or hydraulic fluid
tank covers. This is particularly important
when using a high-pressure washing unit.
Do not spray water directly on electric components or
the instrument panel. Put a plastic bag over the filler
cap of the fuel tank and secure with a rubber band.
This will prevent water from entering the venting hole in
the filler cap. This could otherwise cause operational
disturbance, for example, a clogged filter.
If there is a fire in or on the machine, it is best to use an
ABE-class fire extinguisher. However, a BE-class CO
2
extinguisher is also suitable.
If the roller is equipped with a protective structure
(ROPS, Roll Over Protective Structure), or protective
cab, never subject the structure or cab to welding or
drilling. Never attempt to repair a damaged structure or
cab; they must be replaced with new ones.
When an auxiliary starter battery is used, always
connect the positive terminal on the auxiliary battery to
the positive terminal on the roller’s battery, and
negative to negative.
Higher ambient temperature
max. +50°C (122°F)
Temperatures
High-pressure washing
Extinguishing fires
ROPS, protective cab
Starting assistance
CAUTION
CAUTION
29CA 150 M150EN2
2
2
1
56 7 8
34
ELECTRICAL SYSTEM, FUSES
Fig. 42 Instrument panel
3,4. Fuse box
5. VBS relay
6. Main relay
7. Hourmeter relay
8. Lights relay
Fig. 41 Instrument panel
1. Screws (x2)
2. Screws (x8)
Fuses and relays
= Optional
The electrical regulating and control system is
protected by fuses and relays. The number depends on
how much additional equipment the machine is
prepared for.
The two fuse boxes (3, 4) and the relays (5, 6, 7, 8) are
located behind the lower instrument plate, which is
removed by unscrewing the screws (1 and 2).
The machine is equipped with a 12 V electrical system
and an alternator.
Connect the battery to the correct polarity
(– to ground). The cable between battery
and alternator must not be disconnected
when the engine is running.
WARNING
30 CA 150 M150EN2
Main fuses
Fig. 44 Engine compartment
1. Main fuse
2. Fuel solenoid relay
3. Start relay
The main fuse (1) is located behind the battery
disconnecter. The fuse a flat pin fuse. The fuel solenoid
relay (2) and the start relay (3) are also fitted here.
Main fuse 30 A (Green)
Fuses
Fig. 43 Fuse box, left side
7.5A 1. Hourmeter
7.5A 2. VBS relay
7.5A 3. Warning lamp
7.5A 4. Horn
7.5A 5. Fuel gauge
10A 6. Front wiper, cab
Fig. 43 shows the rating and function of the different
fuses. All fuses are flat pin fuses.
321
Fuse box, right side
7.5A 1. High/Low gear
3A 2. Compaction meter
7.5A 3. Hazard beacon
3A 4. Reversing alarm
20A 5. Working lights
20A 6. Working lights
= Optional
1
2
3
4
5
6
ELECTRICAL SYSTEM, FUSES
Loading...